Manufacturing method of scaled blade

Abstract

The invention provides a manufacturing method of a scaled blade. The manufacturing method of the scaled blade comprises the following steps: preparing the shell; a liquid filling material is injected into the shell; carrying out curing treatment on the liquid filling material so as to enable the shell to form a solid structure; an accommodating groove is formed in the solidified filling material; and the prepared and formed force bearing piece is arranged in the containing groove. The problem that in the prior art, the machining and manufacturing time of blades is long is solved.

Description

Technical Field

[0001] The invention relates to the field of wind turbines, and in particular to a method for manufacturing scaled-down blades. Background Art

[0002] In the field of renewable energy, especially in the development of wind power generation technology, the design and optimization of large wind turbine blades is one of the key links to improve wind power generation efficiency and reduce costs. The full-scale experiment of large wind turbine blades is expensive. The traditional scaled blade manufacturing method usually includes designing specific blade plies, material selection and processing technology. This process is not only complicated, but also when it is necessary to compare different structural performances, it is often necessary to design and manufacture multiple scaled blades with different configurations, which significantly prolongs the processing cycle and increases the manufacturing cost. In addition, traditional manufacturing processes may make it difficult to accurately control the internal structure of the blade, especially for composite blades. It is impossible to ensure the precise positioning of the internal load-bearing parts and the structural consistency of the entire blade. Therefore, the blade needs to be processed under this premise.

[0003] As can be seen from the above, the prior art has the problem that the processing and manufacturing time of blades is relatively long. Summary of the invention

[0004] The main purpose of the present invention is to provide a method for manufacturing a scaled-down blade to solve the problem of long processing and manufacturing time of the blade in the prior art.

[0005] In order to achieve the above-mentioned purpose, the present invention provides a method for manufacturing a scaled blade, comprising: preparing a shell; injecting liquid filler into the shell; solidifying the liquid filler to form a solid structure of the shell; opening a receiving groove on the solidified filler; and installing the prepared load-bearing member into the receiving groove.

[0006] Furthermore, the step of opening a receiving groove on the solidified filling material includes: selecting an opening position and a size of the receiving groove.

[0007] Further, the location of the receiving groove is selected, including: a plurality of receiving grooves are provided at intervals along the circumference of the inner side wall of the shell; and each receiving groove extends along the length direction of the shell.

[0008] Further, selecting the size of the receiving groove includes: when opening two adjacent receiving grooves, setting the extension length of the receiving groove close to the front edge of the shell to be greater than the length of the receiving groove close to the rear edge of the shell.

[0009] Furthermore, the prepared load-bearing member is installed into the receiving groove, including: installing a plurality of load-bearing members into the plurality of receiving grooves in a one-to-one correspondence.

[0010] Further, preparing the shell includes: preparing the thickness of the rear edge of the shell to be smaller than the thickness of the front edge of the shell.

[0011] Furthermore, the scaled-down blade manufacturing method also includes: selecting a strip structure made of carbon fiber material as a load-bearing member.

[0012] Furthermore, the scaled blade manufacturing method further comprises preparing a filler before injecting the liquid filler into the shell. During the preparation of the filler,

[0013] Add a reinforcing agent to the base material; adjust the amount of the reinforcing agent added to obtain a filler material with a preset density.

[0014] Further, the filling material is prepared, including: selecting a foaming material as a base material; adjusting the amount of the reinforcing agent added to obtain a density of 100 kg / m 3 ~150kg / m 3 Filling material.

[0015] Furthermore, the scaled-down blade manufacturing method further includes coating the outer peripheral side of the shell with a film layer after the prepared load-bearing member is installed into the receiving groove.

[0016] By applying the technical solution of the present invention, the scaled blade manufacturing method includes preparing a shell; injecting liquid filler into the shell; curing the liquid filler to form a solid structure of the shell; opening a receiving groove on the cured filler; loading the prepared load-bearing member into the receiving groove, and preparing the shell into a suitable size according to actual needs, and then injecting liquid filler into the shell. When the liquid filler is filled into the shell, it can adapt to shells of different structural sizes. After the liquid filler is cured, it can fill the entire shell, thereby forming a solid structure to enhance the structural strength of the shell. The opening position of the receiving groove is selected on the cured filler according to actual needs, and the prepared load-bearing member is placed in the receiving groove. There is no need to set up an installation space and a reinforcement structure in advance inside the shell. The solid structure blade can be quickly prepared by converting the liquid and solid states of the filler and setting the load-bearing member. The processing is simple, and the formation can be rapid, shortening the manufacturing process and time, and solving the problem of long processing and manufacturing time of the blades in the prior art. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings constituting a part of the present application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0018] Figure 1 A flow chart showing a method for manufacturing a scaled blade in a specific embodiment of the present invention; and

[0019] Figure 2A schematic structural diagram showing an angle of a blade in a specific embodiment of the present invention is shown;

[0020] Figure 3 A schematic structural diagram of a blade at another angle in a specific embodiment of the present invention is shown.

[0021] The above drawings include the following reference numerals:

[0022] 10. Shell; 11. Front edge; 12. Rear edge; 20. Filling material; 30. Load-bearing member. DETAILED DESCRIPTION

[0023] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0024] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meanings as commonly understood by ordinary technicians in the technical field to which this application belongs.

[0025] In the present invention, unless otherwise specified, the directional words used, such as "up, down, top, bottom", usually refer to the directions shown in the drawings, or to the components themselves in the vertical, perpendicular or gravity directions; similarly, for ease of understanding and description, "inside and outside" refer to the inside and outside relative to the outline of each component itself, but the above-mentioned directional words are not used to limit the present invention.

[0026] Obviously, the above-described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0027] In order to solve the problem of long processing and manufacturing time of blades in the prior art, the present invention provides a method for manufacturing scaled-down blades.

[0028] like Figures 1 to 3 As shown, the scaled blade manufacturing method includes: preparing a shell 10; injecting a liquid filler 20 into the shell 10; curing the liquid filler 20 to form a solid structure of the shell 10; opening a receiving groove on the cured filler 20; and installing the prepared load-bearing member 30 into the receiving groove.

[0029] The shell 10 is prepared into a suitable size according to actual needs, and then a liquid filler 20 is injected into the shell 10. When the liquid filler 20 is filled into the shell 10, it can adapt to shells 10 of different structural sizes. After the liquid filler 20 is solidified, it can fill the entire shell 10, thereby forming a solid structure to enhance the structural strength of the shell 10. The opening position of the receiving groove is selected on the solidified filler 20 according to actual needs, and the prepared load-bearing member 30 is placed in the receiving groove. There is no need to set up an installation space and a reinforcement structure in advance inside the shell 10. The solid structure blade can be quickly prepared by converting the liquid and solid states of the filler 20 and setting the load-bearing member 30. The processing is simple, and it can be quickly formed, shortening the manufacturing process and time.

[0030] In this embodiment, the shell 10 is provided with a accommodating cavity, and the filler 20 enters the accommodating cavity in liquid form. Since the filler 20 is fluid at this time, no matter what structural form the accommodating cavity of the shell 10 is, the filler 20 can fill the entire accommodating cavity, thereby avoiding the presence of hollow areas in some areas of the blades, which would lead to a decrease in the pressure-bearing capacity of the blades.

[0031] In this embodiment, vacuum injection or pressure injection can be used to inject the liquid filler 20 into the housing 10. This process needs to be precisely controlled to avoid over-injection or under-injection, while ensuring that the filler 20 can fully fill all gaps.

[0032] In this embodiment, the filler 20 needs to be cured before the receiving groove is opened. The filler 20 contains foaming material and can be cured by room temperature curing. This method is simple and low in cost. In order to further improve the speed of blade manufacturing and reduce the production cycle, heating curing can be used, such as electric heating, hot air circulation or infrared heating. In actual use, the blades filled with filler 20 can be placed in a large drying box or a large hot air blower can be set. Selecting different curing modes according to the type of filler 20 can improve the curing effect, thereby improving the production efficiency of the blades.

[0033] In this embodiment, the step of forming a receiving groove on the solidified filling material 20 includes: selecting a position and a size of the receiving groove.

[0034] Specifically, the opening position of the receiving groove can be the middle of the filler 20 or the position of the filler 20 close to the inner wall of the shell 10. The number and position of the receiving grooves determine the number and position of the load-bearing members 30. By selecting the opening position of the receiving grooves, different structures can be formed inside the shell 10. At the same time, the width, length and curvature of the receiving grooves are reasonably selected to avoid affecting the overall structural strength of the blade.

[0035] In this embodiment, the length of the accommodating groove is parallel to the length direction of the blade, so that a longitudinal skeleton along the length direction of the blade is formed inside the housing 10 after the load-bearing member 30 is installed in place.

[0036] In another optional embodiment of the present application, the length direction of the receiving groove is parallel to the width direction of the shell 10. The filling material 20 is injected layer by layer, and the shell 10 is arranged into multiple areas along its length direction. Whenever the filling material 20 completes the filling of an area, a receiving groove is opened on the solidified filling material and a load-bearing member 30 is placed. This step is repeated until the receiving cavity of the shell 10 is filled. In this embodiment, the length direction of the load-bearing member 30 is parallel to the width direction of the blade, and multiple load-bearing members 30 are arranged at intervals along the length direction of the blade.

[0037] In this embodiment, the positions of the receiving grooves are selected, including: a plurality of receiving grooves are provided at intervals along the circumference of the inner side wall of the housing 10; and each receiving groove extends along the length direction of the housing.

[0038] Specifically, a plurality of accommodating grooves are arranged at intervals along the circumferential side of the inner wall of the shell 10 so as to improve the bending strength of the blade in the length direction. When the blade is actually in use, one end is connected to the main shaft and rotates under the action of wind force. After the accommodating groove accommodates the load-bearing member 30, the structural strength of the blade can be strengthened.

[0039] In another embodiment of the present application not shown in the figure, a plurality of accommodating grooves are spaced along the inner wall of the shell 10 to form two inner and outer circles, and the plurality of accommodating grooves are staggered, that is, the accommodating grooves located in the inner circle are located between the two accommodating grooves in the outer circle.

[0040] Furthermore, the thickness and width of the accommodating groove are not unique, so as to adapt to the load-bearing members 30 of different structural sizes.

[0041] In this embodiment, the size of the receiving groove is selected, including: when two adjacent receiving grooves are formed, the extension length of the receiving groove near the front edge 11 of the shell 10 is set to be greater than the length of the receiving groove near the rear edge 12 of the shell 10 .

[0042] It should be noted that the leading edge 11 refers to Figure 2 The left side of the housing 10, the rear edge 12 refers to Figure 2 The right side of the middle shell 10.

[0043] Specifically, the shape of the shell 10 is similar to that of a wing, and the lengths of the multiple accommodating grooves gradually decrease along the width direction of the shell 10, so as to adapt to the need for the leading edge 11 of the shell 10 to bear a larger aerodynamic load. The length of the accommodating grooves of the leading edge 11 is longer, thereby preventing a longer load-bearing member 30 to improve the structural strength of the leading edge 11.

[0044] In this embodiment, the prepared load-bearing member 30 is installed into the receiving groove, which includes: installing a plurality of load-bearing members 30 into the plurality of receiving grooves in a one-to-one correspondence.

[0045] Specifically, the distribution of the multiple load-bearing members 30 in the shell 10 is not uniform. The number of load-bearing members 30 provided at the leading edge 11 of the shell 10 is greater than the number of load-bearing members 30 at the trailing edge 12 of the shell 10, in order to cope with the higher aerodynamic loads encountered by the leading edge 11 when rotating at high speed, especially under high wind speed conditions. Increasing the number of load-bearing members 30 at the leading edge 11 can better disperse the load and reduce stress concentration, thereby improving the structural stability of the blade under extreme conditions. The leading edge 11 is the part of the blade that is most susceptible to wind and sand, rain erosion and hail impact. Adding load-bearing members 30 can enhance the protection ability of the leading edge, reduce the damage to the blade caused by external environmental factors, and ultimately achieve improved wind energy conversion efficiency and reduced maintenance costs.

[0046] In this embodiment, the load-bearing member 30 is accurately positioned by a positioning tool or a fixture. In order to improve the matching strength between the load-bearing member 30 and the filler 20, an adhesive is provided on the surface of the load-bearing member 30. When multiple load-bearing members 30 are installed, the load-bearing member 30 at the front edge 11 is installed first, and then the load-bearing member 30 at the rear edge 12 is gradually installed. Optionally, in order to speed up production efficiency, each load-bearing member 30 is provided with a number, and the corresponding receiving groove is also provided with a number for corresponding assembly.

[0047] In this embodiment, preparing the shell 10 includes: preparing the thickness of the rear edge 12 of the shell 10 to be smaller than the thickness of the front edge 11 of the shell 10 .

[0048] Specifically, the front edge 11 of the housing 10 is relatively thick and smooth, while the rear edge 12 is relatively thin and sharp. Figure 3 As shown, the blade generates lift in the downwind direction, while reducing resistance and improving energy conversion efficiency. The thickness of the leading edge 11 is not uniform. The thickness of the leading edge 11 gradually decreases in the direction away from the main axis, that is, the thickness of the leading edge 11 gradually decreases from the root to the tip of the blade. The root of the blade is connected to the main axis to increase the thickness so that it can withstand higher mechanical stress and gravity, while the tip part is thinner, which can reduce the overall weight of the blade, increase the rotation speed and reduce air resistance. Optionally, the trailing edge 12 is provided with serrations or bends to reduce noise and avoid the formation of vortices at high wind speeds, which affects the service life and structural strength of the blade.

[0049] In this embodiment, when preparing the shell 10, the original size of the blade is proportionally reduced according to actual needs, and a complete mold is prepared. Composite materials are used as the constituent materials of the shell 10, such as carbon fiber reinforced composite materials, which can ensure both light weight and structural strength. The composite materials are placed in the mold and pressed into shape using a laminator.

[0050] In this embodiment, the scaled-down blade manufacturing method further includes: selecting a strip structure made of carbon fiber material as the load-bearing member 30 .

[0051] Specifically, the load-bearing member 30 is a strip-shaped structure that is easy to process and produce, and can effectively improve production efficiency. Moreover, the load-bearing member 30 made of carbon fiber significantly enhances the bending strength and rigidity of the blade, while maintaining light weight to avoid causing the blade to be too heavy. Optionally, the load-bearing member 30 and the shell 10 are made of the same material, and the load-bearing member 30 is produced simultaneously during the production of the shell 10. If the same material is used, there is no need to replace the material, which saves working time and can avoid the cost increase caused by using different materials.

[0052] In this embodiment, the scaled blade manufacturing method also includes preparing the filler 20 before injecting the liquid filler 20 into the shell 10. During the preparation of the filler 20, a reinforcing agent is added to the base material; and the amount of the reinforcing agent added is adjusted to obtain a filler 20 of a preset density.

[0053] Specifically, the filler 20 with a preset density is obtained by mixing the reinforcing agent and the base material, so as to ensure that the solid structure formed by the filler 20 has sufficient structural strength. The filler 20 is an important part of the blade. If the density is too low, a large number of holes will be easily formed on the surface or inside of the filler 20 after the liquid filler 20 is solidified, resulting in insufficient solid structure strength of the blade.

[0054] In this embodiment, the filling material 20 is prepared, including: selecting a foaming material as a base material; adjusting the amount of the reinforcing agent added to obtain a density of 100 kg / m 3 ~150kg / m 3 Filling material 20.

[0055] Specifically, the foaming material can be polyurethane foam or epoxy resin foam, and the reinforcing agent can be microspheres, nanoparticles, fibers and polymer compounds. Microspheres can be used to reduce density, and fibers (such as carbon fibers or glass fibers) can enhance mechanical properties. Optionally, an appropriate amount of hollow microspheres or microbeads and fibers are added to the base material. When the density of the filler 20 is within the above range, the filler 20 has better performance and can just fill the entire shell 10 after curing.

[0056] In this embodiment, after the filling material 20 is prepared, the performance of the filling material 20 is tested. The density, mechanical properties and durability of the filling material 20 are tested to determine whether the use requirements are met.

[0057] In this embodiment, the scaled blade manufacturing method further includes coating the outer peripheral side of the shell 10 with a film layer after the prepared load-bearing member 30 is installed into the receiving groove.

[0058] Specifically, the film layer is a polyurethane coating or a composite film to reduce the air resistance when the blades rotate. When the film layer is set, the selected material is evenly coated on the outer surface of the shell by spraying, coating or heat shrinking process to form a film layer. When the heat shrinking process is used, the temperature and time need to be controlled to ensure that the film is close to the shell 10 to form a smooth surface without wrinkles.

[0059] Furthermore, after the film layer is set, the edges of the blades are sealed to prevent moisture and dust from penetrating and affecting the structural integrity and aerodynamic performance of the blades.

[0060] In this embodiment, after the film layer is coated on the outer peripheral side of the shell 10, the blade is also tested, including using non-destructive testing technology to detect whether there are large gaps inside the blade, performing static and dynamic mechanical property tests on the blade, and testing the aerodynamic performance of the blade in a wind tunnel.

[0061] From the above description, it can be seen that the above-mentioned embodiments of the present invention achieve the following technical effects: the scaled blade manufacturing method includes: preparing a shell 10; injecting a liquid filler 20 into the shell 10; curing the liquid filler 20 to form a solid structure of the shell 10; opening a receiving groove on the cured filler 20; loading the prepared load-bearing member 30 into the receiving groove, preparing the shell 10 into a suitable size according to actual needs, and then injecting the liquid filler 20 into the shell 10. When the liquid filler 20 is filled into the shell 10, it can be adapted to With shells 10 of different structural sizes, the liquid filler 20 can fill the entire shell 10 after solidification, thereby forming a solid structure to enhance the structural strength of the shell 10. The location of the receiving groove is selected on the solidified filler 20 according to actual needs, and the prepared load-bearing member 30 is placed in the receiving groove. There is no need to set up installation space and reinforcement structure inside the shell 10 in advance. The solid structure blade can be quickly prepared by converting the liquid and solid states of the filler 20 and setting the load-bearing member 30. The processing is simple, the shape can be quickly formed, and the manufacturing process and time are shortened.

[0062] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0063] It should be noted that the terms "upper", "lower", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the terms used in this way can be interchanged where appropriate, so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein.

[0064] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for manufacturing a scaled-down blade, characterized in that: include: preparing a shell; injecting liquid filler into the shell; Solidifying the liquid filler so that the shell forms a solid structure; Opening a receiving groove on the solidified filling material; The prepared load-bearing member is installed into the receiving groove.

2. The method for manufacturing a scaled-down blade according to claim 1, characterized in that: The step of opening a receiving groove on the solidified filling material comprises: Select the location and size of the receiving groove.

3. The method for manufacturing a scaled-down blade according to claim 2, characterized in that: The step of selecting the opening position of the receiving groove comprises: A plurality of the accommodating grooves are provided at intervals along the circumference of the inner side wall of the shell; Each of the accommodating grooves extends along the length direction of the shell.

4. The method for manufacturing a scaled-down blade according to claim 2, characterized in that: The step of selecting the size of the receiving groove comprises: When two adjacent accommodating grooves are formed, the extension length of the accommodating groove close to the front edge of the shell is set to be greater than the length of the accommodating groove close to the rear edge of the shell.

5. The method for manufacturing a scaled-down blade according to claim 1, characterized in that: The step of placing the prepared load-bearing member into the receiving groove comprises: The plurality of load-bearing members are installed in the plurality of accommodating grooves in a one-to-one correspondence.

6. The method for manufacturing a scaled-down blade according to claim 1, characterized in that: The preparation of the shell comprises: The thickness of the rear edge of the shell is made smaller than the thickness of the front edge of the shell.

7. The method for manufacturing a scaled-down blade according to claim 1, characterized in that: The scaled blade manufacturing method further comprises: A strip structure made of carbon fiber material is selected as the load-bearing member.

8. The method for manufacturing a scaled-down blade according to claim 1, characterized in that: The scaled-down blade manufacturing method further comprises preparing the filler before injecting the liquid filler into the shell. During the preparation of the filler, Adding a strengthening agent to the base material; The amount of the reinforcing agent added is adjusted to obtain the filler with a preset density.

9. The method for manufacturing a scaled-down blade according to claim 8, characterized in that: The preparation of the filler comprises: Choose foam material as the base material; The amount of the reinforcing agent added was adjusted to obtain a density of 100 kg / m 3 ~150kg / m 3 of the filler.

10. The method for manufacturing a scaled-down blade according to any one of claims 1 to 9, characterized in that: The scaled blade manufacturing method further comprises, after the prepared load-bearing member is installed into the receiving groove, A thin film layer is coated on the outer peripheral side of the shell.

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