Wind power blade main beam manufacturing method and wind power blade

Abstract

The invention relates to a wind power blade main beam manufacturing method and a wind power blade. The manufacturing method of the wind power blade girder comprises the following steps: providing a pultrusion plate; at least one surface of the pultrusion plate is coated with a thermoplastic resin material to form a thermoplastic resin layer, the pultrusion plate and the thermoplastic resin layer form an integral structure, and the pultrusion plate and the thermoplastic resin layer form a pultrusion plate finished product; a main beam mold is provided, a main beam middle body formed by stacking the multiple pultrusion plate finished products is arranged in the main beam mold, the main beam middle body comprises multiple layers of pultrusion plate finished products, and each layer of pultrusion plate finished products comprises multiple pultrusion plate finished products; a vacuum film is laid on the main beam middle body; vacuumizing equipment is used for exhausting air, so that negative pressure is formed in the vacuum film; heating the thermoplastic resin layer so as to melt the thermoplastic resin layer and fill gaps among the pultrusion plates; and thermoplastic resin formed after the thermoplastic resin layer is melted is subjected to curing treatment, so that the main beam is formed. According to the manufacturing method of the wind power blade main beam, the quality of the main beam is improved, and the safety of the wind power blade is improved.

Description

Technical Field

[0001] The present application relates to the field of wind power generation, and in particular to a method for manufacturing a main beam of a wind turbine blade and a wind turbine blade. Background Art

[0002] The main beam is the main load-bearing member or structural member in the wind turbine blade. The main beam uses multiple pultruded plates as the layer material. At present, the length of the wind turbine blade reaches 40m to 100m or more, and the root diameter of the wind turbine blade reaches 2m to 4m or more. For example, the length of a large wind turbine blade is generally more than 80m. The thickness of the main beam of the wind turbine blade is generally more than 50mm, and the width is also 300mm-600mm. In the manufacturing process of the main beam of the wind turbine blade, multiple pultruded plates with a certain thickness and width are first stacked in the thickness direction and spliced ​​in the width direction, and then the resin is infused and cured by the infusion molding process to form the entire main beam. However, since multiple pultruded plates are stacked to form a multi-layer structure, infusion defects such as poor impregnation or dry yarn will occur between different pultruded plates, thereby affecting the quality of the main beam product and adversely affecting the safety of the wind turbine blade. Summary of the invention

[0003] The present application provides a method for manufacturing a main beam of a wind turbine blade and a wind turbine blade, which can be beneficial to improving the product quality of the main beam and improving the safety of the wind turbine blade.

[0004] In a first aspect, an embodiment of the present application provides a method for manufacturing a wind turbine blade main beam, which comprises:

[0005] Provide pultruded panels;

[0006] Coating a thermoplastic resin material on at least one surface of a pultruded plate to form a thermoplastic resin layer, wherein the pultruded plate and the thermoplastic resin layer form an integral structure, and the pultruded plate and the thermoplastic resin layer form a pultruded plate finished product;

[0007] A main beam mold is provided, and a main beam intermediate body formed by stacking a plurality of pultruded plate finished products is arranged in the main beam mold, wherein the main beam intermediate body comprises a plurality of layers of pultruded plate finished products, and each layer of pultruded plate finished products comprises a plurality of pultruded plate finished products;

[0008] Laying a vacuum membrane on the middle of the main beam;

[0009] Use vacuum equipment to extract air to create negative pressure inside the vacuum film;

[0010] heating the thermoplastic resin layer so that the thermoplastic resin layer melts and fills the gaps between the pultruded plates;

[0011] The thermoplastic resin formed by melting the thermoplastic resin layer is cured to form the main beam.

[0012] The method for manufacturing the main beam of a wind turbine blade provided in an embodiment of the present application forms a finished pultruded board by directly setting a thermoplastic resin layer on a pultruded board. Then, multiple finished pultruded boards are stacked to form a main beam intermediate. Multiple finished pultruded boards are stacked along the thickness direction and the width direction of the pultruded board. The main beam intermediate is heated to melt the thermoplastic resin layer. The thermoplastic resin after the thermoplastic resin layer is melted can infiltrate the pultruded board, and the thermoplastic resin can connect the various pultruded boards after solidification, so that each pultruded board and the solidified thermoplastic resin together form the main beam. The method for manufacturing the main beam of a wind turbine blade in an embodiment of the present application can replace the infusion molding process to make the main beam, and can simplify the main beam molding process, thereby eliminating the complex process of the infusion molding process, eliminating the laying of infusion auxiliary materials, and eliminating the steps of resin mixing infusion. Therefore, the quality of the main beam formed by the method for manufacturing the main beam of a wind turbine blade in an embodiment of the present application is more stable and reliable, and the safety of the wind turbine blade is improved.

[0013] In some feasible embodiments, the cross-section of the pultruded board is rectangular, and thermoplastic resin layers are provided on the upper and lower surfaces of the pultruded board along the thickness direction of the pultruded board to form a pultruded board product. The multi-layer pultruded board products in the main beam intermediate body are stacked along the thickness direction of the pultruded board.

[0014] Since the multi-layer pultruded plate finished product is stacked along the thickness direction of the pultruded plate, two thermoplastic resin layers can be formed between the upper and lower pultruded plates by providing thermoplastic resin layers on both the upper and lower surfaces of the pultruded plate. After the thermoplastic resin layer is heated and melted, the pultruded plate located on the upper layer can squeeze the fluid thermoplastic resin below under the action of its own gravity, so that the thermoplastic resin can easily flow in all directions, thereby facilitating the fluid thermoplastic resin to infiltrate the gaps between the pultruded plates, improving the infiltration effect of the thermoplastic resin, and reducing the possibility of poor infiltration.

[0015] In some achievable embodiments, along a width direction of the pultruded board, a distance is provided between the thermoplastic resin layer disposed on at least one of the upper surface and the lower surface and an edge of the pultruded board.

[0016] In the same layer of pultruded plate products in the middle of the main beam, the thermoplastic resin layers on each pultruded plate product may have a spacing between them and do not contact each other, so that a space to be filled can be formed. After the thermoplastic resin layer is heated and melted, the flowing thermoplastic resin will flow to the edge of the pultruded plate to achieve full filling, and at the same time, it can help reduce the possibility of the thermoplastic resin overflowing from the edge of the outermost pultruded plate. In the case of setting the quantitative gram weight of the thermoplastic resin layer, the thermoplastic resin formed by heating and melting the thermoplastic resin layer is not easy to overflow from the edge of the outermost pultruded plate, so that the thermoplastic resin residue is not easy to appear on the outer surface of the final formed main beam, so that after the main beam is demoulded, it is no longer necessary to grind the main beam separately to treat the thermoplastic resin enriched on the outer surface or to grind the main beam separately to treat the unqualified bonding surface formed by the overflow of the thermoplastic resin.

[0017] In some achievable embodiments, the distance between the thermoplastic resin layer provided on at least one of the upper surface and the lower surface and the edge of the pultruded board is in a range of 3 mm to 5 mm.

[0018] In some practicable embodiments, an air-conducting fiber layer is laid between any two adjacent layers of pultruded board products.

[0019] After the thermoplastic resin layer is heated and melted, the flowing thermoplastic resin can squeeze the gas between the pultruded plates and guide it to the external environment through the gas guide fiber layer, effectively reducing the possibility of bubbles appearing during the thermoplastic resin being compressed and solidified.

[0020] In some achievable embodiments, the cross-section of the pultruded plate is rectangular, and in the main beam intermediate body, thermoplastic resin layers are provided on surfaces corresponding to each other of any two adjacent pultruded plates.

[0021] In any two adjacent pultruded plates, thermoplastic resin layers are arranged on the surfaces corresponding to each other, so that the thermoplastic resin layers at different positions can contact each other. After the thermoplastic resin layers at different positions are heated and melted, the flowing thermoplastic resin can be connected as a whole to ensure that the thermoplastic resin fully infiltrates each pultruded plate and reduce the possibility of poor infiltration.

[0022] In some achievable embodiments, multiple layers of pultruded plate products in the main beam intermediate body are stacked along the thickness direction of the pultruded plate, and any two adjacent layers of pultruded plate products are in direct contact with each other.

[0023] Since thermoplastic resin layers are provided on the surfaces corresponding to each other in any two adjacent pultruded plates, the thermoplastic resin layers at different positions can contact each other, so that after the thermoplastic resin layers at different positions are heated and melted, the flowing thermoplastic resin can be connected as a whole, and there is no need to squeeze the gas in the gap between different pultruded plates. In the process of forming the main beam intermediate body, it is no longer necessary to lay the gas-conducting fiber layer, thereby simplifying the process and saving materials.

[0024] In some achievable embodiments, an interface protective layer is provided on the thermoplastic resin layer of the pultruded board product, and the interface protective layer is used to protect the thermoplastic resin layer underneath. The interface protective layer is removed before the pultruded board product is stacked and arranged in a main beam mold to form a main beam intermediate.

[0025] If the thermoplastic resin layer is contaminated, after the thermoplastic resin layer is melted, bubbles will be generated in the thermoplastic resin at the contaminant, or the contaminant will affect the fluidity of the thermoplastic resin and cause poor wetting. The interface protection layer of the embodiment of the present application can protect the thermoplastic resin layer below, effectively reducing the possibility of contamination of dust, fiber and other contaminants on the thermoplastic resin layer, so that the thermoplastic resin layer remains clean and tidy, effectively solving the above technical problems.

[0026] In some achievable embodiments, the thickness of the thermoplastic resin layer ranges from 800 micrometers to 1500 micrometers.

[0027] When the thickness of the thermoplastic resin layer is less than 800 microns, the overall volume of the thermoplastic resin layer is relatively small, which makes the quantitative setting of the thermoplastic resin layer in grams relatively small. There is a possibility that the thermoplastic resin layer cannot effectively fill the gaps between the pultruded plates after melting, resulting in poor wetting of the pultruded plates. When the thickness of the thermoplastic resin layer is greater than 1500 microns, the volume of the thermoplastic resin layer is relatively large, which makes the quantitative setting of the thermoplastic resin layer in grams relatively large. There is a possibility that the thermoplastic resin layer overflows after filling the gaps between the pultruded plates after melting, resulting in the enrichment of thermoplastic resin on the outer surface of the main beam after molding or the formation of an unqualified bonding surface. The method of taking the thickness of the thermoplastic resin layer in the range of 800 microns to 1500 microns can effectively reduce the possibility of the above-mentioned technical problems.

[0028] In some feasible methods, an isolation film and a first adhesive layer are laid on the main beam mold, a main beam intermediate body is formed on the first adhesive layer, a second adhesive layer is laid on the main beam intermediate body, the first adhesive layer and the second adhesive layer cover the main beam intermediate body, and a vacuum film is laid on the second adhesive layer.

[0029] The first adhesive absorbing layer is laid on the isolation film. After the thermoplastic resin layer is heated and melted, the fluid thermoplastic resin can flow to the bottom of the main beam intermediate body, and the first adhesive absorbing layer can be used to absorb the thermoplastic resin overflowing from the bottom of the main beam intermediate body, so as to reduce the possibility of the bottom surface of the main beam intermediate body being enriched with thermoplastic resin or the thermoplastic resin overflowing to form an unqualified bonding surface.

[0030] The second adhesive absorbing layer can cover the main beam intermediate body. The second adhesive absorbing layer can cover the upper surface, left side and right side of the main beam intermediate body. After the thermoplastic resin layer is heated and melted, the fluid thermoplastic resin has the possibility of overflowing from the upper surface, left side and right side of the main beam intermediate body. The second adhesive absorbing layer can be used to absorb the thermoplastic resin overflowing from the upper surface, left side and right side of the main beam intermediate body, so as to reduce the possibility of the upper surface, left side and right side of the main beam intermediate body being enriched with thermoplastic resin or the thermoplastic resin overflowing to form an unqualified bonding surface.

[0031] In some achievable embodiments, a thermoplastic resin layer is formed by spraying thermoplastic resin powder or thermoplastic resin particles on at least one surface of the pultruded plate using a spraying process.

[0032] The spraying process can perform quantitative spraying on the surface of the pultruded board, which is conducive to forming a thermoplastic resin layer of uniform thickness on the surface of the pultruded board, and can easily and accurately spray a pre-calculated quantitative amount of thermoplastic resin on the surface of the pultruded board to form a thermoplastic resin layer.

[0033] In a second aspect, an embodiment of the present application provides a wind turbine blade, which includes a main beam manufactured by the above-mentioned wind turbine blade main beam manufacturing method. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The features, advantages and technical effects of exemplary embodiments of the present application will be described below with reference to the accompanying drawings.

[0035] Figure 1 A schematic diagram of the structure of a wind turbine generator set provided in some embodiments of the present application;

[0036] Figure 2 A schematic diagram of the structure of a blade provided in some embodiments of the present application;

[0037] Figure 3 A schematic diagram of a partial cross-sectional structure of a blade provided in some embodiments of the present application;

[0038] Figure 4 A schematic diagram of a process for manufacturing a wind turbine blade main beam provided in some embodiments of the present application;

[0039] Figure 5 A schematic diagram of the structural layout of a method for manufacturing a wind turbine blade main beam provided in some embodiments of the present application;

[0040] Figure 6 A schematic diagram of a manufacturing process of a pultruded plate product provided in some embodiments of the present application;

[0041] Figure 7 A schematic diagram of a partial structure of a pultruded plate product provided in some embodiments of the present application;

[0042] Figure 8 A schematic diagram of a partial structure of a main beam intermediate body provided in some embodiments of the present application;

[0043] Fig. 9 A schematic diagram of a partial structure of a main beam intermediate body provided in some embodiments of the present application;

[0044] Fig.10 A schematic diagram of a partial structure of a connection state between an interface protection layer and a pultruded plate product provided in some embodiments of the present application;

[0045] Fig.11 A schematic diagram of the structural layout of a method for manufacturing a wind turbine blade main beam provided in some embodiments of the present application.

[0046] In the drawings, the drawings are not necessarily drawn to scale.

[0047] Description of reference numerals:

[0048] 10. pultruded board; 11. upper surface; 12. lower surface; 20. thermoplastic resin layer; 30. pultruded board finished product; 40. main beam mold; 50. main beam intermediate; 60. vacuum membrane; 70. air-conducting fiber layer; 80. interface protection layer;

[0049] 100, wind turbine generator set; 110, blade; 120, main beam; 130, shell; 140, web;

[0050] 200, fiber yarn; 210, dipping tank; 220, pultrusion device; 230, spraying equipment; 240, traction device; 250, cutting device;

[0051] 300, isolation film; 310, first adhesive absorption layer; 320, second adhesive absorption layer; 330, air extraction pipe;

[0052] X, thickness direction;

[0053] Y, width direction. DETAILED DESCRIPTION

[0054] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0055] Unless otherwise defined, all technical and scientific terms used in this application have the same meanings as those commonly understood by technicians in the technical field of this application; the terms used in the specification of this application are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" in the specification and claims of this application and the above-mentioned drawings and any variations thereof are intended to cover non-exclusive inclusions. The terms "first", "second", etc. in the specification and claims of this application or the above-mentioned drawings are used to distinguish different objects, rather than to describe a specific order or a primary and secondary relationship.

[0056] Reference to "embodiment" in this application means that a particular feature, structure, or characteristic described in conjunction with the embodiment may be included in at least one embodiment of the present application. The appearance of the phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments.

[0057] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", and "attached" 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 a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0058] In the embodiments of the present application, the same reference numerals represent the same components, and for the sake of brevity, detailed descriptions of the same components are omitted in different embodiments. It should be understood that the thickness, length, width and other dimensions of various components in the embodiments of the present application shown in the drawings, as well as the overall thickness, length, width and other dimensions of the integrated device are only exemplary descriptions and should not constitute any limitation to the present application.

[0059] The term "plurality" used in the present application refers to two or more (including two).

[0060] Figure 1 The structure of the wind turbine generator set 100 is schematically shown. Figure 1 As shown, an embodiment of the present application provides a wind turbine generator set 100 .

[0061] The wind turbine generator set 100 includes a tower, a nacelle and a wind rotor. The nacelle is arranged at the top of the tower. The wind rotor includes a hub and blades 110. The blades 110 are connected to the hub. The hub is connected to the main shaft of the nacelle. The blades 110 can generate torque under the action of wind. The blades 110 and the hub drive the main shaft of the nacelle to rotate, thereby converting wind energy into mechanical energy. The main shaft of the nacelle can be connected to the rotor of the generator, thereby converting mechanical energy into electrical energy.

[0062] Figure 2 The structure of the blade 110 is schematically shown. Figure 3 The partial cross-sectional structure of the blade 110 is schematically shown. Figure 2 and Figure 3 As shown, the embodiment of the present application provides a blade 110. The blade 110 includes a main beam 120, a shell 130 and a web 140. The main beam 120 is connected to the shell 130. The web 140 is arranged between two main beams 120 arranged at intervals. The web 140 can support the main beam 120.

[0063] In the related art, pultruded plates are used as the layering material of the main beam 120. In the process of making the pultruded plate, the continuous fiber yarn is impregnated with a thermosetting resin, and then the continuous fiber impregnated with the resin is passed through a pultrusion molding die of a predetermined shape. The pultrusion molding die pultrudes the continuous fiber impregnated with the resin to form a continuous pultruded plate. The continuous pultruded plate enters the traction machine and is led out. Subsequently, according to the size design requirements of the main beam 120, the continuous pultruded plate is cut to form a plurality of pultruded plates to be used as the main beam 120. In the manufacturing process of the main beam 120 of the wind turbine blade 110, a plurality of pultruded plates with a certain thickness and width are first stacked in the thickness direction of the pultruded plate, and spliced ​​in the width direction of the pultruded plate to form a multi-layer pultruded plate. An interlayer fabric is laid on each layer of the pultruded plate. The interlayer fabric includes carbon fiber cloth or carbon-glass blended fabric. Then, an infusion molding process is used to perform resin infusion and curing to form the entire main beam 120. However, due to the low permeability and poor wettability of the interlayer fabric, defects such as poor local impregnation or even dry yarn often occur in the main beam 120 manufactured by the infusion molding process.

[0064] The embodiment of the present application provides a method for manufacturing a main beam of a wind turbine blade, which can replace the infusion molding process to manufacture the main beam 120, and can simplify the molding process of the main beam 120, thereby eliminating the complicated process of the infusion molding process, eliminating the steps of laying out the auxiliary materials for infusion, and eliminating the steps of mixing and infusing the resin. Therefore, the quality of the main beam 120 molded by the method for manufacturing a main beam of a wind turbine blade in the embodiment of the present application is more stable and reliable, and the safety of the wind turbine blade 110 is improved.

[0065] Figure 4 The process of the method for manufacturing the main beam of a wind turbine blade is schematically shown. Figure 5 The structural layout of the wind turbine blade main beam manufacturing method is schematically shown. Figure 4 and Figure 5 As shown, the embodiment of the present application provides a method for manufacturing a main beam of a wind turbine blade, which comprises:

[0066] Providing a pultruded sheet 10;

[0067] A thermoplastic resin material is coated on at least one surface of the pultruded plate 10 to form a thermoplastic resin layer 20, the pultruded plate 10 and the thermoplastic resin layer 20 form an integral structure, and the pultruded plate 10 and the thermoplastic resin layer 20 form a pultruded plate finished product 30;

[0068] A main beam mold 40 is provided, and a main beam intermediate body 50 formed by stacking a plurality of pultruded plate finished products 30 is arranged in the main beam mold 40, wherein the main beam intermediate body 50 includes a plurality of pultruded plate finished products 30, and each layer of pultruded plate finished products 30 includes a plurality of pultruded plate finished products 30;

[0069] Laying a vacuum membrane 60 on the main beam intermediate body 50;

[0070] Use a vacuum device to evacuate air so that the vacuum film 60 is under negative pressure;

[0071] Heating the thermoplastic resin layer 20 so that the thermoplastic resin layer 20 melts and fills the gaps between the pultruded plates 10;

[0072] The thermoplastic resin formed by melting the thermoplastic resin layer 20 is cured to form the main beam 120 .

[0073] The method for manufacturing the main beam of a wind turbine blade provided in an embodiment of the present application forms a pultruded plate product 30 by directly setting a thermoplastic resin layer 20 on a pultruded plate 10. Then, multiple pultruded plate products 30 are stacked to form a main beam intermediate 50. Multiple pultruded plate products 30 are stacked along the thickness direction X and the width direction Y of the pultruded plate 10. The main beam intermediate 50 is heated to melt the thermoplastic resin layer 20. The thermoplastic resin after the thermoplastic resin layer 20 is melted can infiltrate the pultruded plate 10, and the thermoplastic resin can connect each pultruded plate 10 after solidification, so that each pultruded plate 10 and the solidified thermoplastic resin together form a main beam 120. The method for manufacturing the main beam of a wind turbine blade in an embodiment of the present application can replace the infusion molding process to make the main beam 120, and can simplify the molding process of the main beam 120, thereby eliminating the complex process of the infusion molding process, eliminating the laying of infusion auxiliary materials, and eliminating the steps of resin mixing infusion. Therefore, the quality of the main beam 120 formed by the method for manufacturing the main beam of a wind turbine blade according to the embodiment of the present application is more stable and reliable, thereby improving the safety of the wind turbine blade 110 .

[0074] The wind turbine blade main beam manufacturing method provided in the embodiment of the present application shortens the main beam 120 molding cycle while improving the product quality of the main beam 120, and no longer needs to detect the infiltration quality between the layer structures in the main beam 120. The wind turbine blade main beam manufacturing method provided in the embodiment of the present application has the characteristics of simple structure, clear manufacturing route, reliable product quality and high efficiency.

[0075] In some achievable ways, during the process of manufacturing the pultruded plate 10, the pultrusion die pultrudes the continuous fiber impregnated with resin to form a continuous pultruded plate 10. A thermoplastic resin layer 20 is formed on the continuous pultruded plate 10. The pultruded plate 10 with the thermoplastic resin layer 20 enters the tractor and is led out. The pultruded plate 10 with the thermoplastic resin layer 20 is cut and wound to form a spare plate material roll. Subsequently, according to the size design requirements of the main beam 120, the plate material roll is unwound and cut to form a pultruded plate finished product 30 to be used as the main beam 120.

[0076] In some examples, a spraying process is used to spray thermoplastic resin powder or thermoplastic resin particles on at least one surface of the pultruded board 10 to form a thermoplastic resin layer 20. Thermoplastic resins include, but are not limited to, polymethyl methacrylate (PMMA), polybutylene terephthalate (PBT), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polyamide (PA), polyoxymethylene (POM), polycarbonate (PC), and polyphenylene oxide. The spraying process can perform quantitative spraying on the surface of the pultruded board 10, which is conducive to forming a thermoplastic resin layer 20 of uniform thickness on the surface of the pultruded board 10, and can easily and accurately spray a pre-calculated quantitative gram amount of thermoplastic resin on the surface of the pultruded board 10 to form a thermoplastic resin layer 20.

[0077] For example, Figure 6 The manufacturing process of the pultruded plate product 30 is schematically shown. Figure 6 As shown, during the forming process of the pultruded board 10, the fiber yarn 200 passes through the resin dipping tank 210 to form the dipped fiber. The molten thermosetting resin is contained in the dipped tank 210. Thermosetting resins include unsaturated polyester resins, vinyl resins, and epoxy resins. The melting point of the thermosetting resin in the embodiment of the present application is higher than that of the thermoplastic resin, so that when the thermoplastic resin is heated, the thermosetting resin does not melt. After passing through the guide plate, the dipped fiber enters the pultrusion forming device 220 for pultrusion forming to form a continuous pultruded board 10. A spraying device 230 is used to spray on the continuous pultruded board 10 to form a thermoplastic resin layer 20. The traction device 240 pulls the pultruded board 10 with the thermoplastic resin layer 20 and conveys the continuous pultruded board 10 to the cutting device 250. The cutting device 250 cuts the continuous pultruded board 10 to form a board section to be wound. Then the board section is wound by a winder to form a board material roll. Subsequently, according to the size design requirements of the main beam 120 , the plate material roll is unrolled and cut for a second time to form a pultruded plate product 30 to constitute the main beam 120 .

[0078] In some achievable ways, after the continuous pultruded sheet 10 is cut to form a plurality of pultruded sheets 10 to form the main beam 120, and before the pultruded sheet 10 is placed in the main beam mold 40, a thermoplastic resin material is coated on the surface of the pultruded sheet 10 to form a thermoplastic resin layer 20, thereby forming a pultruded sheet finished product 30. In some examples, a spraying process is used to spray thermoplastic resin powder or thermoplastic resin particles on the surface of the pultruded sheet 10 to form the thermoplastic resin layer 20.

[0079] In some achievable ways, in the main beam mold 40, a plurality of pultruded plate products 30 are stacked to form the main beam intermediate body 50. Alternatively, after a plurality of pultruded plate products 30 are stacked to form the main beam intermediate body 50, the main beam intermediate body 50 is bound and fixed using a fiber mesh tape. Then, the main beam intermediate body 50 is hoisted as a whole into the main beam mold 40 using a hoisting tool.

[0080] In some achievable ways, Figure 7 The partial structure of the finished pultruded board 30 is schematically shown. Figure 7 As shown, the cross section of the pultruded plate 10 is rectangular. The four sides in the cross section of the pultruded plate 10 are perpendicular to each other. Along the thickness direction X of the pultruded plate 10, a thermoplastic resin layer 20 is provided on both the upper surface 11 and the lower surface 12 of the pultruded plate 10 to form a pultruded plate product 30. The multi-layer pultruded plate product 30 in the main beam intermediate body 50 is stacked along the thickness direction X of the pultruded plate 10. The multiple pultruded plate products 30 in each layer are spliced ​​along the width direction Y of the pultruded plate 10.

[0081] In the related art, in order to meet the manufacturing process requirements of the main beam 120, the cross section of the pultruded plate 10 is usually structurally designed. For example, the four corners of the pultruded plate 10 need to be polished twice to make the four corners of the cross section of the pultruded plate 10 have rounded corner structures. However, it is impossible to lay a release cloth at the position of the rounded corner structure of the pultruded plate 10.

[0082] By adopting the method for manufacturing the main beam of a wind turbine blade provided in the embodiment of the present application, the surface of the pultruded plate 10 does not need to be further processed (for example, rounded corners) to meet the use requirements. Therefore, the pultruded plate 10 with a rectangular cross section can be fully covered with a demoulding cloth on the outer surface, and the manufacturing process is simplified while meeting the design requirements.

[0083] Since the multi-layer pultruded plate product 30 is stacked along the thickness direction X of the pultruded plate 10, the thermoplastic resin layer 20 is provided on both the upper surface 11 and the lower surface 12 of the pultruded plate 10, so that two layers of thermoplastic resin layers 20 can be formed between the upper and lower pultruded plates 10. After the thermoplastic resin layer 20 is heated and melted, the pultruded plate 10 located at the upper layer can squeeze the thermoplastic resin with fluidity below under the action of its own gravity, so that the thermoplastic resin can easily flow in all directions, thereby facilitating the flowing thermoplastic resin to infiltrate the gaps between the pultruded plates 10, improving the infiltration effect of the thermoplastic resin, and reducing the possibility of poor infiltration.

[0084] For some examples, see Figure 7 As shown, along the width direction Y of the pultruded board 10 , there is a distance D between the thermoplastic resin layer 20 disposed on at least one of the upper surface 11 and the lower surface 12 of the pultruded board 10 and the edge of the pultruded board 10 .

[0085] In the same layer of pultruded plate products 30 of the main beam intermediate body 50, the thermoplastic resin layers 20 on each pultruded plate product 30 may have a spacing between them and do not contact each other, so that a space to be filled can be formed. After the thermoplastic resin layer 20 is heated and melted, the flowing thermoplastic resin will flow to the edge of the pultruded plate 10 to achieve full filling, and at the same time, it can be helpful to reduce the possibility of the thermoplastic resin overflowing from the edge of the outermost pultruded plate 10. In the case of setting the quantitative gram of the thermoplastic resin layer 20, the thermoplastic resin formed by heating and melting the thermoplastic resin layer 20 is not easy to overflow from the edge of the outermost pultruded plate 10, so that the thermoplastic resin residue is not easy to appear on the outer surface of the final formed main beam 120, so that after the main beam 120 is demoulded, it is no longer necessary to grind the main beam 120 separately to treat the thermoplastic resin enriched on the outer surface or to grind the main beam 120 separately to treat the unqualified bonding surface formed by the overflow of the thermoplastic resin.

[0086] Exemplarily, along the width direction Y of the pultruded board 10, there is a spacing D between the thermoplastic resin layer 20 disposed on the upper surface 11 of the pultruded board 10 and the edge of the pultruded board 10, and there is a spacing D between the thermoplastic resin layer 20 disposed on the lower surface 12 of the pultruded board 10 and the edge of the pultruded board 10. Along the width direction Y of the pultruded board 10, there is a spacing D between the thermoplastic resin layer 20 disposed on the upper surface 11 of the pultruded board 10 and both edges of the pultruded board 10. Along the width direction Y of the pultruded board 10, there is a spacing D between the thermoplastic resin layer 20 disposed on the lower surface 12 of the pultruded board 10 and both edges of the pultruded board 10.

[0087] In the width direction Y of the pultruded plate 10, there may be a gap between the two adjacent pultruded plates 10 on the left and right, that is, there is a gap between the left side of one pultruded plate 10 and the right side of the other pultruded plate 10. After the thermoplastic resin layer 20 provided on the upper and lower adjacent pultruded plates 10 is heated and melted, the flowing thermoplastic resin can fill the gap between the two adjacent pultruded plates 10 on the left and right, so as to ensure that the thermoplastic resin fully infiltrates each pultruded plate 10 and reduce the possibility of poor infiltration.

[0088] Exemplarily, along the width direction Y of the pultruded plate 10, the distance D between the thermoplastic resin layer 20 provided on at least one of the upper surface 11 and the lower surface 12 of the pultruded plate 10 and the edge of the pultruded plate 10 ranges from 3 mm to 5 mm. For example, the distance D between the thermoplastic resin layer 20 provided on at least one of the upper surface 11 and the lower surface 12 of the pultruded plate 10 and the edge of the pultruded plate 10 may be 3 mm, 4 mm or 5 mm.

[0089] In some achievable ways, Figure 8 The partial structure of the main beam intermediate body 50 is schematically shown. Figure 8 As shown, an air-conducting fiber layer 70 is laid between any two adjacent layers of pultruded plate products 30. In the main beam intermediate body 50, each layer of pultruded plate products 30 and each air-conducting fiber layer 70 are alternately stacked. The air-conducting fiber layer 70 has good air-conducting performance. After the thermoplastic resin layer 20 is heated and melted, the flowing thermoplastic resin can squeeze the gas between the pultruded plates 10 and guide it to the external environment through the air-conducting fiber layer 70, effectively reducing the possibility of bubbles appearing during the thermoplastic resin being compressed and solidified.

[0090] In some examples, the material of the air-conducting fiber layer 70 may include at least one of glass fiber and carbon fiber. The air-conducting fiber layer 70 laid between two adjacent layers of the pultruded board product 30 is a dry yarn, that is, no resin material is provided on the air-conducting fiber layer 70 .

[0091] In some examples, the air-conducting fiber layer 70 may be an integral layer structure. Along the width direction Y of the pultruded board 10 , the width of the air-conducting fiber layer 70 may be greater than, equal to, or less than the width of the entire pultruded board product 30 .

[0092] In some examples, multiple air conducting fiber layers 70 may be spliced ​​to each other.

[0093] In some examples, in the main beam intermediate body 50, the upper surface 11 and the lower surface 12 of the pultruded plate 10 are provided with a thermoplastic resin layer 20. The pultruded plate 10 located above the air-conducting fiber layer 70 has a thermoplastic resin layer 20 between it and the air-conducting fiber layer 70, and the pultruded plate 10 located below the air-conducting fiber layer 70 has a thermoplastic resin layer 20 between it and the air-conducting fiber layer 70, so that for one air-conducting fiber layer 70, both the upper and lower sides of the air-conducting fiber layer 70 are provided with a thermoplastic resin layer 20. After the thermoplastic resin layers 20 on both sides of the air-conducting fiber layer 70 are heated and melted, the flowing thermoplastic resin can simultaneously infiltrate the air-conducting fiber layer 70 from both upper and lower directions and flow in the air-conducting fiber layer 70, thereby effectively ensuring that the air-conducting fiber layer 70 obtains a good infiltration effect and reducing the possibility of poor infiltration.

[0094] In some achievable ways, Fig. 9 The partial structure of the main beam intermediate body 50 is schematically shown. Fig. 9 As shown, the cross section of the pultruded plate 10 is rectangular. In the main beam intermediate body 50, any two adjacent pultruded plates 10 have thermoplastic resin layers 20 disposed on their surfaces corresponding to each other.

[0095] by Fig. 9 The structure shown is used as an example for illustration. The pultruded plate 10 in the upper left corner and the pultruded plate 10 below are two adjacent pultruded plates 10. The lower surface 12 of the pultruded plate 10 in the upper left corner corresponds to the upper surface 11 of the pultruded plate 10 below. The lower surface 12 of the pultruded plate 10 in the upper left corner is provided with a thermoplastic resin layer 20. The upper surface 11 of the pultruded plate 10 below is provided with a thermoplastic resin layer 20. For another example, the pultruded plate 10 in the upper left corner and the pultruded plate 10 on the right are two adjacent pultruded plates 10. The right surface of the pultruded plate 10 in the upper left corner corresponds to the left side surface of the pultruded plate 10 on the right. The right surface of the pultruded plate 10 in the upper left corner is provided with a thermoplastic resin layer 20. The left side surface of the pultruded plate 10 on the right is provided with a thermoplastic resin layer 20. By analogy, in any two adjacent pultruded plates 10, the surfaces corresponding to each other are provided with a thermoplastic resin layer 20.

[0096] In any two adjacent pultruded plates 10, the thermoplastic resin layers 20 are arranged on the surfaces corresponding to each other, so that the thermoplastic resin layers 20 at different positions can contact each other, so that after the thermoplastic resin layers 20 at different positions are heated and melted, the flowing thermoplastic resin can be connected as a whole to ensure that the thermoplastic resin fully infiltrates each pultruded plate 10, thereby reducing the possibility of poor infiltration.

[0097] In some examples, along the thickness direction X of the pultruded plate 10, the multiple layers of pultruded plate products 30 in the main beam intermediate body 50 are stacked, and any two adjacent layers of pultruded plate products 30 are in direct contact with each other. Any two adjacent thermoplastic resin layers 20 are in direct contact with each other.

[0098] Since the thermoplastic resin layers 20 are disposed on the surfaces corresponding to each other in any two adjacent pultruded plates 10, the thermoplastic resin layers 20 at different positions can contact each other, so that after the thermoplastic resin layers 20 at different positions are heated and melted, the flowing thermoplastic resin can be connected as a whole, and there is no need to squeeze the gas in the gaps between different pultruded plates 10. In the process of forming the main beam intermediate body 50, it is no longer necessary to lay the air-conducting fiber layer 70, thereby simplifying the process and saving materials.

[0099] In some achievable ways, Fig.10 The local structure of the interface protection layer and the pultruded plate product 30 in the connected state is schematically shown. Fig.10 As shown, an interface protection layer 80 is provided on the thermoplastic resin layer 20 of the pultruded plate product 30, and the interface protection layer 80 is used to protect the thermoplastic resin layer 20 below. Before the pultruded plate product 30 is stacked and arranged in the main beam mold 40 to form the main beam intermediate 50, the interface protection layer 80 is removed.

[0100] When the pultruded plate finished product 30 is not stacked in the main beam mold 40, the pultruded plate finished product 30 needs to be transferred and stacked for storage. When the pultruded plate finished product 30 is transferred, the interface protection layer 80 can separate the pultruded plate finished product 30 from the transfer device, effectively reducing the possibility of friction or collision between the pultruded plate finished product 30 and the transfer device, which may cause partial peeling of the thermoplastic resin layer 20. When the pultruded plate finished product 30 is stacked for storage, the interface protection layer 80 can separate the upper and lower adjacent pultruded plate finished products 30, effectively reducing the possibility of friction or collision between the upper and lower adjacent pultruded plate finished products 30, which may cause partial peeling of the thermoplastic resin layer 20.

[0101] If the thermoplastic resin layer 20 is contaminated, after the thermoplastic resin layer 20 is melted, bubbles will be generated in the thermoplastic resin at the contaminant, or the contaminant will affect the fluidity of the thermoplastic resin and cause poor wetting. The interface protection layer 80 of the embodiment of the present application can protect the thermoplastic resin layer 20 below, effectively reducing the possibility of contamination of dust, fiber and other contaminants on the thermoplastic resin layer 20, so that the thermoplastic resin layer 20 remains clean, effectively solving the above technical problems.

[0102] In some examples, the interface protection layer 80 may be a release cloth or a plastic film.

[0103] In some achievable embodiments, the thickness of the thermoplastic resin layer 20 ranges from 800 micrometers to 1500 micrometers. In some examples, the thickness of the thermoplastic resin layer 20 ranges from 1000 micrometers to 1500 micrometers. For example, the thickness of the thermoplastic resin layer 20 may be 900 micrometers, 1100 micrometers, or 1300 micrometers.

[0104] When the thickness of the thermoplastic resin layer 20 is less than 800 microns, the overall volume of the thermoplastic resin layer 20 is relatively small, so that the gram weight of the thermoplastic resin layer 20 is relatively small, and there is a possibility that the thermoplastic resin layer 20 cannot effectively fill the gaps between the pultruded plates 10 after melting, resulting in poor wetting of the pultruded plates 10. When the thickness of the thermoplastic resin layer 20 is greater than 1500 microns, the volume of the thermoplastic resin layer 20 is relatively large, so that the gram weight of the thermoplastic resin layer 20 is relatively large, and there is a possibility that the thermoplastic resin layer 20 overflows after filling the gaps between the pultruded plates 10 after melting, resulting in the enrichment of thermoplastic resin on the outer surface of the main beam 120 after molding or the formation of an unqualified bonding surface. The method of taking the thickness of the thermoplastic resin layer 20 in the range of 800 microns to 1500 microns can effectively reduce the possibility of the above-mentioned technical problems.

[0105] In some achievable ways, Fig.11 The structural layout of the wind turbine blade main beam manufacturing method is schematically shown. Fig.11 As shown, an isolation film 300 and a first adhesive layer 310 are laid on the main beam mold 40. A main beam intermediate body 50 is formed on the first adhesive layer 310. A second adhesive layer 320 is laid on the main beam intermediate body 50. The first adhesive layer 310 and the second adhesive layer 320 cover the main beam intermediate body 50. A vacuum film 60 is laid on the second adhesive layer 320.

[0106] Before laying the isolation film 300 on the main beam mold 40, the surface of the main beam mold 40 is cleaned to remove dust, glue residue and other dirt on the surface of the main beam mold 40. Then, the isolation film 300 is laid on the main beam mold 40. The isolation film 300 can isolate the surface of the main beam mold 40, thereby protecting the surface of the main beam mold 40.

[0107] The first adhesive absorbing layer 310 is laid on the isolation film 300. After the thermoplastic resin layer 20 is heated and melted, the fluid thermoplastic resin can flow to the bottom of the main beam intermediate body 50, and the first adhesive absorbing layer 310 can be used to absorb the thermoplastic resin overflowing from the bottom of the main beam intermediate body 50, so as to reduce the possibility of the bottom surface of the main beam intermediate body 50 being enriched with thermoplastic resin or the thermoplastic resin overflowing to form an unqualified bonding surface.

[0108] In some examples, the width of the first adhesive absorbing layer 310 may be greater than the width of the main beam intermediate body 50 . Along the thickness direction X of the pultruded plate 10 , the orthographic projection of the main beam intermediate body 50 is located within the orthographic projection of the first adhesive absorbing layer 310 .

[0109] In some examples, the first adhesive absorbing layer 310 may be an adhesive absorbing felt.

[0110] The second adhesive absorbing layer 320 can cover the main beam intermediate body 50. The second adhesive absorbing layer 320 can cover the top, left side and right side of the main beam intermediate body 50. After the thermoplastic resin layer 20 is heated and melted, the thermoplastic resin with fluidity has the possibility of overflowing from the top, left side and right side of the main beam intermediate body 50. The second adhesive absorbing layer 320 can be used to absorb the thermoplastic resin overflowing from the top, left side and right side of the main beam intermediate body 50, so as to reduce the possibility of the top, left side and right side of the main beam intermediate body 50 being enriched with thermoplastic resin or the thermoplastic resin overflowing to form an unqualified bonding surface.

[0111] In some examples, the second adhesive absorbing layer 320 may be an adhesive absorbing felt.

[0112] In some examples, an air extraction pipe 330 is provided between the edges of the first adhesive absorption layer 310 and the second adhesive absorption layer 320. The first adhesive absorption layer 310 and the second adhesive absorption layer 320 cover the air extraction pipe 330. The air extraction pipe 330 is connected to the air extraction port on the main beam mold 40. The vacuum device extracts air through the air extraction pipe 330. After the value displayed by the vacuum device remains stable, the air extraction is stopped and the pressure is maintained, so as to provide environmental conditions that meet the requirements for the main beam intermediate body 50 to form the main beam 120. After the pressure maintenance is completed, the main beam mold 40 is heated. When the outer surface temperature of the main beam mold 40 is lower than 170 degrees Celsius (℃), the outer surface of the main beam mold 40 is covered with insulation cotton. When the outer surface temperature of the main beam mold 40 is higher than 200 degrees Celsius (℃), the insulation cotton is removed. The thermoplastic resin layer 20 in the main beam intermediate body 50 is melted by heating, and is fully infiltrated under a negative pressure environment to fill the gaps between each pultruded plate 10. The cured thermoplastic resin may connect the pultruded panels 10 to form the main beam 120 .

[0113] The embodiment of the present application also provides a wind turbine blade 110, which includes a main beam 120 manufactured by the wind turbine blade main beam manufacturing method. The main beam 120 formed by the wind turbine blade main beam manufacturing method of the embodiment of the present application has more stable and reliable quality, thereby improving the safety of the wind turbine blade 110.

[0114] 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 is no structural conflict. 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 method for manufacturing a main beam of a wind turbine blade, characterized in that: include: Provide pultruded panels; Coating a thermoplastic resin material on at least one surface of the pultruded plate to form a thermoplastic resin layer, wherein the pultruded plate and the thermoplastic resin layer form an integral structure, and the pultruded plate and the thermoplastic resin layer form a pultruded plate finished product; Providing a main beam mold, placing a main beam intermediate body formed by stacking a plurality of the pultruded plate finished products in the main beam mold, wherein the main beam intermediate body comprises a plurality of the pultruded plate finished products, and each layer of the pultruded plate finished products comprises a plurality of the pultruded plate finished products; Laying a vacuum film on the middle body of the main beam; Using a vacuum device to evacuate air so that the vacuum film has a negative pressure; heating the thermoplastic resin layer so that the thermoplastic resin layer melts and fills the gaps between the pultruded plates; The thermoplastic resin formed by melting the thermoplastic resin layer is cured to form a main beam.

2. The method for manufacturing a wind turbine blade main beam according to claim 1, characterized in that: The cross-section of the pultruded plate is rectangular. The thermoplastic resin layer is arranged on the upper surface and the lower surface of the pultruded plate along the thickness direction of the pultruded plate to form the pultruded plate product. The multiple layers of the pultruded plate product in the main beam intermediate body are stacked along the thickness direction of the pultruded plate.

3. The method for manufacturing a wind turbine blade main beam according to claim 2, characterized in that: In a width direction of the pultruded plate, the thermoplastic resin layer provided on at least one of the upper surface and the lower surface has a gap with an edge of the pultruded plate.

4. The method for manufacturing a wind turbine blade main beam according to claim 3, characterized in that: The distance between the thermoplastic resin layer provided on at least one of the upper surface and the lower surface and the edge of the pultruded plate ranges from 3 mm to 5 mm.

5. The method for manufacturing a wind turbine blade main beam according to claim 2, characterized in that: An air-conducting fiber layer is laid between any two adjacent layers of the pultruded board product.

6. The method for manufacturing a wind turbine blade main beam according to claim 1, characterized in that: The cross section of the pultruded plate is rectangular. In the main beam intermediate body, any two adjacent pultruded plates have the thermoplastic resin layer disposed on their surfaces corresponding to each other.

7. The method for manufacturing a wind turbine blade main beam according to claim 6, characterized in that: Along the thickness direction of the pultruded plate, the multiple layers of the pultruded plate products in the main beam intermediate body are stacked, and any two adjacent layers of the pultruded plate products are in direct contact with each other.

8. The method for manufacturing a wind turbine blade main beam according to any one of claims 1 to 7, characterized in that: An interface protective layer is arranged on the thermoplastic resin layer of the pultruded board product, and the interface protective layer is used to protect the thermoplastic resin layer below. Before the pultruded board product is stacked and arranged in the main beam mold to form the main beam intermediate, the interface protective layer is removed.

9. The method for manufacturing a wind turbine blade main beam according to any one of claims 1 to 7, characterized in that: The thickness of the thermoplastic resin layer ranges from 800 microns to 1500 microns.

10. The method for manufacturing a wind turbine blade main beam according to any one of claims 1 to 7, characterized in that: An isolation film and a first adhesive layer are laid on the main beam mold, the main beam intermediate body is formed on the first adhesive layer, a second adhesive layer is laid on the main beam intermediate body, the first adhesive layer and the second adhesive layer cover the main beam intermediate body, and the vacuum film is laid on the second adhesive layer.

11. The method for manufacturing a wind turbine blade main beam according to any one of claims 1 to 7, characterized in that: The thermoplastic resin layer is formed by spraying thermoplastic resin powder or thermoplastic resin particles on at least one surface of the pultruded plate using a spraying process.

12. A wind turbine blade, characterized in that: It comprises a main beam manufactured by the method for manufacturing a main beam of a wind turbine blade as described in any one of claims 1 to 11.

Images