A manufacturing method of a wind power coupling suitable for a high-speed shaft end of a wind turbine generator

Abstract

This invention discloses a manufacturing method for a wind turbine coupling suitable for the high-speed shaft end of a wind turbine. The wind turbine coupling includes a composite material intermediate tube and flange one and flange two. The composite material intermediate tube is formed by impregnating reinforcing fiber yarn with matrix resin and winding and curing it. The manufacturing method involves setting both flanges into an hourglass shape, which is larger at both ends and smaller in the middle. The inner circumferential surfaces of both ends of the composite material intermediate tube are set to match the shape of the hourglass-shaped flanges. During manufacturing, the inner liner tube is assembled between the two flanges to form an integral structure. Then, the two flanges and the inner liner tube are installed on a winding fixture. The winding fixture is then hoisted into a winding machine. Finally, the reinforcing fiber yarn impregnated with matrix resin is wound onto the two flanges and the inner liner tube using the winding machine to form the composite material intermediate tube. After curing, the wind turbine coupling is finally manufactured. The inner circumferential surfaces of both ends of the composite material intermediate tube respectively engage with the two hourglass-shaped flanges to form an axial limiting structure.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a wind turbine coupling, and more particularly to a method for manufacturing a wind turbine coupling suitable for the high-speed shaft end of a wind turbine, belonging to the field of wind turbine coupling manufacturing technology. Background Technology

[0002] Wind turbine couplings play a crucial role in wind turbine units. Overvoltage or overcurrent in the coupling can cause the entire wind turbine to exceed its withstand limits, resulting in breakdown or burnout and incurring high maintenance costs. A wind turbine coupling consists of a central tube and flanges at both ends of the central tube. The two ends of the coupling are connected to the generator and the wind turbine gearbox via the flanges, respectively. The central tube plays a vital role in torque transmission and insulation. There are two existing central tube structures: First, using pure steel components as the intermediate tube, and then using rubber components and other insulating components, this intermediate section structure is not only heavy, but also has a large moment of inertia, and the electrical insulation material is of low grade and the insulation effect is not good. Second, fiberglass tubes are used as intermediate tubes, and then steel parts are bonded to the fiberglass tubes with glue.

[0003] The latter uses fiberglass tubing, which has advantages such as light weight, high strength, low price, good insulation performance, and strong design flexibility. It is used to transmit torsional torque, achieve displacement compensation, insulate against parasitic current, and reduce vibration and absorb vibration energy. It has been widely used in the field of transmission.

[0004] In existing wind turbine couplings using fiberglass tubes as the intermediate pipe, the intermediate pipe and two flanges are manufactured separately. Adhesive is then applied to both ends of the intermediate pipe and the flanges. The flanges are then inserted into both ends of the intermediate pipe, thus bonding and fixing them together to form the coupling. During manufacturing, one side of the flange and the inner circumference of both ends of the intermediate pipe are designed with a matching tapered structure, with the smaller end of the tapered structure located near the middle of the intermediate pipe and the larger end near the end of the intermediate pipe. However, this tapered bonding method between the intermediate pipe and flanges suffers from insufficient connection strength. Especially after a period of use, adhesive failure due to factors such as adhesive material, manufacturing process, and aging can lead to structural debonding when the coupling is subjected to axial tension. This can result in the flanges detaching from the intermediate pipe and the wind turbine coupling disintegrating.

[0005] Chinese utility model patent with authorization announcement number CN201177015Y and authorization announcement date of January 7, 2009 discloses a flexible coupling for wind turbine generator sets, comprising: a cylindrical body, flanges disposed at both ends of the cylindrical body, bushings A and B respectively connected to a flange by bolts, rubber gaskets and elastic diaphragms respectively disposed between bushing A and the flange, and between bushing B and the flange, wherein the cylindrical body is a fiberglass cylinder; each flange is also fixedly connected or integrated with a conical sleeve or a cylindrical sleeve, and each end of the fiberglass cylinder is respectively fitted and fixedly bonded or fixedly connected to a conical sleeve or a cylindrical sleeve.

[0006] Chinese utility model patent with authorization announcement number CN219673136U and authorization announcement date of September 12, 2023 discloses a series torque limiter for wind power couplings, including a fiberglass tube, a flange, a friction flange, and a friction disc. Flanges are provided on both sides inside the fiberglass tube. The outer diameter of the right flange is the same as the outer diameter of the fiberglass tube. The right flange is fixedly connected to the pressure plate by multiple adjusting bolts B evenly distributed in the circumferential direction. A necked stepped ring A is provided on the right end face of the right flange, and a necked stepped ring B is provided on the left end face of the pressure plate. Stepped ring A and stepped ring B form an annular channel. The left disc of the friction flange is located within the annular channel, and the extended annular surface of the right side of the friction flange is located on the outer circumference of the pressure plate. The friction disc is fixed to the right side of the friction flange and the pressure plate. Friction plates C and A are respectively provided between the corresponding stepped surfaces of stepped rings A and B and the left disc of the friction flange. Friction plate B is provided between the right stepped surface of the pressure plate and the left side of the friction disc.

[0007] As can be seen from the two patent documents mentioned above, the intermediate pipe and the flange are connected by a tapered adhesive method. Therefore, there will be a problem of insufficient connection strength. After a period of use, when the adhesive fails and the coupling is subjected to axial tension, the flange will detach from the intermediate pipe, and the wind power coupling structure will disintegrate.

[0008] In summary, designing a manufacturing method for wind turbine couplings suitable for high-speed shaft ends of wind turbine units, so that the manufactured wind turbine couplings can enhance the connection strength between the intermediate tube and the flange, and avoid the phenomenon of the flange detaching from the intermediate tube and the wind turbine coupling structure disintegrating when the coupling is subjected to axial tensile force after a period of use due to adhesive failure, thereby improving the quality and service life of wind turbine couplings, is an urgent technical problem to be solved. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to address the deficiencies in the existing technology by providing a method for manufacturing a wind turbine coupling suitable for the high-speed shaft end of a wind turbine. The wind turbine coupling manufactured by this method enhances the connection strength between the intermediate tube and the flange, and avoids the phenomenon that the flange will detach from the intermediate tube and the wind turbine coupling structure will disintegrate when the coupling is subjected to axial tensile force after a period of use due to adhesive failure. This improves the quality and service life of the wind turbine coupling.

[0010] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: a manufacturing method for a wind turbine coupling suitable for the high-speed shaft end of a wind turbine, the wind turbine coupling comprising a composite material intermediate tube and flange one and flange two disposed at both ends of the composite material intermediate tube, the composite material intermediate tube being formed by impregnating reinforcing fiber yarn with matrix resin and winding and curing; the manufacturing method comprising setting both flanges into an hourglass shape, wider at both ends and narrower in the middle, and setting the inner circumferential surfaces of both ends of the composite material intermediate tube into a shape matching the hourglass-shaped flanges; during manufacturing, the inner liner tube is assembled onto the two flanges. The flanges are integrated into a single structure. Then, the two flanges and the inner liner are installed onto the winding fixture. The winding fixture is then hoisted into the winding machine. One end of the winding fixture is locked by the winding machine, and the other end of the winding fixture is tightened by the winding machine. Finally, the reinforcing fiber yarn impregnated with the matrix resin is wound onto the two flanges and the inner liner to form a composite material intermediate tube. After curing, the wind turbine coupling is finally manufactured. After the wind turbine coupling is manufactured, the inner circumferential surfaces of both ends of the composite material intermediate tube are respectively engaged with the two hourglass-shaped flanges to form an axial limiting structure.

[0011] Preferably, the reinforcing fiber yarn is made of glass fiber, polyester fiber, aramid fiber, or carbon fiber; and the matrix resin is made of epoxy resin, unsaturated polyester, vinyl ester resin, or phenolic resin.

[0012] Preferably, both flange one and flange two include a central straight-edge ring, an outer straight-edge ring disposed at one end of the central straight-edge ring, and an inner conical ring disposed at the other end of the central straight-edge ring. One end of the central straight-edge ring is connected to one end of the outer straight-edge ring, and the other end of the central straight-edge ring is connected to the small end of the inner conical ring. The outer diameter of the central straight-edge ring is set as D1, the outer diameter of the outer straight-edge ring is set as D2, then D2 > D1, and the outer diameter of the large end of the inner conical ring is set as D3, then D3 > D1. The central straight-edge ring, the outer straight-edge ring, and the inner conical ring form an hourglass-shaped flange that is large at both ends and small in the middle.

[0013] Preferably, the inner circumferential surface of the composite material intermediate tube includes a central straight edge circumferential surface and two end straight edge circumferential surfaces, one and two respectively, located on both sides of the central straight edge circumferential surface. A tapered circumferential surface is also provided between the end straight edge circumferential surface and the central straight edge circumferential surface. A tapered circumferential surface is also provided between the end straight edge circumferential surface and the central straight edge circumferential surface. One end of the end straight edge circumferential surface is connected to the small end of the tapered circumferential surface. The large end of the tapered circumferential surface is connected to one end of the central straight edge circumferential surface. The other end of the central straight edge circumferential surface is connected to the large end of the tapered circumferential surface. The small end of the tapered circumferential surface is connected to one end of the end straight edge circumferential surface. After the wind turbine coupling is manufactured, the straight edge ring and the inner conical ring of flange one are respectively engaged and contacted with the straight edge circumferential surface one and the conical circumferential surface one of the end of the composite material intermediate pipe, and the straight edge ring and the inner conical ring of flange two are respectively engaged and contacted with the straight edge circumferential surface two and the conical circumferential surface two of the end of the composite material intermediate pipe to form an axial limiting structure.

[0014] Preferably, the specific steps of the manufacturing method are as follows: S1. Materials and Equipment: Clean the two flanges by removing oil, sandblast the joint section, and prepare the inner lining pipe. S2, Mold assembly: Assemble the inner liner between the two flanges cleaned and sandblasted in step S1. Assemble the two flanges onto the winding tooling coated with release agent according to the designed length of the intermediate body structure of the coupling. The two flanges and the inner liner form the winding mandrel of the intermediate body structure of the coupling. S3. Mold installation: The assembled winding mandrel of the intermediate coupling structure is hoisted into the winding machine, one end is locked with a three-jaw chuck, and the other end is tightened and centered with an ejector pin; S4. Cleaning: Clean the assembled winding mandrel and apply release agent to the straight edge rings on the outer sides of the two flanges. S5. Winding: The reinforcing fiber yarn is drawn out from the yarn rack, impregnated with the prepared matrix resin in the impregnation tank, and then pulled to the winding mandrel prepared in step S4. The designed winding program is then called to wind the yarn. S6. Remove the composite material winding intermediate tube obtained in step S5 from the winding machine and place it in a ventilated drying oven for curing. S7. Demolding: The composite material cured in step S6 is wound around the intermediate tube winding part, and the winding fixture is pulled out by the demolding machine to obtain the intermediate structure blank of the wind power coupling. S8. Machining: The intermediate structure blank of the coupling obtained in step S7 is machined to finally produce the wind power coupling.

[0015] Preferably, during the winding process in step S5, the designed procedure is followed: first, one flange is wound, and the reinforcing fiber yarn impregnated with the matrix resin is embedded in the recessed space C formed by the straight edge ring and the inner conical ring of the flange for thread winding. After the recessed space C is fully threaded, the recessed space C formed by the straight edge ring and the inner conical ring of the other flange is wound. When the recessed space C of the other flange is also fully threaded, the reinforcing fiber yarn impregnated with the matrix resin is wound back and forth between the two flanges according to the designed winding procedure, that is, wound from one flange through the inner liner to the other flange, and then wound from the other flange through the inner liner to the other flange, and so on, repeatedly crisscrossing until the composite material winding intermediate tube winding part is formed.

[0016] Preferably, during the winding process in step S5, the winding is performed according to the designed procedure, winding from one flange through the inner liner to another flange, and then winding from the other flange through the inner liner to another flange, and so on, repeatedly crisscrossing until the composite material winding intermediate tube is formed.

[0017] Preferably, during the winding process, an annular winding process is inserted into the cross-winding process.

[0018] Preferably, a convex-concave interlocking structure is provided between the inner circumferential surfaces of the two ends of the composite material intermediate tube and the contact surfaces of the two hourglass-shaped flanges.

[0019] Preferably, protrusions are provided on the outer circumferential surfaces of the straight-edge ring body in the middle and the conical ring body on the inner side of the two flanges, and grooves matching the protrusions are provided on the first and second straight-edge circumferential surfaces and the second conical circumferential surface at the end of the composite material intermediate pipe; the interlocking structure is formed by the contact between the protrusions and the grooves. or Grooves are provided on the outer circumferential surfaces of the straight-edge ring body in the middle and the conical ring body on the inner side of the two flanges. Protrusions matching the grooves are provided on the first straight-edge circumferential surface and the first conical circumferential surface at the end of the composite material intermediate tube, as well as on the second straight-edge circumferential surface and the second conical circumferential surface at the end. The interlocking structure is formed by the contact between the protrusions and the grooves.

[0020] The beneficial effects of this invention are as follows: The connection strength between the intermediate tube and the flange of the wind turbine coupling manufactured by this invention is not only guaranteed by the adhesive bonding of the impregnated matrix resin, but also by the axial limiting structure formed by the composite material intermediate tube and the hourglass-shaped flange. In other words, in this embodiment, the connection strength between the intermediate tube and the flange of the wind turbine coupling is jointly guaranteed by the adhesive force and the axial limiting structure, together resisting the axial tensile force borne by the wind turbine coupling. This avoids the phenomenon of the flange detaching from the intermediate tube and the wind turbine coupling structure disintegrating when the coupling is subjected to axial tensile force after a period of use due to adhesive failure. This improves the quality and service life of the wind turbine coupling. Furthermore, no other adhesive is used besides the impregnated matrix resin, thus avoiding the impact of adhesive materials, processes, and aging on the coupling. The specific manufacturing steps provided in this invention simplify the entire preparation process of the wind turbine coupling and reduce manufacturing costs. Furthermore, this invention incorporates a tongue-and-groove interlocking structure between the inner circumferential surfaces of the composite material intermediate tube at both ends and the contact surfaces of the two hourglass-shaped flanges. This interlocking structure increases the contact area between the inner circumferential surfaces of the composite material intermediate tube and the two hourglass-shaped flanges without increasing the overall volume of the wind turbine coupling, thus increasing the adhesive strength of the impregnated matrix resin. Another function is that the mechanical structure formed by the interlocking structure enhances the mechanical torsional resistance of the wind turbine coupling. This allows the invention to utilize the resin adhesive force and the interlocking mechanical force to resist torsional torque, giving the wind turbine coupling significant torsional resistance. This helps resist the increasing torque, further preventing structural disintegration of the wind turbine coupling and thus improving its quality and service life. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the axial cross-sectional structure of the wind turbine coupling in an embodiment of the present invention; Figure 2 This is a schematic diagram of the axial cross-sectional structure of the flange in an embodiment of the present invention; Figure 3 This is a schematic diagram of the axial cross-sectional structure of the composite material intermediate tube in an embodiment of the present invention; Figure 4 This is a schematic axial cross-sectional view of the wind turbine coupling during manufacturing, as shown in this embodiment of the invention. Figure 1 ; Figure 5 This is a schematic axial cross-sectional view of the wind turbine coupling during manufacturing, as shown in this embodiment of the invention. Figure 2 ; Figure 6 This is a three-dimensional structural diagram of the flange in an embodiment of the present invention; Figure 7 for Figure 2Enlarged structural diagram of section A in the middle; Figure 8 for Figure 4 Enlarged structural diagram of section B in the middle; Figure 9 This is a schematic axial cross-sectional view of the wind turbine coupling during manufacturing, as shown in this embodiment of the invention. Figure 3 ; In the diagram: 1. Composite material intermediate tube; 2. Flange 1; 3. Flange 2; 4. Middle straight-edge ring; 5. Outer straight-edge ring; 6. Inner conical ring; 7. Middle straight-edge circumferential surface; 8. End straight-edge circumferential surface 1; 9. End straight-edge circumferential surface 2; 10. Conical circumferential surface 1; 11. Conical circumferential surface 2; 12. Inner liner; 13. Winding fixture; 14. Protrusion; 15. Groove; 16. Connecting ring; 161. Stepped section; 17. Reinforcing fiber yarn. Detailed Implementation

[0022] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] Example: Figure 1 As shown, a method for manufacturing a wind turbine coupling suitable for the high-speed shaft end of a wind turbine unit is disclosed. The wind turbine coupling includes a composite material intermediate tube 1 and flanges 2 and 3 disposed at both ends of the composite material intermediate tube. The composite material intermediate tube 1 is formed by impregnating reinforcing fiber yarn with matrix resin and then winding and curing it. The manufacturing method involves arranging both flanges into an hourglass shape, wider at both ends and narrower in the middle, and shaping the inner circumferential surfaces of both ends of the composite material intermediate tube 1 to match the hourglass-shaped flanges. During manufacturing, as follows... Figure 4 and Figure 5 As shown, the inner liner 12 is assembled between the two flanges to form an integral structure. Then, the two flanges and the inner liner 12 are fitted onto the winding fixture 13, which is a cylindrical rotating body. The winding fixture 13 is then hoisted into the winding machine as a whole. One end of the winding fixture 13 is locked using the three-jaw chuck of the winding machine, and the other end of the winding fixture 13 is tightened and aligned using the pin of the winding machine. Finally, the reinforcing fiber yarn impregnated with the matrix resin is wound onto the two flanges and the inner liner 12 using the winding machine to form the composite material intermediate tube 1. After curing, the wind turbine coupling is finally manufactured. After the wind turbine coupling is manufactured, the inner circumferential surfaces of both ends of the composite material intermediate tube 1 are respectively engaged with the two hourglass-shaped flanges to form an axial limiting structure.

[0024] In manufacturing the wind turbine coupling of this embodiment, when assembling the composite material intermediate tube and the two flanges, the flanges in this embodiment cannot be inserted from the end of the composite material intermediate tube as in the prior art due to the aforementioned axial limiting structure. Therefore, the manufacturing method described above was used to achieve the production of the wind turbine coupling in this embodiment. After the wind turbine coupling in this embodiment is manufactured, the connection strength between its intermediate tube and flange is not only guaranteed by the adhesive of the impregnated matrix resin, but also by the axial limiting structure formed by the composite material intermediate tube and the hourglass-shaped flange. In other words, the connection strength between the intermediate tube and flange of the wind turbine coupling in this embodiment is jointly guaranteed by the adhesive force and the axial limiting structure, which together resist the axial tensile force borne by the wind turbine coupling. This avoids the phenomenon that the flange will detach from the intermediate tube and the wind turbine coupling structure will disintegrate when the coupling is subjected to axial tensile force after a period of use due to adhesive failure. This improves the quality and service life of the wind turbine coupling. In addition, no other adhesive is used besides the impregnated matrix resin, so the coupling will not be affected by adhesive materials, processes, aging, etc.

[0025] The reinforcing fiber yarn can be made of glass fiber, polyester fiber, or aramid fiber, etc. For products that do not require insulation performance, carbon fiber yarn can also be used. The matrix resin can be a thermosetting resin such as epoxy resin, unsaturated polyester, vinyl ester resin, or phenolic resin, and its matching curing agent. The matrix resin refers to the resin mixture that wets the reinforcing fiber material during the winding process, and the mixture includes the matrix resin itself and the corresponding curing agent. In this embodiment, the reinforcing fiber yarn is alkali-free glass fiber yarn, the matrix resin is epoxy resin, and the curing system is an anhydride curing system.

[0026] like Figures 1 to 3 As shown, both flange 2 and flange 3 include a central straight-edge ring 4, an outer straight-edge ring 5 located at one end of the central straight-edge ring 4, and an inner conical ring 6 located at the other end of the central straight-edge ring 4. One end of the central straight-edge ring 4 is connected to one end of the outer straight-edge ring 5, and the other end of the central straight-edge ring 4 is connected to the small end of the inner conical ring 6. The central straight-edge ring 4, the outer straight-edge ring 5, and the inner conical ring 6 can be integrated into a single structure. If the outer diameter of the central straight-edge ring 4 is set as D1, and the outer diameter of the outer straight-edge ring 5 is set as D2, then D2 > D1. If the outer diameter of the large end of the inner conical ring 6 is set as D3, then D3 > D1. The central straight-edge ring 4, the outer straight-edge ring 5, and the inner conical ring 6 together form an hourglass-shaped flange that is large at both ends and small in the middle.

[0027] The inner circumferential surface of the composite material intermediate tube 1 includes a central straight edge circumferential surface 7 and two end straight edge circumferential surfaces 8 and 9 respectively located on both sides of the central straight edge circumferential surface 7. A tapered circumferential surface 10 is also provided between the end straight edge circumferential surface 8 and the central straight edge circumferential surface 7. A tapered circumferential surface 11 is also provided between the end straight edge circumferential surface 9 and the central straight edge circumferential surface 7. One end of the end straight edge circumferential surface 8 is connected to the small end of the tapered circumferential surface 10. The large end of the tapered circumferential surface 10 is connected to one end of the central straight edge circumferential surface 7. The other end of the central straight edge circumferential surface 7 is connected to the large end of the tapered circumferential surface 11. The small end of the tapered circumferential surface 11 is connected to one end of the end straight edge circumferential surface 9.

[0028] After the wind turbine coupling is manufactured, the straight edge ring 4 and the inner conical ring 6 of flange 12 are respectively engaged with the straight edge circumferential surface 8 and the conical circumferential surface 10 of the end of the composite material intermediate tube 1, and the straight edge ring 4 and the inner conical ring 6 of flange 23 are respectively engaged with the straight edge circumferential surface 9 and the conical circumferential surface 11 of the end of the composite material intermediate tube 1 to form an axial limiting structure.

[0029] like Figure 1 As shown, one end of the inner liner tube 12 is connected to the large end of the inner tapered ring 6 of the flange 1 2, and the other end of the inner liner tube 12 is connected to the large end of the inner tapered ring 6 of the flange 2 3.

[0030] The specific steps of the manufacturing method in this embodiment are as follows: S1. Materials and Equipment: Clean the two flanges by degreasing, sandblast the joint section, and prepare the inner liner pipe. S2, Mold assembly: such as Figure 4 As shown, the inner liner is assembled between the two flanges that are cleaned and sandblasted in step S1. The two flanges are then assembled onto the winding tooling coated with release agent according to the designed length of the intermediate body structure of the coupling. The two flanges and the inner liner form the winding mandrel of the intermediate body structure of the coupling. S3. Mold installation: The assembled winding mandrel of the intermediate coupling structure is hoisted into the winding machine, one end is locked with a three-jaw chuck, and the other end is tightened and centered with an ejector pin; S4. Cleaning: Clean the assembled winding mandrel with alcohol, and apply release agent to the straight edge ring 5 on the outer side of the two flanges. S5, winding: such as Figure 2 and Figure 9As shown, alkali-free glass fiber yarn is drawn from the yarn rack, impregnated with prepared epoxy resin in an impregnation tank, and then pulled to the winding mandrel prepared in step S4. The designed winding program is then called for winding. According to the designed program, one flange is wound first. The reinforcing fiber yarn 17 impregnated with the matrix resin is embedded in the recessed space C formed by the straight edge ring 4 and the inner conical ring 6 in the middle of the flange for thread winding. After the recessed space C is fully threaded, the recessed space C formed by the straight edge ring 4 and the inner conical ring 6 in the middle of the other flange is wound. When the recessed space C of the other flange is also fully threaded, the outermost circumferential surface of the reinforcing fiber yarn 17 after the two flanges are fully wound is flush with the outermost circumferential surface of the inner liner tube 12. Then, according to the designed winding program, the reinforcing fiber yarn 17 impregnated with the matrix resin is wound back and forth between the two flanges, that is, wound from one flange through the inner liner tube 12 to the other flange, and then wound from the other flange through the inner liner tube 12 to the other flange, and so on, until the desired result is achieved. Figure 5 As shown, cross-winding forms a composite material wound intermediate tube. Here, annular winding can also be inserted into the cross-winding process, such as multiple layers of cross-winding, with annular winding inserted in the inner, middle, and outer layers respectively. It should be noted that it is also possible to skip filling the recessed space C first and instead directly cross-wind between the two flanges. S6. Remove the composite material winding intermediate tube obtained in step S5 from the winding machine and place it in a ventilated drying oven for curing. S7. Demolding: The composite material cured in step S6 is wound around the intermediate tube winding part, and the winding fixture is pulled out by the demolding machine to obtain the intermediate structure blank of the wind power coupling. S8. Machining: The intermediate structure blank of the coupling obtained in step S7 is machined to finally produce the wind power coupling.

[0031] By designing the specific steps described above, the entire fabrication process of the wind turbine coupling is simplified and the manufacturing cost is reduced.

[0032] A problem exists in the existing technology: as the power of wind turbines continues to increase, the swept area of ​​their blades also increases, leading to a greater torque transmitted from the blades. To counteract this increasing torque, current methods primarily involve increasing the bonding area between the intermediate tube and the flange. However, this results in the continuous enlargement of the fiberglass intermediate tube, consequently increasing the size of the coupling. Furthermore, when the adhesive between the intermediate tube and the flange of existing wind turbine couplings ages and fails, the flange may detach from the intermediate tube under significant torque, causing the wind turbine coupling structure to disintegrate. To this end, the applicant made further improvements: a concave-convex interlocking structure was designed between the inner circumferential surfaces of both ends of the composite material intermediate tube 1 and the contact surfaces of the two hourglass-shaped flanges. One function of this interlocking structure is to increase the contact area between the inner circumferential surfaces of both ends of the composite material intermediate tube 1 and the two hourglass-shaped flanges without increasing the overall volume of the wind turbine coupling, thus increasing the adhesive strength of the impregnated matrix resin. Another function is that the mechanical structure formed by the interlocking structure increases the mechanical torsional resistance of the wind turbine coupling. Therefore, this embodiment can use the resin adhesive force of the interlocking structure and the interlocking mechanical force to resist torsional torque, giving the wind turbine coupling a high torsional resistance, thus resisting the increasing torque and further preventing the wind turbine coupling structure from disintegrating, thereby further improving the quality and service life of the wind turbine coupling.

[0033] like Figure 2 and Figure 3 As shown, protrusions 14 are provided on the outer circumferential surfaces of the middle straight-edge ring 4 and the inner conical ring 6 of the two flanges. Grooves 15 matching the protrusions 14 are provided on the end straight-edge circumferential surface 8, the end conical circumferential surface 10, the end straight-edge circumferential surface 9, and the end conical circumferential surface 11 of the composite material intermediate pipe 1. The protrusions 14 and the grooves 15 engage to form the interlocking structure. Alternatively, the protrusions 14 can be provided on the end straight-edge circumferential surface 8, the end conical circumferential surface 10, the end straight-edge circumferential surface 9, and the end conical circumferential surface 11 of the composite material intermediate pipe 1, and the grooves 15 can be provided on the outer circumferential surfaces of the middle straight-edge ring 4 and the inner conical ring 6 of the two flanges. The protrusion 14 can be designed as a step, ring, or pin, or other structure that is not conducive to rotation or twisting. The step, ring, or pin can be a spherical, hemispherical, pointed, trapezoidal, or other shapes of protrusion. The groove 15 can be an axially extending, radially extending, or obliquely extending groove, including various shapes and depths. During manufacturing, the protrusion or groove is first machined on the flange, and then a winding machine is used to wind the composite material intermediate tube to form the corresponding groove or protrusion.

[0034] like Figure 6As shown, multiple protrusions 14 are provided on the outer circumferential surfaces of the central straight-edge ring 4 and the inner conical ring 6 of the flange, and these protrusions 14 are staggered on the outer circumferential surfaces of the central straight-edge ring 4 and the inner conical ring 6. Correspondingly, the grooves 15 provided on the end straight-edge circumferential surface 8 and the conical circumferential surface 10, as well as the end straight-edge circumferential surface 9 and the conical circumferential surface 11 of the composite material intermediate pipe 1, are also staggered. This further increases the interlocking force formed by the interlocking structure, thereby further increasing the mechanical torsional resistance of the wind turbine coupling.

[0035] like Figure 2 , Figure 6 and Figure 7 As shown, a connecting ring 16 is also provided on the small end of the tapered ring 6 on the inner side of both flanges, and a stepped portion 161 is provided on the end of the connecting ring 16, such as... Figure 4 and Figure 8 As shown, when the inner liner 12 is assembled between the two flanges, it is done by installing both ends of the inner liner 12 onto the stepped portions 161 of the two flanges respectively, thereby assembling the inner liner 12 between the two flanges into an integral structure.

[0036] In summary, the connection strength between the intermediate tube and flange of the wind turbine coupling manufactured by this invention is not only guaranteed by the adhesive bonding of the impregnated matrix resin, but also by the axial limiting structure formed by the composite material intermediate tube and the hourglass-shaped flange. In other words, the connection strength between the intermediate tube and flange of the wind turbine coupling in this embodiment is jointly guaranteed by the adhesive force and the axial limiting structure, together resisting the axial tensile force borne by the wind turbine coupling. This avoids the phenomenon of the flange detaching from the intermediate tube and the wind turbine coupling structure disintegrating when the coupling is subjected to axial tensile force after a period of use due to adhesive failure. This improves the quality and service life of the wind turbine coupling. Furthermore, no other adhesive is used besides the impregnated matrix resin, eliminating the impact of adhesive materials, processes, and aging on the coupling. The specific manufacturing steps provided in this invention simplify the entire preparation process of the wind turbine coupling and reduce manufacturing costs. Furthermore, this invention incorporates a tongue-and-groove interlocking structure between the inner circumferential surfaces of the composite material intermediate tube at both ends and the contact surfaces of the two hourglass-shaped flanges. This interlocking structure increases the contact area between the inner circumferential surfaces of the composite material intermediate tube and the two hourglass-shaped flanges without increasing the overall volume of the wind turbine coupling, thus increasing the adhesive strength of the impregnated matrix resin. Another function is that the mechanical structure formed by the interlocking structure enhances the mechanical torsional resistance of the wind turbine coupling. This allows the invention to utilize the resin adhesive force and the interlocking mechanical force to resist torsional torque, giving the wind turbine coupling significant torsional resistance. This helps resist the increasing torque, further preventing structural disintegration of the wind turbine coupling and thus improving its quality and service life.

[0037] In the embodiments, "multiple" refers to "two or more". The above embodiments are for illustrative purposes only and are not intended to limit the invention. Those skilled in the art can make various changes or modifications without departing from the spirit and scope of the invention. Therefore, all equivalent technical solutions should also fall within the protection scope of the invention, which is defined by the claims.

Claims

1. A manufacturing method of a wind power coupling suitable for a high speed shaft end of a wind turbine, the wind power coupling comprising a composite intermediate pipe and a flange one and a flange two arranged at both ends of the composite intermediate pipe, the composite intermediate pipe being formed by winding and curing a matrix resin impregnated with reinforcing fiber yarns, characterized in that: The manufacturing method involves setting both flanges into an hourglass shape, wider at both ends and narrower in the middle, and setting the inner circumferential surfaces of both ends of the composite material intermediate tube to match the shape of the hourglass flanges. During manufacturing, the inner liner is assembled between the two flanges to form an integral structure. Then, the two flanges and the inner liner are installed on a winding fixture. The winding fixture is then hoisted into a winding machine. One end of the winding fixture is locked by the winding machine, and the other end of the winding fixture is tightened by the winding machine. Finally, the reinforcing fiber yarn impregnated with the matrix resin is wound onto the two flanges and the inner liner to form a composite material intermediate tube. After curing, the wind turbine coupling is finally manufactured. After the wind turbine coupling is manufactured, the inner circumferential surfaces of both ends of the composite material intermediate tube are engaged with the two hourglass flanges to form an axial limiting structure. Both flange one and flange two include a central straight-edge ring, an outer straight-edge ring located at one end of the central straight-edge ring, and an inner conical ring located at the other end of the central straight-edge ring. One end of the central straight-edge ring is connected to one end of the outer straight-edge ring, and the other end of the central straight-edge ring is connected to the small end of the inner conical ring. The outer diameter of the central straight-edge ring is set as D1, the outer diameter of the outer straight-edge ring is set as D2, then D2 > D1, and the outer diameter of the large end of the inner conical ring is set as D3, then D3 > D1. The central straight-edge ring, the outer straight-edge ring, and the inner conical ring form an hourglass-shaped flange that is large at both ends and small in the middle.

2. The manufacturing method according to claim 1, characterized by: The reinforcing fiber yarn is made of glass fiber, polyester fiber, aramid fiber or carbon fiber; the matrix resin is made of epoxy resin, unsaturated polyester, vinyl ester resin or phenolic resin.

3. The manufacturing method according to claim 1, characterized in that: The inner circumferential surface of the composite material intermediate tube includes a central straight edge circumferential surface and two end straight edge circumferential surfaces, one and two respectively, located on both sides of the central straight edge circumferential surface. A tapered circumferential surface is also provided between the end straight edge circumferential surface and the central straight edge circumferential surface. A tapered circumferential surface is also provided between the end straight edge circumferential surface and the central straight edge circumferential surface. One end of the end straight edge circumferential surface is connected to the small end of the tapered circumferential surface. The large end of the tapered circumferential surface is connected to one end of the central straight edge circumferential surface. The other end of the central straight edge circumferential surface is connected to the large end of the tapered circumferential surface. The small end of the tapered circumferential surface is connected to one end of the end straight edge circumferential surface. After the wind turbine coupling is manufactured, the straight edge ring and the inner conical ring of flange one are respectively engaged and contacted with the straight edge circumferential surface one and the conical circumferential surface one of the end of the composite material intermediate pipe, and the straight edge ring and the inner conical ring of flange two are respectively engaged and contacted with the straight edge circumferential surface two and the conical circumferential surface two of the end of the composite material intermediate pipe to form an axial limiting structure.

4. The manufacturing method according to claim 3, characterized in that: The specific steps of the manufacturing method are as follows: S1. Materials and Equipment: Clean the two flanges by degreasing, sandblast the joint section, and prepare the inner liner pipe. S2, Mold assembly: Assemble the inner liner between the two flanges cleaned and sandblasted in step S1. Assemble the two flanges onto the winding tooling coated with release agent according to the designed length of the intermediate body structure of the coupling. The two flanges and the inner liner form the winding mandrel of the intermediate body structure of the coupling. S3. Mold installation: The assembled winding mandrel of the intermediate coupling structure is hoisted into the winding machine, one end is locked with a three-jaw chuck, and the other end is tightened and centered with an ejector pin; S4. Cleaning: Clean the assembled winding mandrel and apply release agent to the straight edge rings on the outer sides of the two flanges. S5. Winding: The reinforcing fiber yarn is drawn out from the yarn rack, impregnated with the prepared matrix resin in the impregnation tank, and then pulled to the winding mandrel prepared in step S4. The designed winding program is then called to wind the yarn. S6. Remove the composite material winding intermediate tube obtained in step S5 from the winding machine and place it in a ventilated drying oven for curing. S7. Demolding: The composite material cured in step S6 is wound around the intermediate tube winding part, and the winding fixture is pulled out by the demolding machine to obtain the intermediate structure blank of the wind power coupling. S8. Machining: The intermediate structure blank of the coupling obtained in step S7 is machined to finally produce the wind power coupling.

5. The manufacturing method according to claim 4, characterized in that: During the winding process in step S5, the designed procedure is followed. First, one flange is wound. The reinforcing fiber yarn impregnated with the matrix resin is embedded in the recessed space C formed by the straight edge ring and the inner conical ring of the flange and wound threadedly. After the recessed space C is fully wound, the recessed space C formed by the straight edge ring and the inner conical ring of the other flange is wound. When the recessed space C of the other flange is also fully wound, the reinforcing fiber yarn impregnated with the matrix resin is wound back and forth between the two flanges according to the designed winding procedure. That is, it is wound from one flange through the inner liner to the other flange, and then wound from the other flange through the inner liner to the other flange. This cross-winding is repeated until the cross-winding forms a composite material winding intermediate tube winding part.

6. The manufacturing method according to claim 4, characterized in that: During the winding process in step S5, the winding is performed according to the designed procedure, winding from one flange through the inner liner to another flange, and then winding from the other flange through the inner liner to another flange, and so on, until the composite material winding intermediate tube is formed.

7. The manufacturing method according to claim 5, characterized in that: During the winding process, an annular winding process is inserted into the cross-winding process.

8. The manufacturing method according to any one of claims 1 to 7, characterized in that: A convex-concave interlocking structure is provided between the inner circumferential surfaces of the two ends of the composite material intermediate tube and the contact surfaces of the two hourglass-shaped flanges.

9. The manufacturing method according to claim 8, characterized in that: Both flanges have protrusions on the outer circumferential surfaces of the middle straight-edge ring and the inner conical ring. The end straight-edge circumferential surface one and the end conical circumferential surface two of the composite material intermediate tube are each provided with grooves that match the protrusions. The interlocking structure is formed by the contact between the protrusions and the grooves. or Grooves are provided on the outer circumferential surfaces of the straight-edge ring body in the middle and the conical ring body on the inner side of the two flanges. Protrusions matching the grooves are provided on the first straight-edge circumferential surface and the first conical circumferential surface at the end of the composite material intermediate tube, as well as on the second straight-edge circumferential surface and the second conical circumferential surface at the end. The interlocking structure is formed by the contact between the protrusions and the grooves.

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