Wind power blade design method capable of preventing cloth layer from being empty and wind power blade
By designing a groove-shaped hollow at the trailing edge corner of the suction surface of the wind turbine blade and making a grooved core material, the problem of fabric layer gaps was solved, the production quality and aerodynamic performance of the blade were improved, the amount of resin was reduced, and the overall rigidity of the blade was enhanced.
Patent Information
- Application Number
- CN202510953077.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-10
- Publication Date
- 2025-11-07
AI Technical Summary
The fiber layer at the trailing edge corner of the suction surface of wind turbine blades is prone to gaps, leading to resin enrichment issues and affecting the production quality and aerodynamic performance of the blades.
A groove-shaped cutout is designed at the rear edge corner of the suction surface. The groove core material is made and spliced with other core materials. When laying the fiberglass cloth, a smooth transition is ensured to avoid gaps in the cloth layer.
By designing a grooved core material, the problem of gaps in the fabric layers was solved, improving the production quality and aerodynamic performance of the blades, reducing resin enrichment, and enhancing the overall rigidity of the blades.
Smart Images
Figure CN120911072A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of wind turbine blade production and manufacturing, in particular to a wind turbine blade design method for preventing ply gaps and a wind turbine blade. BACKGROUND
[0002] Wind energy has become one of the most potential new energy types due to its excellent green energy characteristics, and has been widely used and developed. As one of the most core components of a wind turbine generator unit, the design quality and production and manufacturing quality of a wind turbine blade are prerequisites for stable and efficient operation of the unit.
[0003] Almost all operation failure problems of wind field blades are related to production and manufacturing, and most of the defects generated in the production and manufacturing process can be classified as being caused by unreasonable design, unreasonable process method, unreasonable quality control, and raw material problems. For a blade with a blunt trailing edge (also known as a trailing edge), the corner of the entire SS surface (Suction Side) of the trailing edge from the blade root to the maximum chord length is limited by the 3D aerodynamic shape of the entire blade, and presents an inner corner of about R20-40mm. The fiberglass fabric used in the production and manufacturing process of the blade has poor softness and too much hardness. The hardness of each type of fiberglass fabric is obviously different, and the three-axis fiberglass fabric used in this area is obviously harder than the two-axis fiberglass fabric. The corner position between the plies is prone to gaps. More importantly, the vertical surface of the blunt trailing edge has a core material inclined angle extending to the corner, and the SS surface profile also has a core material inclined angle in the trailing edge corner direction. The tips of the two inclined angles converge at the trailing edge corner, which causes the inner corner angle of the trailing edge corner of the SS surface to be smaller when laying the blade root reinforcement layer and the inner skin reinforcement layer, and the plies are more prone to gaps and rich resin.
[0004] The aerodynamic shape of the blade determines the power curve of the blade. By adjusting the trailing edge corner of the trailing edge structure of the blade on the SS surface from a small angle design to a large angle design, the production and manufacturing is beneficial, but it has an impact on the power curve of the blade, and also has an impact on the rigidity of the blade. SUMMARY
[0005] To solve the technical problem that the shape of the trailing edge corner of the suction surface of the wind turbine blade is too sharp and prone to ply gaps and rich resin between the plies, the present application provides a wind turbine blade design method for preventing ply gaps, and a wind turbine blade.
[0006] The technical scheme of the wind turbine blade design method for preventing ply gaps in the present application is as follows: A wind turbine blade design method for preventing ply gaps, comprising the following steps: S1, the inclined angle of the corner side of the suction surface rear edge vertical surface core material is removed according to the equal width, the inclined angle of the corner side of the large surface core material of the suction surface is removed according to the equal width, and a groove-shaped hollow with a fixed width is formed at the corner of the suction surface rear edge; S2, the groove core material is designed and manufactured according to the shape of the groove-shaped hollow, the outer surface of the groove core material is attached to the mold, the value of the inner surface round angle of the groove core material is greater than the value of the outer surface round angle, the thickness of the splicing position of the groove core material and the corner side of the suction surface rear edge vertical surface core material is equal, and the thickness of the splicing position of the groove core material and the corner side of the large surface core material of the suction surface is equal; S3, the glass fiber cloth is laid in the mold in which the large surface core material of the suction surface, the groove core material and the suction surface rear edge vertical surface core material are laid.
[0007] As a preferred implementation manner of the wind power blade design method for preventing the cloth layer from being hollowed out, the step S2 of designing and manufacturing the groove core material according to the shape of the groove-shaped hollow comprises the following steps: The groove-shaped hollow is marked every one meter from the root section starting from the corner of the rear suction surface rear edge to the corner of the tip section ending at the corner of the suction surface, and the width size of each marked position is recorded. The model data of the rear edge corner is output from the 3D model of the wind power blade, and the outer shape size of the groove-shaped hollow position is cut from the model data of the rear edge corner in combination with the width size of the marked position. Based on the outer shape size of the groove-shaped hollow position, the value of the inner surface round angle is enlarged, and the groove core material is manufactured based on the outer shape size of the enlarged groove-shaped hollow position.
[0008] As a preferred implementation manner of the wind power blade design method for preventing the cloth layer from being hollowed out, the value of the outer surface round angle of the groove core material is 20-40 mm, and the value of the outer surface round angle is greater than 40 mm.
[0009] As a preferred implementation manner of the wind power blade design method for preventing the cloth layer from being hollowed out, when the large surface core material of the suction surface, the groove core material and the suction surface rear edge vertical surface core material are laid, they are laid in the order of the large surface core material of the suction surface, the groove core material and the suction surface rear edge vertical surface core material.
[0010] As a preferred implementation manner of the wind power blade design method for preventing the cloth layer from being hollowed out, when the groove core material is manufactured, the back-sticking grid cloth is pasted on the inner surface of the groove core material.
[0011] As a preferred implementation manner of the wind power blade design method for preventing the cloth layer from being hollowed out, when the large surface core material of the suction surface, the groove core material and the suction surface rear edge vertical surface core material are laid, if a protruding step appears at the splicing position of the groove core material and the large surface core material of the suction surface and / or the suction surface rear edge vertical surface core material, the groove core material is pressed.
[0012] As a preferred implementation manner of the wind power blade design method of the gap of the protective cloth layer, the chamfer angle of the corner side of the suction surface rear edge vertical surface core material is removed according to the equal width in step S1, and after the chamfer angle of the corner side of the suction surface large surface core material is removed according to the equal width, the included angle between the corner side of the suction surface rear edge vertical surface core material and the inner surface of the mold and the included angle between the corner side of the suction surface large surface core material and the inner surface of the mold are between 90°-100°.
[0013] The technical scheme of the wind power blade in the application is as follows: A wind power blade is prepared by using the wind power blade design method of the gap of the protective cloth layer.
[0014] The beneficial effects of the application include: The application enlarges the fillet value of the corner of the suction surface rear edge by the groove core material, so that the inner surface of the corner position after the groove core material is laid is smoothly transitioned, thereby making the laying of the glass fiber cloth easier and more adherent, and the problem of the rich resin of the corner of the suction surface rear edge can be completely solved. BRIEF DESCRIPTION OF DRAWINGS
[0015] In order to more clearly illustrate the technical scheme of the application, the drawings required to be used in the description will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.
[0016] Figure 1 It is a schematic diagram of the rich resin state of the corner of the suction surface rear edge at the present stage; Figure 2 It is a schematic diagram of the corner structure of the suction surface rear edge after the corner side core material chamfer angle of the suction surface rear edge vertical surface core material and the suction surface large surface core material is removed in the specific embodiment of the application; Figure 3 It is a schematic diagram of the corner structure of the suction surface rear edge after the suction surface rear edge vertical surface core material, the groove core material and the suction surface large surface core material are laid; Figure 4 It is a schematic diagram of the corner structure of the suction surface rear edge after the glass fiber cloth layer on the core material is laid; Figure 5 It is a local enlarged schematic diagram of the corner structure of the suction surface rear edge after the glass fiber cloth layer on the core material is laid.
[0017] List of components and reference numerals: 1, glass fiber cloth layer on the core material; 2, rich resin; 3, suction surface rear edge vertical surface core material; 4, suction surface large surface core material; 5, groove core material. DETAILED DESCRIPTION
[0018] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0019] Reference Figure 1 The principle behind the current problem of fabric gaps appearing at the rear edge corner of the suction surface is as follows: The corner radius of the suction surface is too low, resulting in an overly abrupt change in shape. The fiberglass cloth itself has a certain degree of rigidity, and the triaxial fiberglass used in this area is even harder than biaxial fiberglass fabric. This makes it easier for the layers to overlap at the corner, leading to resin accumulation between the fabric layers. Secondly, the angled core material on both the corner side of the trailing edge and the corner side of the suction surface in the wind turbine blade structure design further exacerbates the shape change at the corner. This makes the gaps between the fiberglass cloth layers on the upper core material more pronounced compared to the lower core material, resulting in a more severe resin accumulation problem.
[0020] This embodiment first discloses a wind turbine blade design method to prevent the fabric layer from being exposed, including the following steps: S1. Reference Figure 2 The beveled angle on the corner side of the suction surface rear edge core material 3 is removed with equal width, and the beveled angle on the corner side of the suction surface large surface core material 4 is removed with equal width, thus forming Figure 2 The suction surface shown has a fixed-width groove-shaped cutout at the rear edge corner. In this embodiment, after removing the beveled angle of the corner side of the suction surface core material 4 according to the same width, the included angle between the corner side of the suction surface rear edge vertical core material 3 and the inner surface of the mold, and the included angle between the corner side of the suction surface core material 4 and the inner surface of the mold are between 90° and 100°.
[0021] S2. Based on the shape of the grooved hollow, design and manufacture the grooved core material 5. First, based on the grooved hollow from the blade root section starting from the rear edge corner of the suction surface to the blade tip section ending at the rear edge corner of the suction surface, mark every meter from the blade root to the blade tip and record the width dimension of each marked position. Then, the trailing edge corner model data is output from the 3D model of the wind turbine blade, and the outer dimensions of the groove-shaped hollow position are extracted from the trailing edge corner model data by combining the width dimensions of the marked position. Based on the external dimensions of the groove-shaped hollowed-out area, the radius of the inner surface is enlarged. The groove core material 5 is then fabricated based on the enlarged external dimensions of the groove-shaped hollowed-out area, referring to... Figure 3Finally, the outer surface of the groove core material 5 is made to conform to the mold, the inner surface of the groove core material 5 is rounded with a value greater than the value of the outer surface rounding, the profile change of the inner surface of the suction surface rear edge corner is slowed down, for example, the outer surface rounding value of the groove core material 5 is 20-40mm, and the outer surface rounding value is greater than 40mm. When the groove core material 5 is processed and manufactured, the thickness of the splicing position of the groove core material 5 and the corner side of the suction surface rear edge vertical core material 3 is equal, the thickness of the splicing position of the groove core material 5 and the corner side of the suction surface large area core material 4 is equal, so that the groove core material 5 on both sides is smoothly transitioned. In this embodiment, the processing method for manufacturing the groove core material 5 is consistent with the suction surface large area core material 4, and the back adhesive glass cloth is pasted on the inner surface of the groove core material 5.
[0022] S3, refer to Figure 4 and Figure 5 In the mold laid with the suction surface large area core material 4, the groove core material 5, and the suction surface rear edge vertical core material 3, the inner surface of the corner position after laying the groove core material 5 is smoothly transitioned, so that the glass cloth is laid more easily and closely, and the problem of rich resin 2 at the suction surface rear edge corner can be completely solved. In this embodiment, when the suction surface large area core material 4, the groove core material 5, and the suction surface rear edge vertical core material 3 are laid, they are laid in the order of the suction surface large area core material 4, the groove core material 5, and the suction surface rear edge vertical core material 3. If there is a protruding step at the splicing position of the groove core material 5 and the suction surface large area core material 4 and / or the suction surface rear edge vertical core material 3, it indicates that there is a gap in the glass cloth under the groove core material 5, which can be corrected and prevented by pressing the groove core material 5 and the like. At the same time, whether there is a protruding step at the splicing position of the groove core material 5 and the suction surface large area core material 4 and / or the suction surface rear edge vertical core material 3 can also be used as one of the standards for checking whether there is a gap in the glass cloth under the groove core material 5.
[0023] In a more detailed embodiment, the wind turbine blade design method for preventing the fabric layer from being empty in this embodiment is as follows: The core material of the suction surface trailing edge corner is normally laid in the blade production process. The core material of the suction surface trailing edge is chamfered back to the trailing edge side, and the core material near the trailing edge corner is removed. The core material of the suction surface large surface is removed at an angle from the trailing edge corner side. The chamfered width of the core material removed on both sides of the trailing edge corner must be uniform, to ensure that the core material of the trailing edge vertical surface is uniform from the trailing edge corner, and to ensure that the core material of the trailing edge corner of the suction surface large surface is uniform from the trailing edge corner. Thus, the core material on both sides of the trailing edge corner presents a flat and equal-width concave groove from the trailing edge starting position of the blade root section to the trailing edge end position of the maximum chord length of the blade. Then, the core material of the concave groove from the trailing edge corner starting position of the blade root section to the trailing edge corner end position of the blade tip section is uniformly numbered and the width change size is recorded in detail every meter from the blade root to the blade tip. The trailing edge corner model data is output from the 3D model of the blade, and the width size information of the marked position can be directly extracted from the model to obtain the shape size of the filling core material of the corner concave groove position. The final thickness of the core material at both ends of the concave groove is equal to the thickness of the trailing edge vertical surface side and the large surface near the suction surface corner, to ensure that the core material is laid smoothly in the chord direction. However, when the concave groove core material 5 is actually processed, the lower surface of the concave groove core material 5 is consistent with the aerodynamic model data extracted, that is, the original design R20-40mm, but the thickness of the overall concave groove core material 5 can be increased, the corner radius of the inner surface of the concave groove core material 5 is designed to be greater than R40mm, and the thickness of the core material on both sides of the concave groove core material 5 is equal to the thickness of the core material on both sides. In addition, the core material is pasted with a grid cloth on the large circular arc corner surface of the concave groove core material 5, and the pre-cutting processing method of the core material is consistent with that of the core material plate. During the laying process, the core material 4 of the large surface of the suction surface is laid first, then the concave groove core material 5 of the corner of the suction surface is laid, and finally the trailing edge vertical surface core material is laid. After the core material is laid, the concave groove core material 5 can be effectively improved by pressing the core material under the glass fiber cloth layer, and it can also be used for reverse inspection. If the concave groove core material 5 is convex in the chord direction, it indicates that the core material under the glass fiber cloth layer is seriously hollowed out at the trailing edge corner, and timely discovery and timely remedy can be achieved. The upper surface of the core material is laid, the corner radius of the core material is increased, the profile at the corner is flattened, and the glass fiber cloth layer 1 on the upper surface of the core material is easily flat and real at the trailing edge corner. Thus, the problem of internal rich resin 2 at the trailing edge corner can be completely avoided during the forming process of the blade shell.
[0024] Figures 1-4 The outer contour in each of FIGS. 1A-1C is the shape of a cross section of a portion of a wind turbine blade having a corner structure. In the production of a wind turbine blade, two half shells of the wind turbine blade, i.e., a pressure surface half shell and a suction surface half shell, are usually produced first, and then the two half shells are bonded and molded to complete the main body of the wind turbine blade. In the present embodiment, the suction surface is located in the lower half shell portion of the wind turbine blade. Figures 1-4
[0025] The embodiment is very effective in controlling the resin-rich 2 between the lower cloth layers of the trailing edge corner core material, the upper and lower interfaces of the core material layer, and the resin-rich 2 between the upper cloth layers of the core material. In particular, the resin-rich 2 at the upper and lower interfaces of the core material and between the upper cloth layers of the core material can be significantly controlled during the production and manufacturing of wind turbine blades.
[0026] The embodiment also discloses a wind turbine blade prepared by the above-mentioned wind turbine blade design method of preventing cloth layer gaps.
[0027] The above description of disclosed embodiments enables those skilled in the art to carry out or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to these embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A design method for wind turbine blades to prevent fabric layer gaps, characterized in that, Includes the following steps: S1. Remove the beveled corner of the rear edge vertical core material (3) of the suction surface according to the same width, and remove the beveled corner of the large surface core material (4) of the suction surface according to the same width, forming a groove-shaped hollow with a fixed width at the rear edge corner of the suction surface. S2. Based on the shape of the grooved hollow, the grooved core material (5) is designed and manufactured. The outer surface of the grooved core material (5) is fitted with the mold. The value of the inner surface radius of the grooved core material (5) is greater than the value of the outer surface radius. The thickness of the grooved core material (5) and the corner of the suction surface rear edge vertical core material (3) are equal. The thickness of the grooved core material (5) and the corner of the suction surface large surface core material (4) are equal. S3. Fiberglass cloth is laid in the mold containing the suction surface core material (4), the groove core material (5), and the suction surface rear edge vertical core material (3).
2. The method of designing a wind turbine blade with a voided fibre cloth layer according to claim 1, wherein, Step S2 involves designing and manufacturing the grooved core material (5) according to the shape of the grooved hollow, which includes the following steps: Based on the groove-shaped cutout at the corner of the blade root segment starting from the trailing edge corner of the suction surface and ending at the corner of the blade tip segment, the width dimension of each marked position is recorded every meter from the blade root to the blade tip. Output the trailing edge corner model data from the 3D model of the wind turbine blade, and extract the outer dimensions of the groove-shaped hollow position from the trailing edge corner model data by combining the width dimensions of the marked position. Based on the external dimensions of the groove-shaped hollow position, the value of the inner surface radius is enlarged, and the groove core material is made based on the enlarged external dimensions of the groove-shaped hollow position (5).
3. The method of designing a wind turbine blade with a voided fibre cloth layer according to claim 1, wherein, The outer surface radius of the groove core material (5) is 20-40mm, and the outer surface radius is greater than 40mm.
4. The method of designing a wind turbine blade with a voided fibre- reinforced layer according to claim 1, wherein When laying the suction surface core material (4), groove core material (5), and suction surface rear edge vertical core material (3), lay them in the order of suction surface core material (4), groove core material (5), and suction surface rear edge vertical core material (3).
5. The method of designing a wind turbine blade with a voided fibre cloth layer according to claim 1, wherein, When making the grooved core material (5), the backing mesh cloth is pasted on the inner surface of the grooved core material (5).
6. The method of designing a wind turbine blade with a voided fibre cloth layer according to claim 1, wherein, When laying the suction surface core material (4), the groove core material (5), and the suction surface rear edge vertical core material (3), if a raised step appears at the splicing position of the groove core material (5) and the suction surface core material (4) and / or the suction surface rear edge vertical core material (3), then the groove core material (5) shall be pressurized.
7. The method of designing a wind turbine blade with a voided fibre cloth layer according to claim 1, wherein, In step S1, the angle of the corner of the suction surface rear edge vertical core material (3) is removed according to the equal width, and the angle of the corner of the suction surface large surface core material (4) is removed according to the equal width. After that, the angle between the corner of the suction surface rear edge vertical core material (3) and the inner surface of the mold, and the angle between the corner of the suction surface large surface core material (4) and the inner surface of the mold are between 90° and 100°.
8. A wind turbine blade, characterised in that The wind turbine blade is prepared using the design method for preventing the fabric layer from being slack, as described in any one of claims 1-7.