Die and manufacturing method thereof, web plate manufacturing method, web plate and wind generating set

Abstract

The invention relates to a mold and a manufacturing method thereof, a web plate manufacturing method, a web plate and a wind generating set, and the mold comprises a supporting part which is provided with a supporting surface, and the supporting surface extends in the first direction; the main body part is arranged on the supporting surface and extends in the first direction; the flange part extends in the first direction and is arranged on at least one side of the main body part in the second direction, the first direction intersects with the second direction, the flange part and the main body part jointly define a flange forming cavity, the flange forming cavity is provided with an opening formed in the second direction, the flange part is made of an elastic material, and the hardness of the flange part is lower than that of the main body part; the flange part has a first state and a second state and can be switched between the first state and the second state through elastic deformation; wherein the area of the opening in the second state is larger than that of the opening in the first state. According to the mold, the machining efficiency and the product yield can be improved.

Description

Technical Field

[0001] The present application relates to the technical field of wind power generation, and in particular to a mold and a manufacturing method thereof, a web manufacturing method, a web and a wind power generator set. Background Art

[0002] In existing wind turbines, blades are an important component. In order to ensure that longer blades have good structural strength, a web is usually provided inside the blade. The web is usually connected to the inner surface of the blade shell and used to provide support. On this basis, the web usually includes a main body and flanges at both ends of the main body for connection with the shell. As large blades continue to pursue better aerodynamic shapes, the curvature of the curved surface in the main beam area is gradually increasing. Therefore, the angle between the web bonding flange that is arranged in accordance with the main beam area and the web body is also changing more and more. It is easy to have a problem that the angle is too small, resulting in the web being difficult to demold after forming.

[0003] Therefore, there is an urgent need for a mold that can improve production efficiency and product yield, as well as a corresponding mold manufacturing method, a web manufacturing method, a web and a wind turbine generator set. Summary of the invention

[0004] The embodiments of the present application provide a mold and a method for manufacturing the same, a web manufacturing method, a web and a wind turbine generator set, wherein the mold can improve processing efficiency and product yield.

[0005] In the first aspect, according to an embodiment of the present application, a mold is proposed, which is applied to a web, including: a support portion, having a support surface, which extends along a first direction; a main body portion, which is arranged on the support surface and extends along the first direction; a flange portion, which extends along the first direction and is arranged on at least one side of the main body portion in a second direction, the first direction intersects with the second direction, the flange portion and the main body portion together enclose a flange forming cavity, the flange forming cavity has an opening arranged along the second direction, the flange portion is made of an elastic material and the hardness of the flange portion is lower than the hardness of the main body portion, the flange portion has a first state and a second state and can switch between the first state and the second state through elastic deformation; wherein the area of ​​the opening in the second state is larger than the area of ​​the opening in the first state.

[0006] According to one aspect of an embodiment of the present application, the flange portion includes two sub-portions, and the two sub-portions are respectively arranged on two opposite sides of the main body portion in the second direction; the two sub-portions are respectively provided with flange forming cavities, and the openings of the two flange forming cavities are arranged opposite to each other.

[0007] According to one aspect of an embodiment of the present application, the main body has a first profile on the side facing away from the support portion, and the flange has a second profile. At least part of the first profile and the second profile together enclose a flange forming cavity, and at least one side edge of the opening is located on the first profile.

[0008] According to one aspect of an embodiment of the present application, the second mold surface is provided with a guide groove connected to the flange forming cavity, the notch of the guide groove is provided on the second mold surface, and the guide groove is recessed in a direction away from the flange forming cavity, and the guide groove extends along the first direction.

[0009] According to one aspect of an embodiment of the present application, in a cross section perpendicular to the first direction, a cross-sectional shape formed by the guide groove is semicircular, and a radius of the guide groove is 1 mm to 4 mm.

[0010] According to one aspect of the embodiment of the present application, the second molding surface is provided with a plurality of protrusions that protrude in a direction close to the flange molding cavity, and the protrusions extend along the first direction.

[0011] According to one aspect of the embodiment of the present application, in a cross section perpendicular to the first direction, a cross-sectional shape formed by the protrusion is semicircular or semi-elliptical, and a protrusion size of the protrusion is 1 mm to 4 mm.

[0012] According to one aspect of the embodiment of the present application, the flange portion contains at least one of silicone and rubber, and the hardness of the flange portion is 50HD to 55HD.

[0013] In the second aspect, according to an embodiment of the present application, a method for manufacturing a mold is proposed, including: providing a support portion and a main body portion, and connecting the main body portion to the support portion; providing a flange portion mold and an elastic substrate, and filling the elastic substrate into the flange portion mold; curing the elastic substrate to obtain a preparatory body; removing the flange portion mold and trimming the preparatory body to obtain a flange portion; and setting the flange portion on a side of the support portion close to the main body portion.

[0014] According to one aspect of an embodiment of the present application, the step of providing a flange mold and an elastic substrate includes: making the flange mold consist of multiple sub-molds, and filling the elastic substrate into the multiple sub-molds respectively; the step of removing the flange mold and trimming the preparation body includes: connecting and setting multiple preparation bodies to assemble to form a flange.

[0015] According to one aspect of an embodiment of the present application, the step of connecting and setting a plurality of prepared bodies includes: bonding and connecting the plurality of prepared bodies; or, the step of connecting and setting a plurality of prepared bodies includes: detachably connecting and setting the plurality of prepared bodies via fasteners.

[0016] According to one aspect of an embodiment of the present application, the step of connecting and setting a plurality of preparations and the step of setting the flange portion on a side of the support portion close to the main body portion also includes: applying a force greater than or equal to 80N to a plurality of interconnected preparations; detecting a plurality of preparations to determine whether plastic deformation and / or dislocation occurs in the plurality of preparations; and removing preparations that have undergone plastic deformation and / or dislocation.

[0017] In a third aspect, according to an embodiment of the present application, a method for manufacturing a web is proposed, comprising: providing a mold in any embodiment of the first aspect; laying molding auxiliary materials and a web structure layer on the main body and in the flange portion, so that the flange portion is in a first state to obtain a matrix to be formed; and solidifying the matrix to be formed to obtain the web.

[0018] According to one aspect of an embodiment of the present application, the steps of laying forming auxiliary materials and a web structure layer on the main body and in the flange part include: adjusting the relative position of the flange part and the main body in the second direction, and setting a limiting structure on the side of the flange part away from the main body; applying a force to the flange part to put the flange part in the second state; laying forming auxiliary materials and a web structure layer on the side of the main body away from the support part and in the flange forming cavity; switching the flange part to the first state.

[0019] According to one aspect of an embodiment of the present application, the steps of laying forming auxiliary materials and a web structural layer on the main body and in the flange part include: removing the flange part to separate the flange part from the support part and the main body; laying forming auxiliary materials and a flange structural layer in the flange part to obtain a flange base; solidifying the flange base to obtain a web flange; moving the flange part and the web flange to the support part together; adjusting the relative position of the flange part and the main body in the second direction, and setting a limiting structure on the side of the flange part away from the main body; laying forming auxiliary materials and a main structural layer on the side of the main body away from the support part to obtain a base to be formed.

[0020] According to one aspect of an embodiment of the present application, the step of laying forming auxiliary materials and a main structural layer on a side of the main body away from the support portion also includes: extending at least a portion of the main structural layer in the second direction to connect with the web flange.

[0021] According to one aspect of an embodiment of the present application, the step of laying molding auxiliary materials and a web structure layer on the main body and in the flange part also includes: making the molding auxiliary materials include an isolation film, a guide net and a vacuum film; the step of curing and molding the substrate to be molded includes: placing the substrate to be molded in a negative pressure state and pouring resin material into it; placing the substrate to be molded in a preset temperature condition to allow it to be cured and molded.

[0022] In a fourth aspect, according to an embodiment of the present application, a web is proposed, which is manufactured by the manufacturing method in any embodiment of the third aspect.

[0023] In a fifth aspect, a wind turbine generator set is proposed according to an embodiment of the present application, comprising the web in any embodiment of the fourth aspect.

[0024] The embodiment of the present application provides a mold for manufacturing a web, the mold includes a support portion, a main body portion and a flange portion, wherein the flange portion is arranged on the side of the main body portion and can be used to form the bonding flange portion of the web. The flange portion is made of a relatively soft elastic material, and can change the structural shape and the opening size of the forming cavity arranged in the flange portion through its own elastic deformation, thereby reducing the possibility of the flange portion causing scratches and wear on the formed web flange, and at the same time, the web flange formed therein can be taken out without disassembly through its own deformation, thereby enabling the mold to be used to form a web with an acute-angle flange while simplifying the processing steps and improving the processing efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The features, advantages and technical effects of exemplary embodiments of the present application will be described below with reference to the accompanying drawings.

[0026] Figure 1 It is a structural schematic diagram of a mold provided by an embodiment of the present application;

[0027] Figure 2 yes Figure 1 A magnified view of the area P shown;

[0028] Figure 3 is a flow chart of a mold manufacturing method provided by an embodiment of the present application;

[0029] Figure 4 is a flow chart of a mold manufacturing method provided by another embodiment of the present application;

[0030] Figure 5 is a flow chart of a web manufacturing method provided by an embodiment of the present application;

[0031] Figure 6 is a flow chart of a web manufacturing method provided by another embodiment of the present application;

[0032] Figure 7 is a flow chart of a web manufacturing method provided by yet another embodiment of the present application;

[0033] Figure 8 It is a schematic diagram of the structure of a wind turbine generator set provided in one embodiment of the present application.

[0034] In the drawings, the same reference numerals are used for the same components. The drawings are not drawn to scale.

[0035] in:

[0036] 100-mould; 200-wind turbine generator set;

[0037] 10-supporting part; 20-main body; 30-flange part;

[0038] 11-support surface; 21-first profile; 31-flange forming cavity; 32-sub-portion; 33-second profile;

[0039] 311- opening; 331- guide groove; 332- protrusion;

[0040] Y - Second direction. DETAILED DESCRIPTION

[0041] The features and exemplary embodiments of various aspects of the present application will be described in detail below. In the detailed description below, many specific details are proposed to provide a comprehensive understanding of the present application. However, it is obvious to those skilled in the art that the present application can be implemented without the need for some of these specific details. The following description of the embodiments is only to provide a better understanding of the present application by illustrating examples of the present application. In the accompanying drawings and the following description, at least some of the known structures and technologies are not shown to avoid unnecessary ambiguity in the present application; and, for clarity, the size of some structures may be exaggerated. In addition, the features, structures or characteristics described below may be combined in one or more embodiments in any suitable manner.

[0042] The directional words appearing in the following description are all directions shown in the figures, and do not limit the specific structures in the molding mold and molding method of this application. In the description of this application, it should also be noted that, unless otherwise clearly specified and limited, the meaning of "multiple" is more than two, and the terms "installation" and "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected or indirectly connected; the directions or positional relationships indicated by the terms "upper", "lower", "left", "right", "inside", "outside", etc. are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to the specific circumstances.

[0043] In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0044] In existing wind turbines, blades are very critical components. In order to ensure that blades with a larger length have good structural strength, the blades are usually provided with main beams in two opposite areas of the shell, and webs are provided between the main beams and inside the blades. The webs usually include a main body and flanges located at both ends of the main body and used to connect to the main beam area. On this basis, the size of the angle between the main body of the web and the flange usually needs to be designed according to the curvature and inclination direction of the main beam area, and there is a possibility that the flange and the main body are at an acute angle.

[0045] On this basis, the applicant found that the existing webs are usually manufactured by vacuum infusion similar to blades. In this method, it is usually necessary to first lay layers on a mold of corresponding shape, and then infuse materials such as resin. When manufacturing the webs with acute angles, the angle may cause the flanges on both sides of the web to be narrow at the bottom and wide at the top, which is not easy to demold after molding.

[0046] In response to the above problems, some existing processing methods adopt the method of setting part of the structure in the mold as a detachable structure, that is, setting a detachable small pad or gasket near the web flange, taking out the web together with the pad / gasket during demoulding, and then removing the pad / gasket, or conversely, first removing the pad / gasket after the web is solidified and formed, and then taking out the formed web, which has cumbersome processing steps and low production efficiency. In addition, the position of the pad / gasket is unstable, which is easy to cause deformation of the ply due to misalignment, and finally leads to problems with the structural strength or surface flatness of the manufactured web.

[0047] In order to solve the above problems, the embodiments of the present application provide a mold and a manufacturing method thereof, a manufacturing method of a web, a web and a wind turbine generator set. The mold can improve processing efficiency and product yield.

[0048] It can be understood that the following embodiments of the present application only illustrate the application of the manufacturing method to the web in a wind turbine blade as an example, but the application of the manufacturing method provided in the embodiments of the present application is not limited to the following embodiments, and can also be used in other situations where there are negative angles in the mold used in the infusion molding process that are difficult to demold, and to protect them.

[0049] In order to better understand this application, Figures 1 to 8 The mold and its manufacturing method, the web manufacturing method, the web and the wind turbine generator set provided in the embodiments of the present application are described in detail.

[0050] Please also read Figures 1 to 2 , Figure 1 is a schematic diagram of the structure of a mold provided by an embodiment of the present application, Figure 2 yes Figure 1Magnified view of area P shown.

[0051] In the first aspect, according to an embodiment of the present application, a mold 100 is proposed, which is applied to a web, including: a support portion 10, having a support surface 11, and the support surface 11 extends along a first direction; a main body portion 20, arranged on the support surface 11 and extending along the first direction; a flange portion 30, extending along the first direction and arranged on at least one side of the main body 20 in a second direction Y, the first direction intersects with the second direction Y, the flange portion 30 and the main body 20 together enclose a flange forming cavity 31, the flange forming cavity 31 has an opening 311 arranged along the second direction Y, the flange portion 30 is made of an elastic material and the hardness of the flange portion 30 is lower than the hardness of the main body 20, the flange portion 30 has a first state and a second state and can switch between the first state and the second state through elastic deformation; wherein, the area of ​​the opening 311 in the second state is larger than the area of ​​the opening 311 in the first state.

[0052] The embodiment of the present application firstly proposes a mold 100 for manufacturing a web, which can be optionally applied to a blade of a wind turbine generator set 200 and used to provide support to the blade from the inside.

[0053] The mold 100 includes a support portion 10 for providing support and fixing, a main body portion 20 for correspondingly forming a main body portion 20 in the middle of the web, and a flange portion 30 for correspondingly forming a connecting flange on at least one side of the web. The support portion 10 can be made of metal material to have good structural strength and load-bearing capacity. The support portion 10 has a support surface 11 for placing the main body portion 20 and the flange portion 30. The support surface 11 can be a flat surface and can be provided with structures for installing limit blocks, fasteners or other related components, such as connection holes.

[0054] The main body 20 and the flange 30 can both be arranged on the support surface 11 to facilitate the joint molding of the web. The main body 20 and the flange 30 can be optionally placed on the support surface 11 and positioned with the assistance of limit blocks to facilitate movement or assembly and disassembly; or, the main body 20 and the flange 30 can be optionally detachably connected to the support portion 10 by fastener connection, clip connection, crimping, etc., so that their relative position is more stable during use; or, one of the main body 20 and the flange 30 can be fixedly connected to the support portion 10 by adhesive connection, etc., while the other can be detachably connected to the support portion 10 or simply placed thereon, so as to stabilize its position and facilitate demoulding of the web after molding.

[0055] The main body 20 is used to form the main body 20 located in the middle of the web, which can be optionally extended along a plane or a curved surface close to a plane, and can be specifically designed according to the specific blade shape to be installed. The main body 20 is arranged on the support surface 11, and extends along the first direction, that is, the length direction of the web to be formed, together with the support surface 11. Except for the bottom surface abutting against the support surface 11, the other surfaces of the main body 20 that are not in contact with the support surface 11 are at least partially arranged in accordance with the shape of the web to be formed.

[0056] Exemplarily, the connection between the web main body portion 20 and the flange portion 30 can be connected by a rounded corner. This position can be selected to correspond to the junction between the top surface and the side surface of the main body portion 20. The top surface and the side surface junction line of the main body portion 20 can be chamfered according to the radius required for the web. In this way, the web formed by the mold 100 can accurately have the corresponding rounded corners, and the error between this position and the design model of the web can be smaller.

[0057] The flange portion 30 is arranged on at least one side of the main body 20 in the second direction Y, that is, the width direction. For example, in an embodiment in which one of the bonding flanges on both sides of the web to be formed has an acute angle with the main body 20 and the other has an obtuse angle with the main body 20, the flange portion 30 can be provided on the side with the acute angle, and the flange with the obtuse angle can be formed together with the web body through the main body 20 on the other side, so that the web as a whole can still be easily demolded.

[0058] The flange part 30 is made of a relatively soft elastic material, which can be elastically deformed under the action of external force, thereby reducing the possibility of damage to the flange part 30 with low strength due to scratches or collisions, thereby improving the product yield. The flange part 30 can be optionally formed with the main body 20 to form a nearly enveloping structure, enclosing the interior of the flange part 30 and part of the space between the flange part 30 and the main body 20 to form a flange forming cavity 31, and the flange forming cavity 31 has an opening 311 connected to the outside along the second direction Y.

[0059] The flange part 30 has a first state and a second state and can switch between the two states through its own elastic deformation. The first state can be selected as the state of the flange part 30 in the process of forming the web or the state without external force. In this state, the flange forming cavity 31 inside it is arranged in accordance with the web to be formed for forming. Correspondingly, the second state can be selected as the state after the flange part 30 is elastically deformed by external force. Specifically, the upper half of the flange part 30 can be opened from the upper edge of the opening 311 in the direction away from the main body 20, so that the area of ​​the opening 311 is expanded until the web flange can be taken out of the flange forming cavity 31.

[0060] By setting the flange part 30 to be made of an elastic material, the flange with a negative angle, that is, an acute angle with the main body of the web, can be easily removed by changing the shape after the internal web is formed, so that the entire web is easy to demold. At the same time, the flange part 30 can easily change its state through external forces, so the formed web can be removed without disassembling the mold 100, thereby improving processing efficiency.

[0061] In some optional embodiments, the flange portion 30 includes two sub-portions 32, and the two sub-portions 32 are respectively arranged on two opposite sides of the main body portion 20 in the second direction Y; the two sub-portions 32 are respectively provided with flange forming cavities 31, and the openings 311 of the two flange forming cavities 31 are relatively arranged.

[0062] Optionally, the flange portion 30 may include two sub-portions 32 arranged relatively to each other in the second direction Y, and the two sub-portions 32 are respectively located on the opposite sides of the main body portion 20 and are respectively used to form the flange portions 30 on both sides. The two sub-portions 32 can be optionally respectively enclosed with the two ends of the main body portion 20 to form two flange forming cavities 31, and the shapes and sizes of the two flange forming cavities 31 are respectively the same as the flanges at the two ends of the web to be formed.

[0063] Optionally, the two flange forming cavities 31 in the two sub-parts 32 respectively have openings 311, and the height of the openings 311 can be selected to correspond to the thickness of the web to be formed, and the two openings 311 can be arranged facing each other along the second direction Y, that is, both are arranged on the side facing the main body 20, so that the flange and the web body can be formed together. Optionally, the two sub-parts 32 can be made of the same material to facilitate processing, and both have the ability to switch between the first state and the second state through their own elastic deformation.

[0064] In some optional embodiments, the main body portion 20 has a first mold surface 21 on the side facing away from the support portion 10, and the flange portion 30 has a second mold surface 33. At least part of the first mold surface 21 and the second mold surface 33 together enclose a flange forming cavity 31, and at least one side edge of the opening 311 is located on the first mold surface 21.

[0065] Optionally, the web forming cavity in the mold 100 that is arranged in the shape of the web to be formed can be formed by the main body 20, the flange 30, and auxiliary materials such as the vacuum bag to be laid. On this basis, the main body 20 and the flange 30 can respectively have a first molding surface 21 and a second molding surface 33 for forming the web forming cavity. Optionally, the first molding surface 21 can be arranged on the top surface and the side surface of the main body 20 that are not in contact with the support part 10, and the second molding surface can be arranged inside the flange 30 and constitute a part of the cavity wall of the aforementioned flange forming cavity 31.

[0066] Further, the flange forming cavity 31 may be formed by the second mold surface 33 and a partial area of ​​the first mold surface 21, and the opening 311 of the flange forming cavity 31 may be located between the first mold surface 21 and the second mold surface 33, that is, the two opposite edges in the thickness direction of the main body 20 may be located at the main body 20 and the flange 30, respectively. Optionally, the lower edge of the opening 311, that is, the edge of one side close to the support portion 10, may be located at the first mold surface 21, and the upper edge of the opening 311 may be located at the second mold surface 33.

[0067] By forming the opening 311 between the main body 20 and the flange 30, the area of ​​the opening 311 can be easily increased by flipping outward a portion of the area above the opening 311 when switching the shape of the flange 30, thereby further facilitating the operation and reducing the impact on the belly plate after molding.

[0068] In some optional embodiments, the second mold surface 33 is provided with a guide groove 331 connected to the flange forming cavity 31, the notch of the guide groove 331 is provided on the second mold surface 33, and the guide groove 331 is recessed in a direction away from the flange forming cavity 31, and the guide groove 331 extends along the first direction.

[0069] In order to allow the web flange disposed in the flange forming cavity 31 to be fully injection molded, a corresponding structure may be provided in the flange portion 30 and on the wall of the flange forming cavity 31, so that after the layers are laid, the position may be formed so that the resin or other filling material for injection can pass smoothly. Optionally, the structure may be a guide groove 331 extending along the first direction.

[0070] On this basis, the notch of the guide groove 331 is set on the second molding surface 33, and can be recessed in a direction away from the flange molding cavity 31 to form a guide groove 331 connected to the flange molding cavity 31. In the process of using the mold 100 to form a web, it is usually necessary to lay a structural layer in the flange molding cavity 31, such as glass fiber cloth or carbon fiber cloth, etc. When the laying is completed and the pouring is performed, the guide groove 331 with recesses on both sides can make the pouring material flow more conveniently and quickly along the first direction, so that the pouring material can more completely infiltrate the aforementioned structural layer, reducing the possibility of defects such as dry yarn in the formed web.

[0071] Optionally, the extension dimension of the guide groove 331 in the first direction can be the same as or similar to the extension dimension of the flange portion 30, so that the pouring material has a relatively uniform distribution density at various locations in the flange length direction, thereby making the formed web structure uniform. The second molding surface 33 can be provided with a plurality of guide grooves 331, and these guide grooves 331 can be optionally extended in parallel with each other and arranged at equal intervals.

[0072] In some optional embodiments, in a cross section perpendicular to the first direction, the cross-sectional shape formed by the guide groove 331 is semicircular, and the radius of the guide groove 331 is 1 mm to 4 mm.

[0073] In the embodiment where the second molding surface 33 is provided with a guide groove 331, the guide groove 331 can have a smaller cross-sectional area, reducing the possibility that the guide groove 331 affects the overall strength and other parameters of the web after molding. On this basis, in the cross section perpendicular to the extension direction of the guide groove 331, the cross-sectional figure formed by the guide groove 331 can be semicircular, so that the guide groove 331 is easy to process, and the radius of the semicircular cross-sectional figure can be between 1mm and 4mm, and can be further selected as 1mm to 3mm, so as to reduce the possibility that the guide groove 331 affects the web on the basis that the guide groove 331 can make the pouring material flow fully.

[0074] In some optional embodiments, the second molding surface 33 is provided with a plurality of protrusions 332 protruding toward the direction close to the flange molding cavity 31 , and the protrusions 332 extend along the first direction.

[0075] Corresponding to the aforementioned guide groove 331, in order to form a gap between the layer structure and the second mold surface 33 for the flow of the pouring material, the second mold surface 33 may also be provided with a protrusion 332, which is protruded from the second mold surface 33 and extends into the flange forming cavity 31. After the pouring auxiliary material and the structural layer are laid in the flange forming cavity 31, the protrusion 332 can partially lift the aforementioned layer structure and form channels for the pouring material to flow through on both sides in its width direction.

[0076] The protrusion 332 may extend in the first direction similarly to the guide groove 331. In this direction, the protrusion 332 may extend completely and have the same or similar size as the flange portion 30. Alternatively, the protrusion 332 may include multiple sections of sub-protrusions 332, which are at least partially arranged in the first direction, and the sum of their extension sizes may be the same or similar to the size of the flange portion 30. In an embodiment in which a plurality of protrusions 332 are provided, the protrusions 332 may be partially provided to include a plurality of sub-portions 32, or the protrusions 332 may all extend completely in the first direction.

[0077] In some optional embodiments, in a cross section perpendicular to the first direction, a cross-sectional shape formed by the protrusion 332 is semicircular or semi-elliptical, and a protruding dimension of the protrusion 332 is 1 mm to 4 mm.

[0078] Similar to the size and structure of the aforementioned groove, the protrusion 332 can be semicircular or semi-elliptical to facilitate processing and reduce the impact on the flange structural strength. The protrusion size of the second molded surface 33 protruding from both sides of the width direction can be selected to be 1mm to 4mm, and further selected to be 1mm to 3mm, to further reduce the possibility of the protrusion 332 affecting the web.

[0079] In some optional embodiments, the flange portion 30 contains at least one of silicone and rubber, and the hardness of the flange portion 30 is 50HD-55HD.

[0080] Optionally, in order to enable the flange portion 30 in the mold 100 to have certain compressive support performance and elastic deformation performance, the flange portion 30 can be made of a similar elastomeric material such as silicone or rubber. This type of material can easily change its own hardness, heat resistance, corrosion resistance and other parameters by changing processing conditions such as specific material ratios or preparation methods to obtain the desired flange portion 30.

[0081] Specifically, the flange portion 30 may be made of a fluorine-containing silicone material. The fluorine-containing silicone has good stability at both room temperature and high temperature, and can stably maintain elasticity, so that it can be used for a long time in the range of -50°C to +200°C. By setting the flange portion 30 to be made of fluorine-containing silicone, the flange portion 30 can have a long service life and can remain stable during the process of heating and curing the base material constituting the web.

[0082] Furthermore, by changing the types of materials mixed during the manufacture of silicone, the material ratio, the types of additives, the processing technology and other manufacturing conditions, the hardness of the silicone can be easily changed to be within the range of Shore hardness 50HD to 55HD. The flange part 30 is set within this hardness range so that the flange part 30 can maintain a preset shape under a negative pressure environment, and the flange part 30 can remove the internal web flange from the opening 311 through its own elastic deformation. At the same time, the silicone can also change its own shape and become fluid, which is convenient for curing and molding through the mold 100 to obtain the corresponding flange part 30.

[0083] See also Figure 3 , Figure 3 1 is a flow chart of a mold manufacturing method provided by an embodiment of the present application. In a second aspect, according to an embodiment of the present application, a method for manufacturing a mold 100 is proposed, comprising:

[0084] S1, providing a support portion 10 and a main body portion 20, and connecting the main body portion 20 to the support portion 10;

[0085] S2, providing a flange mold and an elastic substrate, and filling the elastic substrate into the flange mold;

[0086] S3, curing the elastic base material to obtain a preparation;

[0087] S4, removing the flange mold and trimming the prepared body to obtain the flange 30;

[0088] S5. Dispose the flange portion 30 on a side of the support portion 10 close to the main body portion 20 .

[0089] The embodiment of the present application also provides a method for manufacturing the mold 100 in any embodiment of the first aspect, specifically, first including step S1 of providing a support portion 10 and a main body portion 20, the support portion 10 can be made of a metal structure and have a relatively flat support surface 11, and the support surface 11 can extend in a direction parallel to or close to a horizontal plane. Each surface of the main body portion 20 that extends in the first direction and does not abut against the support portion 10 can be configured to conform to the web to be formed. When the main body portion 20 is disposed on the support portion 10, any one of the connection methods such as bonding, clamping, crimping, and fastener connection can be selected.

[0090] In step S2, the flange part 30 can be prepared. Specifically, a flange part mold is first provided, that is, a mold 100 whose inner cavity is configured to conform to the shape of the flange part 30. Then, an elastic substrate is provided. The elastic substrate should be in a fluid state and can flow to fill the flange part mold so as to manufacture the flange part 30 by casting. The elastic substrate can be selected from materials such as liquid silicone.

[0091] Specifically, this step may include cleaning the inner surface of the flange mold, applying a release agent, mixing and stirring a preset liquid elastic substrate, degassing the elastic substrate after stirring, introducing the degassing elastic substrate into the flange 30 mold, using a scraper to remove bubbles and smooth the surface, etc. The present application does not make any specific limitations on this, as long as it can be used to complete the casting and molding process of the flange 30.

[0092] In step S3, the elastic substrate filled in the flange mold is placed under a preset temperature condition for a certain period of time to solidify it. The temperature condition can be room temperature or the elastic substrate is heated to a preset temperature. During the curing process, the elastic substrate can be pressed at regular intervals, and demolding can be performed when its surface viscosity drops below a preset standard. Alternatively, a Shore hardness tester can be used for testing to confirm that the hardness of the elastic substrate is within a preset range, such as between 50HD and 55HD, and then demolding can be performed.

[0093] In step S4 , the cured preparation is removed from the flange mold, and the removed preparation is trimmed, such as by trimming with a wallpaper knife or polishing with sandpaper, to obtain a flange 30 with a smooth surface.

[0094] In step S5 , the flange portion 30 may be disposed on the support surface 11 and located on at least one side of the main body portion 20 in the second direction Y, so as to facilitate forming of the web.

[0095] The casting method can be used to process the flange part 30 with a complex shape in a relatively simple and quick manner, thereby reducing the error between the flange part 30 and the design model, and making it easier to process the elastic material.

[0096] See also Figure 4 , Figure 4 FIG. 1 is a flow chart of a mold manufacturing method provided by another embodiment of the present application. In some optional embodiments, step S2 of providing a flange mold and an elastic substrate includes:

[0097] S21, making the flange mold consist of a plurality of sub-molds, and filling the plurality of sub-molds with elastic base materials respectively;

[0098] The step S4 of removing the flange mold and trimming the preparation includes:

[0099] S41, connecting and arranging a plurality of prepared bodies to form a flange portion 30.

[0100] Optionally, when processing the flange portion 30 , since the overall structure of the flange portion 30 is relatively complex, the flange portion 30 may be divided into a plurality of blocks, which are processed separately and then connected after being formed.

[0101] Specifically, in step S2, the flange mold can be split into a plurality of independent sub-molds corresponding to the aforementioned blocks, and appropriate amounts of elastic substrates are poured into the sub-molds respectively. The sub-molds can be cured together under the same conditions, or the sub-molds can be cured separately to obtain a plurality of preparations.

[0102] In step S4 , the plurality of prepared bodies may be trimmed accordingly, and then the trimmed prepared bodies may be spliced ​​accordingly according to the aforementioned division method to form the flange portion 30 .

[0103] Dividing the flange portion 30 into a plurality of blocks and processing them separately can reduce the processing difficulty and improve the processing accuracy.

[0104] In some optional embodiments, the step S41 of connecting and arranging a plurality of preparations comprises:

[0105] bonding and connecting a plurality of preparations;

[0106] Alternatively, the step S41 of connecting and setting a plurality of preparations includes:

[0107] A plurality of preparation bodies are detachably connected and arranged by fasteners.

[0108] When the prepared bodies are connected in step S41, they can be connected by bonding or by detachable connection using fasteners.

[0109] In the embodiment using adhesive connection, the bonding surface of each prepared body can be first polished with sandpaper, and after all dust is removed by visual surface inspection or scanning, adhesive is applied to the surface, and external force is applied to pressurize the surfaces with adhesive after they are butt-jointed, and the pressure is removed after the bonding is firm.

[0110] In the embodiment of connection by fasteners, the position where the fasteners are arranged should be staggered from the second molding surface 33 of the flange portion 30 to reduce the possibility that the joints between the fasteners or the preparations interfere with the molding of the web flange.

[0111] In some optional embodiments, the step S41 of connecting and arranging the plurality of preparations and the step S5 of arranging the flange portion 30 on a side of the support portion 10 close to the main body portion 20 further includes:

[0112] S42, applying a force greater than or equal to 80N to the plurality of interconnected preparations;

[0113] S43, detecting the multiple preparations to determine whether plastic deformation and / or dislocation occurs in the multiple preparations;

[0114] S44. Remove the preparation that has undergone plastic deformation and / or dislocation.

[0115] Optionally, a step of testing the flange 30 may be included between the step of connecting the preparation and the step of placing the flange 30 on the support 10. Specifically, a force may be first applied to the flange 30 formed by connecting the preparation, and the force should exceed a preset value to simulate the situation in which the flange 30 is in a negative pressure environment during the perfusion process. Specifically, the magnitude of the force should exceed 80N, and may further be selected to exceed 100N.

[0116] After the force is applied, the flange part 30 can be inspected. If the spliced ​​flange part 30 has problems such as misalignment between the preparations or irreversible plastic deformation at a certain position, the preparation can be removed and a new preparation can be recast to replace it. Alternatively, the flange part 30 can be discarded as a whole and remade.

[0117] See also Figure 5 , Figure 5 : is a flow chart of a method for manufacturing a web provided by an embodiment of the present application. In a third aspect, a method for manufacturing a web is proposed according to an embodiment of the present application, comprising:

[0118] S6. Provide the mold 100 in any embodiment of the first aspect;

[0119] S7, laying forming auxiliary materials and web structure layers on the main body 20 and in the flange 30, so that the flange 30 is in a first state, so as to obtain a matrix to be formed;

[0120] S8, solidifying and shaping the matrix to be formed to obtain a web.

[0121] The embodiment of the present application also provides a method for manufacturing a web using the mold 100 in any embodiment of the first aspect. Specifically, the method first includes step S6 of providing the mold 100, which may also include cleaning and positioning the mold 100.

[0122] In step S7, forming auxiliary materials and web structural layers are laid on the mold 100, that is, the layer structure required for web forming is laid in the flange part 30 and on the main body part 20, wherein the forming auxiliary materials may include an isolation membrane, a guide net, etc., and the web structural layer may include glass fiber cloth, carbon fiber cloth or core material and other structures required for forming the web.

[0123] Optionally, in step S7, the web structure layer can be laid simultaneously to the main body 20 and the flange 30, or the web can be divided into a web body and a web flange, and the corresponding layer structures of the two can be laid separately. When the laying is completed, the flange 30 should be in a first state so that it can be enclosed with the main body 20 to form a flange forming cavity 31 that is arranged in accordance with the design model of the web.

[0124] After the laying is completed, in step S8, the to-be-formed matrix formed by the aforementioned laying layers can be solidified and formed to obtain the desired web.

[0125] See also Figure 6 , Figure 6 is a flow chart of a web manufacturing method provided by another embodiment of the present application. In some optional embodiments, step S7 of laying the forming auxiliary material and the web structure layer on the main body 20 and in the flange 30 includes:

[0126] S71, adjusting the relative position of the flange portion 30 and the main body portion 20 in the second direction Y, and providing a limiting structure on a side of the flange portion 30 away from the main body portion 20;

[0127] S72, applying a force to the flange portion 30 to place the flange portion 30 in a second state;

[0128] S73, laying forming auxiliary materials and a web structure layer on the side of the main body 20 away from the support part 10 and in the flange forming cavity 31;

[0129] S74, switching the flange portion 30 to the first state.

[0130] In the step S7 of performing the layer laying, the main body 20 and the flange 30 can be arranged on the support surface 11 according to the preset position, and then the relative position between the main body 20 and the flange 30 can be adjusted in step S71, so that the flange forming cavity 31 enclosed by the two is consistent with the design model of the web flange, and then the flange 30 and the main body 20 can be limited by connecting the limiting structure to the support surface 11. Optionally, the main body 20 and the support 10 can be connected to each other, and a plurality of limiting blocks can be arranged on the side of the flange 30 away from the main body 20, so that the relative position between the flange 30 and the main body 20 is fixed.

[0131] In the step of laying the web structure layer to the mold 100, the layer structure therein can be easily laid by switching the flange part 30 to the second state. Specifically, before laying the layer, a force can be first applied to the flange part 30 in step S72 to switch it to the second state and have a larger opening 311, so that the layer structure can be laid therein through the opening 311. Then, in step S73, the web structure layer is laid to the flange part 30 and the main body part 20 together, and in step S74, the flange part 30 is switched to the first state to form the flange forming cavity 31.

[0132] By laying the web structural layer on the main body 20 and the flange 30 at the same time, the web main body and the web flange can be formed simultaneously in a one-time infusion molding process, thereby simplifying the processing steps and improving the processing efficiency. At the same time, by switching between the first state and the second state, the structural layer can be conveniently laid in the flange molding cavity 31, thereby further improving the processing efficiency.

[0133] See also Figure 7 , Figure 7 FIG. 1 is a flow chart of a web manufacturing method provided by another embodiment of the present application. In some optional embodiments, step S7 of laying forming auxiliary materials and web structural layers on the main body 20 and in the flange 30 includes:

[0134] S75, remove the flange portion 30, so that the flange portion 30, the support portion 10 and the main body portion 20 are separated from each other;

[0135] S76, laying forming auxiliary materials and flange structure layers in the flange portion 30 to obtain a flange base;

[0136] S77, solidifying and molding the flange base to obtain a web flange;

[0137] S78, moving the flange portion 30 and the web flange to the support portion 10;

[0138] S79: adjusting the relative position of the flange portion 30 and the main body portion 20 in the second direction Y, and providing a limiting structure on a side of the flange portion 30 away from the main body portion 20;

[0139] S710, laying a molding auxiliary material and a main structure layer on a side of the main body 20 away from the support part 10 to obtain a matrix to be molded.

[0140] Corresponding to the aforementioned integral molding, the web plate can also adopt a structural form in which the web plate body and the web plate flange are separately molded. Specifically, in the layering step S7, a step S75 of separating and removing the flange portion 30 can be first included, at which time the flange portion 30 can be moved to another supporting structure, or the main body portion 20 can be removed, leaving only the flange portion 30 on the supporting surface 11 of the supporting portion 10.

[0141] Subsequently, in step S76, the flange part 30 may be layered, and the molding auxiliary materials required for molding and the flange structure layer required for forming the web flange may be laid in the flange part 30. It is understandable that the flange molding cavity 31 for molding the web flange in the mold 100 is composed of the main body 20 and the flange part 30. In the embodiment where the flange part 30 is separated to form the web flange separately, the position of the original main body 20 may be replaced by a component such as a pad of a corresponding shape, or the placement direction of the flange part 30 may be reversed so that its second molding surface 33 is set upward, and the fiber effect provided by the original main body 20 may be replaced by molding auxiliary materials such as a vacuum bag. In this way, the molded web flange can match the shape of the design model.

[0142] In step S77, the flange base obtained by the aforementioned layering in the flange portion 30 is solidified and formed, and vacuum infusion solidification molding can be used to manufacture the web flange.

[0143] Then in step S78 and step S79, the flange portion 30 and the cured web flange therein are moved onto the support portion 10 and assembled with the main body portion 20, and the relative positions of the two are adjusted so that the contour of the web flange matches the contour of the main body portion 20, and then the flange portion 30 is fixed at a preset position by a limiting structure.

[0144] In step S710, the molding auxiliary materials required for molding and the main structural layers required for the web body are laid on the main body 20 to form a structural form in which the web flange has been solidified and formed and the web body has completed the layer structure laying. The substrate to be molded is solidified again to obtain the required web as a whole.

[0145] In some optional embodiments, the step S710 of laying the auxiliary molding material and the main structure layer on the side of the main body 20 away from the support part 10 further includes:

[0146] S711. Extend at least a portion of the main structural layer in the second direction Y to connect with the web flange.

[0147] When laying the various layers of structure required for the web body, the structural layer used to constitute the web body can be extended at least partially along the second direction Y until it connects with the web flange. The connection here can refer to the surface of the web flange exposed to the outside at the opening 311 of the flange forming cavity 31, or the connection here can also refer to the extension of the aforementioned structural layer into the flange forming cavity 31.

[0148] Extending the main structural layer to connect with the web flange can enable the web body and the web flange to be connected together through the solidified infusion material layer and the structural layer therein after the web body is formed, thereby improving the stability and reliability of the connection between the web body and the web flange, and further improving the overall structural reliability of the web.

[0149] In some optional embodiments, step S7 of laying the forming auxiliary material and the web structure layer on the main body 20 and in the flange 30 further includes:

[0150] The molding auxiliary materials include an isolation film, a flow guide net and a vacuum film;

[0151] The step S8 of curing the matrix to be formed comprises:

[0152] The substrate to be molded is placed under negative pressure and resin material is poured into it;

[0153] The substrate to be formed is placed under a preset temperature condition to solidify it.

[0154] As mentioned above, when manufacturing the web, the method of pumping negative pressure on the substrate to be formed and performing resin infusion can be used for manufacturing. According to this manufacturing method, the forming auxiliary materials in the aforementioned laying step can include corresponding structures such as isolation membranes, guide nets and vacuum bags. At the same time, in the curing and molding step, the substrate to be formed can be first placed in a negative pressure environment, and after the resin and other materials are infused and infiltrated, it can be cured at room temperature or by heating, and then demolded and reshaped to obtain the desired web.

[0155] In a fourth aspect, according to an embodiment of the present application, a web is proposed, which is manufactured by the manufacturing method in any embodiment of the third aspect.

[0156] See also Figure 8 , Figure 8 2 is a schematic diagram of the structure of a wind turbine generator set 200 provided in one embodiment of the present application. In a fifth aspect, according to an embodiment of the present application, a wind turbine generator set is provided, comprising a web in any embodiment of the fourth aspect.

[0157] The web and wind turbine generator set 200 in the embodiment of the present application have all the beneficial effects of the method for manufacturing the web in the third aspect. For details, please refer to the specific description of the method for manufacturing the web in the above embodiments, which will not be repeated in this embodiment.

[0158] Although the present application has been described with reference to preferred embodiments, various modifications may be made thereto and parts thereof may be replaced with equivalents without departing from the scope of the present application. In particular, the various technical features mentioned in the various embodiments may be combined in any manner as long as there are no structural conflicts. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A mold, applied to a web, characterized in that: include: A supporting portion having a supporting surface, wherein the supporting surface extends along a first direction; A main body, disposed on the support surface and extending along the first direction; A flange portion extending along the first direction and arranged on at least one side of the main body portion in the second direction, the first direction intersecting with the second direction, the flange portion and the main body portion jointly enclose a flange forming cavity, the flange forming cavity having an opening arranged along the second direction, the flange portion being made of an elastic material and having a lower hardness than the main body portion, the flange portion having a first state and a second state and being able to switch between the first state and the second state through elastic deformation; Wherein, the area of ​​the opening in the second state is larger than the area of ​​the opening in the first state.

2. The mold according to claim 1, characterized in that: The flange portion includes two sub-portions, and the two sub-portions are respectively arranged on two opposite sides of the main body portion in the second direction; The two sub-parts are respectively provided with the flange forming cavities, and the openings of the two flange forming cavities are arranged opposite to each other.

3. The mold according to claim 1, characterized in that: The main body has a first profile on a side away from the support portion, and the flange has a second profile. At least part of the first profile and the second profile together enclose the flange forming cavity, and at least one side edge of the opening is located on the first profile.

4. The mold according to claim 3, characterized in that: The second profile is provided with a guide groove connected to the flange forming cavity, the notch of the guide groove is provided on the second profile, and the guide groove is recessed in a direction away from the flange forming cavity, and the guide groove extends along the first direction.

5. The mold according to claim 4, characterized in that: In a cross section perpendicular to the first direction, the cross-sectional shape formed by the guide groove is semicircular, and the radius of the guide groove is 1 mm to 4 mm.

6. The mold according to claim 3, characterized in that: The second molding surface is provided with a plurality of protrusions which are arranged to protrude in a direction close to the flange molding cavity, and the protrusions extend along the first direction.

7. The mold according to claim 6, characterized in that: In a cross section perpendicular to the first direction, a cross-sectional shape formed by the protrusion is semicircular or semi-elliptical, and a protrusion size of the protrusion is 1 mm to 4 mm.

8. The mold according to claim 1, characterized in that: The flange portion contains at least one of silicone and rubber, and the hardness of the flange portion is 50HD to 55HD.

9. A method for manufacturing a mold, characterized in that: include: Providing a support portion and a main body portion, and connecting the main body portion to the support portion; Providing a flange mold and an elastic substrate, and filling the elastic substrate into the flange mold; solidifying the elastic base material to obtain a preparation; removing the flange mold and trimming the prepared body to obtain the flange; The flange portion is arranged on a side of the support portion close to the main body portion.

10. The manufacturing method according to claim 9, characterized in that: The step of providing a flange mold and an elastic substrate comprises: The flange mold is composed of a plurality of sub-molds, and the elastic base material is filled in the plurality of sub-molds respectively; The step of removing the flange mold and trimming the prepared body comprises: A plurality of the prepared bodies are connected and arranged to be assembled to form the flange portion.

11. The manufacturing method according to claim 10, characterized in that: The step of connecting and arranging a plurality of the prepared bodies comprises: bonding and connecting a plurality of the prepared bodies; Alternatively, the step of connecting and arranging a plurality of the prepared bodies comprises: A plurality of the preparation bodies are detachably connected and arranged by fasteners.

12. The manufacturing method according to claim 10, characterized in that: The step of connecting and arranging the plurality of the prepared bodies and the step of arranging the flange portion on a side of the support portion close to the main body portion further includes: Applying a force greater than or equal to 80N to the plurality of mutually connected preparations; Detecting the plurality of prepared bodies to determine whether plastic deformation and / or dislocation occurs in the plurality of prepared bodies; The plastically deformed and / or dislocated preparation is removed.

13. A method for manufacturing a web, characterized in that: include: Providing a mold according to any one of claims 1 to 8; Laying forming auxiliary materials and a web structure layer on the main body and in the flange part, so that the flange part is in the first state, so as to obtain a matrix to be formed; The matrix to be formed is solidified and formed to obtain a web.

14. The manufacturing method according to claim 13, characterized in that: The step of laying the forming auxiliary material and the web structure layer on the main body and in the flange part comprises: Adjusting the relative position of the flange portion and the main body portion in the second direction, and providing a limiting structure on a side of the flange portion away from the main body portion; Applying a force to the flange portion so that the flange portion is in the second state; Laying the forming auxiliary material and the web structure layer on a side of the main body away from the supporting portion and in the flange forming cavity; The flange portion is switched to the first state.

15. The manufacturing method according to claim 13, characterized in that: The step of laying the forming auxiliary material and the web structure layer on the main body and in the flange part comprises: Remove the flange portion to separate the flange portion from the support portion and the main body portion; Laying forming auxiliary materials and flange structural layers in the flange portion to obtain a flange base; Solidifying and shaping the flange matrix to obtain a web flange; Moving the flange portion and the web flange together to the support portion; Adjusting the relative position of the flange portion and the main body portion in the second direction, and providing a limiting structure on a side of the flange portion away from the main body portion; A molding auxiliary material and a main structure layer are laid on a side of the main body away from the support portion to obtain a matrix to be molded.

16. The manufacturing method according to claim 15, characterized in that: The step of laying the forming auxiliary material and the main structure layer on the side of the main body away from the support part also includes: At least a portion of the main structural layer is extended in the second direction to meet the web flange.

17. The manufacturing method according to claim 13, characterized in that: The step of laying the forming auxiliary material and the web structure layer on the main body and in the flange part also includes: The molding auxiliary materials include an isolation film, a flow guide net and a vacuum film; The step of curing the matrix to be formed comprises: The substrate to be formed is placed under negative pressure and resin material is poured into the substrate; The matrix to be formed is placed under a preset temperature condition to solidify it.

18. A web, characterized in that: The method is prepared by the method according to any one of claims 13 to 17.

19. A wind turbine generator set, characterized in that: Comprising a web as claimed in claim 18.

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