Vacuum system for wind power blade mold and control method

Abstract

The invention discloses a wind power blade mold vacuum system and a control method, the wind power blade mold vacuum system comprises a mold steel frame, a vacuum main pipeline, a vacuum branch pipeline, a vacuum nozzle, a connecting structure of the vacuum nozzle, a spiral pipe, a vacuum pump set, a valve set, a vacuum data acquisition device, a control system and the like, a main cross beam pipe of a die steel frame serves as a vacuum main pipeline, and a K-shaped inclined strut and a cross bracing pipe of the steel frame serve as branch pipelines. Through the integrated design of the mold steel frame and the vacuum pipeline, an independent pipeline is replaced, and the air exhaust efficiency is optimized; according to the control method for the vacuum system of the wind power blade mold, a partition control strategy and multi-stage monitoring are combined, and intelligent starting and stopping, abnormal accurate response and data visualization of the vacuum pump are achieved. The system integrated structure is innovative and intelligently controlled, the manufacturing cost is remarkably reduced, and the blade production quality and the automation level are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of wind turbine blade manufacturing, and in particular to a wind turbine blade mold vacuum system and control method, which are particularly suitable for optimization and automatic control of mold vacuum pipelines in RIM vacuum infusion process. Background Art

[0002] Wind turbine blades are manufactured using the RIM vacuum infusion process. Maintaining a constant vacuum during the blade forming process is crucial. Currently, vacuum is ensured by installing vacuum nozzles and vacuum lines on the blade mold. Each mold is equipped with 2-8 vacuum pumps connected to the mold vacuum lines for vacuum extraction. The molds are divided into windward and leeward molds. Each mold has independent primary and secondary vacuum main lines fixed to the mold steel frame. Vacuum nozzles on these main lines are connected to vacuum nozzles on the mold flange using spiral steel pipes.

[0003] Patent CN201210581854.4, entitled "Apparatus and Method for Integrated Forming of Wind Turbine Blades," relates to an apparatus and method for integrated forming of horizontal-axis wind turbine blades. The apparatus includes a vacuum extraction system, a pressurizing device, a resin defoaming system, a resin supply system, and a resin collection system. The wind turbine blades are manufactured using positive pressure-assisted vacuum infusion, optimizing the traditional process and improving efficiency and quality. However, this method does not address issues such as installation difficulty, production efficiency, and air extraction efficiency caused by overly large or undersized vacuum piping diameters.

[0004] Patent CN201811008501.9 discloses an intelligent control system for the production process of large-scale wind turbine blades, including a central control system, a video monitoring system, a blade production system, and an equipment fault detection system. The central control system is connected to the video control system, the blade production system, and the equipment fault detection system. The blade production system includes a mold temperature field control system, a blade vacuum infusion control system, a blade flip control system, and a workshop environment monitoring system. The equipment fault detection system includes a glue dispensing equipment monitoring system, a punching equipment monitoring system, and a paint spraying equipment monitoring system. This patent centrally monitors mold temperature, vacuum infusion, flipping, etc., and implements data collection and remote control through sensors and networks. However, this intelligent monitoring device has many functional modules, all of which are single-point monitoring, making it impossible to achieve precise control of partitions.

[0005] CN202322018305.2 provides a distributed vacuum pumping system for wind turbine blade molds. This utility model installs a wireless pressure acquisition device on each exhaust pipe branch to collect multi-point pressure values ​​for the blade mold. The collected pressure values ​​are uploaded to the control unit, enabling distributed monitoring of the relevant vacuum status during the processes of the blade mold, such as infusion, pressure holding, mold closing, and post-curing. In addition, when there is a leak during infusion, hidden dangers in the production process can be discovered immediately, reducing the frequency of major quality accidents. However, although this utility model proposes distributed vacuum pumping, it does not solve the problem of complex pipeline structure and thus affecting efficiency.

[0006] In summary, the existing wind turbine blade mold vacuum system-level monitoring and control methods have the following technical problems: The diameter of the vacuum pipeline is an important factor affecting the vacuuming efficiency. If the diameter is too large, the manufacturing and installation difficulties will increase and the cost will rise. If the diameter is too small, the vacuuming efficiency of the system will be low and the blade production efficiency will be low.

[0007] The traditional independent vacuum pipeline has a limited diameter, many bends, and low air extraction efficiency. When the vacuum pipeline passes through the hydraulic flip arm, a bend needs to be made to bypass it. As the blade length becomes longer, the hydraulic flip arm also increases, and the number of bends in the vacuum pipeline also increases. Under the current condition of limited pipe diameter, the increase in bends further affects the vacuum extraction efficiency.

[0008] Currently, the start and stop of the vacuum pump and the opening and closing of the first and second vacuums in the mold vacuum system are all controlled manually, and there is a lack of system vacuum monitoring and alarm functions. Situations such as failure to start, wrong start, or delayed start often occur, resulting in blade quality defects or even scrapping. Independent vacuum pipelines increase material costs, and the installation process requires the production of welding brackets and fixed round pipes, which increases mold manufacturing costs and manufacturing time. Summary of the Invention

[0009] The present invention provides a wind turbine blade mold vacuum system and control method. By replacing independent pipelines with an integrated design of a mold steel frame and a vacuum pipeline, the system solves the problems of limited vacuum pipeline diameter and increased bends affecting the extraction efficiency, reduces manufacturing costs, and shortens mold manufacturing time. Combined with a zoning control strategy and multi-stage vacuum monitoring, the system realizes intelligent start and stop of the vacuum pump, automatic control of opening and closing of the first and second vacuums, automatic start at low vacuum, abnormal alarm, and data visualization, thus avoiding product quality defects or scrap caused by blade vacuum failure and solving the problems of structural redundancy, high manual dependence, and difficult data tracing in the prior art.

[0010] The wind turbine blade mold vacuum system described in the present invention is an integrated design of steel frame and pipeline. The mold steel frame pipe is designed as a mold vacuum pipeline. Combined with the steel frame structure, the mold vacuum is controlled by valve group design and vacuum data acquisition design. The vacuum pump group can realize automatic start and stop and low vacuum automatic start and stop according to process requirements, and the first and second vacuums are automatically opened and closed, and a low vacuum alarm and vacuum data are automatically stored.

[0011] Wind turbine blade molds are composed of two parts: the windward side mold and the leeward side mold.

[0012] The windward side and leeward side of the wind turbine blade mold described in the present application are both provided with independent vacuum pipelines and vacuum pump groups to form a complete mold vacuum system.

[0013] This patent is explained using the vacuum system of the mold on the leeward side of a wind turbine blade, and the vacuum system of the mold on the windward side is the same.

[0014] The design scheme of the wind turbine blade mold vacuum system is as follows: The vacuum system of the wind turbine blade leeward side mold consists of a first vacuum main line, a first vacuum branch line, a second vacuum main line, a second vacuum branch line, vacuum nozzles of the first and second vacuum main lines, a steel wire spiral tube, a vacuum pump group, a valve group, a vacuum data acquisition device and a control system.

[0015] The mold steel frame and vacuum pipeline are integrated into one design. The main crossbeam pipe of the mold steel frame serves as the vacuum main pipeline, forming a through channel through sealed welding and hose connection; the diagonal bracing and cross bracing pipes of the steel frame serve as branch pipelines, connecting the front and rear edge main pipelines to form a redundant passage.

[0016] There are main crossbeam tubes along the front and rear edges of the upper and lower parts of the mold steel frame, which play the role of supporting the steel frame and connecting with the mold flange. This patent uses the main crossbeam rectangular tubes at the upper front and rear edges as one vacuum main line, and the main crossbeam rectangular tubes at the lower front and rear edges as two vacuum main lines.

[0017] During the production process, the main crossbeam pipe of each section of the mold is connected, the ends are sealed, and the pipe joints are sealed and welded to prevent air leakage; The mold is designed in sections, and every two sections need to be butted together. To prevent the main pipe seal from being damaged during the mold butt welding and disassembly process, a margin is reserved at both ends of the section to seal the main beam pipe end. The mold segment uses a hose of appropriate diameter to connect the main beam pipe into a whole, forming a connected first vacuum main line; The mold steel frame is welded with K-shaped braces at regular intervals, providing support for the mold frame and securing the cross-section plates. At least two K-shaped braces are used in each mold section to serve as branch lines connecting the leading and trailing main lines. These branches connect the leading and trailing main lines, creating multiple pathways and serving as the primary vacuum branch lines. The connection points are secured by welding to prevent blockage and prevent vacuum extraction. The connection points are secured by welding, ensuring a tight seal.

[0018] The main crossbeam tubes along the front and rear edges of the upper part of the mold steel frame serve as the first vacuum main line, and the main crossbeam tubes along the front and rear edges of the lower part serve as the second vacuum main line, forming a through channel through sealing welding and hose connection.

[0019] At least two cross bracing pipes are selected from each section of the mold as the second branch pipes to connect the second main pipes at the front edge and the rear edge; the connection points are fixed by welding.

[0020] The "K"-shaped diagonal bracing and transverse bracing pipes of the steel frame serve as the first and second vacuum branch pipes, connecting the leading edge and trailing edge main pipes to form a redundant passage.

[0021] The main crossbeam tube, serving as the main conduit, requires vacuum connection to the mold surface. Holes are drilled on the lower surface of the tube to match the vacuum nozzle's outer diameter. This can be done before or after welding. The hole diameter matches the nozzle's outer diameter, and the nozzle is secured to the main conduit by welding. Orienting the nozzle downward after welding prevents resin from clogging the main conduit.

[0022] The downward vacuum nozzle is welded on the lower plane of the main pipeline and connected to the mold flange vacuum nozzle through a steel wire spiral tube to avoid resin blockage.

[0023] The mold flange is protected by a fiberglass flange. Holes are drilled in the flange for mounting, and a vacuum nozzle with a base is glued in place. The vacuum nozzles face downward and are divided into two types: primary and secondary. Connect the mold fiberglass flange vacuum nozzle and the main line vacuum nozzle using a steel spiral tube of matching diameter, establishing a vacuum connection between the main line and the fiberglass portion of the mold. Ensure a tight seal by wrapping the steel spiral tube around the main line several times to store excess glue and allow for continued use after cutting.

[0024] The mold's steel frame has main crossbeams along its front and rear edges, providing support. This patented design utilizes these lower crossbeams as secondary vacuum lines, replacing the original two independent vacuum lines. During production, each crossbeam is connected, sealed at both ends, and welded together to prevent leaks.

[0025] The same vacuum main line design is used, with the mold sections separated by reserved welding distances, and the two sections connected by flexible pipes. The I-beams for the tilting arms are welded to the lower main crossbeam, and the anchors are specially protected to prevent welding leaks.

[0026] Cross braces are installed at regular intervals to support the mold frame. At least two cross braces are used as branch lines for each mold section, connecting the leading and trailing main lines. The connection points are secured by welding, ensuring a tight seal.

[0027] The second vacuum nozzle is manufactured using the same method as the other nozzles. Holes are drilled on the rectangular upper surface of the main beam according to the process location, and the second vacuum nozzle is welded to the main vacuum nozzle. A steel spiral pipe with a matching diameter is used to connect the mold fiberglass flanged second vacuum nozzle to the second vacuum nozzle to ensure a tight seal.

[0028] The mold is divided into three areas along the axis: the blade root, the middle of the blade, and the tip of the blade. In each area, one vacuum main line and two vacuum main lines are made to connect to the vacuum pump. After positioning, an opening is first made on the side of the main line pipe. The opening diameter is equivalent to the diameter of the connecting circular pipe, and the cross-sectional area of ​​the circular pipe is equivalent to the cross-sectional area of ​​the main beam pipe. A connecting flange is made and welded. The center opening of the flange is equivalent to the diameter of the circular pipe. The flange has threaded holes and is welded to the main beam pipe at the opening position. One end of the circular iron pipe is connected to the flange with a hose. A sealing gasket is added to the flange connection to ensure sealing. The other end is connected to the vacuum pump through the flange with a hose. Two circular pipes are welded to the vacuum pump buffer tank and flanges of the same model are made to connect to the first vacuum main line and the second vacuum main line respectively.

[0029] The complete vacuum piping system design on the leeward side is shown in the figure below: vacuum pump - connecting pipeline - primary and secondary vacuum main lines (primary and secondary vacuum branch lines) - main line vacuum nozzle - steel wire spiral pipe - mold fiberglass vacuum nozzle.

[0030] The design of the vacuum system for the windward mold is basically the same. The main difference is that the windward side needs to be flipped, so a hose is needed to connect the main line and the vacuum pump to the pipeline without affecting the flipping of the mold.

[0031] The windward side vacuum pump and the leeward side vacuum pump can be shared or configured independently.

[0032] The above mold vacuum pipelines 1 and 2 are distinguished by color and airflow direction markings, and welding or bolting is used to formulate a connection plan to ensure good sealing, and vacuum monitoring is carried out before being put into use.

[0033] The mold vacuum system control requires a vacuum gauge to collect the system vacuum value. In order to realize the vacuum value collection, recording and zoning control, the vacuum gauge layout plan is as follows: vacuum gauges are installed at the vacuum nozzles of the first and second vacuum main lines (in each area), and vacuum gauges are installed at the docking position of each section of the mold main line (usually 4, and the number can be increased as needed), 1 is installed on each branch line, at least 1 is installed on each vacuum pump buffer tank, and 1 is installed on each vacuum pump and main line connecting pipe.

[0034] The mold vacuum line is opened and closed by a solenoid valve. To achieve automatic opening and closing of the line, a solenoid valve is installed on each vacuum pump main line connection line. To prevent electromagnetic failure from affecting normal production or product quality, a manual valve is installed on each main line connection line.

[0035] The vacuum system is controlled in three stages: vacuuming, pressure holding and testing, and infusion and curing. Automatic control is achieved by setting time and vacuum parameters using a programmable controller. Examples of programmable controller parameter settings include: primary vacuum pumping time, target vacuum value, and vacuum deviation; secondary vacuum pumping time, target vacuum value, and vacuum deviation; pressure holding time and vacuum deviation; and infusion and curing time, vacuum value, and vacuum deviation.

[0036] Vacuuming: After the control program parameters are set, the vacuum pump starts and enters the vacuuming stage. The solenoid valve of the main vacuum line opens to draw the vacuum. If the vacuum values ​​of all vacuum gauges in the mold vacuum system are within the target vacuum value deviation within the set time, the vacuum pump automatically stops. At the same time, the solenoid valve of the first vacuum system closes, and the sound and light alarm sounds and turns green. If the vacuum set value is not reached within the set time, the sound and light alarm emits a different sound and turns yellow. The vacuum is the same during the second vacuuming process.

[0037] Pressure Holding Test Phase: After the vacuum pump and main line solenoid valves are closed, the system automatically enters the pressure holding test phase. If all vacuum gauge values ​​are within the tolerance range within the set pressure holding time, the system can proceed to the infusion and curing phase. The vacuum pump stops, the first and second vacuum main line solenoid valves close, and the audible and visual alarm sounds and illuminates green. If the vacuum value exceeds the tolerance range during the pressure holding time, the audible and visual alarm emits a different tone and illuminates yellow.

[0038] Infusion and curing phase: After the system passes the pressure test phase, it automatically enters the infusion and curing phase. The vacuum pump starts working and the first and second vacuum main line solenoid valves open. When the infusion and curing set time expires, the vacuum pump automatically stops working.

[0039] During the above infusion and curing stages, if the system vacuum performance is good and the vacuum gauge values ​​are within the set deviation range, the vacuum pump will automatically stop. If the vacuum value exceeds the set deviation, a different sound prompt will be emitted and a red light will be displayed (the light will automatically change to green if the vacuum value is within the set deviation range). The system will prioritize the vacuum pump in the area where the vacuum gauge is located that exceeds the deviation value. If the vacuum value deviation in this area increases or the vacuum value in other areas exceeds the tolerance, the other vacuum pumps will be activated in sequence.

[0040] The control system can display the operating status of the vacuum pump group and the vacuum count value in real time and generate vacuum images at each stage. Sound and light alarm lights are set around the mold to facilitate operators to observe the equipment operating status, data changes and alarm conditions in a timely manner.

[0041] The control system can select unified control of the leeward side mold and the windward side mold, or can control them separately.

[0042] The control system records and stores vacuum value data, vacuum pump operating time, and system alarm conditions in real time, while generating visual images and storing recorded files on the server. The files stored on the server can be viewed, exported, and printed in real time.

[0043] The wind turbine blade mold vacuum system and control method have the following excellent effects: First, the structure is simplified. The independent vacuum pipeline system of the mold is transformed into a channel using the mold steel frame structure, so that the vacuum pipeline and the mold steel frame are integrated. After the improvement, the original independent vacuum pipeline is cancelled, the overall structure of the mold is simplified, the material cost of the vacuum pipeline is reduced, and the production efficiency is improved without the need for independent manufacturing and installation.

[0044] Secondly, the vacuuming efficiency is greatly improved. The vacuum pipeline and the mold steel frame are integrated and improved. The cross-sectional area of ​​the vacuum pipeline is larger than the original vacuum tube cross-sectional area, which reduces the influence of the vacuum tube diameter on the pumping efficiency. The improved main pipeline is arranged along the leading and trailing edges of the blade without any bends, which reduces the influence of the bends on the pumping efficiency and greatly improves the pumping efficiency.

[0045] Third, precise control is achieved by automatically controlling the mold vacuuming process through a program, improving the level of automation. The control system utilizes dual control of time and vacuum level to enhance reliability, reduce manual operation, and avoid quality losses caused by human error. Automatic vacuum pump start / stop and sequential zone start / stop control reduce vacuum pump unit operating time, saving energy and reducing consumption. Selectable control modes and programmable parameters enhance the control system's flexibility and adaptability.

[0046] Fourth, a closed data loop is formed, storing vacuum value data, vacuum pump operating time, and system alarm files on the server, while generating visual images to provide data support for subsequent production process traceability, quality analysis, and vacuum pump maintenance. In addition, this patented technical solution features a high degree of visualization, including sound and light alarms, equipment operating status display, and program operation image display, making it easy to observe and judge. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 : Schematic diagram of the complete vacuum pipeline system structure on the leeward side, the mold steel frame-vacuum pipeline integrated structure, showing the main pipeline branch pipeline and redundant passage.

[0048] Among them, 1 the first vacuum main line, 2 the mold fiberglass turning over, 3 the vacuum nozzle, 4 the steel wire spiral tube, 5 the connecting pipeline, 6 the vacuum pump, 7 the solenoid valve, 8 the second vacuum main line, 9 the solenoid valve, 10 the first vacuum branch line, 11 the second vacuum branch line.

[0049] Figure 2 : Schematic diagram of the mold steel frame segmented structure, showing the vacuum pipeline connection of the wind turbine blade mold steel frame segmented structure, the vacuum pump partition layout, the vacuum pump and pipeline connection method, and the vacuum gauge layout schematic diagram.

[0050] Figure 3 : Flowchart of the wind turbine blade mold vacuum control method.

[0051] Figure 4 : The wind turbine blade mold control system controls the display interface DETAILED DESCRIPTION

[0052] The wind power mold vacuum system construction process and structure description The upper part of the mold steel frame has main crossbeam rectangular tubes along the front and rear edges, which play the role of supporting the steel frame and connecting with the mold flange (2). In this solution, the upper main crossbeam rectangular tube is used as the first vacuum main line (1) to replace the original independent vacuum line. During the production process, each section of the mold main crossbeam rectangular tube is connected, sealed at both ends, and the square tube joints are sealed and welded to prevent air leakage; The mold is designed in sections, and the two sections need to be butted together. To prevent the main pipe seal from being damaged during the mold butt welding and disassembly process, a margin is reserved at both ends of the section to seal the end of the main beam rectangular tube; The mold segment part uses a hose of appropriate diameter to connect the main crossbeam rectangular tube into a whole, forming a connected first vacuum main line (1); The mold steel frame is welded with square tubes at intervals to form a "K"-shaped diagonal brace, which plays the role of supporting the mold steel frame and welding the fixed cross-section plate. At least two "K"-shaped structures are selected as branch pipes for each mold section to connect the front edge and rear edge main pipes to form the first vacuum branch pipe (10). The function of the branch pipe is to connect the front edge and rear edge main pipes of the mold to form multiple passages to avoid blockage of one pipe and inability to draw vacuum. The connection points are fixed by welding, and attention should be paid to the welding sealing during welding.

[0053] The main crossbeam rectangular tube, serving as the main conduit, requires vacuum connection to the mold surface. A hole is drilled on the lower surface of the main crossbeam rectangular tube at the desired vacuum nozzle location (this can be done before or after welding). The hole diameter matches the outer diameter of the vacuum nozzle. The nozzle is then secured to the main conduit by welding. Orienting the nozzle downward after welding prevents resin from clogging the main conduit.

[0054] The installation process position on the mold fiberglass flange (2) requires drilling and gluing a vacuum nozzle with a base. The vacuum nozzles (7) are all downward and are divided into one vacuum nozzle and two vacuum nozzles. The mold fiberglass flange (2) vacuum nozzle (3) and the main line vacuum nozzle are connected using a steel wire spiral tube (4) with a matching pipe diameter, and the main line is connected to the mold fiberglass part by vacuum. The steel wire spiral tube needs to be fixed to ensure sealing. The steel wire spiral tube (4) is wrapped around the main line several times to store excess glue and can still be used after cutting the excess glue.

[0055] The lower part of the mold steel frame has main crossbeam rectangular tubes along the front and rear edges, which play the role of supporting the steel frame. In this solution, the lower main crossbeam rectangular tube is used as the second vacuum main line (8) to replace the original independent two vacuum lines. During the production process, each section of the mold main crossbeam rectangular tube is connected, sealed at both ends, and the square tube joints are sealed and welded to prevent air leakage.

[0056] The same vacuum main line design is used, with the mold sections separated by reserved welding distances, and the two sections connected by flexible pipes. The I-beams for the tilting arms are welded to the rectangular tubes of the lower main crossbeam, and the anchors are specially protected to prevent welding leaks.

[0057] The mold steel frame is supported by cross-bracing square tubes at intervals. At least two cross-bracing square tubes are selected as branch pipes for each mold section to connect the front edge and rear edge main pipes to form a second vacuum branch pipe (11). The connection points are fixed by welding, and attention should be paid to the welding seal during welding.

[0058] The rectangular upper plane of the main crossbeam is drilled according to the process position and the vacuum nozzle of the second vacuum main line is welded. The second vacuum nozzle of the mold fiberglass flange is connected to the vacuum nozzle of the second vacuum main line with a steel wire spiral pipe of matching pipe diameter to ensure sealing.

[0059] The mold is divided into three areas along the axis: the blade root, the middle of the blade, and the tip of the blade. In each area, one vacuum main line and two vacuum main lines are made to connect to the vacuum pump. After positioning, an opening is first made on the side of the rectangular tube of the main line. The opening diameter is equivalent to the straight drop of the connecting round tube, and the cross-sectional area of ​​the round tube is equivalent to the cross-sectional area of ​​the main beam rectangular tube. A connecting flange is made and welded. The center opening of the flange is equivalent to the diameter of the round tube. The flange has threaded holes and is welded to the main beam rectangular tube at the opening position. One end of the circular iron pipe is connected to the flange with a hose. A sealing gasket is added to the flange connection to ensure sealing. One end is connected to the vacuum pump through the flange with a hose. Two round tubes are welded to the vacuum pump buffer tank and flanges of the same model are made to connect to the first vacuum main line and the second vacuum main line respectively.

[0060] The complete vacuum piping system design on the leeward side is as follows Figure 1 : Vacuum pump - connecting pipeline - the first and second vacuum main pipelines (the first and second vacuum branch pipelines) - main pipeline vacuum nozzle - steel wire spiral tube - mold fiberglass vacuum nozzle.

[0061] The design of the vacuum system for the windward mold is basically the same. The main difference is that the windward side needs to be flipped, so a hose is needed to connect the main line and the vacuum pump to the pipeline without affecting the flipping of the mold.

[0062] The windward side vacuum pump (6) and the leeward side vacuum pump can be shared or configured independently.

[0063] The above mold vacuum pipelines 1 and 2 are distinguished by color and airflow direction markings, and welding or bolting is used to formulate a connection plan to ensure good sealing, and vacuum monitoring is carried out before being put into use.

[0064] The control of the mold vacuum system requires a vacuum gauge to collect the system vacuum value. In order to realize the vacuum value collection, recording and zoning control, the vacuum gauge layout plan is as follows: a vacuum gauge is installed at the vacuum nozzle of the first and second vacuum main lines (in each area), a vacuum gauge (7) is installed at the docking position of each section of the mold main line (usually 4, the number can be increased as needed), one is installed on each branch line, at least one is installed on each vacuum pump (6) buffer tank, and one is installed on each vacuum pump and main line connecting pipe.

[0065] The opening and closing of the mold vacuum pipeline is achieved by switching the electromagnetic valve (9). To achieve automatic opening and closing of the pipeline, a electromagnetic valve is installed on each vacuum pump main pipeline connection pipeline. To prevent electromagnetic failure from affecting normal production or product quality, a manual valve is installed on each connecting main pipeline.

[0066] The vacuum gauges are numbered and divided into corresponding zones for the upper and lower mold vacuum pumps. Sound and light alarm lights are installed around the mold to facilitate operators to monitor the equipment's operating status in a timely manner.

[0067] Vacuuming stage: 1. Set the vacuum target value to -0.095MPa and the vacuuming time to 40 minutes. If the vacuum reaches the target value within 40 minutes, the audible and visual alarm will illuminate green and emit intermittent beeps. If the vacuum does not reach the target value within 40 minutes, the audible and visual alarm will illuminate yellow and emit rapid, intermittent beeps, warning that leaks may need to be checked. The vacuum pump will continue to pump until the vacuum reaches the set target value, at which point the audible and visual alarm will illuminate green and emit intermittent beeps. 2. Set the vacuum level to the same value.

[0068] Pressure Holding Test Phase: After both the primary and secondary vacuum levels reach the target vacuum values, the vacuum pumps run for 5 minutes before entering the pressure holding test phase. The primary vacuum pump and valve automatically shut down, while the secondary vacuum pump and valve open to continue vacuuming. The set vacuum value for the pressure holding phase is -0.095 MPa, with a hold time of 10 minutes and a tolerance threshold of ±0.005 MPa. If the vacuum value is within the set tolerance after 10 minutes, the test passes, and the audible and visual alarm lights up green and emits an intermittent beeping sound. If the vacuum value exceeds the set tolerance after 10 minutes, the test fails, and the audible and visual alarm lights up yellow and emits a rapid, intermittent beeping sound. The vacuum gauge data display screen displays real-time vacuum values ​​in order of vacuum level. Based on the vacuum gauge data, a preliminary leak location can be identified and the leak point can be found. After locating the leak point, select Pressure Holding Test on the system interface and retry the procedure until the test passes.

[0069] Infusion and Curing Phase: After the vacuum test passes, the first vacuum pump and valve automatically open. Both vacuum pumps and valves are now running and open. The infusion and curing phase is set for 6 hours, with a vacuum target of -0.095 MPa, a start / stop tolerance of ±0.005 MPa, and a low vacuum alarm of -0.085 MPa. If the system vacuum performance is good and within the set target deviation range, the audible and visual alarm illuminates green and emits an intermittent beeping sound, and the vacuum pump automatically stops. If the vacuum value exceeds the set deviation range, the audible and visual alarm illuminates yellow and emits a rapid, intermittent beeping sound. The vacuum pump in the corresponding area is activated based on the vacuum count and number. When the vacuum value reaches the set target, the vacuum pump automatically stops, and the audible and visual alarm illuminates green and emits an intermittent beeping sound. When the vacuum value reaches the alarm threshold, the audible and visual alarm illuminates red and emits a continuous beeping sound. When the infusion and curing time reaches the set time, the audible and visual alarm illuminates yellow and emits a "shutdown" sound. After a delay of 5 minutes without any operation, the vacuum pump automatically shuts down.

[0070] System operation interface is displayed in layers and grades The control system can select unified control of the leeward side mold and the windward side mold, or can control them separately.

[0071] The control system's user interface displays real-time status of the vacuum pump, solenoid valve, vacuum pump run time, and the vacuum tank's vacuum level. This visual interface facilitates operational status monitoring. The vacuum pump run time provides data support for equipment maintenance. When the equipment and solenoid valve are open, a green block appears in the open status column; when closed, a red block appears in the closed status column.

[0072] Vacuum data is recorded every minute, and the control system interface displays each zone and its corresponding vacuum value in real time, allowing for easy viewing of real-time vacuum data. Real-time curves are generated, each with a different color to distinguish it, making it easy to view overall vacuum data changes. Vacuum data is stored on the server, producing a data table that records data every minute, including the time and the vacuum value of each vacuum gauge over time. The stored real-time curves and data tables can be used for process analysis and data traceability.

[0073] The system allows real-time viewing of alarm information. After the program is running, an alarm log is generated. Alarm information includes the alarm time and alarm content, such as: Time: 3:20, Alarm Content: Low vacuum alarm during PS surface perfusion stage. When an alarm occurs, a flashing red block will appear in the alarm information column on the operation interface. Click to view the red flashing block.

[0074] Data curves, data tables, and alarm logs are stored in the server and can be viewed, exported, and printed in real time.

Claims

1. A wind turbine blade mold vacuum system, characterized by: It consists of mold steel frame, vacuum main pipeline and branch pipeline, vacuum nozzle and its connection structure, vacuum pump group, valve group, vacuum data acquisition device and control system. The mold steel frame and vacuum pipeline are integrated into one design. The main crossbeam pipe of the mold steel frame serves as the main vacuum pipeline, which is connected by sealing welding and hoses to form a through channel. The diagonal bracing and cross bracing pipes of the steel frame serve as branch pipelines, connecting the front and rear edge main pipelines to form a redundant passage. The vacuum data acquisition device is a plurality of vacuum gauges (7); The control system is control software.

2. The wind turbine blade mold vacuum system according to claim 1, characterized in that: The structures of the mold vacuum systems for the leeward and windward sides of the wind turbine blades each include a first vacuum main line (1), a first vacuum branch line (10), a second vacuum main line (8), a second vacuum branch line (11), and vacuum nozzles for the first and second vacuum main lines; The upper and lower parts of the mold steel frame are provided with main crossbeam tubes along the front and rear edges, the main crossbeam rectangular tubes at the upper front and rear edges serve as the first vacuum main line (1), and the main crossbeam rectangular tubes at the lower front and rear edges serve as the second vacuum main line (8); The mold segmented part uses a hose with an appropriate diameter to connect the main beam pipe into a whole, forming a connected first and second vacuum main pipes.

3. The wind turbine blade mold vacuum system according to claim 1, characterized in that: During the production process, the main crossbeam pipe of each section of the mold is connected, the ends are sealed, and the pipe joints are sealed and welded to prevent air leakage.

4. The wind turbine blade mold vacuum system according to claim 1, characterized in that: The mold steel frame has pipes welded to form a "K"-shaped diagonal brace at intervals. At least two "K"-shaped structures are selected as branch pipes for each mold section to connect the first main pipes at the front edge and the rear edge to form multiple passages, which are the first vacuum branch pipes (10). The connection points are fixed by welding. At least two cross bracing pipes are selected from each section of the mold as the second branch pipe (11) to connect the second main pipes at the front edge and the rear edge; the connection points are fixed by welding.

5. The wind turbine blade mold vacuum system according to claim 1, characterized in that: The main crossbeam tube is used as the main pipeline to connect the mold surface to vacuum. The lower plane of the main crossbeam tube is drilled at the corresponding position according to the position requirements of the vacuum nozzle. The hole diameter matches the outer diameter of the vacuum nozzle. The vacuum nozzle is fixed to the main pipeline by welding. The lower plane of the main pipeline is welded to the downward vacuum nozzle and connected to the mold flange vacuum nozzle (3) through a spiral tube (4).

6. The wind turbine blade mold vacuum system according to claim 1, characterized in that: The vacuum nozzles are all downward and are divided into a first vacuum nozzle and a second vacuum nozzle; the mold glass fiber reinforced plastic flange (2) vacuum nozzle (3) and the main line vacuum nozzle are connected using spiral tubes with matching pipe diameters, and the main line (1) is connected to the mold glass fiber reinforced plastic part by vacuum; the steel wire spiral tube (4) is fixed.

7. The method for preparing a wind turbine blade mold vacuum system according to any one of claims 1 to 6, characterized in that: Here are the steps: The mold is divided into three areas along the axial direction: blade root, blade middle, and blade tip. A first vacuum main line (1) and a second vacuum main line (8) in each area are made into pipelines connected to a vacuum pump. After the point is determined, an opening is made on the side of the main pipe. The opening diameter should be equal to the diameter of the connecting round pipe, and the cross-sectional area of ​​the round pipe should be equal to the cross-sectional area of ​​the main beam pipe. Weld the flange to the main crossbeam tube at the opening position. One end of the iron pipe is connected to a flange by a hose, and the other end is connected to a vacuum pump (6) by a flange by a hose; Two pipes are welded to the buffer tank of the vacuum pump (6) and are connected to the first vacuum main line (1) and the second vacuum main line (8) via flanges respectively; A vacuum gauge (7) is installed at the vacuum nozzle of the first and second vacuum main lines of each area; at least four vacuum gauges (7) are installed at the segmented docking position of each section of the mold main line; one is installed on each branch line, at least one is installed on each vacuum pump buffer tank, and at least one is installed on each vacuum pump and main line connecting pipe.

8. The method according to claim 7, characterized in that: The flange has a threaded hole; a sealing rubber gasket is added to the flange connection; a solenoid valve (9) is installed on each vacuum pump main line connecting pipeline (5); and a manual valve is installed on each connecting main line.

9. A method for controlling a vacuum system according to any one of claims 1 to 8, characterized in that: include: During the vacuuming phase, the pump group will automatically start and stop according to the preset target value and time, and if the limit is exceeded, the zone sound and light alarm will be triggered; Monitor vacuum stability during the pressure maintenance phase and prioritize starting the pump group in the faulty area when the deviation exceeds the limit; Data is associated with steel frame partitions in real time and a visual chart is generated, which is then stored on the server to support process traceability; The partitioned sound and light alarm includes: a yellow light warning when the vacuum exceeds the limit, a red light alarm and positioning of the leakage area when the pressure maintenance fails; the alarm signal is bound to the steel frame partition, and the control interface highlights the abnormal location.

10. The control method according to claim 9, characterized in that: The vacuum system control is divided into three stages: vacuuming stage, pressure holding and testing stage, and infusion and curing stage. The programmable controller is used to set time and vacuum parameters to achieve automatic control. Vacuuming stage: After the control program parameters are set, the vacuum pump is started to enter the vacuuming stage. The electromagnetic valve of the vacuum main line is opened to vacuumize. The vacuum pump automatically stops working when the vacuum values ​​of all vacuum gauges in the mold vacuum system are within the target vacuum value deviation within the set time. At the same time, the vacuum electromagnetic valve is closed, and the sound and light alarm sounds a prompt and displays a green light. If the vacuum setting value is not reached within the set time, the sound and light alarm emits a different sound prompt and displays a yellow light. The vacuum is the same during the second vacuuming process; Pressure holding test stage: After the vacuum pump and the electromagnetic valve of the main line are closed, the pressure holding test stage will be automatically entered. If the vacuum values ​​of all vacuum gauges are within the deviation range within the set pressure holding time, the infusion and curing stage can be entered. The vacuum pump will stop working, and the electromagnetic valves of the first and second vacuum main lines will be closed. The sound and light alarm will sound a prompt and display a green light. If the vacuum value exceeds the deviation range within the pressure holding time, the sound and light alarm will emit different sound prompts and display a yellow light. Infusion and curing stage: After the system passes the pressure holding test stage, it automatically enters the infusion and curing stage. The vacuum pump starts working and the electromagnetic valves of the first and second vacuum main lines are opened. When the infusion and curing set time is up, the vacuum pump automatically stops working. If the vacuum value exceeds the set deviation, a different sound prompt will be issued and a red light will be displayed. If the vacuum value is within the set deviation range, the light will automatically change to green. The system will prioritize starting the vacuum pump in the area where the vacuum gauge exceeds the deviation value. When the vacuum value deviation in this area increases or the vacuum value in other areas exceeds the tolerance, other vacuum pumps will be started in sequence. The control system can display the operating status of the vacuum pump group and the vacuum counter value in real time and generate vacuum images at each stage. Sound and light alarm lights are set around the mold to facilitate operators to observe the equipment operating status, data changes and alarm conditions in a timely manner. The control system can select unified control of the leeward side mold and the windward side mold, or control them separately; The control system records and stores vacuum value data, vacuum pump operating time, and system alarm conditions in real time, while generating visual images and storing recorded files on the server. The files stored on the server can be viewed, exported, and printed in real time.

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