Blade rear edge bonding gap control method
By laying the isolation layer and plastic filling materials in the blind adhesive area of the wind power blade trailing edge, combining the pressing technology of mold and heating structure, and vacuum infusion molding technology, the problem of difficulty in controlling the adhesive gap of the blade trailing edge in the prior art is solved, and precise control and efficient production are achieved.
Patent Information
- Application Number
- CN202411768988.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-04
- Publication Date
- 2025-03-04
AI Technical Summary
The prior art is difficult to effectively control the bonding gap between the trailing edge of the wind power blade, resulting in unstable bonding quality and affecting the wind energy utilization efficiency and load bearing capacity of the wind turbine.
By laying the isolation layer and plastic filler material in the blind adhesive area of the trailing edge, pressing and curing is performed using molds and heating structures, and combining vacuum infusion molding technology, the thickness and size of the filling material in the trailing edge bonding area are accurately controlled.
Accurate control of the adhesive gap of the blade trailing edge is achieved, ensuring that it is within the range of 6±4mm, improving the quality and production efficiency of blades, and enhancing the performance and safety of wind power blades.
Smart Images
Figure CN119550671A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of wind turbine blades, and in particular relates to a method for controlling a bonding gap at a trailing edge of a blade. Background Art
[0002] Wind power generation is an important form of utilizing wind energy at present, and is also a relatively mature technology among various renewable energy utilization technologies. The proportion of wind power generation in the world's electricity has increased rapidly in recent years. With the continuous increase in the power of a single wind turbine, the rotor blades are getting bigger and bigger, and their performance directly affects the wind energy utilization efficiency of the wind turbine and the load on the unit.
[0003] The blade structure is mainly composed of the windward skin, leeward skin, main beam, web and trailing edge UD. The windward skin, leeward skin and web are all sandwich structures filled with core materials to reduce the weight of the blade and increase the structural stability. The windward skin, leeward skin and web are bonded together by adhesive. The blade bonding area is the weak link in the overall structure, and the bonding quality is greatly affected by the quality of the adhesive itself and the actual bonding process.
[0004] The current blade bonding process is to use adhesive to bond and solidify the web and the lower shell (windward skin), then apply adhesive between the leading edge, trailing edge, and leading and trailing edge webs and the upper shell (leeward skin), and then through mold closing, finally bond the upper and lower shells into a whole.
[0005] The blade trailing edge bonding area is the swing load bearing area, which has a greater impact on the swing stiffness and torsional stiffness. The process requires that the blade trailing edge bonding gap should meet 6±4mm, but there is currently no good method to control the bonding gap. Summary of the invention
[0006] The object of the present invention is to provide a method for controlling the bonding gap of the trailing edge of a blade, so that the bonding gap of the trailing edge meets the process design requirement of 6±4 mm.
[0007] In order to achieve the above object, the technical solution of the present invention is: a method for controlling the gap of the trailing edge of a blade, comprising the following steps:
[0008] Plastic filling material profiling in the rear edge blind bonding area: mark the bonding width of the rear edge bonding area according to the starting position requirements of the bonding parameters of the mold closing rear edge; lay an isolation layer in the rear edge blind bonding profiling area, and the chord width of the isolation layer exceeds the bonding width on the front edge side and exceeds the parting line on the rear edge side; apply plastic filling material or structural adhesive to the rear edge bonding area; after the mold is buckled, the plastic filling material or structural adhesive is extruded, and the heating structure of the mold rear edge profiling area is turned on, and solidified after heating;
[0009] Measurement of spatial dimensions of unit cross-sectional area: After heating is completed, open the mold, and make axial metric marks and chordal marks for each distance a of the press area on the press sample according to the metric marks of the mold; according to the metric marks, cut the cross section of each distance a, and copy the end face to form a cross-sectional diagram, or collect and record the data of the end face, and draw a cross-sectional diagram based on the data;
[0010] Calculation of the processing thickness of the fillable material in the trailing edge bonding area: recalculate the processing thickness of the fillable material in the trailing edge according to the cross-sectional view, and process the fillable material in the trailing edge bonding area according to the recalculated processing thickness of the fillable material;
[0011] The blind bonding area of the trailing edge can be filled with material by infusion molding: After the cloth layer wraps the processed trailing edge bonding area, the material can be filled with material, and then vacuum infusion molding is performed to form the trailing edge filling material;
[0012] Verification of the size of the fillable material on the trailing edge: Make axial metric marks and chordal marks for each distance a on the profiling sample at the metric mark on the mold, and place the plastic filling material; then buckle the mold, turn over the hydraulic system, and buckle the PS surface for a test mold; after opening the mold, verify whether the adhesive layer on the trailing edge is within 6±4mm; if it is not within this range, continue to place the plastic filling material and perform profiling again, so as to optimize the size of the trailing edge filling material.
[0013] Furthermore, an isolation layer is laid in the blind bonding area of the trailing edge, and the chord-wise width of the isolation layer exceeds the bonding width on the leading edge side, and exceeds the parting line on the trailing edge side; specifically, an isolation layer is laid in the blind bonding area of the trailing edge, and the chord-wise width of the isolation layer exceeds the bonding width by 500 mm on the leading edge side, and exceeds the parting line by 300 mm on the trailing edge side.
[0014] Further, after the heating is completed, the mold is opened, and according to the mold meter mark, axial meter marks and chordal marks for each distance b in the profiling area are made on the profiling sample; according to the meter mark, the cross section at each distance a is cut, and the end face is copied to form a cross-sectional view, or the data of the end face is collected and recorded, and the cross-sectional view is drawn according to the data; specifically, after the heating is completed, the mold is opened, and according to the mold meter mark, axial meter marks and chordal marks for each 50mm in the cross section of the profiling area are made on the profiling sample; according to the meter mark, the cross section every 0.5m is cut, and the end face is copied to form a cross-sectional view, or the data of the end face is collected and recorded, and the cross-sectional view is drawn according to the data.
[0015] Furthermore, a plastic filling material or structural adhesive is applied to the trailing edge bonding area. Specifically, a 5-10mm thick plastic filling material or structural adhesive is scraped at 0.1m before and after every 0.5m section in the trailing edge bonding area, and then the pre-prepared profile core material is laid in sequence on the scraping glue area; a 5-10mm thick plastic filling material or structural adhesive is scraped between each layer of core material, and a 10-20mm thick plastic filling material or structural adhesive is scraped on the surface of the outermost core material.
[0016] Furthermore, a plastic filling material or structural adhesive is applied to the bonding area at the rear edge. Specifically, the full thickness of the plastic filling material or structural adhesive is scraped at the bonding area at the rear edge, and the plastic filling material or structural adhesive axially exceeds the start and end positions by 10-50mm, and chordally exceeds the bonding width by 10-50mm; after the laying of the profiling material of each section is completed, the profiling area is covered with a vacuum bag film, and the chordally width of the vacuum bag film exceeds the bonding width by 500mm on the leading edge side and exceeds the parting line by 300mm on the trailing edge side.
[0017] Further, the heating structure of the mold rear edge profiling area is turned on, and curing is performed after heating; specifically, the water heating of the mold rear edge profiling area is turned on, the temperature is raised to 65° C., and the curing is performed at a constant temperature for 8 hours.
[0018] Furthermore, the processing thickness of the fillable material at the trailing edge is recalculated according to the cross-sectional view. Specifically, the thickness of the cloth layer after forming is calculated according to the number of wrapped cloth layers and specifications of the blind-bonded material at the trailing edge, and the corresponding cloth layer thickness is subtracted from the cross-sectional view data. Finally, the fillable material in the processable blind-bonded area of the trailing edge is confirmed.
[0019] The beneficial effects of this technical solution are:
[0020] ① The present invention can quickly obtain the bonding filling material size that meets the actual trailing edge cavity, has a controllable matching scheme, effectively improves the blade quality, avoids repeated modifications to confirm the actual size of the trailing edge filling material, and improves the production efficiency of wind turbine blades.
[0021] ② On the basis of the trailing edge filling material, plastic material can be placed to perform profiling again and collect data to further optimize the thickness of the trailing edge filling material, which can effectively control the gap in the trailing edge bonding area to meet the design or process requirements and greatly improve the quality and product safety of the blade. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Figure 1 It is a flow chart of a method for controlling the bonding gap of a blade trailing edge according to the present invention;
[0023] Figure 2 A schematic diagram of the bonding width marking line of the trailing edge bonding area;
[0024] Figure 3 The schematic diagram of the laying position of the isolation layer is shown in FIG.
[0025] Figure 4 This is a schematic diagram of the scraping position;
[0026] Figure 5 is a schematic diagram of the pressed sample;
[0027] Figure 6 Schematic diagram of data collection on the end surface;
[0028] Figure 7 This is a schematic diagram for calculating machining thickness;
[0029] Figure 8 This is a schematic diagram of the injection molding of fillable materials;
[0030] Fig. 9 Schematic diagram of blind bonding of the trailing edge. DETAILED DESCRIPTION
[0031] The following is further described in detail through specific implementation methods:
[0032] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0033] The embodiment is basically as shown in the attached Figure 1 A method for controlling the gap between the trailing edge of a blade and the bonding agent, comprising the following steps:
[0034] S1: Plastic filling material pressing of the rear edge blind bonding area: Figure 2 As shown in the figure, use a marker pen to mark the bonding width of the rear edge bonding area of the main mold according to the starting position requirements of the bonding parameters of the rear edge of the mold closing; lay an isolation layer (specifically, discarded vacuum bag film or isolating material) in the blind bonding pressure molding area of the rear edge. The chord width of the isolation layer exceeds the bonding width by 500mm on the leading edge side and 300mm on the trailing edge side. Figure 3 As shown. Apply plastic filling material or structural adhesive to the rear edge bonding area; after the mold is buckled, the plastic filling material or structural adhesive is squeezed out, turn on the water heating of the rear edge pressing area of the mold, raise the temperature to 65°C, and keep the temperature constant for 8 hours to cure. Note: To prevent the cross-sectional position of the plastic filling material from shifting, use paper tape to fix the area on each cross section before buckling the mold to prevent it from sliding down. Among them, the following two solutions can be used to apply plastic filling material or structural adhesive to the rear edge bonding area: ① As Figure 4As shown, use a plastic scraper or other tools to scrape 5-10mm thick plastic filling material or structural adhesive at 0.1m before and after every 0.5m section in the rear edge bonding area, and then lay the pre-prepared waste surface core materials in sequence to the scraping glue area; in order to ensure that the plastic filling material or structural adhesive is scraped between each layer of core material, and 10-20mm of plastic filling material or structural adhesive is scraped on the surface of the outermost core material to ensure that the plastic filling material or structural adhesive is extruded after the mold is buckled. ② Use a plastic scraper or other tool to scrape the full thickness of plastic filling material or structural adhesive in the rear edge bonding area to ensure that the plastic filling material or structural adhesive exceeds the start and end positions axially by 10-50mm and exceeds the bonding width chordally by 10-50mm; after the profiling material of each section is laid, use the discarded vacuum bag film to cover the profiling area. The chordal width of the vacuum bag film exceeds the bonding width by 500mm on the leading edge side and 300mm on the trailing edge side.
[0035] S2: Measurement of spatial dimensions of unit cross-sectional area: After heating is completed, open the mold and check the pressing condition; according to the mold meter mark, make axial meter marks and chordal marks every 50mm on the pressing sample for every 0.5m section of the pressing area; Figure 5 As shown, according to the meter mark, use a cutting machine to cut a cross section every 0.5m, and copy the end face onto A4 or A3 paper to form a cross-sectional view, or collect and record the end face data (such as Figure 6 The measurement of the male mold size of the filling material for the press must be accurate, and the overall error must be controlled within the range of ±2mm to ensure the mold clearance size of subsequent products.
[0036] S3: Calculation of the thickness of the fillable material in the rear edge bonding area: Recalculate the thickness of the fillable material in the rear edge according to the cross-sectional view, such as Figure 7 As shown, the thickness of the cloth layer after forming is calculated according to the number of wrapped cloth layers and specifications of the rear edge blind bonding material, and the corresponding cloth layer thickness is subtracted from the cross-sectional data, and finally the fillable material in the processable rear edge blind bonding area is confirmed. The fillable material in the rear edge bonding area is processed according to the recalculated processing thickness of the fillable material.
[0037] S4: Filling material infusion molding of the rear edge blind bonding area: After the rear edge bonding area can be filled with material wrapped by the cloth layer, vacuum infusion molding is performed to form the rear edge filling material. Figure 8 The specific perfusion process is as follows:
[0038] 1) Mould position identification verification
[0039] Verify the starting and ending points of the fabric layers, core material transition points, etc., and make and paste clear markings.
[0040] 2) Fabric overlap and start and end point control
[0041] Overlap control: Lay the structural layers in sequence according to the design or process requirements of different projects, and strictly control the overlapping width during the laying process of the fabric layers, which is generally 50-70mm; during the on-site operation, if it is found that the kit size does not meet the requirements, the operator must make corrections in accordance with the process and quality requirements to ensure that the final laying meets the process requirements.
[0042] Start and end point control: During the laying process, control the start and end points of the laying to meet the process requirements.
[0043] 3) Core material placement control
[0044] Core material gap control, control from the aspects of gap filling and core material fixing.
[0045] 1. Gap filling: During the laying process, control the gaps between core materials to be ≤3mm. When laying the core materials, if the gaps are ≥3mm, use a special repair box to cut the core materials into small pieces to determine the shape of the gaps. Make sure that the upper and lower cross-sections of the cut core materials are basically consistent and match the shape of the gaps. There should not be cavities inside after filling. Reduce the generation of rich resin and the influence of invisible flow channels generated by the core material gaps on the infusion system.
[0046] 2. Resin nails: After the core material is laid, resin nails can be used to fix the core material joints. Resin nails can also be used to fix the core material in other locations (mainly where the deformation is large) if necessary. When using resin nails, it is necessary to ensure that the resin nails are nailed into the core material and are not allowed to exceed the core material surface by more than 1mm.
[0047] 3. Core material step control: According to the design requirements, if there are steps in the core material, grind a certain chamfer on the core material, and then arrange the vacuum auxiliary materials. After the laying is completed, open the vacuum pump valve, start vacuuming, and adjust the vacuum bag film to make it close to the flange corners, runners, exhaust vacuum tubes, etc., so that the vacuum bag film is not tight after the vacuum is tightened. At the same time, press the position of the sealing strip along the edge of the mold to make the vacuum bag film, the sealing strip and the mold close to each other without air leakage. After one layer of bag film is tightened, when the vacuum pump reading is ≥83Kpa, seal the second layer of bag film, and connect the two layers of bag film with a guide net or breathable cotton. The guide net or breathable cotton is laid in a "Z" shape to connect the front and rear edges and extend from the root of the mold to the tip of the mold;
[0048] After sealing the two layers of bag film, insert the spiral steel wire tube into the injection seat. After the connection is completed, when the vacuum gauge reading in the first layer of bag film is less than 20mbar, close the vacuum pump and the exhaust pipeline valve of the first layer, keep all the exhaust ports open, continue to evacuate the second layer of bag film, and start to maintain pressure. The pressure maintenance rule is that the change does not exceed 15mbar within 10 minutes, indicating that the bag film is in good sealing condition and vacuum infusion can be carried out;
[0049] At the beginning of pouring, the mold is set at 35-50℃, and after pouring, it is adjusted to 65-85℃ until it cures for 5-8 hours. After the product surface is checked and cured, the surface of the filling material is tested every 5m, and the cross-section chord position is randomly selected. At the same time, the Tg value is measured according to the "Fiberglass and Adhesive Tg Test Specification". Tg>70℃ and Shore hardness>55HD are qualified. At the same time, open the quilt, turn off the hot water circulation, and turn on the cold water circulation.
[0050] S5: Verification of the size of the fillable material at the rear edge: Fig. 9 As shown, firstly, an empty test mold is carried out, and the axial meter mark and the chordal mark every 50mm are made on the molding sample block at the mold meter mark every 0.5m section in the molding area, and plastic oil clay is placed; then the mold is buckled, the hydraulic system is turned over, and the PS surface is buckled for a test mold closing; after opening the mold, it is verified whether the rear edge bonding layer is within 6±4mm; if it is not within this range, plastic oil clay is placed again for molding again and data is collected to optimize the size of the rear edge filling material.
[0051] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.
[0052] The above is only an embodiment of the present invention. The common sense such as the known specific structure and characteristics in the scheme is not described in detail here. The ordinary technicians in the relevant field know all the common technical knowledge in the technical field of the invention before the application date or priority date, can obtain all the existing technologies in the field, and have the ability to apply the conventional experimental means before that date. The ordinary technicians in the relevant field can improve and implement this scheme in combination with their own abilities under the enlightenment given by this application. Some typical known structures or known methods should not become obstacles for ordinary technicians in the relevant field to implement this application. It should be pointed out that for those skilled in the art, without departing from the structure of the present invention, several deformations and improvements can be made, which should also be regarded as the protection scope of the present invention, which will not affect the effect of the implementation of the present invention and the practicality of the patent. The protection scope required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.
Claims
1. A method for controlling the gap of a blade trailing edge bonding, characterized in that: The following steps are involved: Plastic filling material profiling in the rear edge blind bonding area: mark the bonding width of the rear edge bonding area according to the starting position requirements of the bonding parameters of the mold closing rear edge; lay an isolation layer in the rear edge blind bonding profiling area, and the chord width of the isolation layer exceeds the bonding width on the front edge side and exceeds the parting line on the rear edge side; apply plastic filling material or structural adhesive to the rear edge bonding area; after the mold is buckled, the plastic filling material or structural adhesive is extruded, and the heating structure of the mold rear edge profiling area is turned on, and solidified after heating; Measurement of spatial dimensions of unit cross-sectional area: After heating is completed, open the mold and make axial metric marks and chordal marks for each distance a of the cross section in the profiling area on the profiling sample according to the metric marks of the mold; According to the meter mark, cut the cross section at each distance a, and copy the end face to form a cross-sectional view, or collect and record the data of the end face, and draw a cross-sectional view based on the data; Calculation of the processing thickness of the fillable material in the trailing edge bonding area: recalculate the processing thickness of the fillable material in the trailing edge according to the cross-sectional view, and process the fillable material in the trailing edge bonding area according to the recalculated processing thickness of the fillable material; The blind bonding area of the trailing edge can be filled with material by infusion molding: After the cloth layer wraps the processed trailing edge bonding area, the material can be filled with material, and then vacuum infusion molding is performed to form the trailing edge filling material; Verification of the size of the fillable material at the rear edge: Make the axial mark and the mark of each distance a in the chord direction on the press-forming sample block at the section of each distance a in the press-forming area of the mold mark, and place the plastic filling material; then buckle the mold, turn over the hydraulic system, and buckle the PS surface for a test mold; After opening the mold, verify whether the adhesive layer at the rear edge is within 6±4mm; if it is not within this range, continue to place the plastic filling material and press it again to optimize the size of the filling material at the rear edge.
2. The method for controlling the gap of the trailing edge of a blade according to claim 1, characterized in that: An isolation layer is laid in the blind bonding area of the trailing edge, and the chord-wise width of the isolation layer exceeds the bonding width on the leading edge side, and exceeds the parting line on the trailing edge side; specifically, an isolation layer is laid in the blind bonding area of the trailing edge, and the chord-wise width of the isolation layer exceeds the bonding width by 500 mm on the leading edge side, and exceeds the parting line by 300 mm on the trailing edge side.
3. The method for controlling the gap of the trailing edge of a blade according to claim 1, characterized in that: After the heating is completed, the mold is opened, and the axial meter mark and the mark of each distance a in the chord direction are made on the press-forming sample block according to the meter mark of the mold for the cross section of each distance b in the press-forming area; according to the meter mark, the cross section of each distance a is cut, and the end face is copied to form a cross-sectional view, or the data of the end face is collected and recorded, and the cross-sectional view is drawn according to the data; specifically, after the heating is completed, the mold is opened, and the axial meter mark and the mark of each 50mm in the chord direction are made on the press-forming sample block for the cross section of each 0.5m in the press-forming area according to the meter mark of the mold; According to the meter mark, cut the cross section every 0.5m, and copy the end face to form a cross-sectional view, or collect and record the data of the end face, and draw a cross-sectional view based on the data.
4. The method for controlling the gap of the trailing edge of a blade according to claim 1, characterized in that: Apply plastic filling material or structural adhesive to the trailing edge bonding area. Specifically, apply 5-10mm thick plastic filling material or structural adhesive at 0.1m before and after every 0.5m section in the trailing edge bonding area, and then lay the pre-prepared profile core material in sequence to the glue-scraping area; apply 5-10mm thick plastic filling material or structural adhesive between each layer of core material, and apply 10-20mm plastic filling material or structural adhesive on the surface of the outermost core material.
5. The method for controlling the gap of the trailing edge of a blade according to claim 1, characterized in that: Apply plastic filling material or structural adhesive to the rear edge bonding area. Specifically: scrape the full thickness of plastic filling material or structural adhesive to the rear edge bonding area. The plastic filling material or structural adhesive axially exceeds the start and end positions by 10-50mm, and the chordal exceeds the bonding width by 10-50mm. After the profiling material of each section is laid, use vacuum bag film to cover the profiling area. The chordal width of the vacuum bag film exceeds the bonding width by 500mm on the leading edge side and exceeds the parting line by 300mm on the trailing edge side.
6. The method for controlling the gap of the trailing edge of a blade according to claim 1, characterized in that: The heating structure of the rear edge profiling area of the mold is turned on, and the curing is performed after heating; specifically, the water heating of the rear edge profiling area of the mold is turned on, the temperature is raised to 65° C., and the curing is performed at a constant temperature for 8 hours.
7. The method for controlling the gap of the trailing edge of a blade according to claim 1, characterized in that: Recalculate the processing thickness of the fillable material at the trailing edge according to the cross-sectional view. Specifically, calculate the thickness of the cloth layer after forming according to the number of wrapped cloth layers and specifications of the blind-bonded material at the trailing edge, subtract the corresponding cloth layer thickness based on the cross-sectional view data, and finally confirm the fillable material in the processable blind-bonded area of the trailing edge.