A method for resolving blade defects

Abstract

The application discloses a method for solving blade defects, comprising the steps of blade aerodynamic design, structural layer design, shell layer laying and vacuum auxiliary material laying; in the step of blade aerodynamic design, the obtuse trailing edge angle of the blade is designed as an obtuse arc structure, and a blade mold is prepared; in the step of structural layer design, a connecting glass fiber layer is arranged between the obtuse trailing edge core material and the non-obtuse trailing edge area core material of the blade; in the step of shell layer laying, the first layer of glass fiber layer is laid on the inner surface of the blade mold and bonded to the obtuse trailing edge corner of the blade mold, the first unidirectional air-permeable layer is laid in the non-obtuse trailing edge corner area of the blade mold, the structural layer and the auxiliary layer are laid above the first layer of glass fiber layer, and the overall layer laying is completed; in the step of vacuum auxiliary material laying, the laying area of the vacuum auxiliary material is larger than the laying area of the overall layer. The application solves the problem of resin-rich defects of the obtuse trailing edge of a large blade.

Description

Technical Field

[0001] The present application relates to the technical field of blade manufacturing, and more particularly, to a method for resolving blade defects. Background Art

[0002] The blade shell pouring process in the wind turbine blade production process is one of the most critical processes. Its biggest feature is that the pouring process is irreversible and cannot be stopped, and pouring defects directly affect the blade molding quality and the total molding cycle.

[0003] During the infusion process of large blades, resin-rich defects usually appear at the blunt trailing edge of the blade. Defects at this location are more difficult to repair in the subsequent process, and the repair cycle is long, which directly affects the total molding cycle of the blade.

[0004] Therefore, how to solve the resin-rich defect of the blunt trailing edge of large blades has become a technical problem that needs to be solved urgently by those skilled in the art. Summary of the Invention

[0005] In view of this, an object of the present application is to provide a method for solving blade defects, so as to solve the resin-rich defect of the blunt trailing edge of a large blade.

[0006] To achieve the above objectives, this application provides the following technical solutions:

[0007] A method for resolving blade defects, comprising the steps of:

[0008] The blade is aerodynamically designed, the blunt trailing edge of the blade is designed to be an obtuse angle, and the blunt trailing edge of the blade is an arc-shaped structure, and a blade mold is prepared;

[0009] Structural ply design, providing a connecting glass fiber ply between the blunt trailing edge core material and the non-blunt trailing edge core material of the blade;

[0010] Laying the shell plies, laying the first layer of glass fiber ply on the inner surface of the blade mold and fixing it to the blunt trailing edge corner of the blade mold with adhesive material, laying the first unidirectional air permeable layer in the non-blunt trailing edge corner area of ​​the blade mold, and laying the structural ply and auxiliary ply on top of the first layer of glass fiber ply until the entire ply is laid;

[0011] Laying the vacuum auxiliary material, laying the vacuum auxiliary material on the top of the overall paving layer, and the laying area of ​​the vacuum auxiliary material is larger than the laying area of ​​the overall paving layer.

[0012] Optionally, the above method for resolving blade defects further comprises the steps of:

[0013] Vacuuming: vacuuming the bottom of the vacuum auxiliary material through the conveying pipeline until the pressure maintenance is completed;

[0014] Infusion and curing: pouring resin glue into the bottom of the vacuum auxiliary material through the conveying pipeline and curing it.

[0015] Optionally, in the above method for resolving blade defects, the vacuuming step further includes compacting the laying area of ​​the vacuum auxiliary material.

[0016] Optionally, in the above-mentioned method for resolving blade defects, in the steps of infusion and curing, the resin glue is cured by heating or pressurizing.

[0017] Optionally, in the above method for resolving blade defects, in the mold lamination step, a second one-way air-permeable layer is laid on top of the overall lamination.

[0018] Optionally, in the above method for resolving blade defects, the first one-way air-permeable layer is one of a one-way air-permeable film, a continuous mat and a chopped strand mat; and / or,

[0019] The second one-way breathable layer is one of a one-way breathable film, a continuous mat and a chopped strand mat.

[0020] Optionally, in the above method for resolving blade defects, in the step of structural ply design, the connecting glass fiber ply is multi-layered, and each layer of the connecting glass fiber ply is prefabricated into an integrated structure.

[0021] Optionally, in the above method for resolving blade defects, in the step of aerodynamic design of the blade, the blunt trailing edge angle of the blade is not less than 120°.

[0022] Optionally, in the above-mentioned method for resolving blade defects, in the step of laying the mold layer, the adhesive material is glass fiber tape or double-sided tape.

[0023] Optionally, in the above method for resolving blade defects, in the step of laying the vacuum auxiliary material, the increase in the laying area of ​​the vacuum auxiliary material is not less than 1% of the laying area of ​​the entire layer.

[0024] The method for solving blade defects provided by the present application is to design the blunt trailing edge angle of the blade to be an obtuse angle in the early stage of the blade aerodynamic design, and the blunt trailing edge of the blade is an arc-shaped structure, avoiding the aerodynamic design of the straight-angle blunt trailing edge, so that the prepared blade mold lays the hardware foundation for solving the subsequent optimization of the blunt trailing edge resin-rich problem. At the same time, in the structural layer design stage, the blunt trailing edge core material of the blade and the core material of the non-blunt trailing edge area are designed separately, and a connecting glass fiber layer is set between the two, thereby eliminating the problem that the structural layer cannot be completely fitted. In the step of laying the shell layer, the first layer of glass fiber layer is laid on the inner surface of the blade mold, and is fixed to the blunt trailing edge corner of the blade mold with an adhesive material, and the first one-way breathable layer is laid in the non-blunt trailing edge corner area of ​​the blade mold to prevent impurities and gas from entering, and the structural layer and auxiliary layer are laid on top of the first layer of glass fiber layer until the overall layer laying is completed. When laying the vacuum auxiliary material, it is laid above the overall layup, and the laying area of ​​the vacuum auxiliary material is larger than the laying area of ​​the overall layup to ensure that there is a margin when laying the vacuum auxiliary material, which can prevent overhead operation, thereby resolving the resin-rich defect on the blunt trailing edge of the blade. As can be seen from the above example, the method for resolving blade defects provided by this application solves the problem of resin-rich defects on the blunt trailing edge of large blades by comprehensively considering the blade aerodynamic design, structural layup design, shell layup, and vacuum auxiliary material laying processes.

[0025] The technical features mentioned above, the technical features described below, and the technical features shown individually in the accompanying drawings may be combined arbitrarily, as long as the combined technical features do not conflict with each other. All possible feature combinations are technical contents explicitly described in this document. Any of the multiple sub-features included in the same statement can be applied independently and does not necessarily have to be applied in conjunction with the other sub-features. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without any creative work.

[0027] Figure 1 Schematic diagram of the method flow for solving blade defects provided in the embodiment of the present application Figure 1 ;

[0028] Figure 2 Schematic diagram of the method flow for solving blade defects provided in the embodiment of the present application Figure 2 . DETAILED DESCRIPTION

[0029] The core of this application is to provide a method for solving blade defects, so as to solve the resin-rich defect of the blunt trailing edge of large blades.

[0030] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0031] During the infusion process of large blades, resin-rich defects usually appear at the blunt trailing edge of the blade. Defects at this location are more difficult to repair in the subsequent process, and the repair cycle is long, which directly affects the total molding cycle of the blade.

[0032] For this reason, Figure 1 As shown, the embodiment of the present application discloses a method for resolving blade defects, including step S100 of blade aerodynamic design, step S101 of structural layup design, step S102 of laying mold layup, and step S103 of laying vacuum auxiliary materials. By comprehensively considering the blade aerodynamic design step S100, the structural layup design step S101, the mold layup step S102, and the vacuum auxiliary material laying step S103, the problem of resin-rich defects on the blunt trailing edge of large blades is resolved.

[0033] The following will be combined Figure 1 and Figure 2 The method for solving blade defects disclosed in the embodiments of the present application is specifically explained and illustrated.

[0034] Step S100, blade aerodynamic design;

[0035] By designing the blade's blunt trailing edge angle to be obtuse and adopting a circular arc structure, the aerodynamic design of the blunt trailing edge with a straight edge is avoided. This allows the prepared blade mold to lay the hardware foundation for subsequent optimization of the blunt trailing edge resin enrichment. Alternatively, the blade's blunt trailing edge angle can adopt an arc structure of no less than 120 degrees, so that the prepared blade mold can lay the hardware foundation for subsequent optimization of the blunt trailing edge resin enrichment.

[0036] Step S101, structural layer design;

[0037] A connecting glass fiber ply is provided between the blunt trailing edge core material and the non-blunt trailing edge core material of the blade. Specifically, during the structural ply design stage, the blunt trailing edge core material and the non-blunt trailing edge core material of the blade are designed separately, and a connecting glass fiber ply is provided between the two, thereby eliminating the problem of the structural ply not being able to fully fit together. The connecting glass fiber ply can be multi-layered, and each connecting glass fiber ply can be stacked on-site in sequence, or prefabricated into an integrated structure and then assembled on-site. It should be noted that the non-blunt trailing edge area refers to the area of ​​the blade other than the blunt trailing edge.

[0038] Step S102, laying the shell layer;

[0039] A first fiberglass layup is applied to the inner surface of the blade mold and secured to the blunt-end corner of the blade mold with an adhesive. A first unidirectional breathable layer is applied to the non-blunt-end corner of the blade mold. Structural and auxiliary layers are then applied above the first fiberglass layup until the entire layup is complete. A second unidirectional breathable layer can be applied above the entire layup to facilitate residual resin removal and assist in air extraction during the infusion process, thereby improving infusion quality and addressing the resin-rich condition at the blunt-end edge of the blade. Alternatively, fiberglass tape or double-sided tape can be used as the adhesive to secure the first fiberglass layup to the blunt-end corner of the blade mold. Furthermore, the first and second unidirectional breathable layers can be constructed of unidirectional breathable film to prevent the ingress of impurities and gases. Continuous mat or chopped strand mat can also be used for the first and second unidirectional breathable layers, although this is not a limitation herein. It should be noted that the structural ply refers to the main structure of the blade and the part that bears the main load, and the auxiliary ply refers to the ply that assists in realizing other functions of the blade or improves local performance, which can be used to improve the performance and function of the structural ply.

[0040] Step S103, laying vacuum auxiliary materials;

[0041] Lay the vacuum auxiliary material above the overall layup, with the layup area larger than the overall layup area to ensure a margin when laying the vacuum auxiliary material, thus preventing overhead operation. Optionally, the vacuum auxiliary material layup area increment should be no less than 1% of the overall layup area, effectively preventing overhead operation and effectively resolving the resin-rich defect problem on the blunt trailing edge of the blade.

[0042] The method for solving blade defects disclosed in the embodiment of the present application is to design the blunt trailing edge angle of the blade to be an obtuse angle in the early stage of the blade aerodynamic design, and the blunt trailing edge of the blade is an arc-shaped structure, avoiding the aerodynamic design of the straight-angle blunt trailing edge, so that the prepared blade mold lays the hardware foundation for solving the subsequent optimization of the blunt trailing edge resin-rich problem. At the same time, in the structural ply design stage, the blunt trailing edge core material of the blade and the core material of the non-blunt trailing edge area are designed separately, and a connecting glass fiber ply is provided between the two, thereby eliminating the problem that the structural ply cannot be fully fitted. In the step of laying the shell ply, the first layer of glass fiber ply is laid on the inner surface of the blade mold, and at the same time, it is fixed to the blunt trailing edge corner of the blade mold with an adhesive material, and the first one-way breathable layer is laid in the non-blunt trailing edge corner area of ​​the blade mold to prevent impurities and gas from entering, and the structural ply and auxiliary ply are laid on top of the first layer of glass fiber ply until the overall ply is laid. When laying vacuum auxiliary materials, lay them above the overall paving layer, and the laying area of ​​the vacuum auxiliary materials is larger than the laying area of ​​the overall paving layer to ensure that there is a margin when laying the vacuum auxiliary materials, which can prevent overhead operation.

[0043] The method for solving blade defects disclosed in the embodiment of the present application solves the problem of resin-rich defects on the blunt trailing edge of large blades by comprehensively considering the blade aerodynamic design, structural lay-up design, shell lay-up and vacuum auxiliary material laying processes.

[0044] like Figure 2 As shown, the method for resolving blade defects further includes step S104 of vacuuming and step S105 of pouring and curing.

[0045] Step S104, vacuuming;

[0046] The vacuum auxiliary material is evacuated through the conveying pipeline until the pressure is maintained. Specifically, during the vacuum evacuation process, the laying area of ​​the vacuum auxiliary material can be compacted to further achieve the anti-overhead operation until the pressure is maintained.

[0047] Step S105, pouring and curing;

[0048] By connecting the vacuum delivery pipeline to the glue injection equipment, resin glue can be poured into the lower part of the vacuum auxiliary material through the delivery pipeline. It can then be cured by heating or pressurizing to ensure the strength of the blade shell. It should be noted that during the pouring and curing process, the resin glue flow in the pouring area and the working condition of the one-way air permeable layer must be checked, and any abnormalities during the process must be promptly addressed to ensure the pouring quality of the blade shell.

[0049] The terms "first," "second," and so on in the specification, claims, and drawings of this application are used to distinguish between different items, not to describe a specific order. Furthermore, the terms "including," "having," and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or apparatus comprising a series of steps or elements is not limited to the listed steps or elements and may include steps or elements that are not listed.

[0050] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present application. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for resolving blade defects, characterized in that: Including steps: The blade is aerodynamically designed, the blunt trailing edge of the blade is designed to be an obtuse angle, and the blunt trailing edge of the blade is an arc-shaped structure, and a blade mold is prepared; Structural ply design, providing a connecting glass fiber ply between the blunt trailing edge core material and the non-blunt trailing edge core material of the blade; Laying the shell plies, laying the first layer of glass fiber ply on the inner surface of the blade mold and fixing it to the blunt trailing edge corner of the blade mold with adhesive material, laying the first unidirectional air permeable layer in the non-blunt trailing edge corner area of ​​the blade mold, and laying the structural ply and auxiliary ply on top of the first layer of glass fiber ply until the entire ply is laid; Laying the vacuum auxiliary material, laying the vacuum auxiliary material on the top of the overall paving layer, and the laying area of ​​the vacuum auxiliary material is larger than the laying area of ​​the overall paving layer.

2. The method for resolving blade defects according to claim 1, characterized in that: Also includes the steps: Vacuuming: vacuuming the bottom of the vacuum auxiliary material through the conveying pipeline until the pressure maintenance is completed; Infusion and curing: pouring resin glue into the bottom of the vacuum auxiliary material through the conveying pipeline and curing it.

3. The method for resolving blade defects according to claim 2, characterized in that: The vacuuming step further includes compacting the laying area of ​​the vacuum auxiliary material.

4. The method for resolving blade defects according to claim 2, characterized in that: In the steps of pouring and curing, the resin glue is cured by heating or pressurizing.

5. The method for resolving blade defects according to claim 1, characterized in that: In the mold lamination step, a second one-way breathable layer is laid on top of the overall lamination.

6. The method for resolving blade defects according to claim 5, characterized in that: The first one-way breathable layer is one of a one-way breathable film, a continuous mat and a chopped strand mat; and / or, The second one-way breathable layer is one of a one-way breathable film, a continuous mat and a chopped strand mat.

7. The method for resolving blade defects according to claim 1, characterized in that: In the step of designing the structural ply, the connecting glass fiber ply is multi-layered, and each layer of the connecting glass fiber ply is prefabricated into an integrated structure.

8. The method for resolving blade defects according to claim 1, characterized in that: In the step of aerodynamic design of the blade, the blunt trailing edge angle of the blade is not less than 120°.

9. The method for resolving blade defects according to claim 1, characterized in that: In the step of laying the mold layer, the adhesive material is glass fiber tape or double-sided tape.

10. The method for resolving blade defects according to claim 1, characterized in that: In the step of laying the vacuum auxiliary material, the increase in the laying area of ​​the vacuum auxiliary material is not less than 1% of the laying area of ​​the entire paving layer.

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