Scaled blade manufacturing method

Abstract

This invention provides a method for manufacturing scaled-down blades. The method includes: preparing a shell; injecting a liquid filler into the shell; solidifying the liquid filler to form a solid structure in the shell; creating a receiving groove in the solidified filler; and inserting a pre-formed load-bearing component into the receiving groove. This invention solves the problem of long processing and manufacturing time for blades in the prior art.

Description

Technical Field

[0001] This invention relates to the field of wind turbines, and more specifically, to a method for manufacturing scaled-down blades. Background Technology

[0002] In the field of renewable energy, especially in the development of wind power technology, the design and optimization of large wind turbine blades is one of the key links in improving wind power efficiency and reducing costs. Full-scale testing of large wind turbine blades is costly. Traditional scaled-down blade manufacturing methods typically involve designing specific blade layups, material selection, and processing techniques. This process is not only complex, but when comparing the performance of different structures, it often requires designing and manufacturing multiple scaled-down blades with different configurations, significantly extending the processing cycle and increasing manufacturing costs. Furthermore, traditional manufacturing processes may struggle to precisely control the internal structure of the blade, especially for composite material blades, making it difficult to ensure the precise positioning of internal load-bearing components and the overall structural consistency of the blade. Therefore, blade processing is necessary under these circumstances.

[0003] As can be seen from the above, the existing technology has the problem of long processing and manufacturing time for blades. Summary of the Invention

[0004] The main objective of this invention is to provide a method for manufacturing scaled-down blades, thereby solving the problem of long processing and manufacturing time for blades in the prior art.

[0005] To achieve the above objectives, the present invention provides a method for manufacturing scaled-down blades, comprising: preparing a shell; injecting a liquid filler into the shell; solidifying the liquid filler to form a solid structure in the shell; creating a receiving groove on the solidified filler; and inserting the prepared load-bearing component into the receiving groove.

[0006] Furthermore, a receiving groove is made in the cured filler, including: selecting the location and size of the receiving groove.

[0007] Furthermore, the selection of the location for the receiving groove includes: opening multiple receiving grooves at intervals along the circumference of the inner sidewall of the housing; each receiving groove extends along the length of the housing.

[0008] Furthermore, the selection of the size of the receiving slot includes: when creating two adjacent receiving slots, setting the extension length of the receiving slot near the front edge of the housing to be greater than the length of the receiving slot near the rear edge of the housing.

[0009] Further, the prepared load-bearing components are installed into the receiving grooves, including: installing multiple load-bearing components one by one into multiple receiving grooves.

[0010] Furthermore, the preparation of the shell includes: preparing the thickness of the rear edge of the shell to be less than the thickness of the front edge of the shell.

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

[0012] Furthermore, the scaled-down blade manufacturing method also includes preparing the filler material before injecting the liquid filler material into the casing, during the preparation of the filler material...

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

[0014] Further, the filler is prepared by: selecting a foaming material as the base material; and adjusting the amount of reinforcing agent added to obtain a density of 100 kg / m³. 3 ~150kg / m 3 The filler.

[0015] Furthermore, the method for manufacturing scaled-down blades also includes covering the outer periphery of the shell with a thin film layer after the prepared load-bearing component is inserted into the receiving groove.

[0016] The method for manufacturing scaled-down blades using the technical solution of this invention includes: preparing a shell; injecting liquid filler into the shell; solidifying the liquid filler to form a solid structure in the shell; creating a receiving groove on the solidified filler; and inserting the prepared load-bearing component into the receiving groove. The shell is prepared to a suitable size according to actual needs, and then liquid filler is injected into it. When the liquid filler fills the shell, it can adapt to shells of different structural sizes. After solidification, the liquid filler can fill the entire shell, thus forming a solid structure and enhancing the structural strength of the shell. The location of the receiving groove on the solidified filler is selected according to actual needs, and the prepared load-bearing component is placed in the receiving groove. This eliminates the need to pre-set installation space and reinforcing structures inside the shell. Furthermore, by utilizing the liquid-solid conversion of the filler and setting the load-bearing component, a solid blade structure can be quickly prepared. The process is simple, allows for rapid molding, shortens manufacturing processes and time, and solves the problem of long processing and manufacturing time for blades in the prior art. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0018] Figure 1 A flowchart illustrating a method for manufacturing scaled-down blades according to a specific embodiment of the present invention is shown; and

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

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

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

[0022] 10. Shell; 11. Leading edge; 12. Trailing edge; 20. Filler; 30. Load-bearing component. Detailed Implementation

[0023] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0025] In this invention, unless otherwise stated, directional terms such as "upper," "lower," "top," and "bottom" are generally used in relation to the direction shown in the accompanying drawings, or in relation to the vertical, perpendicular, or gravitational direction of the component itself; similarly, for ease of understanding and description, "inner" and "outer" refer to the inner and outer contours of each component itself, but the above directional terms are not intended to limit this invention.

[0026] Obviously, the embodiments described above are merely some, not all, embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

[0027] To address the problem of long processing and manufacturing time for blades in existing technologies, this invention provides a method for manufacturing scaled-down blades.

[0028] like Figures 1 to 3 As shown, the method for manufacturing scaled-down blades includes: preparing a shell 10; injecting liquid filler 20 into the shell 10; solidifying the liquid filler 20 to make the shell 10 form a solid structure; opening a receiving groove on the solidified filler 20; and installing the prepared load-bearing component 30 into the receiving groove.

[0029] By preparing the shell 10 to a suitable size according to actual needs, liquid filler 20 is then injected into the shell 10. After 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 solidifies, it can fill the entire shell 10, thereby forming a solid structure and enhancing 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 component 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. Moreover, by using the liquid and solid conversion of the filler 20 and setting the load-bearing component 30, a solid structure blade can be quickly prepared. The processing is simple, it can be quickly formed, and the manufacturing process and time are shortened.

[0030] In this embodiment, the housing 10 is provided with a receiving cavity, and the filler 20 enters the receiving cavity in liquid form. Since the filler 20 is fluid at this time, the filler 20 can fill the entire receiving cavity regardless of the structural form of the receiving cavity of the housing 10, thus avoiding the presence of hollow areas in some parts of the blade, which would reduce the pressure bearing capacity of the blade.

[0031] In this embodiment, the liquid filler 20 can be injected into the housing 10 using vacuum injection or pressure injection. This process requires precise control to avoid over-injection or under-injection, while ensuring that the filler 20 fully fills 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 at room temperature. This method is simple and low-cost. To further improve the speed of blade manufacturing and reduce the production cycle, a heat curing method 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 oven or a large hot air blower can be set up. Selecting different curing modes according to the type of filler 20 can improve the curing effect and thus improve the production efficiency of the blades.

[0033] In this embodiment, creating a receiving groove on the cured filler 20 includes selecting the location and size of the receiving groove.

[0034] Specifically, the receiving groove can be located in the middle of the filler 20 or near the inner wall of the housing 10. The number and location of the receiving grooves determine the number and location of the load-bearing components 30. By selecting the location of the receiving grooves, different structures can be formed inside the housing 10. At the same time, the width, length, and curvature of the receiving grooves should be reasonably selected to avoid affecting the overall structural strength of the blade.

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

[0036] In another optional embodiment of this application, the length direction of the receiving groove is parallel to the width direction of the housing 10. The filler 20 is injected layer by layer, dividing the housing 10 into multiple regions along its length. After each region is filled, a receiving groove is formed on the cured filler and a load-bearing member 30 is placed. This step is repeated until the receiving cavity of the housing 10 is completely 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 spaced apart along the length direction of the blade.

[0037] In this embodiment, the selection of the location of the receiving groove includes: opening a plurality of receiving grooves at intervals along the circumference of the inner sidewall of the housing 10; each receiving groove extends along the length direction of the housing.

[0038] Specifically, multiple receiving slots are spaced along the circumference of the inner wall of the housing 10 to improve the bending strength of the blade in the length direction. When the blade is actually used, one end is connected to the main shaft and rotates under the action of wind force. After the receiving slots accommodate the load-bearing member 30, they can strengthen the structural strength of the blade.

[0039] In another embodiment of this application (not shown), a plurality of receiving grooves are spaced apart to form two concentric rings along the inner wall of the housing 10, and the plurality of receiving grooves are staggered, that is, the receiving groove located in the inner ring is located between the two receiving grooves in the outer ring.

[0040] Furthermore, the thickness and width of the receiving groove are not unique, thus adapting to load-bearing components 30 with different structural dimensions.

[0041] In this embodiment, selecting the size of the receiving groove includes: when opening two adjacent receiving grooves, setting the extension length of the receiving groove near the front edge 11 of the housing 10 to be greater than the length of the receiving groove near the rear edge 12 of the housing 10.

[0042] It should be noted that leading edge 11 refers to Figure 2 The left side of the shell 10, the trailing 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 an airfoil, and the length of the multiple receiving slots gradually decreases along the width direction of the shell 10, so as to accommodate the large aerodynamic load that the leading edge 11 of the shell 10 needs to withstand. The longer length of the receiving slots of the leading edge 11 prevents the long load-bearing member 30 from being used to improve the structural strength of the leading edge 11.

[0044] In this embodiment, the prepared load-bearing component 30 is installed into the receiving groove, including: installing multiple load-bearing components 30 one by one into multiple receiving grooves.

[0045] Specifically, the distribution of the multiple load-bearing components 30 within the shell 10 is not uniform. The leading edge 11 of the shell 10 has more load-bearing components 30 than the trailing edge 12. This is to cope with the higher aerodynamic loads encountered by the leading edge 11 during high-speed rotation, especially under high wind speed conditions. Increasing the number of load-bearing components 30 at the leading edge 11 can better distribute the load, reduce stress concentration, and thus improve the structural stability of the blade under extreme conditions. Furthermore, the leading edge 11 is the part of the blade most susceptible to erosion from wind, sand, rain, and hail. Increasing the number of load-bearing components 30 can enhance the protective capability of the leading edge, reduce damage to the blade from external environmental factors, and ultimately improve wind energy conversion efficiency and reduce maintenance costs.

[0046] In this embodiment, the load-bearing component 30 is accurately positioned using a positioning tool or clamp. To improve the fit strength between the load-bearing component 30 and the filler 20, an adhesive is applied to the surface of the load-bearing component 30. When installing multiple load-bearing components 30, the load-bearing component 30 at the leading edge 11 is installed first, followed by the load-bearing component 30 at the trailing edge 12. Optionally, to accelerate production efficiency, each load-bearing component 30 is numbered, and the corresponding receiving slot is also numbered for easy assembly.

[0047] In this embodiment, the preparation of the housing 10 includes: preparing the thickness of the trailing edge 12 of the housing 10 to be less than the thickness of the leading edge 11 of the housing 10.

[0048] Specifically, the leading edge 11 of the shell 10 is thicker and smoother, while the trailing edge 12 is thinner and sharper. Figure 3 As shown, this design allows the blades to generate lift in the downwind direction while reducing drag and improving energy conversion efficiency. The thickness of the leading edge 11 is not uniform; it gradually decreases in thickness away from the main axis, meaning the thickness decreases from the root to the tip of the blade. The thicker thickness at the root, connecting to the main axis, allows it to withstand higher mechanical stress and gravity, while the thinner tip reduces the overall weight of the blade, increasing rotational speed and reducing air resistance. Optionally, the trailing edge 12 may have serrations or bends to reduce noise and prevent the formation of vortices at high wind speeds, which could affect the blade's lifespan and structural strength.

[0049] In this embodiment, when the shell 10 is prepared, 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 lightweight and structural strength. The composite material is placed in the mold and pressed into shape using a laminator.

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

[0051] Specifically, the load-bearing component 30 has a strip-shaped structure, which facilitates processing and production, effectively improving production efficiency. Furthermore, the load-bearing component 30, made of carbon fiber, significantly enhances the bending strength and stiffness of the blades while maintaining lightweight construction, preventing excessive blade weight. Optionally, the load-bearing component 30 and the housing 10 can be made of the same material. The load-bearing component 30 is manufactured simultaneously with the housing 10. Using the same material eliminates the need for material changes, saving time and avoiding increased costs associated with using different materials.

[0052] In this embodiment, the method for manufacturing scaled-down blades further includes preparing the filler 20 before injecting the liquid filler 20 into the housing 10, adding a reinforcing agent to the base material during the preparation of the filler 20, and adjusting the amount of reinforcing agent added to obtain a filler 20 with a preset density.

[0053] Specifically, a filler 20 with a preset density is obtained by mixing the reinforcing agent and the base material in a predetermined ratio, thereby ensuring that the solid structure formed after the filler 20 is filled has sufficient structural strength. As an important part of the blade, if the density of the filler 20 is too low, the liquid filler 20 will easily form a large number of pores on its surface or inside after solidification, resulting in insufficient strength of the solid structure of the blade.

[0054] In this embodiment, the preparation of filler 20 includes: selecting a foaming material as the base material; adjusting the amount of reinforcing agent added to obtain a density of 100 kg / m³. 3 ~150kg / m 3 20g of filler.

[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, etc. Microspheres can be used to reduce density, and fibers (such as carbon fiber or glass fiber) can enhance mechanical properties. Optionally, an appropriate amount of hollow microspheres or microbeads and fibers can be added to the base material. When the density of the filler 20 is within the above range, the filler 20 has good performance and can just fill the entire shell 10 after curing.

[0056] In this embodiment, after the filler 20 is prepared, the performance of the filler 20 is tested. Tests are conducted on the density, mechanical properties, and durability of the filler 20 to determine whether it meets the usage requirements.

[0057] In this embodiment, the method for manufacturing scaled-down blades further includes covering the outer periphery of the housing 10 with a thin film layer after the prepared load-bearing member 30 is inserted into the receiving groove.

[0058] Specifically, the thin film layer is a polyurethane coating or composite film to reduce air resistance during blade rotation. When setting the thin film layer, the selected material is uniformly coated onto the outer surface of the shell using spraying, coating, or heat-shrinking processes to form the thin film layer. When using a heat-shrinking process, temperature and time must be controlled to ensure the film adheres tightly to the shell 10, forming a smooth, wrinkle-free surface.

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

[0060] In this embodiment, after the thin film layer is coated on the outer periphery of the housing 10, the blade is also inspected. This includes using non-destructive testing techniques 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 embodiments of the present invention achieve the following technical effects: The method for manufacturing scaled-down blades includes: preparing a shell 10; injecting liquid filler 20 into the shell 10; solidifying the liquid filler 20 to make the shell 10 form a solid structure; opening a receiving groove on the solidified filler 20; inserting the prepared load-bearing component 30 into the receiving groove; by preparing the shell 10 to a suitable size according to actual needs, and then injecting liquid filler 20 into the shell 10, the liquid filler 20 can be appropriately sized after filling the shell 10. With shells 10 of different sizes, the liquid filler 20 can be solidified to fill the entire shell 10, thereby forming a solid structure and enhancing the structural strength of the shell 10. The location of the receiving groove can be selected on the solidified filler 20 according to actual needs, and the prepared load-bearing component 30 can be placed in the receiving groove. There is no need to set up installation space and reinforcement structure inside the shell 10 in advance. Moreover, by using the liquid and solid conversion of the filler 20 and setting the load-bearing component 30, the solid structure blade can be quickly prepared. The processing is simple, it can be quickly formed, and the manufacturing process and time are shortened.

[0062] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

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

[0064] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing scaled-down blades, characterized in that, include: Prepare the shell; Injecting liquid filler into the shell; The liquid filler is solidified to form a solid structure in the shell. A receiving groove is formed in the cured filler; The prepared load-bearing component is inserted into the receiving groove; The step of creating a receiving groove in the cured filler includes: Select the location and size of the receiving slot; The selection of the location for the receiving slot includes: A plurality of receiving grooves are provided at intervals along the circumferential side of the inner sidewall of the housing; Each of the accommodating grooves extends along the length direction of the housing; Selecting the size of the receiving slot includes: When creating two adjacent receiving slots, the extension length of the receiving slot near the front edge of the housing is set to be greater than the length of the receiving slot near the rear edge of the housing. The preparation of the shell includes: The thickness of the trailing edge of the housing is made smaller than the thickness of the leading edge of the housing; The method for manufacturing scaled-down blades further includes: A strip structure made of carbon fiber is selected as the load-bearing component; The method for manufacturing the scaled-down blades further includes preparing the filler material before injecting the liquid filler material into the housing; during the preparation of the filler material... Add reinforcing agents to the base material; Adjust the amount of the reinforcing agent added to obtain the filler with a preset density; The preparation of the filler includes: Choose foamed materials as the base material; Adjust the amount of the reinforcing agent added to obtain the filler with a density of 100 kg / m³ to 150 kg / m³; The method for manufacturing scaled-down blades further includes, after the prepared load-bearing component is inserted into the receiving groove... The thin film layer is coated on the outer periphery of the housing; The shell is constructed using composite materials, and the thin film layer is a polyurethane coating.

2. The method for manufacturing scaled-down blades according to claim 1, characterized in that, The step of inserting the prepared load-bearing component into the receiving groove includes: The load-bearing components are installed one by one into the receiving slots.

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