Wind power blade forming method and wind power blade

Abstract

The invention relates to the field of wind power blades, and discloses a wind power blade forming method and a wind power blade. The wind power blade forming method comprises the steps that a windward side shell body part and a first baffle part are poured and formed into a windward side shell in a windward side shell mold; the leeside shell main body part and the second baffle part are poured and molded into a leeside shell in a leeside shell mold; the windward side shell mold and the leeward side shell mold are closed, so that the first baffle part and the second baffle part are spliced; and reinforcing layers are laid at the splicing position of the windward side shell and the leeward side shell and the splicing position of the first baffle part and the second baffle part to form the wind power blade with the baffles. The installation difficulty of the baffle is reduced.

Description

Technical Field

[0001] This application belongs to the field of wind turbine blades, and particularly relates to a method for forming a wind turbine blade and a wind turbine blade. Background Art

[0002] The wind turbine blade is a core component of a wind power generation unit. Through aerodynamic design (such as airfoil structure and angle optimization), wind energy is converted into mechanical energy, which in turn drives the generator to generate electricity.

[0003] A baffle is provided at the root of the wind turbine blade. The baffle separates the blade cavity from the hub, preventing residues inside the blade (such as broken bolts and debris) from falling and damaging the hub, thus ensuring the safe operation of the wind turbine. With the continuous increase in the size of wind turbine blades, the installation difficulty of the baffle has become one of the important problems that need to be solved urgently. Summary of the Invention

[0004] The embodiments of this application provide a method for forming a wind turbine blade and a wind turbine blade, which can reduce the installation difficulty of the baffle.

[0005] On the one hand, the embodiments of this application provide a method for forming a wind turbine blade, including: in the windward shell mold, pouring and molding the windward shell main body part and the first baffle part into the windward shell; in the leeward shell mold, pouring and molding the leeward shell main body part and the second baffle part into the leeward shell; closing the windward shell mold and the leeward shell mold so that the first baffle part and the second baffle part are spliced; laying a reinforcing layer at the splicing joint of the windward shell and the leeward shell and at the splicing joint of the first baffle part and the second baffle part to form a wind turbine blade with a baffle.

[0006] In some alternative embodiments of this application, pouring and molding the windward shell main body part and the first baffle part into the windward shell in the windward shell mold includes: laying the windward shell main body part on the windward shell mold. The windward shell main body part sequentially includes a root section, a middle section, and a tip section along the span direction; placing the first baffle part at the root section of the windward shell main body part; laying at least a connecting layer at one end of the first baffle part close to the windward shell main body part, and the connecting layer overlaps with the windward shell main body part; pouring a matrix material into the windward shell mold and curing to form the windward shell.

[0007] In some alternative embodiments of the present application, pouring a matrix material into the windward shell mold and curing to form the windward shell includes: laying a runner assembly between the main body portion of the windward shell and the first baffle portion, the runner assembly being in communication with the pouring system; covering the runner assembly with a vacuum bag in communication with the vacuum pumping system, the first air extraction port of the vacuum bag being disposed at one end of the first baffle portion facing away from the main body portion of the windward shell, and the second air extraction port of the vacuum bag being opposite to the main body portion of the windward shell; closing the first air extraction port, opening the second air extraction port, performing vacuum pumping, and performing the first-stage pouring of the matrix material; after the first stage is completed, opening the first air extraction port and performing the second-stage pouring of the matrix material.

[0008] In some alternative embodiments of the present application, placing the first baffle portion at the blade root section of the main body portion of the windward shell includes: laying a mounting core material with grooves at the blade root section of the main body portion of the windward shell; inserting the first baffle main body into the groove.

[0009] In some alternative embodiments of the present application, laying a connection layer at least at one end of the first baffle portion close to the main body portion of the windward shell, the connection layer overlapping with the main body portion of the windward shell includes: laying the connection layer through the first baffle main body to cover the mounting core material and overlapping with the main body portion of the windward shell.

[0010] In some alternative embodiments of the present application, laying a connection layer at least at one end of the first baffle portion close to the main body portion of the windward shell, the connection layer overlapping with the main body portion of the windward shell includes: laying the connection layer to cover the mounting core material and the first baffle main body and overlapping with the main body portion of the windward shell.

[0011] In some alternative embodiments of the present application, closing the windward shell mold and the leeward shell mold so that the first baffle portion and the second baffle portion are spliced includes: coating an adhesive layer at at least one opposite end of the first baffle portion and the second baffle portion; closing the windward shell mold and the leeward shell mold, and bonding the first baffle portion and the second baffle portion through the adhesive layer.

[0012] In some alternative embodiments of the present application, molding the main body portion of the windward shell and the first baffle portion into the windward shell in the windward shell mold includes: sequentially laying an outer skin layer, a girder layer, a shell core material layer, and an inner skin layer in the windward shell mold; placing the first baffle portion on the inner skin layer; pouring a matrix material into the windward shell mold and curing to form the windward shell.

[0013] In some alternative embodiments of the present application, a wind turbine blade with a baffle is formed by laying a reinforcing layer at the joint of the windward surface shell and the leeward surface shell and at the joint of the first baffle portion and the second baffle portion, including: forming an inner reinforcing layer at the joint of the windward surface shell and the leeward surface shell and at the joint of the first baffle portion and the second baffle portion inside the closed mold shell; forming an outer reinforcing layer at the joint of the windward surface shell and the leeward surface shell and at the joint of the first baffle portion and the second baffle portion outside the closed mold shell, thus forming a wind turbine blade with a baffle.

[0014] In some alternative embodiments of the present application, after the windward surface shell main body portion and the first baffle portion are injection molded into the windward surface shell in the windward surface shell mold, it further includes: opening a lightning protection installation hole in the first baffle portion; installing a lightning protection device inside the windward surface shell.

[0015] On the other hand, an embodiment of the present application further provides a wind turbine blade, which sequentially includes a root section, a middle section, and a tip section along the span direction, and further includes: a windward surface shell, including an integrally formed windward surface shell main body portion and a first baffle portion, the first baffle portion being located at the root section of the windward surface shell main body portion; a leeward surface shell, including an integrally formed leeward surface shell main body portion and a second baffle portion, the second baffle portion being located at the root section of the leeward surface shell main body portion; the windward surface shell main body portion and the leeward surface shell main body portion are covered and connected, and the first baffle portion and the second baffle portion are oppositely connected; a reinforcing layer, provided at the connection between the windward surface shell main body portion and the leeward surface shell main body portion and at the connection between the first baffle portion and the second baffle portion.

[0016] In some alternative embodiments of the present application, the first baffle portion includes a first baffle main body, a mounting core material, and a connection layer. The mounting core material is laid on the windward surface shell main body portion. The mounting core material includes a groove facing away from the windward surface shell main body portion. The first baffle main body is placed in the groove, and the connection layer covers the first baffle main body and the mounting core material and is connected to the windward surface shell main body portion.

[0017] In some alternative embodiments of the present application, along the span direction, the thickness of the mounting core material has a decreasing trend from both sides of the groove to both ends of the mounting core material.

[0018] In some alternative embodiments of the present application, the wind turbine blade further includes an adhesive layer, and the adhesive layer is placed between the first baffle portion and the second baffle portion.

[0019] The wind turbine blade forming method and wind turbine blade according to the embodiments of the present application. The baffle is divided into a first baffle part and a second baffle part. The first baffle part is integrally formed by pouring with the main body part of the windward side shell, which improves the connection strength between the first baffle part and the main body part of the windward side shell. The second baffle part is integrally formed by pouring with the main body part of the leeward side shell, which improves the connection strength between the second baffle part and the main body part of the leeward side shell. The separate forming of the baffle reduces the installation difficulty and improves the strength of the baffle with a split structure. Moreover, the reinforcement layer jointly reinforces the baffle and the wind turbine blade shell, improving the overall strength of the wind turbine blade and making the integrity of the wind turbine blade better. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings required to be used in the embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0021] Figure 1 It is a flowchart of a wind turbine blade forming method provided by some embodiments of the present application;

[0022] Figure 2 It is a schematic structural diagram of a wind turbine blade provided by some embodiments of the present application;

[0023] Figure 3 It is a schematic structural diagram of the mold closing state of a wind turbine blade provided by some embodiments of the present application;

[0024] Figure 4 For Figure 1 It is a specific flowchart of step S1 in

[0025] Figure 5 For Figure 3 It is an exploded view of the windward side shell in

[0026] Figure 6 For Figure 3 It is a schematic overall structure diagram of the windward side shell in

[0027] Figure 7 For Figure 5 It is a schematic structural diagram of the first baffle part in

[0028] Figure 8 For Figure 5 It is a specific flowchart of step S14 in

[0029] Figure 9 It is a schematic partial structure diagram of the windward side shell;

[0030] Figure 10 It is another flowchart of the wind turbine blade forming method according to some embodiments of the present application.

[0031] Reference numerals:

[0032] 100, face shell mold; 101, face shell main body; 102, first baffle part; 110, first baffle body; 111, installation core material; 112, connection layer; 200, leeward face shell mold; 201, leeward face shell main body; 202, second baffle part; 210, reinforcement layer; 220: adhesive layer; 310, runner assembly; 320, vacuum bag; 321, first air extraction port; 322, second air extraction port; L1, blade root section; L2, middle section; L3, blade tip section. Detailed implementation manners

[0033] The embodiments of the technical solutions of the present application will be described in detail below with reference to the accompanying drawings. The following embodiments are only used to illustrate the technical solutions of the present application more clearly, so they are only examples and cannot be used to limit the protection scope of the present application.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which this application belongs; the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" and any variations thereof in the specification and claims of this application and the above drawings are intended to cover non-exclusive inclusion.

[0035] In the description of the embodiments of the present application, technical terms such as "first" and "second" are only used to distinguish different objects and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity, specific order or primary-secondary relationship of the indicated technical features. In the description of the embodiments of the present application, "a plurality of" means more than two unless otherwise specifically defined.

[0036] Referring to "embodiments" herein means that specific features, structures or characteristics described in connection with the embodiments can be included in at least one embodiment of this application. The phrase appears in various places in the specification and does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment mutually exclusive with other embodiments. Those skilled in the art explicitly and implicitly understand that the embodiments described herein can be combined with other embodiments.

[0037] In the description of the embodiments of the present application, the term "and / or" is only a description of the association relationship of associated objects, indicating that three relationships can exist. For example, A and / or B can represent: A exists alone, A and B exist simultaneously, and B exists alone. In addition, the character " / " in this article generally represents an "or" relationship between the associated objects before and after.

[0038] In the description of the embodiments of the present application, the term "plurality" refers to two or more (including two). Similarly, "multiple groups" refers to two or more groups (including two groups), and "multiple pieces" refers to two or more pieces (including two pieces).

[0039] In the description of the embodiments of the present application, the technical terms "center", "longitudinal", "transverse"

[0040] "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right"

[0041] "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise"

[0042] The orientation or positional relationship indicated by "axial direction", "radial direction", "circumferential direction", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the embodiments of the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation on the embodiments of the present application.

[0043] In the description of the embodiments of the present application, unless otherwise clearly specified and limited, technical terms such as "installation", "connection", "connection", "fixation", etc. should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can also be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments of the present application can be understood according to specific situations.

[0044] Wind energy drives a wind turbine through the principle of aerodynamics. The core link is the conversion of wind energy → mechanical energy → electrical energy. A wind turbine consists of a rotor, a nacelle, and a tower. Among them, the rotor (including blades, hub, and fairing) is the key component for energy capture. The blades improve the wind capture efficiency by optimizing the airfoil structure (such as lift-increasing design in low wind speed areas and load-reducing design in high wind speed areas). Its length and chord length distribution directly affect the swept area and power generation. Currently, the blades are mainly made of glass fiber reinforced epoxy resin (GFRP), taking into account lightweight and high strength. The application of carbon fiber significantly reduces the weight (more than 20% weight reduction), especially suitable for ultra-long blades (such as 123-meter class), improving the fatigue resistance performance and adapting to large-capacity units.

[0045] Wind turbine blade baffles are usually made of high-strength, corrosion-resistant, and wear-resistant materials such as carbon fiber composites and glass fiber-reinforced plastics. These materials are lightweight and high-strength, and can meet the usage requirements of the baffle in harsh environments. During the operation of the blade, metal parts or other foreign objects in the nacelle cover are likely to fall into the blade interior, and the internal structure of the blade is likely to be damaged due to the rotation of the blade during operation. During the blade production process, an adhesive is required to install a matching circular baffle at the inner circle of the blade root of the wind turbine blade to prevent metal or other foreign objects in the nacelle cover from falling into the blade cavity during blade operation.

[0046] With the widespread application of wind energy, the size of wind turbine generators is constantly increasing, and the pitch circle of the wind turbine blade root is also getting larger, such as 1800mm, 2300mm, 2800mm, 3200mm, 4200mm, etc. Due to the increase in the pitch circle, the weight of the baffle increases, and the blade baffle is installed during post-treatment, resulting in an increase in the height of personnel installation lifting and internal blade operation.

[0047] In related technologies, the baffle is disassembled and assembled in multiple parts and installed sequentially. However, multiple baffles will reduce the strength of the baffle, and other processes are required for reinforcement, consuming a large amount of manpower and material resources, increasing the operation difficulty, and raising the cost.

[0048] Figure 1 The flowchart of a wind turbine blade forming method provided by some embodiments of the present application; Figure 2 A schematic structural diagram of a wind turbine blade provided by some embodiments of the present application; Figure 3 A schematic structural diagram of the mold closing state of a wind turbine blade provided by some embodiments of the present application.

[0049] As Figures 1 to 3 shown, in some embodiments of the present application, a wind turbine blade forming method includes:

[0050] S1: In the windward shell mold 100, the windward shell main body 101 and the first baffle part 102 are injection molded into a windward shell.

[0051] Exemplarily, the materials required for the windward shell main body 101 are laid in the windward shell mold 100, and then the first baffle part 102 is laid on the side of the windward shell main body 101 away from the windward shell mold 100, and the windward shell main body 101 and the first baffle part 102 are injection molded, so that the windward shell main body 101 and the first baffle part 102 are integrally formed into a windward shell.

[0052] In one example, after laying the windward side housing main body 101 on the windward side housing mold 100, mark the position of the first baffle portion 102 on the windward side housing main body 101 to facilitate positioning the laying position of the first baffle portion 102.

[0053] In some examples, the first baffle portion 102 is disposed at the blade root section L1 of the windward side housing main body 101, and the distance range of the first baffle portion 102 from the end side of the blade root of the windward side housing main body 101 is between 2 cm and 15 cm.

[0054] Exemplarily, the first baffle portion 102 may include a first baffle body and / or include a first baffle body and a mounting core material, and the first baffle body is mounted on the windward side housing main body 101 through the mounting core material.

[0055] As an example, the first baffle portion 102 may be in a semi-circular or non-regular structure of a semi-circle.

[0056] S2: In the leeward side housing mold 200, the leeward side housing main body 201 and the second baffle portion 202 are injection molded into a leeward side housing.

[0057] Exemplarily, lay the materials required for the leeward side housing main body 201 in the leeward side housing mold 200, then lay the second baffle portion 202 on the side of the leeward side housing main body 201 away from the leeward side housing mold 200, and injection mold the leeward side housing main body 201 and the second baffle portion 202 so that the leeward side housing main body 201 and the second baffle portion 202 are integrally formed into a leeward side housing.

[0058] In one example, after laying the leeward side housing main body 201 on the leeward side housing mold 200, mark the position of the second baffle portion 202 on the leeward side housing main body 201 to facilitate positioning the laying position of the second baffle portion 202.

[0059] In some examples, the second baffle portion 202 is disposed at the blade root section L1 of the leeward side housing main body 201, and the distance range of the second baffle portion 202 from the end side of the blade root of the leeward side housing main body 201 is between 2 cm and 15 cm. The second baffle portion 202 corresponds to the position of the first baffle portion 102.

[0060] Exemplarily, the second baffle portion 202 may include a second baffle body and / or include a second baffle body and a mounting core material, and the second baffle body is mounted on the leeward side housing main body 201 through the mounting core material.

[0061] As an example, the second baffle portion 202 can be in a semi-circular or non-regular semi-circular structure. The first baffle portion 102 and the second baffle portion 202 are buckled to form a circle matching the root pitch circle. In some examples, the joint between the first baffle portion 102 and the second baffle can be a plane, a curved surface or other shapes.

[0062] S3: Close the windward side housing mold 100 and the leeward side housing mold 200 so that the first baffle portion 102 and the second baffle portion 202 are spliced.

[0063] Exemplarily, after the windward side housing mold 100 and the leeward side housing mold 200 are closed, the windward side housing main body portion 101 and the leeward side housing main body portion 201 are covered, so that the windward side housing main body portion 101 and the leeward side housing main body portion 201 enclose the cavity of the wind turbine blade, and the first baffle portion 102 and the second baffle portion 202 are spliced relatively to form a complete baffle, and the baffle is placed in the cavity.

[0064] In some examples, the baffle is in a circular sheet flat structure.

[0065] In some examples, glue can be coated at the joint of the windward side housing main body portion 101 and the leeward side housing main body portion 201 to achieve the bonding of the windward side housing main body portion 101 and the leeward side housing main body portion 201. In addition, glue can also be coated at the splicing of the first baffle portion 102 and the second baffle portion 202 to achieve the bonding of the first baffle portion 102 and the second baffle portion 202.

[0066] S4: Lay a reinforcing layer 210 at the splicing of the windward side housing and the leeward side housing and at the splicing of the first baffle portion 102 and the second baffle portion 202 to form a wind turbine blade with a baffle.

[0067] In order to improve the strength of the splicing, a reinforcing layer 210 is laid on the inner surface and / or outer surface at the splicing of the windward side housing and the leeward side housing and at the splicing of the first baffle portion 102 and the second baffle portion 202.

[0068] In some examples, the laying of the reinforcing layer 210 includes: reinforcing from the trailing edge mold joint to the baffle flat joint and then to the leading edge mold joint, and reinforcing from the trailing edge mold joint to the baffle flat joint and then to the leading edge mold joint. The reinforcing layer 210 connects the first baffle portion 102, the second baffle portion 202, the windward side housing and the leeward side housing, which not only enhances the connection strength between the first baffle portion 102 and the second baffle portion 202, but also increases the strength between the baffle and the windward side housing and the leeward side housing.

[0069] Exemplarily, the order of steps S1 and S2 can be interchanged or carried out simultaneously.

[0070] In some embodiments of the present application, the baffle is divided into a first baffle portion 102 and a second baffle portion 202. The first baffle portion 102 is integrally formed by pouring with the windward surface housing main body portion 101, improving the connection strength between the first baffle portion 102 and the windward surface housing main body portion 101. The second baffle portion 202 is integrally formed by pouring with the leeward surface housing main body portion 201, improving the connection strength between the second baffle portion 202 and the leeward surface housing main body portion 201. The split forming of the baffle reduces the installation difficulty and improves the strength of the split-structured baffle. Moreover, the reinforcing layer 210 jointly reinforces the baffle and the wind power blade housing, improving the overall strength of the wind power blade and making the integrity of the wind power blade better.

[0071] Figure 4 For Figure 1 the specific flowchart of step S1 in Figure 5 For Figure 3 the exploded view of the windward surface housing in Figure 6 For Figure 3 the overall structural schematic diagram of the windward surface housing in Figure 7 For Figure 5 the structural schematic diagram of the first baffle portion 102 in

[0072] As Figures 1 to 6 shown, in some embodiments of the present application, for step S1: in the windward surface housing mold 100, the windward surface housing main body portion 101 and the first baffle portion 102 are integrally formed by pouring into the windward surface housing, including the following steps S11 to S14.

[0073] S11: Lay and form the windward surface housing main body portion 101 on the windward surface housing mold 100. The windward surface housing main body portion 101 sequentially includes a root section L1, a middle section L2, and a tip section L3 along the span direction.

[0074] Exemplarily, the root section L1 is the connection area between the blade and the hub, undertaking the core function of transmitting mechanical loads. High-strength composite materials (such as glass fiber, carbon fiber reinforced epoxy resin) and metal embedded parts can be used to enhance the structural stiffness and fatigue resistance. In some examples, the high-strength composite material can be glass fiber, carbon fiber reinforced epoxy resin.

[0075] In some examples, the root section L1 accounts for 15% - 25% of the total length of the blade.

[0076] Exemplarily, the chord length of the middle section L2 gradually changes, narrowing gradually from the root to the tip, and the thickness gradually decreases to reduce the aerodynamic drag. In one example, a web is provided in the middle section L2 to enhance the bending and torsional resistance.

[0077] Exemplarily, the tip section L3 reduces the eddy current loss through an extended or split design, improving the tip speed ratio. In one example, a lightning protection connection point is provided at the tip of the tip section L3, and the current is introduced into the hub through a lightning protection wire inside the web.

[0078] S12: Place the first baffle part 102 at the root section L1 of the windward side housing main body 101.

[0079] Exemplarily, the first baffle part 102 can be arranged radially along the root section L1, and the height of the first baffle part 102 can be the same as that of the windward side housing main body 101.

[0080] In one example, the first baffle part 102 can be placed on the upper surface of the windward side housing main body 101 without connection. Alternatively, the first baffle part 102 can be bonded to the upper surface of the windward side housing main body 101.

[0081] S13: Lay the connection layer 112 at least at one end of the first baffle part 102 close to the windward side housing main body 101, and the connection layer 112 overlaps with the windward side housing main body 101.

[0082] Exemplarily, the first baffle part 102 can be partially or entirely laid with the connection layer 112, so as to overlap with the windward side housing main body 101 to facilitate mutual connection with the windward side housing main body 101 during subsequent pouring and curing processes.

[0083] In some examples, the first baffle part 102 includes a first baffle body 110 and a mounting core material 111. The first baffle body 110 is connected to the windward side housing main body 101 through the mounting core material 111. The connection layer 112 penetrates through the first baffle body 110 and covers the mounting core material 111 to overlap with the windward side housing main body 101 along the span direction.

[0084] In some examples, the first baffle part 102 can include fiberglass, carbon fiber, sandwich materials, etc. Among them, the sandwich material can be foam, balsa wood, etc.

[0085] Exemplarily, the connection layer 112 can be made of fiberglass or carbon fiber.

[0086] S14: Pour the matrix material into the windward side housing mold 100 and cure to form the windward side housing.

[0087] Exemplarily, the matrix material can include one or a combination of epoxy resin, polyurethane resin, and bio-based nylon.

[0088] In some examples, the matrix material penetrates the windward side housing main body 101 along the thickness direction, and penetrates together along the height and thickness directions of the first baffle part 102. And cure to form the windward side housing.

[0089] As an example, vacuum suction can be performed during the pouring of the matrix material to improve the pouring and curing effects.

[0090] In the embodiment of the present application, during the forming process of the windward surface shell, a connection layer 112 is at least partially laid on the first baffle portion 102, so that the first baffle portion 102 and the main body portion 101 of the windward surface shell are formed into one body during the pouring and curing processes, and the connection strength between the first baffle portion 102 and the main body portion 101 of the windward surface shell is improved.

[0091] In one embodiment, the preparation process of the leeward surface shell is the same as that of the windward surface shell, and will not be elaborated here.

[0092] Figure 8 For Figure 5 the specific flowchart of step S14 in Figure 9 is a partial structural schematic diagram of the windward surface shell.

[0093] As Figures 1 to 9 shown, in an embodiment of the present application, for pouring the matrix material into the windward surface shell mold 100 in step S14 and curing to form the windward surface shell, the following steps S141 to S144 are included.

[0094] S141: Lay a runner assembly 310 between the main body portion 101 of the windward surface shell and the first baffle portion 102, and the runner assembly 310 is communicated with the pouring system.

[0095] Exemplarily, the runner assembly 310 may include a guide net and a runner tube. Among them, the runner tube may adopt an ohmic tube. The guide net is laid on the upper surface of the main body portion 101 of the windward surface shell, and the runner tubes may be arranged alternately in the spanwise and chordwise directions, so that when the pouring system injects the matrix material into the runner tubes, the matrix material can be evenly poured onto the main body portion 101 of the windward surface shell and the first baffle portion 102.

[0096] In one example, before laying the runner assembly 310, a release cloth may be laid on the main body portion 101 of the windward surface shell to facilitate subsequent demolding.

[0097] In some examples, the top or side of the first baffle is provided with a runner tube.

[0098] S142: Cover a vacuum bag 320 communicated with the vacuum pumping system on the runner assembly 310. The first air extraction port 321 of the vacuum bag 320 is placed at one end of the first baffle portion 102 facing away from the main body portion 101 of the windward surface shell, and the second air extraction port 322 of the vacuum bag 320 faces the main body portion 101 of the windward surface shell.

[0099] Exemplarily, the vacuum bag 320 covers the entire windward surface housing, and a sealed negative pressure environment is formed by evacuating through a vacuum pumping system, driving the matrix material to infiltrate the fibers of the main body portion 101 and the first baffle portion 102 of the windward surface housing.

[0100] In some examples, the first air extraction port 321 and the second air extraction port 322 can be one or more.

[0101] In some examples, the first air extraction port 321 is placed at the top of the first baffle portion 102. The first air extraction port 321 and the second air extraction port 322 can be individually switched on and off.

[0102] S143: Close the first air extraction port 321, open the second air extraction port 322, evacuate, and perform the first-stage perfusion of the matrix material.

[0103] Exemplarily, when the first air extraction port 321 is closed, the first air extraction port 321 is disconnected from the vacuum pumping system. When the second air extraction port 322 is open, the vacuum pumping system evacuates the entire windward surface housing through the second air extraction port 322.

[0104] In one example, the vacuum pumping system first evacuates the main body portion 101 of the windward surface housing to achieve the penetration of the matrix material into the main body portion 101 of the windward surface housing, ensuring the perfusion effect of the main body portion 101 of the windward surface housing.

[0105] S144: After the first stage is completed, open the first air extraction port 321 and perform the second-stage perfusion of the matrix material.

[0106] Exemplarily, when the first air extraction port 321 is open, the second air extraction port 322 can remain open. The vacuum pumping system performs targeted evacuation of the first baffle portion 102 from the position of the first air extraction port 321, causing the matrix material to continuously be perfused from the main body portion 101 of the windward surface housing along the wall of the first baffle portion 102 to the top. That is, the matrix material is perfused from the bottom to the top of the first baffle portion 102, so that the first baffle portion 102 and the connection layer 112 are evenly penetrated by the matrix material.

[0107] Since the first baffle part 102 protrudes radially from the root of the wind turbine blade towards the windward side of the housing main body part 101, the height of the first baffle part 102 is such that during the infusion process, conventional infusion methods cannot effectively infuse the first baffle part 102, thereby affecting the integral molding of the first baffle part 102 and the windward side housing main body part 101. In this application, by providing a first air extraction port 321 at the top of the first baffle part 102, and first infusing the matrix material into the windward side housing main body part 101 and then into the first baffle part 102, the windward side housing main body part 101 penetrates in place in the thickness direction, and there is sufficient matrix material flowing towards the first baffle part 102. By opening the first air extraction port 321, the matrix material can flow from the bottom to the top of the first baffle part 102, thereby penetrating the first baffle part 102 and improving the infusion effect of the first baffle part 102.

[0108] Further, in a specific embodiment of the present application, for placing the first baffle part 102 on the root section L1 of the windward side housing main body part 101 in step S12, it includes steps S121 and S122.

[0109] S121: Lay an installation core material 111 with grooves on the root section L1 of the windward side housing main body part 101.

[0110] Exemplarily, the installation core material 111 can be made of materials such as foam or balsa wood.

[0111] In one example, the installation core material 111 can be pre-connected to the windward side housing main body part 101 by means of bonding or bolt connection.

[0112] S122: Insert the first baffle main body into the groove.

[0113] Exemplarily, a groove is opened on the side of the installation core material 111 facing away from the windward side housing main body part 101, and the size of the groove matches that of the first baffle main body.

[0114] In the embodiment of the present application, by providing the installation core material 111, the contact area between the first baffle part 102 and the windward side housing main body part 101 is increased, and a groove is opened on the installation core material 111 to facilitate the connection of the first baffle main body to the windward side housing main body part 101 through the installation core material 111, improving the molding convenience of the first baffle part 102.

[0115] In one embodiment, the installation core material 111 and the windward side housing main body part 101 have a smooth transition. For example, the thickness of the installation core material 111 has a tendency to be thicker in the middle and thinner at both ends, reducing the local concentrated stress between the first installation part and the windward side housing main body part 101.

[0116] In addition, in some embodiments of the present application, for at least one end of the first baffle portion 102 close to the windward surface housing main body portion 101 in step S13, a connection layer 112 is laid, and the connection layer 112 overlaps with the windward surface housing main body portion 101, including: the connection layer 112 is laid through the first baffle main body to cover and install the core material 111, and overlaps with the windward surface housing main body portion 101.

[0117] Exemplarily, the first baffle main body may be a formed part, such as a prefabricated part. The connection layer 112 is provided with a hollow area, and the first baffle main body penetrates through the hollow area.

[0118] In one example, the flow channel assembly 310 is laid on the connection layer 112, and a matrix material is poured into the connection layer 112 and the installation core material 111.

[0119] In the embodiments of the present application, by adopting the first baffle main body of a formed part, the pouring forming height is reduced, thereby reducing the pouring difficulty and the forming difficulty of the baffle and the wind power blade housing.

[0120] In some other embodiments of the present application, for at least one end of the first baffle portion 102 close to the windward surface housing main body portion 101 in step S13, a connection layer 112 is laid, and the connection layer 112 overlaps with the windward surface housing main body portion 101, including: the connection layer 112 covers the installation core material 111 and is laid with the first baffle main body, and overlaps with the windward surface housing main body portion 101.

[0121] Exemplarily, the first baffle main body is a semi-finished product, and a formed part is formed through the pouring and curing of the connection layer 112 and the matrix material.

[0122] In one example, the connection layer 112 overlaps with the inner skin of the windward surface housing main body portion 101.

[0123] In the present application, the connection layer 112 wraps and integrally forms the first baffle main body and the installation core material 111, improving the overall strength of the first baffle portion 102, and further improving the integrity of the first baffle portion 102 and the windward surface housing main body portion 101. There is no need to mold the first baffle main body, reducing costs.

[0124] In addition, in some embodiments of the present application, for the step S3 of closing the windward surface housing mold 100 and the leeward surface housing mold 200 so that the first baffle portion 102 and the second baffle portion 202 are spliced, it includes steps S31 and S32.

[0125] S31: Coat an adhesive layer 220 on at least one opposite end of the first baffle portion 102 and the second baffle portion 202.

[0126] Exemplarily, an adhesive layer 220 is coated on one end of the first baffle part 102 close to the second baffle part 202, or an adhesive layer 220 is coated on one end of the second baffle part 202 close to the first baffle part 102, or adhesive layers 220 are coated on both opposite ends of the first baffle part 102 and the second baffle part 202.

[0127] S32: Close the mold of the windward side housing mold 100 and the leeward side housing mold 200, and bond the first baffle part 102 and the second baffle part 202 through the adhesive layer 220.

[0128] In one example, the redundant waste edges of the first baffle part 102 and the second baffle part 202 are cut off, and an adhesive layer 220 is formed by scraping and coating 2 - 10 mm of adhesive. After flipping and closing the mold for bonding, the excess glue at the joint seam of the first baffle part 102 and the second baffle part 202 is leveled.

[0129] As an example, the adhesive layer 220 may include resin, reinforcing material, curing agent, additives, etc.

[0130] In some embodiments of the present application, for the step S1 of molding the windward side housing main body part 101 and the first baffle part 102 into the windward side housing in the windward side housing mold 100, it includes steps S15 to S17.

[0131] S15: Lay the outer skin layer, the girder layer, the housing core material layer, and the inner skin layer in sequence in the windward side housing mold 100.

[0132] Exemplarily, the outer skin is made of fiberglass multi - axial fabric, and a carbon fiber reinforcement layer may be added in some high - load areas.

[0133] In the first layer, 1 - 2 layers of bi - axial fabric can be laid along the mold surface to cover the entire windward side housing area, ensuring that the fiber direction forms ±45° with the blade axis to improve the shear resistance. In areas such as the blade root and leading edge, an additional 2 - 3 layers of multi - axial fabric are stacked, and unidirectional yarns are laid along the girder direction to enhance the tensile strength.

[0134] In one example, the fiberglass multi - axial fabric can be a ±45° bi - axial or 0° / ±45° tri - axial fabric.

[0135] The girder layer can mainly use unidirectional glass fiber fabric, and carbon fiber pultruded plates or prepregs may be embedded in large blades. Lay multiple layers of UD fabric continuously along the blade from the blade root to the blade tip, and the number of layers gradually decreases from 30 - 40 layers in the blade root section L1 to 5 - 10 layers at the blade tip, forming a gradually changing strength distribution.

[0136] The shell core material can be lightweight balsa wood, PVC foam or PET foam. Cut the core material into blocks or strips and fill the non-load-bearing areas (such as the leading edge and trailing edge) on both sides of the girder layer, and temporarily fix it with an adhesive. Adopt a trapezoidal or serrated splicing joint to avoid stress concentration, and cover the surface of the core material with chopped strand mat or thin gauze to enhance the adhesion with the resin.

[0137] The inner skin material is the same as the outer skin material. Continuously lay a biaxial fabric above the shell core material layer, covering the entire interior of the shell, and the edge overlaps with the fiber layer reserved by the outer skin.

[0138] S16: Place the first baffle part 102 on the inner skin.

[0139] S17: Pour the matrix material into the windward shell mold 100 and cure it to form the windward shell.

[0140] Exemplarily, curing can heat the windward shell to improve the curing efficiency.

[0141] In some embodiments of the present application, for the step S4 of laying the reinforcing layer 210 at the splicing joint of the windward shell and the leeward shell and at the splicing joint of the first baffle part 102 and the second baffle part 202 to form a wind power blade with baffles, it includes steps S41 and S42.

[0142] S41: Form an inner reinforcing layer at the splicing joint of the windward shell and the leeward shell and at the splicing joint of the first baffle part 102 and the second baffle part 202 inside the closed mold shell.

[0143] S42: Form an outer reinforcing layer at the splicing joint of the windward shell and the leeward shell and at the splicing joint of the first baffle part 102 and the second baffle part 202 outside the closed mold shell to form a wind power blade with baffles.

[0144] Exemplarily, the inner reinforcing layer and the outer reinforcing layer are respectively connected to the inner skin and the outer skin of the wind power blade.

[0145] In one example, the materials of the inner reinforcing layer and the outer reinforcing layer are the same.

[0146] Figure 10 It is another flowchart of the wind power blade molding method for some embodiments of the present application.

[0147] As Figures 1 to 10 shown, after step S1: molding the windward shell main body part 101 and the first baffle part 102 into a windward shell in the windward shell mold 100, it further includes steps S101 and S102.

[0148] S101: Open a lightning protection installation hole in the first baffle part 102.

[0149] S102: Install a lightning protection device inside the windward shell.

[0150] Exemplarily, the first baffle portion 102 and the second baffle portion 202 are used to drill holes for the lightning protection system, and install corresponding accessories such as fixing and metal parts.

[0151] In the prior art, after the baffle is installed, holes for the lightning protection system, and installation of corresponding accessories such as fixing and metal parts can only be carried out on the cured baffle. This seriously affects the blade production cycle. In this application, the overall installation of the baffle and the installation of the lightning protection system are advanced to the blade forming stage. After the shell is cured, the opening of the lightning protection installation holes and the laying of the lightning protection device can be carried out, and the transfer efficiency is increased to 8 - 10 hours, which can greatly improve the post - treatment transfer efficiency.

[0152] As Figures 1 to 9 shown, an embodiment of this application provides a wind turbine blade, which sequentially includes a root section L1, a middle section L2, and a tip section L3 along the span direction, and further includes a windward shell, a leeward shell, and a reinforcing layer 210.

[0153] The windward shell includes an integrally formed windward shell main body portion 101 and a first baffle portion 102. The first baffle portion 102 is located at the root section L1 of the windward shell main body portion 101; the leeward shell includes an integrally formed leeward shell main body portion 201 and a second baffle portion 202. The second baffle portion 202 is located at the root section L1 of the leeward shell main body portion 201; the windward shell main body portion 101 and the leeward shell main body portion 201 are covered and connected, and the first baffle portion 102 and the second baffle portion 202 are oppositely connected; the reinforcing layer 210 is provided at the connection between the windward shell main body portion 101 and the leeward shell main body portion 201 and at the connection between the first baffle portion 102 and the second baffle portion 202.

[0154] Further, in an embodiment of this application, the first baffle portion 102 includes a first baffle main body, an installation core material 111, and a connection layer 112. The installation core material 111 is laid on the windward shell main body portion 101. The installation core material 111 includes a groove facing away from the windward shell main body portion 101. The first baffle main body is placed in the groove, and the connection layer 112 covers the first baffle main body and the installation core material 111 and is connected to the windward shell main body portion 101.

[0155] In a specific embodiment of this application, along the span direction, the thickness of the installation core material 111 has a decreasing trend from both sides of the groove to both ends of the installation core material 111.

[0156] Exemplarily, the cross - section of the installation core material 111 along the span direction has a triangular, trapezoidal and other structures. And the groove is placed in the middle of the installation core material 111. The installation core material 111 extends circumferentially along the inner surface of the windward shell main body portion 101.

[0157] As an example, the radius of the baffle is R, the depth of the groove is H, and H / R = 1% to 3.1%.

[0158] For example, R = 3200 mm to 4500 mm, and H = 50 mm - 100 mm.

[0159] In one example, both sides of the installation core material 111 along the span direction can be inclined surfaces or stepped surfaces, with a smooth transition.

[0160] In an embodiment of the present application, the wind turbine blade further includes an adhesive layer 220, and the adhesive layer 220 is disposed between the first baffle portion 102 and the second baffle portion 202.

[0161] As described above, only the specific embodiments of the present application are provided. Those skilled in the art can clearly understand that for the convenience and brevity of description, the specific working processes of the above-described systems, modules, and units can refer to the corresponding processes in the foregoing method embodiments, which will not be elaborated herein. It should be understood that the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present application can easily think of various equivalent modifications or substitutions, and these modifications or substitutions should all be covered within the protection scope of the present application.

Claims

1. A method for forming a wind turbine blade, characterized in that, Including: In the windward side shell mold, the windward side shell main body part and the first baffle part are injection molded into the windward side shell; In the leeward side shell mold, the leeward side shell main body part and the second baffle part are injection molded into the leeward side shell; The windward side shell mold and the leeward side shell mold are clamped together so that the first baffle part and the second baffle part are spliced; At the splicing joint of the windward side shell and the leeward side shell and at the splicing joint of the first baffle part and the second baffle part, a reinforcing layer is laid to form a wind power blade with a baffle.

2. The wind power blade forming method according to claim 1, characterized in that The injection molding of the windward side shell main body part and the first baffle part into the windward side shell in the windward side shell mold includes: Laying to form the windward side shell main body part on the windward side shell mold, and the windward side shell main body part sequentially includes a root section, a middle section and a tip section along the span direction; Placing the first baffle part at the root section of the windward side shell main body part; Laying at least a connecting layer at one end of the first baffle part close to the windward side shell main body part, and the connecting layer overlaps with the windward side shell main body part; Injecting a matrix material into the windward side shell mold and curing to form the windward side shell.

3. The wind turbine blade forming method according to claim 2, characterized in that, The injecting of the matrix material into the windward side shell mold and curing to form the windward side shell includes: Laying a runner assembly between the windward side shell main body part and the first baffle part, and the runner assembly is communicated with the injection system; Covering a vacuum bag communicated with the vacuum pumping system on the runner assembly, a first air extraction port of the vacuum bag is placed at one end of the first baffle part facing away from the windward side shell main body part, and a second air extraction port of the vacuum bag is opposite to the windward side shell main body part; Closing the first air extraction port, opening the second air extraction port, performing vacuum pumping, and performing the first-stage injection of the matrix material; After the first stage is completed, opening the first air extraction port and performing the second-stage injection of the matrix material.

4. The wind turbine blade forming method according to claim 2, wherein The placing of the first baffle part at the root section of the windward side shell main body part includes: Laying an installation core material with a groove at the root section of the windward side shell main body part; Inserting the first baffle main body into the groove.

5. The wind turbine blade forming method according to claim 4, characterized in that, The laying of at least a connecting layer at one end of the first baffle part close to the windward side shell main body part, and the connecting layer overlaps with the windward side shell main body part includes: The connecting layer penetrates through the first baffle main body to cover the installation core material for laying and overlaps with the windward side shell main body part.

6. The wind power blade forming method according to claim 4, characterized in that, The laying of at least a connecting layer at one end of the first baffle part close to the windward side shell main body part, and the connecting layer overlaps with the windward side shell main body part includes: The connecting layer covers the installation core material and is laid with the first baffle main body and overlaps with the windward side shell main body part.

7. The wind power blade forming method according to claim 1, characterized in that, The clamping together of the windward side shell mold and the leeward side shell mold so that the first baffle part and the second baffle part are spliced includes: Coating an adhesive layer at at least one end where the first baffle part and the second baffle part are opposite; Clamping the windward side shell mold and the leeward side shell mold together, and the first baffle part and the second baffle part are bonded through the adhesive layer.

8. The wind turbine blade forming method according to any one of claims 1 to 7, characterized in that, The process of injection molding the windward side shell body and the first baffle part into the windward side shell in the windward side shell mold includes the following steps: Lay the outer skin layer, girder layer, shell core material layer, and inner skin layer in sequence in the windward side shell mold; Place the first baffle part on the inner skin layer; Inject the matrix material into the windward side shell mold and cure it to form the windward side shell.

9. The wind power blade forming method according to any one of claims 1 to 7, characterized in that, The process of laying the reinforcing layer at the joint of the windward side shell and the leeward side shell and at the joint of the first baffle part and the second baffle part to form a wind turbine blade with baffles includes the following steps: Form an inner reinforcing layer at the joint of the windward side shell and the leeward side shell and at the joint of the first baffle part and the second baffle part inside the closed mold shell; Form an outer reinforcing layer at the joint of the windward side shell and the leeward side shell and at the joint of the first baffle part and the second baffle part outside the closed mold shell to form a wind turbine blade with baffles.

10. The wind power blade forming method according to any one of claims 1 to 7, characterized in that, After injection molding the windward side shell body and the first baffle part into the windward side shell in the windward side shell mold, the following steps are further included: Open a lightning protection installation hole in the first baffle part; Install a lightning protection device inside the windward side shell.

11. A wind power blade, characterized in that, It includes a root section, a middle section, and a tip section in sequence along the span direction, and further includes: A windward side shell, including an integrally formed windward side shell body and a first baffle part, and the first baffle part is located at the root section of the windward side shell body; A leeward side shell, including an integrally formed leeward side shell body and a second baffle part, and the second baffle part is located at the root section of the leeward side shell body; the windward side shell body and the leeward side shell body are covered and connected, and the first baffle part and the second baffle part are oppositely connected; A reinforcing layer is provided at the connection between the windward side shell body and the leeward side shell body and at the connection between the first baffle part and the second baffle part.

12. The wind power blade according to claim 11, wherein, The first baffle part includes a first baffle main body, a mounting core material, and a connection layer. The mounting core material is laid on the windward side shell body. The mounting core material includes a groove facing away from the windward side shell body. The first baffle main body is placed in the groove. The connection layer covers the first baffle main body and the mounting core material and is connected to the windward side shell body.

13. The wind power blade according to claim 12, wherein, Along the span direction, the thickness of the mounting core material has a decreasing trend from both sides of the groove to both ends of the mounting core material.

14. The wind power blade according to claim 12, characterized in that, It further includes an adhesive layer, and the adhesive layer is placed between the first baffle part and the second baffle part.

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