Manufacturing method for integrally pouring and forming web plate and shell of wind power blade

Abstract

The invention discloses a manufacturing method for integrally pouring and forming a wind power blade web and a shell, which comprises the following steps: S1, manufacturing the wind power blade web in advance, and arranging an air exhaust sealing assembly; laying a shell manufacturing material layer on the shell manufacturing mold; s2, the wind power blade web is hoisted into a preset area of the shell manufacturing mold through a web integrated hoisting tool; s3, an integrated pouring positioning tool is installed, and the front edge web and the rear edge web are locked and positioned through a double-web positioning mechanism; s4, the integrated hoisting tool is moved away; s5, a glue injection pipe and an air exhaust sealing system are arranged on the shell manufacturing mold; s6, air is extracted to preset pressure through the air extraction sealing assembly and the air extraction sealing system; s7, a glue injection pipe is used for injecting a bonding glue solution into the shell vacuum sealing bag; and S8, after the bonding glue liquid is solidified, the glue injection pipe and the air exhaust sealing system are dismantled, a combined product of the wind power blade web and the shell is obtained, and the quality of integrated pouring forming is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of wind turbine blade processing and manufacturing, and in particular to a method for manufacturing a wind turbine blade by integrally pouring a web and a shell. Background Art

[0002] The shell of a wind turbine blade includes a windward shell and a leeward shell. In order to improve the structural strength between the two, a web is bonded between the two. The web is also called a wind turbine blade web.

[0003] Prior art, such as Chinese invention patent publication number CN114311453A, proposes a method for integrally casting the web of a wind turbine blade with the shell. This method utilizes a core mold and positioning brackets to maintain positioning. The web is partially encased in the core mold, with the positioning brackets positioned to one side of the web. The lower end of the core mold rests on the leeward mold. The core mold has a large cross-sectional area, and its lower end acts as a base to maintain balance between the core mold and the web. The web is positioned against the vertical positioning brackets.

[0004] Since the core mold needs to be removed after infusion molding, vacuum-assisted material can only be applied above the leeward mold and on the outer surface of the web. Therefore, when laying the vacuum-assisted material, it is necessary to avoid the lower end of the core mold. When laying the vacuum-assisted material, the positioning bracket needs to be removed to vacuum-assisted material on the outer surface of the web. From then on, the balance is completely achieved by the core mold.

[0005] After pouring, the bonding material is formed on the upper portion of the leeward surface mold and the outer surface of the web, the web and the leeward surface shell are integrally pour-molded, and then the core mold is removed.

[0006] The defects of the above-mentioned prior art are:

[0007] Since a core mold is used to support the web, the core mold needs to be removed at the end, so the core mold cannot support two webs arranged in front and behind at one time. If the front and rear sides of the core mold each support a web, it will be difficult to remove the core mold later. Therefore, the existing technology cannot achieve one-time injection molding of double webs.

[0008] In the solution of the prior art, the vacuum-assisted material needs to avoid the lower end of the core mold. If the vacuum-assisted material includes the lower end of the core mold, then after the injection molding, the core mold is also injected and molded integrally with the leeward shell, making it difficult to remove. Since in the existing solution, the vacuum-assisted material needs to avoid the lower end of the core mold, a recess will be formed on the top of the leeward shell after the core mold is removed, affecting the streamlined structure of the leeward shell. In addition, since the air in the space between the lower end of the core mold and the surrounding vacuum-assisted material cannot be extracted, when the vacuum-assisted material is evacuated to a vacuum state, this part of the gas will be compressed, the pressure will increase, and it will affect the flow of the adhesive material toward the boundary of the area, which will increase the area of ​​the recess.

[0009] In existing solutions, the positioning brackets are removed when the vacuum-assisted material is laid, leaving the core mold entirely responsible for balance. However, when pouring the adhesive, high-pressure flow is generated, potentially causing the core mold to become unstable and affecting the positioning of the web. Furthermore, during pouring, the lower end of the web is held in place solely by the gravity of the core mold and web, without downward pressure. This high-pressure fluid can also cause defects such as tilting or shifting of the web. Summary of the Invention

[0010] The purpose of the present invention is to overcome the shortcomings of the existing technology and provide a method for manufacturing a wind turbine blade web and a shell by integral injection molding, which can realize the injection molding of double webs and the shell at one time. A vacuum sealing assembly is specially provided on the lower flange to ensure the vacuum efficiency of the bottom of the wind turbine blade web and the normal flow of the bonding glue, so that the bonding glue can flow into the bottom of the wind turbine blade web, thereby improving the injection connection effect. During the whole process, the leading edge web and the trailing edge web are clamped and pressed down by the double web positioning mechanism, so that the leading edge web and the trailing edge web remain stable and will not tilt or deflect, thereby improving the quality of the integral injection molding.

[0011] The technical solution of the present invention provides a method for manufacturing a wind turbine blade web and shell by integral injection molding, wherein the shell includes a windward shell or a leeward shell;

[0012] The wind turbine blade web comprises at least a leading edge web and a trailing edge web, and flanges are provided between the upper and lower ends of the leading edge web and the trailing edge web;

[0013] The steps include:

[0014] S1: The wind turbine blade web is prefabricated, and an air extraction sealing assembly is arranged in the flange at the lower end;

[0015] Laying a shell manufacturing material layer on a shell manufacturing mold;

[0016] S2: using a web-integrated lifting tool to lift the wind turbine blade web into a preset area of ​​the shell manufacturing mold;

[0017] S3: Installing an integrated pouring positioning tool, wherein the integrated pouring positioning tool includes a mold positioning mechanism and a double web positioning mechanism;

[0018] The mold is locked and positioned by the mold positioning mechanism and the shell;

[0019] The leading edge web and the trailing edge web are locked and positioned by the double web positioning mechanism, and the flange at the lower end falls on the shell manufacturing material layer;

[0020] S4: removing the integrated lifting tool;

[0021] S5: Arranging a glue injection tube and an air extraction sealing system on the shell manufacturing mold, wherein the air extraction sealing system includes a shell vacuum sealing bag, the shell vacuum sealing bag seals the shell manufacturing material layer and the glue injection tube, and surrounds the lower ends of the leading edge web and the trailing edge web;

[0022] S6: utilizing the vacuum sealing assembly and the vacuum sealing system to pump air to a preset pressure respectively;

[0023] S7: using the glue injection tube to pour adhesive liquid into the vacuum sealing bag of the shell;

[0024] S8: After the adhesive liquid solidifies, the adhesive injection tube and the vacuum sealing system are removed.

[0025] In one of the optional technical solutions, step S1 further includes:

[0026] The edge of the flange at the lower end is widened by more than 20 mm so as to be bonded to the vacuum sealing assembly.

[0027] In one of the optional technical solutions, the vacuum sealing assembly includes a one-way breathable membrane, a guide net, a vacuum pipe and a vacuum sealing membrane laid in sequence from bottom to top;

[0028] The edges of the one-way breathable membrane and the vacuum sealing membrane are respectively bonded to the flange to form a cavity, and the guide net and the exhaust pipe are respectively located in the cavity; the connecting end of the exhaust pipe extends out of the cavity for connection to the air pump;

[0029] The one-way breathable membrane is tightly attached to the shell material layer to ensure the air extraction efficiency at the bottom of the wind turbine blade web and the normal flow of the adhesive.

[0030] In one of the optional technical solutions, the step S1 further includes: arranging a shell main beam on the shell manufacturing mold, and arranging the shell manufacturing material layer around and on the top surface of the shell main beam;

[0031] The shell material layer on the top surface of the shell main beam includes multiple layers of biaxial cloth, which plays a buffering and ventilation function;

[0032] The step S3 further includes: positioning the flange at the lower end onto the biaxial fabric layer.

[0033] In one of the optional technical solutions, a leading edge web reinforcement is arranged in the area where the leading edge web and the shell meet;

[0034] A trailing edge web reinforcement is arranged in the area where the trailing edge web meets the shell.

[0035] In one of the optional technical solutions, the double web positioning mechanism includes a door-shaped mounting frame, a double web chord-direction tightening member, a double web spreading member, and a double web pressing member;

[0036] The leading edge clasp and the trailing edge clasp of the door-shaped mounting frame are respectively provided with double-web chord-wise tightening members capable of horizontal movement and adjustment, for tightening the outer surfaces of the leading edge web and the trailing edge web;

[0037] The double-web support member is connected to the top beam of the door-shaped mounting frame and can slide up and down, and is used to be placed between the leading edge web and the trailing edge web to support the inner surfaces of the leading edge web and the trailing edge web;

[0038] The double-web pressing member is connected to the top beam of the door-shaped mounting frame and can slide up and down, and is used to press down the flanges at the upper ends of the leading edge web and the trailing edge web.

[0039] In one of the optional technical solutions, a plurality of the double-web chord-wise tightening members are respectively provided on the leading edge cladding and the trailing edge cladding and are arranged opposite to each other;

[0040] The double-web positioning mechanism includes two sets of double-web pressing components, and the two sets of double-web pressing components are arranged on opposite sides of the double-web spreading component.

[0041] In one of the optional technical solutions, the wind turbine blade web includes a trailing edge auxiliary web;

[0042] The integrated infusion positioning tool includes an auxiliary web positioning mechanism for clamping and pressing down the trailing edge auxiliary web;

[0043] The step S3 includes:

[0044] Using the auxiliary web positioning mechanism to clamp and press down the trailing edge auxiliary web, positioning the lower end of the trailing edge auxiliary web into a preset area of ​​the shell manufacturing mold and connecting it with the shell manufacturing material layer;

[0045] The step S4 includes:

[0046] The shell vacuum sealing bag surrounds the lower end of the trailing edge auxiliary web.

[0047] In one of the optional technical solutions, an auxiliary web reinforcement is arranged in the area where the trailing edge auxiliary web connects with the shell.

[0048] In one of the optional technical solutions, the auxiliary web positioning mechanism includes a door-shaped connecting frame, a single web chord-direction tightening member, and a single web pressing member;

[0049] The leading edge side plate and the trailing edge side plate of the gate-shaped connecting frame are respectively provided with a single web chord-wise tightening member capable of horizontal movement and adjustment, for tightening the two side surfaces of the trailing edge auxiliary web;

[0050] The single web pressing member is connected to the top plate of the door-shaped connecting frame and can slide up and down, and is used to press down the upper end of the trailing edge auxiliary web.

[0051] The above technical solution has the following beneficial effects:

[0052] The present invention provides a method for integrally pouring and molding a wind turbine blade web and a shell. A double-web positioning mechanism is used to clamp, press down, and position the leading edge web and the trailing edge web, thereby achieving pouring and molding of the double web and the shell in one step. In the present invention, a vacuum sealing assembly is specifically configured in the lower end flanges of the leading edge web and the trailing edge web to extract gas before pouring, thereby ensuring the vacuum efficiency at the bottom of the wind turbine blade web and the normal flow of the adhesive liquid. The adhesive liquid can flow into the bottom of the wind turbine blade web, thereby improving the pouring connection effect. In the present invention, the double-web positioning mechanism is used to clamp, press down, and position the leading edge web and the trailing edge web throughout the entire process, thereby ensuring that the leading edge web and the trailing edge web remain stable and will not tilt or deflect, thereby improving the quality of the integral pouring and molding. In the present invention, since the solution of removing the core mold in the prior art is not adopted, no corresponding recess is formed on the exposed surface of the shell, thereby ensuring the streamlined structure of the shell surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The disclosure of the present invention will become more easily understood with reference to the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of the present invention. In the drawings:

[0054] Figure 1 This is a cross-sectional view of a wind turbine blade according to an embodiment of the present invention, wherein a wind turbine blade web is arranged between the wind surface shell and the leeward surface shell, and the wind turbine blade web includes a leading edge web and a trailing edge web;

[0055] Figure 2 This is a schematic diagram of laying a shell manufacturing material layer on a shell manufacturing mold in one embodiment of the present invention;

[0056] Figure 3 A cross-sectional view of a wind turbine blade web including a leading edge web and a trailing edge web;

[0057] Figure 4 A schematic diagram of a flange at one end provided with an exhaust sealing assembly;

[0058] Figure 5 Schematic diagram of the composition of the vacuum sealing assembly;

[0059] Figure 6 This is a front view of an integrated pouring and positioning tooling of a first structure involved in one embodiment of the present invention;

[0060] Figure 7 This is a front view of an integrated pouring and positioning tooling of a second structure involved in one embodiment of the present invention;

[0061] Figure 8 This is a schematic diagram of using the first structure of the integrated pouring positioning tool to integrally pour the wind turbine blade web and the shell, wherein the wind turbine blade web includes a leading edge web and a trailing edge web;

[0062] Figure 9 This is a schematic diagram of using the second structure of the integrated pouring positioning tool to integrally pour the wind turbine blade web and the shell, wherein the wind turbine blade web includes a leading edge web, a trailing edge web, and a trailing edge auxiliary web;

[0063] Figure 10 A schematic diagram of laying a shell vacuum sealing bag;

[0064] Figure 11 This is a schematic diagram of the removal of the shell vacuum sealing bag, injection tube, etc. after the infusion is completed;

[0065] Figure 12 for Figure 11 A partial enlarged view of

[0066] Figure 13 This is a flow chart of a method for integrally pouring a web and shell of a wind turbine blade provided by one embodiment of the present invention. DETAILED DESCRIPTION

[0067] The following further describes specific embodiments of the present invention with reference to the accompanying drawings. Like components are denoted by like reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, and the terms "inward" and "outward" refer to directions toward or away from the geometric center of a particular component, respectively.

[0068] The present invention provides a method for integrally casting a wind turbine blade web 2 and shell 1, which is used to manufacture a wind turbine blade. The shell 1 of the wind turbine blade includes a windward shell 11 and a leeward shell 12. The wind turbine blade web 2 of the present invention can be integrally cast with the windward shell 11 or with the leeward shell 12. The accompanying drawings only illustrate the integral casting of the wind turbine blade web 2 and leeward shell 12. The integral casting of the wind turbine blade web 2 and windward shell 11 is similar and will not be illustrated in detail here.

[0069] The shell production mold 3 involved in the present invention can be used to produce the windward side shell 11 , and can also be used to produce the leeward side shell 12 .

[0070] In the present invention, if the wind turbine blade web 2 and the windward surface shell 11 are integrally cast, the leeward surface shell 12 is subsequently bonded to the windward surface shell 11 and the wind turbine blade web 2 to form a complete wind turbine blade.

[0071] In the present invention, if the wind turbine blade web 2 and the leeward shell 12 are integrally cast, the windward shell 11 is subsequently bonded to the leeward shell 12 and the wind turbine blade web 2 to form a complete wind turbine blade.

[0072] In the present invention, the glue injection pipe and grouting pump used for shell pouring, and the exhaust pipe and vacuum pump used for vacuuming are the contents of the existing technology. Please refer to the introduction and related illustrations in the existing technology and will not be described in detail in the present invention.

[0073] The adhesive solution in the present invention can be epoxy resin or the like.

[0074] In the present invention, an integrated lifting fixture is used to lift the wind turbine blade web 2 to the predetermined position of the shell mold 3. Then, an integrated pouring and positioning fixture 4 is installed. The integral pouring and positioning fixture 4 is locked and positioned with the shell mold 3. The integral pouring and positioning fixture 4 positions the wind turbine blade web 2, and the integrated lifting fixture is removed.

[0075] The integrated infusion positioning fixture 4 of the first structure includes a main bracket 41, a mold positioning mechanism 42 and a double-web positioning mechanism 43, thereby realizing integrated positioning and infusion molding of the double-webs.

[0076] The integrated pouring and positioning tool 4 of the second structure includes a main bracket 41, a mold positioning mechanism 42, a double web positioning mechanism 43 and an auxiliary web positioning mechanism 44, which realizes the integrated positioning and pouring molding of the double web and the auxiliary web.

[0077] The main bracket 41 is fixedly hung in a designated place, and has longitudinal beams extending downward at both ends. A set of mold positioning mechanisms 42 is provided on the inner side of each longitudinal beam. Support parts such as oil cylinders can be used to support the two ends or sides of the shell manufacturing mold 3 to lock and position it with the shell manufacturing mold 3.

[0078] The double web positioning mechanism 43 is provided at the front middle portion of the main support 41 and is higher than the mold positioning mechanism 42. The double web positioning mechanism 43 is used to clamp, press down, and position the leading edge web 21 and the trailing edge web 22.

[0079] Specifically, the double-web positioning mechanism 43 includes a door-shaped mounting frame 431 , a double-web chord-wise tightening member 432 , a double-web spreading member 433 , a double-web pressing member 434 , and the like.

[0080] The door-shaped mounting frame 431 is integrally arranged with the main bracket 41 , and includes a leading edge hanging plate 4311 , a top beam 4313 and a trailing edge hanging plate 4312 connected in sequence, forming a door shape with an open lower end for the leading edge web 21 and the trailing edge web 22 to enter.

[0081] A double-web chord-wise tensioning member 432 is provided on each of the leading edge clasp 4311 and the trailing edge clasp 4312. The double-web chord-wise tensioning member 432 is arranged generally horizontally and can move forward and backward or telescopically relative to the leading edge clasp 4311 and the trailing edge clasp 4312, thereby achieving horizontal movement and adjustment to tighten the outer surfaces of the leading edge web 21 and the trailing edge web 22. The double-web chord-wise tensioning member 432 can employ a screw-adjustable tensioning mechanism or a telescopic mechanism using a horizontally mounted hydraulic or pneumatic cylinder.

[0082] The double-web support member 433 includes a support member 4331 and a lifting rod 4332 connected to the top of the support member 4331. The lifting rod 4332 is connected to the top beam 4313 and can slide up and down relative to the top beam 4313, thereby driving the support member 4331 to move up and down for adjustment. The lifting rod 4332 can be a screw rod, the lower end of which is connected to the support member 4331 through a bearing, and the upper end of which is connected to a handle. The lifting rod 4332 passes through the internal threaded hole of the top beam 4313 and drives the support member 4331 to move up and down by rotating the screw rod. Since the screw rod is connected to the support member 4331 through a bearing, the support member 4331 can remain fixed when the screw rod rotates. The lifting rod 4332 can also be a sliding rod, which is slidably connected to the top beam 4313, and the lower end of the sliding rod is fixedly connected to the support member 4331. A lifting cylinder is connected between the top beam 4313 and the sliding rod to drive the sliding rod to move up and down, thereby driving the expansion member 4331 to move up and down.

[0083] The support member 4331 can be a plate or a bracket, which can enter obliquely between the leading edge web 21 and the trailing edge web 22 through the flange hole, and cannot pass through the flange hole when laid flat, thereby supporting the inner surface of the leading edge web 21 and the trailing edge web 22 internally to cooperate with the double web chord-direction clamping member 432 to clamp the leading edge web 21 and the trailing edge web 22, and keep the leading edge web 21 and the trailing edge web 22 vertical.

[0084] The double-web pressing member 434 includes a pressing plate 4341 and a lifting rod 4342 connected to the top of the pressing plate 4341. The lifting rod 4342 is connected to the top beam 4313 and can slide up and down relative to the top beam 4313, thereby driving the pressing plate 4341 to move up and down and adjust, and can press on the flanges 23 at the upper ends of the leading edge web 21 and the trailing edge web 22, so that the lower ends of the leading edge web 21 and the trailing edge web 22 and the flanges 23 are kept tightly pressed against the shell material layer 13 on the shell mold 3, thereby improving the effect of the integral infusion molding.

[0085] The lifting rod 4342 can be a screw rod, the lower end of which is connected to the pressure plate 4341 via a bearing, and the upper end of which is connected to a handle. The lifting rod 4342 passes through the internal threaded hole of the top beam 4313, and the pressure plate 4341 is driven up and down by rotating the screw rod. Since the screw rod and the pressure plate 4341 are connected by a bearing, the pressure plate 4341 can remain stationary when the screw rod rotates. The lifting rod 4342 can also be a sliding rod, which is slidably connected to the top beam 4313, and the lower end of the sliding rod is fixedly connected to the pressure plate 4341. A lifting cylinder is connected between the top beam 4313 and the sliding rod to drive the sliding rod up and down, thereby driving the pressure plate 4341 up and down.

[0086] The auxiliary web positioning mechanism 44 is arranged at the rear middle portion of the main support 41 and is higher than the mold positioning mechanism 42. The auxiliary web positioning mechanism 44 is used to clamp and press down the rear edge auxiliary web 25.

[0087] Specifically, the auxiliary web positioning mechanism 44 includes a door-shaped connecting frame 441 , a single web chord-wise tightening member 442 and a single web pressing member 443 .

[0088] The door-shaped connecting frame 441 is integrally provided with the main support 41. The door-shaped connecting frame 441 comprises a leading edge side plate 4411, a top plate 4413 and a trailing edge side plate 4412 connected in sequence, forming a door shape with an open lower end for the trailing edge auxiliary web 25 to enter.

[0089] A single web chord-wise tensioning member 442 is provided on each of the leading edge side panels 4411 and the trailing edge side panels 4412. This member 442 is arranged generally horizontally and can move forward and backward or telescope relative to the leading edge side panels 4411 and trailing edge side panels 4412, thereby achieving horizontal movement and adjustment to tighten the front and rear surfaces of the trailing edge auxiliary web 25. The single web chord-wise tensioning member 442 can employ a screw-adjustable tensioning mechanism or a telescopic mechanism such as a horizontally mounted oil or pneumatic cylinder.

[0090] The structure of the single-web pressing member 443 is similar to that of the double-web pressing member 434, and it also includes a pressure plate and a lifting rod. The lifting rod is connected to the top plate 4413 and can slide up and down, thereby driving the pressure plate to move up and down, and can be pressed on the upper end of the trailing edge auxiliary web 25, so that the trailing edge auxiliary web 25 and the shell manufacturing material layer 13 on the shell manufacturing mold 3 are kept tightly pressed, thereby improving the effect of one-piece infusion molding.

[0091] The following content will detail the integrated injection molding process involved in the present invention:

[0092] like Figure 1-6 、 Figure 8 and Figure 10-13 As shown, an embodiment of the present invention provides a method for manufacturing a wind turbine blade web 2 and a shell 1 by integral injection molding, wherein the shell 1 includes a windward shell 11 or a leeward shell 12 .

[0093] The wind turbine blade web 2 comprises at least a leading edge web 21 and a trailing edge web 22 , and a flange 23 is provided between the upper and lower ends of the leading edge web 21 and the trailing edge web 22 .

[0094] The steps include:

[0095] S1: The wind turbine blade web 2 is manufactured in advance, and an air extraction sealing assembly 24 is arranged in the flange 23 at the lower end.

[0096] A shell manufacturing material layer 13 is laid on the shell manufacturing mold 3 .

[0097] S2: using a web-integrated hoisting tool to hoist the wind turbine blade web 2 into a preset area of ​​the shell manufacturing mold 3 .

[0098] S3: Installing the integrated pouring positioning tool 4 , which includes a mold positioning mechanism 42 and a double web positioning mechanism 43 .

[0099] The mold positioning mechanism 42 is used to lock and position the shell manufacturing mold 3.

[0100] The leading edge web 21 and the trailing edge web 22 are locked and positioned by the double web positioning mechanism 43 , and the flange 23 at the lower end falls on the shell manufacturing material layer 13 .

[0101] S4: Remove the integrated lifting tooling.

[0102] S5: A glue injection tube and an air extraction sealing system are arranged on the shell manufacturing mold 3. The air extraction sealing system includes a shell vacuum sealing bag 5. The shell vacuum sealing bag 5 seals the shell manufacturing material layer 13 and the glue injection tube, and surrounds the lower ends of the leading edge web 21 and the trailing edge web 22.

[0103] S6: Utilize the vacuum sealing assembly 24 and the vacuum sealing system to pump air to a preset pressure.

[0104] S7: Use the glue injection tube to pour the adhesive liquid into the shell vacuum sealing bag 5.

[0105] S8: After the adhesive liquid solidifies, remove the glue injection tube and the vacuum sealing system.

[0106] The present invention provides a method for manufacturing a wind turbine blade web 2 and a shell 1 by integrally pouring and molding. The specific steps are as follows:

[0107] Preparation:

[0108] A shell mold 3 is prepared on the ground, and a shell material layer 13 is laid on the shell mold 3. Shell material layer 13 can be any shell material commonly used in the art, including but not limited to fiberglass and cloth. The laying of shell material layer 13 can be referred to in the prior art and will not be described in detail here.

[0109] The wind turbine blade web 2 is prefabricated, and the leading edge web 21 and the trailing edge web 22 of the wind turbine blade web 2 are manufactured according to the existing conventional web production process. The leading edge web 21 and the trailing edge web 22 are respectively provided with flanges 23 at the upper and lower ends, and the flange at the end that needs to be connected by pouring is called the lower end flange. After the leading edge web 21 and the trailing edge web 22 are assembled, an exhaust sealing component 24 is arranged in the gap between the lower end flanges of the two webs. The edge of the exhaust sealing component 24 is sealed with the edge of the flange 23. The exhaust sealing component 24 is a component that can exhaust air outward and seal the flange, and can be composed of a one-way breathable membrane, an exhaust pipe, a vacuum bag / membrane, etc. It is used to extract the air from the bottom of the leading edge web 21 and the trailing edge web 22 before pouring, so as to allow the bonding glue to flow into the bottom of the leading edge web 21 and the trailing edge web 22.

[0110] Installation work:

[0111] The assembled wind turbine blade web 2 is hoisted into the preset area of ​​the shell manufacturing mold 3 using the web integrated hoisting tool. After the wind turbine blade web 2 is positioned, the pouring positioning tool 4 is installed.

[0112] Specifically, the mold positioning mechanism 42 is used to lock and position the shell manufacturing mold 3, and the double web positioning mechanism 43 is used to lock and position the leading edge web 21 and the trailing edge web 22, and keep the lower end flange 23 on the shell manufacturing material layer 13.

[0113] The integrated lifting fixture is removed, and the wind turbine blade web 2 is completely locked and positioned by the pouring positioning fixture 4 .

[0114] Laying of injection pipes and vacuum sealing system work:

[0115] A guide net and several glue injection pipes are arranged on the shell production mold 3 according to conventional production technology. The glue injection pipes are located above the shell production material layer 13, and one end of the glue injection pipe is connected to the resin barrel through a pipeline.

[0116] Next, an exhaust sealing system is installed on the shell mold 3. This system includes several exhaust pipes and a shell vacuum sealing bag 5. The exhaust pipes are installed on the flanges of the shell mold 3 on both sides. Finally, the shell vacuum sealing bag 5 is placed on the shell mold 3. The shell vacuum sealing bag 5 seals the shell material layer 13, the glue injection pipe, and the exhaust pipe, and also surrounds the lower ends of the leading edge web 21 and the trailing edge web 22.

[0117] Vacuuming work:

[0118] The exhaust pipe in the exhaust sealing assembly 24 and the exhaust pipe in the exhaust sealing system can be connected to different vacuum pumps respectively.

[0119] The vacuum pump is turned on, and the vacuum sealing assembly 24 and the vacuum sealing system are used to evacuate air to a preset pressure, so that the vacuum sealing bag 5 of the shell is substantially in a vacuum state.

[0120] Grouting work:

[0121] Open the glue injection tube in the middle of the shell manufacturing mold 3, and use vacuum negative pressure to inject the resin in the resin barrel into the shell vacuum sealing bag 5 through the glue injection tube to inject adhesive glue (epoxy resin). The adhesive glue will flow to both sides of the shell manufacturing mold 3, and flow into the area where the lower ends of the leading edge web 21 and the trailing edge web 22 are located, surrounding the lower ends of the leading edge web 21 and the trailing edge web 22, and also flow into the bottom surface of the leading edge web 21 and the trailing edge web 22. After the adhesive glue solidifies, it will bond and shape the shell manufacturing material layer 13 to form the shell 1, and firmly connect the leading edge web 21 and the trailing edge web 22 to the shell 1.

[0122] Finishing work:

[0123] After the adhesive solidifies, the shell vacuum sealing bag 5, the glue injection tube and the exhaust tube are removed to obtain the integrally cast combination of the wind turbine blade web 2 and the shell 1. The casting and positioning tooling 4 is subsequently removed as needed.

[0124] In summary, the present invention provides a method for integrally forming the web 2 and shell 1 of a wind turbine blade by injection molding. The leading edge web 21 and the trailing edge web 22 can be clamped, pressed down, and positioned by a double web positioning mechanism 43, so that the injection molding of the double web 2 and the shell 1 can be achieved at one time. In the present invention, a vacuum sealing assembly 24 is specially configured in the lower end flanges 23 of the leading edge web 21 and the trailing edge web 22 to extract gas before injection, thereby ensuring the vacuum efficiency at the bottom of the wind turbine blade web 2 and the normal flow of the adhesive liquid. The adhesive liquid can flow into the bottom of the wind turbine blade web 2, thereby improving the injection connection effect. In the present invention, the leading edge web 21 and the trailing edge web 22 are clamped, pressed down, and positioned by the double web positioning mechanism 43 throughout the entire process, so that the leading edge web 21 and the trailing edge web 22 remain stable and will not tilt or deflect, thereby improving the quality of the integral injection molding. In the present invention, since the solution of removing the core mold in the prior art is not adopted, no corresponding recessed portion is formed on the exposed surface of the shell 1 , thereby ensuring the streamlined structure of the surface of the shell 1 .

[0125] In one embodiment, Figure 3 As shown, step S1 also includes:

[0126] The edge of the flange 23 at the lower end is widened by more than 20 mm to facilitate bonding with the air extraction seal assembly 24. The air extraction seal assembly 24 is arranged without reducing the designed bonding width of the flange 23 at the lower end. Specifically, when manufacturing the web 2 of the wind turbine blade, the edge widening effect is achieved by increasing the laying width of the flange fabric layer. In one embodiment, as Figure 4-5 As shown, the air extraction sealing assembly 24 includes a one-way breathable membrane 241, a guide net 242, an air extraction pipe 243 and a vacuum sealing membrane 244 which are laid out in sequence from bottom to top.

[0127] The edges of the one-way breathable membrane 241 and the vacuum sealing membrane 244 are bonded to the flange 23 to form a cavity, in which the guide net 242 and the exhaust pipe 243 are respectively located. The connection end of the exhaust pipe 243 extends outside the cavity for connection to the air pump.

[0128] The one-way breathable membrane 241 is tightly attached to the shell material layer 13 to ensure the air extraction efficiency at the bottom of the wind turbine blade web 2 and the normal flow of the adhesive.

[0129] In this embodiment, the vacuum seal assembly 24 comprises a one-way breathable membrane 241, a guide net 242, an exhaust pipe 243, and a vacuum sealing membrane 244 / vacuum sealing bag. The one-way breathable membrane 241, the guide net 242, the exhaust pipe 243, and the vacuum sealing membrane 244 / vacuum sealing bag are arranged in order from bottom to top. The one-way breathable membrane 241 and the vacuum sealing membrane 244 / vacuum sealing bag are each bonded to the edge of the center hole of the flange 23 via a sealing strip.

[0130] The one-way air permeable membrane 241 is in contact with the shell material layer 13 and plays a role in filtering the resin during air extraction to prevent the resin from being extracted.

[0131] The guide net 242 is laid below the exhaust pipe 243 to guide the flow and improve the exhaust effect. The exhaust pipe 243 can be a spiral pipe.

[0132] The vacuum sealing film 244 / vacuum sealing bag is used to seal the flange hole, so that the space enclosed by the bottom of the vacuum sealing film 244 / vacuum sealing bag and the shell vacuum sealing bag 5 is sealed, and can be vacuumed subsequently.

[0133] In one embodiment, Figure 2 and Figure 8 As shown, step S1 further includes: arranging a shell main beam 1 a on the shell manufacturing mold 3 , and arranging a shell manufacturing material layer 13 around and on the top surface of the shell main beam 1 a .

[0134] The shell manufacturing material layer 13 on the top surface of the shell main beam 1a includes multiple layers of biaxial cloth laying layers 131, which play a buffering and ventilation function.

[0135] Step S3 also includes positioning the lower flange 23 on the biaxial fabric layer 131 .

[0136] In this embodiment, the shell 1 includes a main structure, that is, a shell main beam 1a, which has a relatively rigid structure and plays a supporting role.

[0137] Several layers of biaxial cloth plies 131 are laid on the top surface of the shell main beam 1a, which play a buffering and ventilation function. They are located in the area connected to the leading edge web 21, the trailing edge web 22 and the flange 23, which helps to improve the air extraction efficiency under the double web and ensure the normal circulation of resin at its bottom, thereby preventing the occurrence of infusion defects.

[0138] A biaxial cloth layer of 800g / ㎡ can be used, and a layer of continuous felt is set on the bottom surface of the biaxial cloth layer to bond with the shell main beam 1a.

[0139] The width of the upper biaxial fabric layer 131 on both sides is about 5 cm wider than that of the lower biaxial fabric layer 131. The fibers of the upper and lower biaxial fabric layers 131 are staggered, and when connected together, they are shear-resistant and can improve structural strength.

[0140] In one embodiment, Figure 11-12 As shown, a leading edge web reinforcement 14 is arranged in the area where the leading edge web 21 connects to the shell 1. The leading edge web reinforcement 14 is located on the front side of the leading edge web 21 and connects to the shell 1 to enhance the connection between the leading edge web 21 and the shell 1. The leading edge web reinforcement 14 is generally L-shaped and can be connected by integral casting using an L-shaped connector.

[0141] like Figure 11-12 As shown, a trailing edge web reinforcement 15 is arranged in the area where the trailing edge web 22 connects to the shell 1. The trailing edge web reinforcement 15 is located on the rear side of the trailing edge web 22 and connects to the shell 1 to enhance the connection between the trailing edge web 22 and the shell 1. The trailing edge web reinforcement 15 is generally L-shaped and can be connected by integral casting using an L-shaped connector.

[0142] In one embodiment, Figure 6-11 As shown, the double-web positioning mechanism 43 includes a door-shaped mounting frame 431 , a double-web chord-wise tightening member 432 , a double-web spreading member 433 and a double-web pressing member 434 .

[0143] The leading edge hanging plate 4311 and the trailing edge hanging plate 4312 of the door-shaped mounting frame 431 are respectively provided with double-web chord-wise tightening members 432 that can be horizontally moved and adjusted, and are used to tighten the outer surfaces of the leading edge web 21 and the trailing edge web 22.

[0144] The double web support member 433 is connected to the top beam 4313 of the door-shaped mounting frame 431 and can slide up and down. It is used to be placed between the leading edge web 21 and the trailing edge web 22 to support the inner surfaces of the leading edge web 21 and the trailing edge web 22.

[0145] The double web pressing member 434 is connected to the top beam 4313 of the door-shaped mounting frame 431 and can slide up and down, and is used to press down the flange 23 at the upper end of the leading edge web 21 and the trailing edge web 22.

[0146] The double web positioning mechanism 43 is used to clamp and position the leading edge web 21 and the trailing edge web 22 as follows:

[0147] The wind turbine blade web 2 composed of the leading edge web 21 and the trailing edge web 22 is extended upward into the door-shaped mounting frame 431, and at the same time, the support member 4331 of the double web support member 433 is operated to pass through the upper end flange; then the double web chord-direction tightening members 432 on the front and rear sides are operated to press the outer surfaces of the leading edge web 21 and the trailing edge web 22, and at the same time, the inner surfaces of the leading edge web 21 and the trailing edge web 22 are supported by the support member 4331, thereby clamping the leading edge web 21 and the trailing edge web 22 to achieve positioning. When the leading edge web 21 and the trailing edge web 22 need to be moved downward, the double web chord-wise tightening member 432 is slightly loosened, and the double web pressing member 434 is used to press on the upper end flanges of the leading edge web 21 and the trailing edge web 22, so that they move downward until they fall to the specified position. The double web pressing member 434 remains in this pressing position, so that the leading edge web 21 and the trailing edge web 22 remain in the specified position. After the leading edge web 21 and the trailing edge web 22 fall to the specified position, the double web chord-wise tightening member 432 can be optionally re-tightened to clamp the leading edge web 21 and the trailing edge web 22 to improve the positioning effect.

[0148] In one embodiment, Figure 6 As shown, a plurality of double-web chord-wise tightening members 432 are respectively provided on the leading edge hanging plate 4311 and the trailing edge hanging plate 4312 and are arranged relative to each other, so as to better clamp the leading edge web 21 and the trailing edge web 22 .

[0149] The double web positioning mechanism 43 includes two sets of double web pressing components 434, which are arranged on opposite sides of the double web expansion component 433 and can be pressed down on opposite sides of the flange 23 synchronously, so that the leading edge web 21 and the trailing edge web 22 are pressed down synchronously.

[0150] In one embodiment, Figure 7 and Figure 9-11 As shown, the wind turbine blade web 2 includes a trailing edge auxiliary web 25 .

[0151] The integral infusion positioning tool 4 includes an auxiliary web positioning mechanism 44 for clamping and pressing down the trailing edge auxiliary web 25 .

[0152] Step S3 includes:

[0153] The auxiliary web positioning mechanism 44 is used to clamp and press down the trailing edge auxiliary web 25 , and the lower end of the trailing edge auxiliary web 25 is positioned within the preset area of ​​the shell manufacturing mold 3 and connected to the shell manufacturing material layer 13 .

[0154] Step S4 includes:

[0155] The shell vacuum sealing bag 5 surrounds the lower end of the trailing edge auxiliary web 25 .

[0156] In this embodiment, the wind turbine blade web 2 includes not only the leading edge web 21 and the trailing edge web 22 , but also a trailing edge auxiliary web 25 . The trailing edge auxiliary web 25 is located at the rear side of the trailing edge web 22 .

[0157] The second structure of the integral pouring positioning tool 4 is required, which includes an auxiliary web positioning mechanism 44. The auxiliary web positioning mechanism 44 can clamp and press down the trailing edge auxiliary web 25.

[0158] The clamping, pressing down and positioning methods of the trailing edge auxiliary web 25 are similar to those of the leading edge web 21 and the trailing edge web 22 and will not be described in detail here.

[0159] By adopting this process, the leading edge web 21, the trailing edge web 22 and the trailing edge auxiliary web 25 can be integrally cast with the shell 1, so that multiple webs can be cast at one time.

[0160] In one embodiment, Figure 11 As shown, an auxiliary web reinforcement 16 is arranged in the area where the trailing edge auxiliary web 25 connects to the shell 1. The auxiliary web reinforcement 16 is arranged on the rear side of the trailing edge auxiliary web 25 and connects to the shell 1 to improve the connection between the trailing edge auxiliary web 25 and the shell 1. The auxiliary web reinforcement 16 is generally L-shaped and can be connected by integral casting using an L-shaped connector.

[0161] In one embodiment, Figure 7 and Figure 9-11 As shown, the auxiliary web positioning mechanism 44 includes a door-shaped connecting frame 441, a single web chord-wise tightening member 442 and a single web pressing member 443.

[0162] The leading edge side plate 4411 and the trailing edge side plate 4412 of the gate-shaped connecting frame 441 are respectively provided with a single web chord-wise tightening member 442 that can be horizontally moved and adjusted, and is used to tighten the two side surfaces of the trailing edge auxiliary web 25.

[0163] The single web pressing member 443 is connected to the top plate 4413 of the door-shaped connecting frame 441 and can slide up and down, and is used to press down the upper end of the trailing edge auxiliary web 25.

[0164] The auxiliary web positioning mechanism 44 is used to clamp and position the trailing edge auxiliary web 25 as follows:

[0165] Use lifting tools, jacking tools, etc. to extend the trailing edge auxiliary web 25 upward into the door-shaped connecting frame 441, and then operate the single web chord-direction tightening members 442 on the front and rear sides to press against the front and rear surfaces of the trailing edge auxiliary web 25, thereby clamping the trailing edge auxiliary web 25 to achieve positioning. When the trailing edge auxiliary web 25 needs to be moved downward, slightly loosen the single web chord-direction tightening member 442, and use the single web pressing member 443 to press on the upper end of the trailing edge auxiliary web 25 to move it downward until it falls to the specified position. The single web pressing member 443 remains in this pressing position to keep the trailing edge auxiliary web 25 in the specified position. After the trailing edge auxiliary web 25 falls to the specified position, you can choose to re-lock the single web chord-direction tightening member 442 to clamp the trailing edge auxiliary web 25 and improve the positioning effect.

[0166] As needed, the above technical solutions can be combined to achieve the best technical effect.

[0167] The above are only the principles and preferred embodiments of the present invention. It should be noted that, for those skilled in the art, several other variations can be made based on the principles of the present invention, which should also be considered as the scope of protection of the present invention.

Claims

1. A method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding, wherein: The housing (1) comprises a windward housing (11) or a leeward housing (12); The invention is characterized in that the wind turbine blade web (2) comprises at least a leading edge web (21) and a trailing edge web (22), and a flange (23) is provided between the upper and lower ends of the leading edge web (21) and the trailing edge web (22); The steps include: S1: The wind turbine blade web (2) is prefabricated, and an air extraction sealing assembly (24) is arranged in the flange (23) at the lower end; Laying a shell manufacturing material layer (13) on a shell manufacturing mold (3); S2: using a web-integrated lifting tool to lift the wind turbine blade web (2) into a preset area of ​​the shell manufacturing mold (3); S3: Installing an integrated pouring positioning tool (4), wherein the integrated pouring positioning tool (4) includes a mold positioning mechanism (42) and a double web positioning mechanism (43); Locking and positioning the mold (42) with the shell production mold (3); The leading edge web (21) and the trailing edge web (22) are locked and positioned by the double web positioning mechanism (43), and the flange (23) at the lower end falls on the shell manufacturing material layer (13); S4: removing the integrated lifting tool; S5: arranging a glue injection pipe and an air extraction sealing system on the shell manufacturing mold (3), wherein the air extraction sealing system comprises a shell vacuum sealing bag (5), wherein the shell vacuum sealing bag (5) seals the shell manufacturing material layer (13) and the glue injection pipe, and surrounds the lower ends of the leading edge web (21) and the trailing edge web (22); S6: utilizing the vacuum sealing assembly (24) and the vacuum sealing system to pump air to a preset pressure; S7: using the glue injection tube to inject adhesive liquid into the shell vacuum sealing bag (5); S8: After the adhesive liquid solidifies, the adhesive injection tube and the vacuum sealing system are removed.

2. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 1, characterized in that: The step S1 further includes: The edge of the flange (23) at the lower end is widened by more than 20 mm so as to be bonded to the air extraction sealing assembly (24).

3. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 1, characterized in that: The air extraction sealing assembly (24) comprises a one-way breathable membrane (241), a flow guide net (242), an air extraction pipe (243) and a vacuum sealing membrane (244) which are sequentially laid from bottom to top; The edges of the one-way breathable membrane (241) and the vacuum sealing membrane (244) are respectively bonded to the flange (23) to form a cavity, and the guide net (242) and the exhaust pipe (243) are respectively located in the cavity; the connecting end of the exhaust pipe (243) extends out of the outside of the cavity and is used to be connected to the air pump; The one-way breathable membrane (241) is tightly attached to the shell manufacturing material layer (13) to ensure the air extraction efficiency at the bottom of the wind turbine blade web (2) and the normal flow of the adhesive liquid.

4. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 1, characterized in that: The step S1 further comprises: arranging a shell main beam (1a) on the shell manufacturing mold (3), and arranging the shell manufacturing material layer (13) around and on the top surface of the shell main beam (1a); The shell manufacturing material layer (13) on the top surface of the shell main beam (1a) includes multiple layers of biaxial cloth laying (131), which plays a buffering and ventilation function; The step S3 also includes: positioning the flange (23) at the lower end onto the biaxial fabric layer (131).

5. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 1, characterized in that: Arranging a leading edge web reinforcement (14) in the area where the leading edge web (21) and the shell (1) meet; A trailing edge web reinforcement (15) is arranged in the area where the trailing edge web (22) and the shell (1) meet.

6. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 1, characterized in that: The double web positioning mechanism (43) comprises a door-shaped mounting frame (431), a double web chord-direction tightening member (432), a double web spreading member (433), and a double web pressing member (434); The leading edge hanging plate (4311) and the trailing edge hanging plate (4312) of the door-shaped mounting frame (431) are respectively provided with double-web chord-wise tightening members (432) capable of horizontal movement and adjustment, for tightening the outer surfaces of the leading edge web (21) and the trailing edge web (22); The double-web support member (433) is connected to the top beam (4313) of the door-shaped mounting frame (431) and is capable of sliding up and down, and is used to be placed between the leading edge web (21) and the trailing edge web (22) to support the inner surfaces of the leading edge web (21) and the trailing edge web (22); The double-web pressing member (434) is connected to the top beam (4313) of the door-shaped mounting frame (431) and can slide up and down, and is used to press down the flange (23) at the upper end of the leading edge web (21) and the trailing edge web (22).

7. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 6, characterized in that: A plurality of the double-web chord-direction tightening members (432) are respectively provided on the leading edge hanging plate (4311) and the trailing edge hanging plate (4312) and are arranged opposite to each other; The double-web positioning mechanism (43) comprises two sets of double-web pressing members (434), and the two sets of double-web pressing members (434) are arranged on opposite sides of the double-web spreading member (433).

8. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 1, characterized in that: The wind turbine blade web (2) includes a trailing edge auxiliary web (25); The integrated pouring positioning tool (4) comprises an auxiliary web positioning mechanism (44) for clamping and pressing down the trailing edge auxiliary web (25); The step S3 includes: The auxiliary web positioning mechanism (44) is used to clamp and press down the trailing edge auxiliary web (25), positioning the lower end of the trailing edge auxiliary web (25) within a preset area of ​​the shell production mold (3) and connecting it with the shell production material layer (13); The step S4 includes: The shell vacuum sealing bag (5) surrounds the lower end of the trailing edge auxiliary web (25).

9. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 8, characterized in that: An auxiliary web reinforcement (16) is arranged in the area where the trailing edge auxiliary web (25) connects with the shell (1).

10. The method for manufacturing a wind turbine blade web (2) and a shell (1) by integral injection molding according to claim 8, characterized in that: The auxiliary web positioning mechanism (44) comprises a door-shaped connecting frame (441), a single web chord-direction tightening member (442), and a single web pressing member (443); The leading edge side plate (4411) and the trailing edge side plate (4412) of the gate-shaped connecting frame (441) are respectively provided with a single web chord-wise tightening member (442) capable of horizontal movement and adjustment, for tightening the two side surfaces of the trailing edge auxiliary web (25); The single web pressing member (443) is connected to the top plate (4413) of the door-shaped connecting frame (441) and is capable of sliding up and down, and is used to press down the upper end of the trailing edge auxiliary web (25).

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