Scale test blade manufacturing method

Abstract

The invention provides a manufacturing method of a scaling test blade. The manufacturing method of the scaling test blade comprises the following steps: processing a first material into a cylinder to enable the cylinder to reach a preset size; the structural shape of the column body is adjusted; a beam cap groove is formed in the column body; the beam cap groove is filled with a second material; and carrying out curing treatment on the column body. The problem that in the prior art, the blade test difficulty of a fan is high is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of large wind turbines, and more particularly, to a method for manufacturing a scaled - down test blade. Background Art

[0002] In the field of wind power generation, the size design and performance verification of large wind turbine blades are key steps to ensure the efficient and safe operation of the wind power system. Traditional methods mostly involve testing full - size blades to obtain accurate test results. However, although the testing of full - size blades can directly reflect their actual working conditions, the high experimental costs and complex experimental conditions limit the frequent implementation of this process, especially in the preliminary evaluation stage of new designs and materials. At the same time, full - size blades are the actual blades used, and they cover a large area, requiring a large test site. Each test consumes a large amount of manpower and material resources. To ensure the effectiveness of the test, multiple tests are required, resulting in high time and cost.

[0003] As can be seen from the above, there is a problem in the prior art that the blade test of the wind turbine is difficult. Summary of the Invention

[0004] The main object of the present invention is to provide a method for manufacturing a scaled - down test blade to solve the problem of high difficulty in blade testing of wind turbines in the prior art.

[0005] To achieve the above object, the present invention provides a method for manufacturing a scaled - down test blade, including: processing a first material into a cylinder to make the cylinder reach a preset size; adjusting the structural shape of the cylinder; opening a beam cap groove on the cylinder; filling a second material into the beam cap groove; and curing the cylinder.

[0006] Further, the method for manufacturing a scaled - down test blade further includes pre - treating the beam cap groove before filling the second material into the beam cap groove.

[0007] Further, filling the second material into the beam cap groove includes the following stages: a heat treatment stage, in which the second material is heat - treated; a filling stage, in which the filling stage includes filling the second material to the opening of the beam cap groove.

[0008] Further, during the implementation of the filling stage, after the second material is filled to the opening of the beam cap groove, the second filling material at the opening is leveled.

[0009] Further, opening a beam cap groove on the cylinder includes selecting the number and position of the beam cap grooves.

[0010] Further, in the step of forming the beam cap grooves on the column, the positions of the beam cap grooves are determined according to the number of the beam cap grooves. Specifically, if there is one beam cap groove, it is arranged in the middle of the column; if there are multiple beam cap grooves, multiple beam cap grooves are formed at intervals along the length direction of the column and / or at intervals along the width direction of the column.

[0011] Further, the method for manufacturing the scaled test blade further includes an intermediate treatment step between filling the second material into the beam cap grooves and curing the column. The intermediate treatment step includes covering the surface of the column with a coating layer.

[0012] Further, the intermediate treatment step further includes performing a smoothing operation on the surface of the coating layer.

[0013] Further, curing the column includes arranging the column in a mold and performing heat treatment on the mold.

[0014] Further, the method for manufacturing the scaled test blade further includes a post-treatment step after the curing treatment of the column. The post-treatment step includes forming a receiving cavity on the column along the length direction from one end of the column and arranging a measuring wire in the receiving cavity.

[0015] Applying the technical solution of the present invention, the method for manufacturing the scaled test blade includes processing the first material into a column to make the column reach a preset size, adjusting the structural shape of the column, forming beam cap grooves on the column, filling a second material into the beam cap grooves, and curing the column. By processing the first material into a column and processing the column, a structure similar to a blade can be obtained and the preset size can be achieved, meeting the length size requirements of the test. By forming beam cap grooves on the column and filling the second material, the structural strength of the entire blade can be improved. After the column is cured, the structural strength of the first material can be strengthened, so that the blade can simulate the stress condition of a real blade during the test. By reasonably designing the preset size, a scaled-down blade can be obtained, avoiding the increased cost of testing a full-size blade and reducing the difficulty of the test. The test can be carried out only in a conventional laboratory, solving the problem of the high difficulty of blade testing in the prior art for a fan. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings forming a part of this application are used to provide a further understanding of the present invention. The schematic embodiments and descriptions thereof of the present invention are used to explain the present invention and do not constitute an improper limitation to the present invention. In the drawings:

[0017] Figure 1 shows a flowchart of the method for manufacturing the scaled test blade in a specific embodiment of the present invention; and

[0018] Figure 2 The structural schematic diagram of the blade in a specific embodiment of the present invention is shown.

[0019] Among them, the above-mentioned drawings include the following reference numerals:

[0020] 10, cylinder; 20, beam cap groove; 30, accommodation cavity. Detailed implementation manners

[0021] It should be noted that, without conflict, the embodiments in this application and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the drawings and in combination with the embodiments.

[0022] It should be pointed out that unless otherwise specified, all technical and scientific terms used in this application have the same meanings as those commonly understood by those of ordinary skill in the technical field to which this application belongs.

[0023] In the present invention, unless otherwise stated, the orientation terms such as "upper, lower, top, bottom" are usually in the directions shown in the drawings, or in the vertical, perpendicular or gravitational directions of the components themselves; similarly, for the convenience of understanding and description, "inner, outer" refer to the inner and outer of the contours of the components themselves, but the above orientation terms do not limit the present invention.

[0024] Obviously, the above-described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present invention without creative efforts shall fall within the protection scope of the present invention.

[0025] In order to solve the problem of the high difficulty of the blade test of the existing technology, the present invention provides a method for manufacturing a scaled-down test blade.

[0026] As Figures 1 to 2 shown, the method for manufacturing a scaled-down test blade includes: processing a first material into a cylinder 10 to make the cylinder 10 reach a preset size. Adjusting the structural shape of the cylinder 10. Opening a beam cap groove 20 on the cylinder 10. Filling the beam cap groove 20 with a second material. Performing a curing treatment on the cylinder 10.

[0027] By opening a beam cap groove 20 on the cylinder 10 and filling it with a second material, the structural strength of the entire blade can be improved. After the cylinder 10 is cured, the structural strength of the first material can be strengthened, so that the blade can simulate the stress condition of the real blade during the test. By reasonably designing the preset size, a scaled-down blade can be obtained, avoiding the increased cost caused by testing the full-size blade and reducing the test difficulty. During the test, it only needs to be carried out in a conventional laboratory.

[0028] It can be understood that by precisely controlling the shape and size of the first material and opening the beam cap groove 20 at specific positions, a basis is provided for subsequent filling of the second material and curing treatment. The finally manufactured scaled test blade can accurately simulate the structural characteristics of the full-size blade.

[0029] In this embodiment, the first material is a rigid foam material.

[0030] Specifically, common foam materials include polyurethane foam (PU), polymethyl methacrylate foam (PMI), and polystyrene foam (EPS). Different types of foam materials are selected according to different needs.

[0031] In this embodiment, the foam material selected is polymethyl methacrylate foam (PMI). Polymethyl methacrylate foam (PMI) has relatively high strength and sufficient dimensional stability.

[0032] Specifically, before selecting the type of foam material, the specific dimension data of the scaled blade are designed according to the size of the blade to be used, and after increasing the dimension values, they are input into equipment such as a digital machine tool or a laser cutting bed. The foam material is cut by the digital machine tool and other equipment to prepare a cylinder 10. The size of the cylinder 10 is larger than the final blade size to facilitate subsequent adjustment of the structure of the cylinder 10.

[0033] Furthermore, the length of the cylinder 10 is the length of the final blade, the width of the cylinder 10 is the maximum chord length of the blade, and the thickness of the cylinder 10 is the outer diameter of the blade root. Processing the length, width, and thickness of the cylinder 10 into preset dimensions can reduce the difficulty of subsequent adjustment of the structure of the cylinder 10.

[0034] In this embodiment, adjusting the structural shape of the cylinder 10 means putting the cylinder 10 into a high-precision machine tool and processing the cylinder 10 according to the structural shape of the blade so that it forms Figure 2 the structural shape shown.

[0035] In this embodiment, the method for manufacturing the scaled test blade further includes preprocessing the beam cap groove 20 before filling the second material into the beam cap groove 20.

[0036] Specifically, the beam cap groove 20 can be processed by a drill press. Since the first material is a foam material, there are cutting debris at the bottom or inner wall of the groove after processing the beam cap groove 20. In order to avoid the debris affecting the filling effect of the second material, it is necessary to clean the debris in the beam cap groove 20.

[0037] In an alternative embodiment of the present application, preprocessing the beam cap groove 20 further includes coating an adhesive layer on the bottom or inner wall of the beam cap groove 20. Preferably, an adhesive layer is provided on the bottom of the groove to improve the connection effect between the second material and the beam cap groove 20.

[0038] In this embodiment, filling the second material into the beam cap groove 20 includes the following stages: a heat treatment stage, which includes heat-treating the second material; and a filling stage, which includes filling the second material to the opening of the beam cap groove 20.

[0039] Specifically, the second material is a carbon fiber prepreg, which includes carbon fibers and epoxy resin. After the second material is filled into the beam cap groove 20, it can be used as a main beam to reinforce the blade, ensuring that the key load-bearing part of the blade has sufficient strength and stiffness, so as to be able to withstand the dynamic load under the action of wind force during the test. By using carbon fiber prepreg, the manufacturing precision of the blade can be improved by precisely controlling the ply thickness, direction, and position of the fibers, so that the distribution and performance of the material can accurately reflect the characteristics of the full-scale blade. Heat-treating the second material can improve the structural strength of the second material, so that the second material also has a certain structural strength when placed in the beam cap groove 20, which is beneficial to improving the structural strength of the beam cap groove 20.

[0040] It should be noted here that the above heat treatment is to heat the second material, activate the resin in the second material by using heat, and improve its fluidity and adhesiveness, which is convenient for the filling process. Through heat treatment, the second material can be more evenly filled into the beam cap groove 20, enhancing the structural strength and stiffness of the blade. The usage process is to first heat-treat the second material, and after it reaches a suitable flow state, quickly fill it into the beam cap groove 20 to ensure the continuity and uniformity of the filling process.

[0041] In another alternative embodiment of the present application, the second material is directly filled into the beam cap groove 20 and through subsequent curing treatment operations, the second material and the column 10 are cured synchronously to improve the structural strength of the second material and the beam cap groove 20.

[0042] In this embodiment, during the implementation of the filling stage, after the second material is filled to the opening of the beam cap groove 20, the second material at the opening is leveled.

[0043] Specifically, in the blade test, the smoothness of the blade surface has an important impact on the test effect of the blade. Whether the second material is placed in the beam cap groove 20 after heat treatment or directly placed in the beam cap groove 20 without heat treatment, the surface of the second material and the column 10 needs to be treated flush to improve the streamline effect of the blade and avoid the test effect of the blade from decreasing due to the second material protruding or recessing into the beam cap groove 20. Optionally, a scraper or a roller is used to remove the excess part of the second material at the opening to ensure the flatness and beauty of the filling surface, while avoiding material waste. It improves the appearance quality and structural precision of the scaled test blade and reduces the difficulty of subsequent processing.

[0044] In this embodiment, forming the beam cap groove 20 on the column 10 includes selecting the number and position of the beam cap grooves 20.

[0045] Specifically, the beam cap groove 20 is used to accommodate the second material to form the main beam. Before processing, the position of the beam cap groove 20 is designed, such as being set in the middle of the blade or on one side of the blade. Different numbers of beam cap grooves 20 will result in different structural strengths of the blade. According to the strength requirements of the blade to be tested, selecting the number and position of the beam cap grooves 20 can improve the overall structural strength of the blade. Optionally, marking lines are drawn at the possible positions where the beam cap grooves 20 can be formed to improve the accuracy of processing. By precisely controlling the number and position of the beam cap grooves 20, the manufactured scaled test blade can more accurately simulate the structural characteristics of the full-scale blade, improving the accuracy and reliability of the experiment.

[0046] In this embodiment, in the step of forming the beam cap groove 20 on the column 10, according to the number of the beam cap grooves 20, the position of the beam cap groove 20 is determined. Among them, if the number of the beam cap grooves 20 is one, the beam cap groove 20 is set in the middle of the column 10; if there are multiple beam cap grooves 20, multiple beam cap grooves 20 are formed at intervals along the length direction of the column 10, and / or multiple beam cap grooves 20 are formed at intervals along the width direction of the column 10.

[0047] Specifically, when the beam cap groove 20 is formed in the middle of the column 10, after the second material is filled in the beam cap groove 20, a main beam is formed in the middle of the column 10, which can provide significant longitudinal rigidity, enabling the blade to remain stable when subjected to wind force, reducing deformation, and thus simulating through experiments the situation where a large wind turbine blade bears a large load during operation and obtaining relatively accurate experimental data. At the same time, the main beam formed by the beam cap groove 20 in the middle of the column 10 helps to control the vibration characteristics of the blade, ensuring that the flapping and pitching frequencies meet the design requirements, and thus better simulating the actual use situation of the full-scale blade, testing and simulating the use stability and service life of the full-scale blade.

[0048] Furthermore, forming the beam cap groove 20 at the edge of the column 10 can mainly be used to enhance the strength and rigidity of the blade edge, preventing excessive deformation or damage in the edge area under extreme loads. The edge is one of the areas where the blade is most concentratedly stressed under wind force. Therefore, the design of the edge beam cap groove can simulate the wind resistance and durability of the full-scale blade. And the edge main beam finally formed by the second material can significantly improve the anti-torsion ability of the blade, thus better testing the wind resistance of the full-scale blade.

[0049] It can be understood that forming the beam cap groove 20 at different positions of the column 10 can simulate the structural strength and stiffness of the blade at different positions, thereby more comprehensively evaluating the design performance of the blade.

[0050] In this embodiment, the method for manufacturing the scaled - down test blade further includes an intermediate processing step between filling the second material into the beam cap groove 20 and curing the column 10. The intermediate processing step includes: covering the surface of the column 10 with a coating layer.

[0051] Specifically, the setting of the coating layer can improve the connection effect between the second material and the beam cap groove 20. The coating layer covers the entire column 10, which is beneficial for the second material and the column 10 to form a whole and is also beneficial for improving the smoothness of the blade.

[0052] It can be understood that setting the coating layer can improve the surface quality and structural integrity of the column 10, and at the same time prevent the leakage of materials during the curing process. It improves the structural integrity of the scaled - down test blade and the reliability of the experiment, and avoids experimental errors caused by poor surface quality.

[0053] In this embodiment, the coating layer is a low - modulus glass fiber prepreg. The low - modulus glass fiber prepreg has a lower density, which can avoid interfering with the test results due to the change in the weight of the blade while wrapping the blade surface. At the same time, the cost of the low - modulus glass fiber prepreg is relatively low, which can further reduce the cost of blade testing.

[0054] Furthermore, by using a high - modulus carbon fiber material prepreg and a low - modulus glass fiber material prepreg at the same time, the similarity of the strength, stiffness, flapping frequency, and pitching frequency of the blade is ensured, thereby improving the accuracy and reliability of the experiment.

[0055] In this embodiment, the intermediate processing step further includes: performing a smoothing and leveling operation on the surface of the coating layer.

[0056] Specifically, the coating layer is processed by moving a scraper or a roller along the length direction of the column 10 to reduce the wrinkles on the surface of the coating layer, discharge the gas inside the coating layer, and obtain a blade with a smooth surface.

[0057] In this embodiment, the coating layer can be set to 1 layer, 2 layers, 3 layers, or 4 layers. Too many coating layers will increase the cost of the test blade and are also prone to uneven positions, which will lead to experimental data errors or even mistakes when testing the blade, and are not conducive to the progress of the experiment. When the coating layer is multiple layers, it is set layer by layer. After each layer completely wraps the blade, the next layer is laid. Optionally, each time the laying of the coating layer for easy measurement is completed, a layer of the coating layer is leveled, thereby reducing the thickness of the entire multiple coating layers and avoiding interference from bubbles or wrinkles inside one layer of the coating layer to the laying of the next layer.

[0058] In this embodiment, curing the column 10 includes: placing the column 10 in a mold; performing heat treatment on the mold.

[0059] Specifically, place the column 10 with the coating layer into the blade mold, and use a fixture to position and fix the column 10 to prevent the column 10 from loosening or tilting during the subsequent heat treatment process. Optionally, a mold release agent is provided at the bottom of the mold to prevent adhesion between the column 10 and the mold after heat treatment of the mold, improving the demolding effect. During the manufacturing process, as a key step to improve product quality and structural stability, the curing treatment ensures the structural performance of the blade and the reliability of the experiment.

[0060] Furthermore, when heat-treating the mold, one of autoclave, infrared heating, electric heating, or microwave heating can be used.

[0061] In this embodiment, between filling the second material into the beam cap groove 20 and curing the column 10, a vacuum treatment is also included for the column 10.

[0062] Specifically, lay a layer of release cloth outside the coating layer to prevent the coating layer from contacting the vacuum bag, and lay a layer of absorbent cloth on the release cloth as needed to adsorb excess resin or volatiles on the coating layer caused by the vacuum operation. One end of the vacuum bag is connected to a vacuum pump. Starting the vacuum pump can discharge the air in the coating layer and even the second material, making the resin penetrate the gaps between the fiber materials, and thus making the surfaces of the second material and the coating layer smoother.

[0063] In this embodiment, an autoclave is used to heat-treat the mold. During the heat treatment process, the curing operation of the resin is accelerated, the structural strength of the second material layer and the coating layer is improved, and the gas in the second material and the coating layer can be further discharged.

[0064] In this embodiment, the method for manufacturing a scaled test blade further includes a post-treatment step after the curing treatment of the column 10. The post-treatment step includes: opening a receiving cavity 30 on the column 10 along the length direction of the column 10 from one end of the column 10; setting a measuring wire in the receiving cavity 30.

[0065] Specifically, open a receiving cavity 30 at one end of the blade formed by the cured column 10, and set and fix the measuring wire in the receiving cavity 30, so as to facilitate observing the effect of the blade during testing using the measuring wire.

[0066] In this embodiment, after the operation of setting the measuring wire in the receiving cavity 30, a speedometer can also be added at the target position of the blade, and the signal wire is led out from the blade root for measuring the vibration and deformation of the blade, making the experimental data more accurate and providing strong data support for subsequent blade design.

[0067] The usage process is as follows: after the curing treatment of the blade is completed, a receiving cavity is opened along the length direction at one end of the cylinder 10, then the measuring wire is arranged in the receiving cavity to ensure the stable connection between the measuring wire and the speedometer, and finally, an experimental test is carried out to monitor the vibration and deformation of the blade.

[0068] 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 a scaled test blade includes: processing a first material into a cylinder 10 to make the cylinder 10 reach a preset size; adjusting the structural shape of the cylinder 10; opening a beam cap groove 20 on the cylinder 10; filling the beam cap groove 20 with a second material; curing the cylinder 10. By opening a beam cap groove 20 on the cylinder 10 and filling it with a second material, the structural strength of the entire blade can be improved. After the cylinder 10 is cured, the structural strength of the first material can be strengthened, so that the blade can simulate the stress condition of the real blade during the test. By reasonably designing the preset size, a scaled-down blade can be obtained, avoiding the increased cost caused by testing a full-size blade and reducing the difficulty of the test. During the test, it only needs to be carried out in a conventional laboratory.

[0069] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0070] It should be noted that the terms "upper", "lower", etc. in the specification, claims and drawings of the present application are used to distinguish similar objects and do not necessarily need to describe a specific order or sequence. It should be understood that such used data can be interchanged under appropriate circumstances so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein.

[0071] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. For those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for manufacturing a scaled test blade, characterized in that: include: Processing the first material into a column (10) so that the column (10) reaches a preset size; Adjusting the structural shape of the column (10); A beam cap groove (20) is provided on the column (10); Filling a second material into the beam cap groove (20); The column (10) is subjected to a curing treatment.

2. The method for manufacturing a scaled test blade according to claim 1, characterized in that: The scaled test blade manufacturing method further comprises pre-treating the spar cap groove (20) before filling the second material into the spar cap groove (20).

3. The method for manufacturing a scaled test blade according to claim 1, characterized in that: The step of filling the beam cap groove (20) with a second material comprises the following stages: a heat treatment stage, wherein the heat treatment stage comprises heat treating the second material; A filling stage, the filling stage comprising filling the second material into the opening of the spar cap groove (20).

4. The method for manufacturing a scaled test blade according to claim 3, characterized in that: During the implementation of the filling stage, after the second material is filled to the opening of the beam cap groove (20), The second material at the opening is leveled.

5. The method for manufacturing a scaled test blade according to claim 1, characterized in that: Providing beam cap grooves (20) on the column (10) includes selecting the number and positions of the beam cap grooves (20).

6. The method for manufacturing a scaled test blade according to claim 5, characterized in that: In the step of providing the beam cap grooves (20) on the column (10), the positions of the beam cap grooves (20) are determined according to the number of the beam cap grooves (20), wherein: If the number of the beam cap groove (20) is one, the beam cap groove (20) is arranged in the middle of the column (10); If there are a plurality of beam cap grooves (20), the plurality of beam cap grooves (20) are spaced apart along the length direction of the column (10), and / or the plurality of beam cap grooves (20) are spaced apart along the width direction of the column (10).

7. The method for manufacturing a scaled test blade according to claim 1, characterized in that: The scaled test blade manufacturing method further comprises an intermediate processing step between filling the second material into the spar cap groove (20) and curing the column (10), wherein the intermediate processing step comprises: coating the surface of the column (10) with a coating layer.

8. The method for manufacturing a scaled-down test blade according to claim 7, characterized in that: The intermediate processing step also includes: smoothing the surface of the coating layer.

9. The method for manufacturing a scaled test blade according to claim 1, characterized in that: The curing treatment of the column (10) comprises: placing the cylinder (10) in a mold; The mold is heat treated.

10. The method for manufacturing a scaled test blade according to any one of claims 1 to 8, characterized in that: The scaled test blade manufacturing method further comprises a post-processing step after the curing treatment of the column (10) is completed, and the post-processing step comprises: A receiving cavity (30) is opened on the column (10) along the length direction of the column (10) from one end of the column (10); The measuring line is arranged in the accommodating cavity (30).

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