Wind turbine blade, wind power generator set, and wind turbine blade forming method

Abstract

The application relates to the technical field of wind power equipment, in particular to a wind power blade, a wind turbine generator and a wind power blade forming method. The wind power blade provided by the application comprises a blade body and a reinforcing rib structure. The blade body comprises an outer shell, a web plate and a trailing edge auxiliary beam, the web plate and the trailing edge auxiliary beam are arranged in a blade inner cavity formed by the outer shell, and are arranged at intervals along a chord direction of the blade body; the reinforcing rib structure is arranged in the blade inner cavity, the reinforcing rib structure comprises a reinforcing rib assembly, and the reinforcing rib assembly extends along the chord direction; the web plate is provided with the reinforcing rib assembly on at least one side in the chord direction, the reinforcing rib assembly is arranged at intervals from a leading edge end of the blade body and the trailing edge auxiliary beam, the reinforcing rib assembly is arranged in close contact with an inner wall surface of at least part of the outer shell and is connected with the outer shell, and is arranged close to a blade root of the blade body relative to a blade tip of the blade body. The wind power blade provided by the application can reduce the damage risk and the weight, thereby improving the power generation efficiency of the wind turbine generator.

Description

Technical Field

[0001] This application relates to the field of wind power equipment technology, and in particular to a wind turbine blade, a wind turbine generator set, and a method for forming wind turbine blades. Background Technology

[0002] Wind turbine blades are typically used to capture wind energy and convert it into mechanical energy, which is then converted into electrical energy by a generator in a wind turbine. A wind turbine blade consists of a blade shell, within which the main beam area has a web structure. The hollow areas on either side of the web structure are divided into the leading edge and trailing edge regions of the blade. With the continuous development of the wind power industry, the size of wind turbine blades is constantly increasing, and the space in their leading and trailing edge regions is also constantly increasing, exacerbating the "breathing" effect and thus increasing the risk of damage to the blade during operation.

[0003] In related technologies, the tangential stiffness and tangential deformation resistance of the blade during operation are usually improved by increasing the thickness of the core material or the amount of fiber material used in the blade shell, thereby reducing the risk of damage to the blade during operation.

[0004] However, the above methods will result in a significant increase in blade weight, and excessively heavy blades will affect the power generation efficiency of wind turbine generators. Summary of the Invention

[0005] This application provides a wind turbine blade, a wind turbine generator set, and a method for forming wind turbine blades, in order to solve the problem that current methods for improving the chordal rigidity and chordal deformation resistance of blades result in excessive blade weight, thereby affecting the power generation efficiency of wind turbine generator sets.

[0006] To achieve the above objectives, the technical solution of this application is as follows:

[0007] In a first aspect, this application provides a wind turbine blade, comprising: a blade body, the blade body including an outer shell, a web, and a trailing edge auxiliary beam, the outer shell forming a blade cavity, the web and the trailing edge auxiliary beam being disposed within the blade cavity, and the web and the trailing edge auxiliary beam being spaced apart along the chordal direction of the blade body; and a reinforcing rib structure disposed within the blade cavity, the reinforcing rib structure including a reinforcing rib assembly extending along the chordal direction; wherein, the web is provided with a reinforcing rib assembly on at least one side in the chordal direction, the reinforcing rib assembly being spaced apart from the leading edge end and the trailing edge auxiliary beam of the blade body, the reinforcing rib assembly being fitted to at least a portion of the inner wall surface of the outer shell and connected to the outer shell, and the reinforcing rib assembly being disposed near the blade root of the blade body relative to the blade tip.

[0008] In one possible implementation, the wind turbine blade provided in this application includes a core material layer, which includes multiple reinforcing units connected in sequence. Each adjacent reinforcing unit has a degree of freedom of movement at the connection position, so that the tilt angle of the side surface of each reinforcing unit facing the inner wall is adapted to and fitted to the corresponding position of the inner wall.

[0009] In one possible implementation, the wind turbine blade provided in this application has multiple deformation grooves on the core material layer, which divide the core material layer into multiple reinforcing units and a first connecting portion connecting two adjacent reinforcing units.

[0010] In one possible implementation, the wind turbine blade provided in this application has a core material layer with a first surface and a second surface opposite to each other along its own thickness direction, the first surface being disposed facing the inner wall surface; each deformation groove has a predetermined groove depth in the direction of the second surface facing the first surface, and at least some of the deformation grooves are spaced apart along the chord direction, and / or, at least some of the deformation grooves are spaced apart along the axial direction of the blade body.

[0011] In one possible implementation, the wind turbine blade provided in this application has a permeation groove on the side where at least one of the first surface and the second surface is located. The permeation groove extends along the thickness direction and is staggered from the deformation groove.

[0012] In one possible implementation, the wind turbine blade provided in this application has a permeation groove that includes at least one of a unidirectional parallel groove and a bidirectional cross groove.

[0013] In one possible implementation, the wind turbine blade provided in this application has permeation holes in the core material layer along its own thickness direction. The permeation holes connect the first surface and the second surface, and the permeation holes are staggered from the deformation grooves.

[0014] In one possible implementation, the wind turbine blade provided in this application has multiple reinforcing units spaced apart from each other and independently arranged. The reinforcing rib assembly also includes a flexible connector, which is disposed on one end face of the core material layer in its thickness direction and connects at least two reinforcing units.

[0015] In one possible implementation, the wind turbine blade provided in this application further includes a reinforcing layer disposed on the outer peripheral surface of the core material layer. The reinforcing layer includes at least one of fiber fabric and laminate, and the reinforcing layer is connected to the inner wall surface.

[0016] In one possible implementation, the wind turbine blade provided in this application has a maximum chord length position between the leading edge and trailing edge of the blade body, and the reinforcing rib assembly extends along the axial direction of the blade body and covers at least a portion of the maximum chord length position.

[0017] In one possible implementation, the wind turbine blade provided in this application includes a reinforcing rib assembly comprising a reinforcing rib having a first width in the axial direction of the blade body, such that the reinforcing rib covers at least a portion of the position of maximum chord length; or, the reinforcing rib assembly comprises two or more reinforcing ribs having a second width in the axial direction, and the two or more reinforcing ribs being arranged sequentially along a predetermined gap in the axial direction.

[0018] In one possible implementation, the wind turbine blade provided in this application has a chamfered end on the side of the reinforcing rib assembly facing away from the inner wall.

[0019] Secondly, this application provides a wind turbine generator set, including the aforementioned wind turbine blades.

[0020] Thirdly, this application provides a method for forming a wind turbine blade, applied to the aforementioned wind turbine blade, comprising:

[0021] The outer shell material, the web, and the trailing edge auxiliary beam are sequentially laid on the forming mold of the blade body;

[0022] A reinforcing material body is laid on at least one side of the web, and the reinforcing material body is connected to the inner wall surface of the shell;

[0023] Establish a vacuum system and a filling system;

[0024] Injection material into the molding mold, and the injection material flows into the outer shell and the reinforcing material;

[0025] The material to be injected has cured and formed the wind turbine blade.

[0026] In one possible implementation, the wind turbine blade forming method provided in this application includes the step of laying a reinforcing material body on at least one side of the web, the reinforcing material body being connected to the inner wall surface of the outer shell, comprising:

[0027] A reinforcing layer is laid on at least one side of the web;

[0028] A core material layer is laid on top of the reinforcing layer;

[0029] A reinforcement layer is then laid on top of the core material layer.

[0030] The wind turbine blade, wind turbine generator set, and wind turbine blade forming method provided in this application include a wind turbine blade comprising a blade body and a reinforcing rib structure. The reinforcing rib structure includes at least one reinforcing rib assembly, which is attached to the inner wall surface of the outer shell. The reinforcing rib assembly avoids the web and trailing edge auxiliary beam of the blade body; that is, it is positioned on at least one side of the web in the chordal direction. The reinforcing rib assembly is spaced apart from the leading edge and trailing edge auxiliary beam of the blade body. This improves the structural strength of the wind turbine blade while avoiding stress concentration at the web and trailing edge auxiliary beam. The reinforcing rib assembly extends along the chordal direction of the blade body and is positioned close to the blade root relative to the blade tip. This improves the chordal stiffness and chordal deformation resistance of the wind turbine blade during operation, thereby reducing the risk of damage during operation and reducing the weight of the wind turbine blade, thus improving the power generation efficiency of the wind turbine generator set. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a schematic diagram of the structure of a wind turbine blade provided in an embodiment of this application;

[0033] Figure 2 This is a schematic diagram showing the connection between the reinforcing rib assembly and the outer shell provided in an embodiment of this application;

[0034] Figure 3 This is a schematic diagram of the core material layer provided in an embodiment of this application;

[0035] Figure 4 for Figure 3 Another structural diagram from a different perspective;

[0036] Figure 5 A cross-sectional view of the blade body provided in the embodiments of this application. Figure 1 ;

[0037] Figure 6 A cross-sectional view of the blade body provided in the embodiments of this application. Figure 2 ;

[0038] Figure 7 A flowchart illustrating the wind turbine blade forming method provided in this application embodiment. Figure 1 ;

[0039] Figure 8A flowchart illustrating the wind turbine blade forming method provided in this application embodiment. Figure 2 .

[0040] Explanation of reference numerals in the attached figures:

[0041] 100 - Blade body;

[0042] 110 - Outer shell; 111 - Inner wall surface;

[0043] 120-webbed plate;

[0044] 130 - Rear edge auxiliary beam;

[0045] 140 - Blade inner cavity;

[0046] 200 - Reinforcing rib structure;

[0047] 210 - Reinforcing rib assembly; 211 - Core material layer; 2111 - First surface; 2112 - Second surface; 2113 - First connecting part; 212 - Reinforcing unit; 213 - Deformation groove; 214 - Permeation hole; 215 - Reinforcing layer; 216 - Reinforcing rib; 217 - Chamfer;

[0048] X - chordal direction; Y - thickness direction of the blade body; Z - axial direction.

[0049] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0050] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the preferred embodiments of this application will be described in more detail below with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0051] It should be noted that in the description of the embodiments of this application, the terms "upper", "lower", "inner", "outer" and other terms indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of description, and do not indicate or imply that the device or component must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the embodiments of this application.

[0052] Furthermore, it should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0053] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "fixation," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0054] Wind turbine blades are typically used to capture wind energy and convert it into mechanical energy, which is then converted into electrical energy by a generator in a wind turbine. A wind turbine blade consists of a blade shell, within which the main beam area has a web structure. The hollow areas on either side of the web structure are divided into the leading edge and trailing edge regions of the blade. With the continuous development of the wind power industry, the size of wind turbine blades is constantly increasing, and the space in their leading and trailing edge regions is also constantly increasing, exacerbating the "breathing" effect and thus increasing the risk of damage to the blade during operation.

[0055] In related technologies, the tangential stiffness and tangential deformation resistance of the blade during operation are typically improved by increasing the thickness of the core material or the amount of fiber material used in the blade shell, thereby reducing the risk of damage to the blade during operation. However, this method leads to a significant increase in blade weight, and excessively heavy blades can affect the power generation efficiency of wind turbine generators.

[0056] In view of this, the wind turbine blade, wind turbine generator set, and wind turbine blade forming method provided in this application include a wind turbine blade comprising a blade body and a reinforcing rib structure. The reinforcing rib structure includes at least one reinforcing rib assembly, which is attached to the inner wall surface of the outer shell. The reinforcing rib assembly avoids the web and trailing edge auxiliary beam of the blade body; that is, the reinforcing rib assembly is positioned on at least one side of the web in the chordal direction. The reinforcing rib assembly is spaced apart from the leading edge and trailing edge auxiliary beam of the blade body. This improves the structural strength of the wind turbine blade while avoiding stress concentration at the web and trailing edge auxiliary beam. The reinforcing rib assembly extends along the chordal direction of the blade body and is positioned close to the blade root relative to the blade tip. This improves the chordal rigidity and chordal deformation resistance of the wind turbine blade during operation, thereby reducing the risk of damage during operation and reducing the weight of the wind turbine blade, thus improving the power generation efficiency of the wind turbine generator set.

[0057] The present application will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0058] See Figures 1 to 6 This application provides a wind turbine blade, including a blade body 100 and a reinforcing rib structure 200. The blade body 100 includes an outer shell 110, a web 120, and a trailing edge auxiliary beam 130. The outer shell 110 encloses a blade inner cavity 140. The web 120 and the trailing edge auxiliary beam 130 are both disposed within the blade inner cavity 140, and are spaced apart along the chordal direction X of the blade body 100. The reinforcing rib structure 200 is disposed within the blade inner cavity 140 and includes a reinforcing rib assembly 210 extending along the chordal direction X.

[0059] Among them, the web plate 120 is provided with a reinforcing rib assembly 210 on at least one side in the chord direction X. The reinforcing rib assembly 210 is spaced apart from the leading edge end and the trailing edge auxiliary beam 130 of the blade body 100. The reinforcing rib assembly 210 is attached to at least part of the inner wall surface 111 of the outer shell 110 and connected to the outer shell 110. The reinforcing rib assembly 210 is located near the blade root of the blade body 100 relative to the blade tip of the blade body 100.

[0060] It should be noted that the outer shell 110 serves as the cladding layer for the wind turbine blade, forming a closed blade cavity 140 through an enclosure. The outer shell 110 is typically made of high-strength, lightweight, and corrosion-resistant materials, such as glass fiber reinforced plastic or carbon fiber reinforced plastic.

[0061] Both the web 120 and the trailing edge auxiliary beam 130 are located within the blade cavity 140 and are spaced apart along the chordal direction X of the blade body 100. The web 120 may be located in the middle of the blade cavity 140 and extend along the axial direction Z of the blade body 100. The web 120 is used to bear the bending and shear stresses generated by the blade body 100 during operation, ensuring the overall rigidity and stability of the blade body 100. The trailing edge auxiliary beam 130 may be an auxiliary support structure located at the trailing edge of the blade body 100, which, together with the web 120, enhances the strength and rigidity of the blade body 100. This arrangement ensures that the load is evenly distributed when the blade body 100 is under stress, improving the overall load-bearing capacity of the blade body 100.

[0062] To further enhance the structural strength of the wind turbine blade, a reinforcing rib assembly 210 is provided on at least one side of the web 120 in the chordal direction X. Optionally, the reinforcing rib assembly 210 can be provided between the trailing edge auxiliary beam 130 and the web 120, or between the leading edge and the web 120. Alternatively, the reinforcing rib assembly 210 can be provided both between the trailing edge auxiliary beam 130 and the web 120 and between the leading edge and the web 120. The reinforcing rib assembly 210 extends along the chordal direction X of the blade body 100 to improve the chordal rigidity and chordal deformation resistance of the blade body 100, thereby reducing the risk of damage to the wind turbine blade during operation.

[0063] Optionally, the reinforcing rib assembly 210 may protrude from the inner wall surface 111 of the outer shell 110. Along the thickness direction Y of the blade body 100, or along the arrangement direction of the windward and leeward sides of the blade body 100, the reinforcing rib assembly 210 may be located on one side of the windward side and protrude from the inner wall surface of the outer shell 110 towards the leeward side. Alternatively, the reinforcing rib assembly 210 may be located on one side of the leeward side and protrude from the inner wall surface of the outer shell 110 towards the windward side. Of course, the outer shell 110 may also have reinforcing rib assemblies 210 at both the windward and leeward sides.

[0064] In addition, the blade body 100 is usually provided with a main beam. When the reinforcing rib assembly 210 is installed, the reinforcing rib assembly 210 is attached to the inner wall surface 111 of the outer shell 110. The reinforcing rib assembly 210 can avoid the web 120, trailing edge auxiliary beam 130 and main beam of the blade body 100. This can improve the structural strength of the wind turbine blade, avoid stress concentration at the web 120, trailing edge auxiliary beam 130 and main beam, and prevent it from affecting the bonding mold of the wind turbine blade.

[0065] It should be noted that the reinforcing rib assembly 210 is positioned closer to the blade root than the blade tip of the blade body 100. During operation, wind turbine blades are subjected to the dynamic forces of wind, generating bending moments and shear forces. These bending moments and shear forces are mainly concentrated in the root region of the blade body 100. Therefore, by configuring the reinforcing rib assembly 210 in this way, the structural rigidity and strength of the blade body 100 can be improved, thereby reducing the risk of wind turbine blade deformation or damage caused by excessive wind force.

[0066] Furthermore, compared to related technologies that improve the chordal rigidity and chordal deformation resistance of the blade during operation by increasing the core material thickness or fiber material usage of the blade shell, the reinforcing rib assembly 210 provided in this application can relatively reduce the weight of the wind turbine blade.

[0067] See Figure 2 and Figure 3 In some embodiments, the reinforcing rib assembly 210 includes a core material layer 211, which includes a plurality of reinforcing units 212. Each reinforcing unit 212 is connected in sequence, and each adjacent reinforcing unit 212 has a degree of freedom of movement at the connection position, so that the inclination angle of the side surface of each reinforcing unit 212 facing the inner wall surface 111 is adapted to and fitted to the corresponding position of the inner wall surface 111.

[0068] Understandably, the connection point between two adjacent reinforcing units 212 is provided with a degree of freedom of movement, allowing them to have a certain relative movement capability at the connection point. This enables each reinforcing unit 212 to be finely adjusted according to the specific shape and curvature of the inner wall surface 111, thereby achieving a closer fit with the inner wall surface 111. When the side surface of the reinforcing unit 212 facing the inner wall surface 111 of the blade contacts the corresponding position of the inner wall surface 111, due to the degree of freedom of movement, the reinforcing unit 212 can adjust its tilt angle to ensure a close fit with the inner wall surface 111.

[0069] Optionally, the degrees of freedom of motion may include rotational degrees of freedom and / or translational degrees of freedom.

[0070] The reinforcing units 212 can be arranged at equal intervals along the axial direction Z and the chordal direction X of the blade body 100. Alternatively, the spacing between the reinforcing units 212 can be adjusted appropriately according to the shape of the blade body 100 and the stress conditions. For example, in areas with high stress, such as near the blade root of the blade body 100, the spacing between the reinforcing units 212 can be appropriately reduced to increase the strength and stiffness of the blade root region. In areas with low stress, the spacing between the reinforcing units 212 can be appropriately increased to reduce the weight of the blade body 100 and lower manufacturing costs.

[0071] Furthermore, the flexible connection between the reinforcing units 212 allows for a more even distribution of stress across the entire reinforcing rib assembly 210 under load, preventing localized overload. This not only improves the load-bearing capacity of the wind turbine blades but also extends their service life, thereby ensuring the stable operation of the wind turbine generator set.

[0072] Optionally, the thickness of the core layer 211 can be set to 5mm-80mm.

[0073] See Figure 3 and Figure 4 In some embodiments, the core material layer 211 is provided with a plurality of deformation grooves 213, which divide the core material layer 211 into a plurality of reinforcing units 212 and a first connecting portion 2113 connecting two adjacent reinforcing units 212.

[0074] Specifically, before installing the reinforcing rib assembly 210, a deformation groove 213 can be formed in the core material layer 211. The deformation groove 213 extends along the thickness direction of the core material layer 211 to the first connecting portion 2113. The thickness of the first connecting portion 2113 in the thickness direction of the core material layer 211 can be set to 1mm-2mm. This setting not only ensures the structural continuity between the reinforcing units 212, but also gives the core material layer 211 a certain degree of deformation capability. In this way, the reinforcing unit 212 can more flexibly adjust its position and tilt angle when it is attached to the inner wall surface 111, thereby achieving a tighter fit.

[0075] Optionally, the core layer 211 can be at least one of balsa wood core layer 211 and foam core layer 211. Both balsa wood core layer 211 and foam core layer 211 have low density, which helps to reduce the weight of the reinforcing rib assembly 210 and even the wind turbine blade, thereby reducing the overall load of the wind turbine generator and improving operating efficiency. Furthermore, both balsa wood core layer 211 and foam core layer 211 have good mechanical properties and stability, which can effectively disperse and absorb the stress generated by the wind turbine blade during operation while ensuring strength, reducing the risk of wind turbine blade damage and extending the service life of the wind turbine blade.

[0076] When the core material layer 211 includes a balsa wood core material layer 211, the length of the reinforcing unit 212 in the axial direction Z of the blade body 100 can be 48mm-52mm, and the width can be 23mm-27mm. When the core material layer 211 includes a foam core material layer 211, the reinforcing unit 212 can be 30±2mm*30±2mm. This configuration can improve the deformability of the core material layer 211, thereby enhancing the adhesion effect with the inner wall surface 111.

[0077] By setting the deformation groove 213, it can be ensured that the stress of the reinforcing rib assembly 210 can be distributed more evenly when under force, reducing the risk of damage to the reinforcing rib assembly 210, while improving the structural stability and load-bearing capacity of the entire wind turbine blade. Furthermore, the setting of the deformation groove 213 makes the strength of the reinforcing rib assembly 210 at the first connection 2113 position less than the strength at the reinforcing unit 212 position. When the side surface of the reinforcing unit 212 facing the inner wall surface 111 of the blade contacts the corresponding position of the inner wall surface 111, it is convenient to adjust the relative position of the two adjacent reinforcing units 212 to ensure the fit requirements with the inner wall surface 111.

[0078] See Figure 4 In some embodiments, the core layer 211 has a first surface 2111 and a second surface 2112 opposite to each other along its own thickness direction, the first surface 2111 being disposed toward the inner wall surface 111; each deformation groove 213 has a predetermined groove depth in the direction of the second surface 2112 toward the first surface 2111, and at least some of the deformation grooves 213 are arranged at intervals along the chordal direction X, and / or, at least some of the deformation grooves 213 are arranged at intervals along the axial direction Z of the blade body 100.

[0079] It should be noted that each deformation groove 213 has a predetermined groove depth in the direction from the second surface 2112 toward the first surface 2111. This allows the core material layer 211 to have deformability, thereby improving the fit with the inner wall surface 111. It also ensures that the deformation groove 213 can absorb and disperse stress in an orderly manner when under force, avoiding stress concentration that could lead to damage. Furthermore, the first connecting portion 2113 can be located on the side where the first surface 2111 is located, so that the core material layer 211 can adapt to the curvature of the inner wall surface 111, while ensuring the connection strength between the core material layer 211 and the inner wall surface 111.

[0080] Optionally, the deformation grooves 213 can be configured to be interwoven in the chordal direction X and the axial direction Z of the blade body 100.

[0081] In some embodiments, a permeation groove (not shown in the figure) is formed on the side where at least one of the first surface 2111 and the second surface 2112 is located. The permeation groove extends along the thickness direction and is staggered from the deformation groove 213.

[0082] Optionally, the reinforcing rib structure 200 can be integrally cast with the blade body 100, or it can be connected to the blade body 100 by hand lay-up molding or secondary bonding.

[0083] When the reinforcing rib structure 200 is integrally cast with the blade body 100, a permeation groove can be formed on the side where the first surface 2111 is located, or on the side where the second surface 2112 is located, or on the side where both the first surface 2111 and the second surface 2112 are located. The permeation groove extends along the thickness direction of the core material layer 211, providing a flow channel for the resin and other injection materials.

[0084] Optionally, multiple permeation tanks can be set, and the depth of the permeation tanks can be set to 1mm-2mm.

[0085] Furthermore, the infiltration groove can be staggered from the deformation groove 213, allowing the resin and other injection materials to pass through the infiltration groove more smoothly and penetrate deeper into the core material layer 211 during the injection process. This facilitates the integral injection molding of the reinforcing rib structure 200 and the blade body 100. This arrangement not only improves injection efficiency but also enhances injection quality. The resin and other injection materials can more fully impregnate the core material layer 211, forming a tighter and stronger bond, thus strengthening the connection between the core material layer 211 and the blade body 100.

[0086] In some embodiments, the permeation channel includes at least one of a unidirectional parallel channel and a bidirectional intersecting channel.

[0087] The unidirectional parallel grooves can be understood as permeation grooves arranged in parallel along the same direction. Optionally, each permeation groove can be arranged parallel along the axial direction of the blade body 100 or parallel along the chordal direction of the blade body 100. By setting the unidirectional parallel grooves, the injection material can be guided to flow in a predetermined direction, reducing the resistance of the injection material during the flow process, thereby improving the injection speed and efficiency.

[0088] Furthermore, the permeation channels may include bidirectional cross channels, which can be understood as two permeation channels arranged in a cross configuration. This arrangement provides more flow channels for the injection material, allowing it to flow freely in multiple directions within the core layer 211. The bidirectional cross channels also more effectively promote uniform wetting of the injection material, contributing to improved permeability and diffusion.

[0089] Optionally, the cross angle of the bidirectional cross groove can be set to 30°-90°. The purpose is to select an angle close to the fiber angle to reduce the risk of stress concentration caused by the deviation between the resin angle and the fiber angle in the bidirectional cross groove, and at the same time, it can play an auxiliary role in penetration and wetting.

[0090] See Figure 3 and Figure 4 In some embodiments, the core material layer 211 has permeation holes 214 along its own thickness direction. The permeation holes 214 connect the first surface 2111 and the second surface 2112. The permeation holes 214 are staggered from the deformation groove 213.

[0091] Understandably, the permeation holes 214 provide a direct and efficient injection channel for the injection material, enabling the injection material to smoothly penetrate from the second surface 2112 to the first surface 2111, thereby ensuring complete wetting of the core material layer 211, improving the efficiency of the injection process, and also enhancing the overall strength and stability of the core material layer 211.

[0092] Furthermore, the staggered arrangement of the permeation holes 214 and the deformation grooves 213 helps to improve the overall mechanical properties and stability of the core layer 211. During the injection process, due to the presence of the permeation holes 214, the injection material can be more evenly distributed within the core layer 211, forming a tighter and stronger bond. This not only enhances the strength and toughness of the core layer 211 but also helps to improve its resistance to deformation. At the same time, the staggered arrangement of the permeation holes 214 and the deformation grooves 213 reduces potential stress concentration points caused by concentrated or uneven distribution of the injection material, further improving the overall reliability and service life of the core layer 211.

[0093] Optionally, the pore size of the permeation hole 214 can be set to 1mm-2mm, for example, the pore size can be 1.4mm, 1.5mm, or 1.6mm.

[0094] It is understood that the above embodiments are all illustrated by taking the example of providing multiple deformation grooves 213 on the core material layer 211 so that two adjacent reinforcing units 212 have degrees of freedom of movement at their connection positions.

[0095] In some other embodiments, multiple reinforcing units 212 may be spaced apart from each other and arranged independently. The reinforcing rib assembly 210 also includes a flexible connector disposed on one end face of the core material layer 211 in its thickness direction and connecting at least two reinforcing units 212.

[0096] Specifically, the core material layer 211 can be cut into multiple independently arranged reinforcing units 212. To further improve the stability and continuity of the reinforcing rib assembly 210, the reinforcing rib assembly 210 is provided with a flexible connector. The reinforcing unit 212 can be attached to the flexible connector, and can be attached to the side of the flexible connector opposite to the inner wall surface 111, so that each reinforcing unit 212 can be finely adjusted according to the specific shape and curvature of the inner wall surface 111, thereby achieving a tighter fit with the inner wall surface 111.

[0097] Alternatively, the flexible connector may include fibrous fabric.

[0098] See Figure 2In some embodiments, the reinforcing rib assembly 210 further includes a reinforcing layer 215 disposed on the outer peripheral surface of the core material layer 211. The reinforcing layer 215 includes at least one of a fiber fabric and a laminate, and the reinforcing layer 215 is connected to the inner wall surface 111.

[0099] By adding a reinforcing layer 215 to the outer peripheral surface of the core layer 211, the overall strength and stability of the reinforcing rib assembly 210 can be further improved. Optionally, the reinforcing layer 215 may include at least one of fiber fabric and laminate.

[0100] The fiber fabric is made of interwoven fiber bundles, which can be made of carbon fiber, glass fiber, or other high-performance fiber materials. The fiber fabric not only provides good tensile and shear strength, but also effectively disperses and resists external loads in multiple directions, thereby improving the overall structural stiffness of the reinforcing rib assembly 210.

[0101] Optionally, the fiber fabric can be single-layered or multi-layered, and can be uniaxial or biaxial fibers. When using multi-layered fibers, a delamination process is required. This delamination process can be understood as staggering the multi-layered fiber fabric in both length and width by a predetermined length to avoid the formation of thickness steps due to the stacking of multiple layers, which could lead to stress concentration and crack formation.

[0102] Laminated boards are typically made by bonding multiple layers of thin sheets together, thus achieving good flexural strength and fatigue resistance while maintaining lightweight properties.

[0103] See Figure 5 and Figure 6 In some embodiments, the blade body 100 has a maximum chord length position between the leading edge and the trailing edge, and the reinforcing rib assembly 210 extends axially along the blade body 100 and covers at least a portion of the maximum chord length position.

[0104] Specifically, the maximum chord length position can be understood as the position where the blade body 100 has the maximum width in the chordal direction X. During the operation of the wind turbine blade, the pressure distribution generated by the wind on the surface of the wind turbine blade is uneven. Near the maximum chord length position, due to the increase in blade width, the wind pressure also increases, resulting in the maximum chord length position bearing greater positive pressure. In order to improve the strength and stability of the maximum chord length position, the reinforcing rib assembly 210 extends along the axial direction Z of the blade body 100 to cover at least a portion of the maximum chord length position, effectively enhancing the load-bearing capacity of the blade body 100 at the maximum chord length position, thereby extending the service life of the blade and improving the reliability and efficiency of the wind turbine generator set.

[0105] In some embodiments, see Figure 5The stiffener assembly 210 includes a stiffener 216 having a first width in the axial direction Z of the blade body 100, such that the stiffener 216 covers at least a portion of the location of the maximum chord length; or, see Figure 6 The reinforcing rib assembly 210 includes two or more reinforcing ribs 216, the two or more reinforcing ribs 216 having a second width in the axial direction Z, and the two or more reinforcing ribs 216 being arranged sequentially along a predetermined gap in the axial direction Z.

[0106] For example, the stiffener assembly 210 may include a stiffener 216 having a first width in the axial direction Z, ensuring that the stiffener 216 can cover at least a portion of the maximum chord length position, thereby effectively improving the strength and stability of the maximum chord length position. Optionally, the first width may account for 5%-75% of the length of the blade body 100, and can be set according to the specifications and structure of the wind turbine blade in specific implementations.

[0107] In other embodiments, the stiffener assembly 210 may also include two or more stiffeners 216. Each stiffener 216 has a second width in the axial direction Z and is arranged sequentially along a predetermined gap. By using multiple stiffeners 216 in combination, the stress and strain experienced by the blade at the maximum chord length position can be further dispersed and resisted, thereby improving the overall load-bearing capacity and stability of the blade. The second width is smaller than the first width, and the setting of the second width and the predetermined gap can be configured according to the specifications and structure of the wind turbine blade, which is not limited herein.

[0108] See Figure 2 In some embodiments, the end of the reinforcing rib assembly 210 facing away from the inner wall surface 111 is provided with a chamfer 217.

[0109] It is understandable that during the long-term operation of wind turbine blades, they will be subjected to various mechanical loads. These loads will generate stress and strain inside the blade body 100. By setting the chamfer 217, the stress and strain can be alleviated to a certain extent, reducing the risk of fatigue damage and thus extending the service life of the wind turbine blade.

[0110] Based on the above embodiments, this application provides a wind turbine generator set, including the wind turbine blades provided in any of the above embodiments.

[0111] The structure of the wind turbine blades has been described in detail in the above embodiments and will not be repeated here.

[0112] See Figure 7 Based on the above embodiments, this application provides a wind turbine blade forming method, applicable to the wind turbine blades provided in any of the above embodiments. The wind turbine blade forming method may include the following steps:

[0113] Step S101: Lay the outer shell material, the web plate 120 and the trailing edge auxiliary beam 130 sequentially on the forming mold of the blade body 100.

[0114] In practice, the surface of the molding mold is first cleaned, a release agent is applied, and a release cloth is laid on the surface of the molding mold. Then, the outer shell material (such as the outer skin) is laid on the surface of the molding mold in sequence, and the prefabricated structural components such as the web plate 120 and the rear edge auxiliary beam 130 are placed using a lifting device.

[0115] Step S102: Lay a reinforcing material body on at least one side of the web 120, the reinforcing material body being connected to the inner wall surface 111 of the outer shell 110.

[0116] Specifically, the reinforcing material is laid above the outer shell material, along the chordal boundary positioning line of the reinforcing material body.

[0117] Step S103: Establish the vacuum system and the injection system.

[0118] Inside the molding die, a perforated release membrane, a flow guide, a glue channel, and a glue inlet are laid sequentially. The glue inlet is connected to an external material inlet pipe. A vacuum material is laid along the front and rear flanges of the molding die, and an external vacuum pump is connected. An absolute pressure gauge is inserted into the vacuum system, and the vacuum membrane is sealed (two layers of vacuum membrane may be used). The vacuum pump is then turned on, and the vacuum value is drawn to a set range. The vacuum pressure drop is tested over a predetermined time. The absolute pressure gauge reading should rise by less than 2 kPa over 15 minutes. Pressure is monitored using a pressure gauge throughout the entire filling process; alternatively, a digital vacuum gauge can be used to maintain pressure. Once the vacuum pressure is ≤-98 kPa and stable, pressure holding begins, and the pressure holding requirement remains unchanged.

[0119] Step S104: Inject injection material into the molding mold, and the injection material flows into the outer shell 110 and the reinforcing material.

[0120] Step S105: The material to be injected is cured to form a wind turbine blade.

[0121] Before pouring, turn on the molding mold heater, set the curing regime, preheat for a certain time, and insulate the predetermined area. After pouring, turn on the molding mold heater according to the curing regime. During the heat release process of the pouring material, perform water bath cooling on the surface of the molding mold. After the heat release peak has passed, cover the entire area with cotton blankets for insulation. The insulation requirement is that after the outer shell 110 skin reaches the specified temperature, it is kept at that temperature for a specified time. After the blade root area and bonding angle of the blade body 100 are completely cured, the curing is confirmed to be complete.

[0122] Optionally, the infusion material can be a resin material, but this application does not limit it.

[0123] The wind turbine blade forming method provided in one embodiment of this application can meet the forming requirements of the blades provided in the above embodiments, so that the formed wind turbine blades have the advantage of good structural performance. At the same time, the forming method can use the same injection system to realize the synchronous forming of the reinforcing rib structure and the blade body, reducing the forming difficulty and production cost of wind turbine blades.

[0124] See Figure 8 In some embodiments, the step of laying a reinforcing material body on at least one side of the web 120, the reinforcing material body communicating with the inner wall surface 111 of the outer shell 110, may include the following steps:

[0125] S201: A reinforcing layer 215 is laid on at least one side of the web 120.

[0126] S202: Lay the core material layer 211 on the reinforcing layer 215.

[0127] S203: A reinforcing layer 215 is laid on the core material layer 211.

[0128] Specifically, the reinforcing material body can be understood as the reinforcing rib assembly 210 provided in any of the above embodiments before preforming. During the molding process, a reinforcing layer 215 can be laid first, then a core material layer 211 can be laid on the reinforcing layer 215, and then another reinforcing layer 215 can be laid. This arrangement can improve the structural strength of the reinforcing material body.

[0129] In addition, the reinforcing material can also be connected to the inner wall surface 111 of the outer shell 110 by hand lay-up or secondary adhesive bonding.

[0130] When using hand lay-up molding, clean the surface of the outer shell 110 skin, remove the release cloth corresponding to the tangential reinforcing material area, or sand the interface. Above the skin of the outer shell 110, along the tangential boundary positioning line of the reinforcing material, sequentially lay up the reinforcing layer 215, the core material layer 211, and the reinforcing layer 215 above the core material layer 211. The hand lay-up molding process can also be replaced by a prepreg process. After the hand lay-up is completed, heat the reinforcing material area for a predetermined time. After passing the test, perform the mold closing operation of the outer shell 110 skin.

[0131] When using a two-stage bonding process, clean the surface of the outer shell 110's skin, remove the release cloth from the area corresponding to the chordal reinforcing rib assembly 210, or sand down the interface. Above the skin of the outer shell 110, along the chordal boundary positioning line of the reinforcing rib assembly 210, bond the pre-formed reinforcing rib assembly 210 to the skin. The adhesive thickness must meet the adhesive thickness requirements. After bonding, heat the area of ​​the reinforcing rib assembly 210 for a predetermined time. After passing the test, perform the outer shell 110 skin mold closing operation.

[0132] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A wind turbine blade, characterized in that, include: The blade body (100) includes a shell (110), a web (120), and a trailing edge auxiliary beam (130). The shell (110) surrounds and forms a blade cavity (140). The web (120) and the trailing edge auxiliary beam (130) are both disposed in the blade cavity (140), and the web (120) and the trailing edge auxiliary beam (130) are spaced apart along the chordal direction (X) of the blade body (100). A reinforcing rib structure (200) is disposed in the inner cavity (140) of the blade. The reinforcing rib structure (200) includes a reinforcing rib assembly (210) which extends along the chordal direction (X). The web (120) has a reinforcing rib assembly (210) on at least one side in the chordal direction (X). The reinforcing rib assembly (210) is spaced apart from the leading edge and trailing edge auxiliary beam (130) of the blade body (100). The reinforcing rib assembly (210) is attached to at least part of the inner wall surface (111) of the outer shell (110) and connected to the outer shell (110). The reinforcing rib assembly (210) is located near the blade root of the blade body (100) relative to the blade tip. The reinforcing rib assembly (210) includes a core material layer (211). The core material layer (211) includes a plurality of reinforcing units (212) and a plurality of deformation grooves (213). The plurality of deformation grooves (213) divide the core material layer (211) to form a plurality of reinforcing units (212) and a first connecting portion (2113) connecting two adjacent reinforcing units (212). The core material layer (211) has a first surface (2111) and a second surface (2112) opposite to each other along its thickness direction. At least one of the first surface (2111) and the second surface (2112) is provided with a permeation groove. The permeation groove extends along the thickness direction. The permeation groove is offset from the deformation groove (213), and the depth of the permeation groove is less than the depth of the deformation groove (213).

2. The wind turbine blade according to claim 1, characterized in that, The first surface (2111) is disposed facing the inner wall surface (111); Each of the deformation grooves (213) has a predetermined groove depth in the direction of the second surface (2112) toward the first surface (2111), and at least some of the deformation grooves (213) are spaced apart along the chordal direction (X), and / or at least some of the deformation grooves (213) are spaced apart along the axial direction (Z) of the blade body (100).

3. The wind turbine blade according to claim 1, characterized in that, The permeation tank includes at least one of a unidirectional parallel tank and a bidirectional intersecting tank.

4. The wind turbine blade according to claim 1, characterized in that, The core material layer (211) has permeation holes (214) along its thickness direction. The permeation holes (214) connect the first surface (2111) and the second surface (2112). The permeation holes (214) are offset from the deformation groove (213).

5. The wind turbine blade according to claim 1, characterized in that, The reinforcing rib assembly (210) further includes a reinforcing layer (215) disposed on the outer peripheral surface of the core material layer (211), the reinforcing layer (215) including at least one of fiber fabric and laminate, and the reinforcing layer (215) being connected to the inner wall surface (111).

6. The wind turbine blade according to any one of claims 1 to 5, characterized in that, The blade body (100) has a maximum chord length position between its leading edge and trailing edge, and the reinforcing rib assembly (210) extends axially along the blade body (100) and covers at least a portion of the maximum chord length position.

7. The wind turbine blade according to claim 6, characterized in that, The reinforcing rib assembly (210) includes a reinforcing rib (216) having a first width in the axial direction (Z) of the blade body (100) such that the reinforcing rib (216) covers at least a portion of the maximum chord length position; Alternatively, the reinforcing rib assembly (210) may include two or more reinforcing ribs (216), the two or more reinforcing ribs (216) having a second width in the axial direction (Z), and the two or more reinforcing ribs (216) being arranged sequentially along a predetermined gap in the axial direction (Z).

8. The wind turbine blade according to any one of claims 1 to 5, characterized in that, The reinforcing rib assembly (210) has a chamfer (217) at the end facing away from the inner wall surface (111).

9. A wind turbine generator set, characterized in that, Including the wind turbine blades as described in any one of claims 1 to 8.

10. A method for forming a wind turbine blade, applied to the wind turbine blade as described in any one of claims 1 to 8, characterized in that, include: On the molding die of the blade body (100), the outer shell material, the web plate (120) and the trailing edge auxiliary beam (130) are laid in sequence; A reinforcing material body is laid on at least one side of the web (120), the reinforcing material body being connected to the inner wall surface (111) of the outer shell (110); Establish a vacuum system and a filling system; Injection material into the molding die, the injection material flowing into the outer shell (110) and the reinforcing material; After the injection material has cured, the wind turbine blade is formed. The step of laying the reinforcing material body on at least one side of the web (120), the reinforcing material body being in communication with the inner wall surface (111) of the outer shell (110), includes: A reinforcing layer is laid on at least one side of the web (120); A core material layer (211) is laid on the reinforcing layer (215). The reinforcing rib assembly (210) includes a core material layer (211). The core material layer (211) includes a plurality of reinforcing units (212) and a plurality of deformation grooves (213). The plurality of deformation grooves (213) divide the core material layer (211) into a plurality of reinforcing units (212) and a first connecting portion (2113) connecting two adjacent reinforcing units (212). The core material layer (211) has a first surface (2111) and a second surface (2112) opposite to each other along its own thickness direction. At least one of the first surface (2111) and the second surface (2112) is provided with a permeation groove. The permeation groove extends along the thickness direction. The permeation groove is staggered from the deformation groove (213), and the groove depth of the permeation groove is less than the groove depth of the deformation groove (213). A reinforcing layer (215) is then laid on the core material layer (211).

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