Method for improving interlaminar defects in a pultruded spar for a wind turbine blade and pultruded spar

Abstract

This invention provides a method for improving interlayer defects in pultruded main beams of wind turbine blades and the resulting pultruded main beam. The method includes an improved process (1): when laying the pultruded main beam, the side guards of the tensioning fixture are removed first, and then it is hoisted and laid. The method of this invention for improving interlayer defects in pultruded main beams of wind turbine blades significantly reduces the number of interlayer defects in the blade pultruded main beam by optimizing the layout of the guiding auxiliary materials and optimizing the timing and method of injection. At the same time, it does not cause significant changes or other problems to the injection whitening quality defects, injection resin dosage, total injection time, blade mass distance, production efficiency, etc.

Description

Technical Field

[0001] This invention belongs to the field of wind turbine blade manufacturing, specifically relating to a method for improving interlayer defects in pultruded main beams of wind turbine blades and pultruded main beams. Background Technology

[0002] The pultruded main beam of a wind turbine blade is usually composed of multiple pultruded plates. These multiple pultruded plates are arranged in a certain direction to form a pultruded plate layer, which in turn constitutes the main beam structure. The pultruded sheet is a composite material sheet formed by pre-impregnating and pultruding uniaxial yarn and epoxy resin in a specific mold and then heating and curing it. The pultruded main beam is composed of multiple layers of the pultruded sheet stacked together. During the design phase, a layer of biaxial fabric is laid between the layers. However, this brings significant adjustments to the blade infusion process. The number of pultruded sheet layers is typically between 5 and 10, with 2 to 6 sheets assembled side-by-side in the width direction. The infusion process is complex, and the resin direction is variable. Furthermore, the pultruded main beam assembly has poor stability, often resulting in misalignment, crossing, and large gaps. Therefore, the infusion of the pultruded main beam into the blade is extremely difficult. During wind turbine blade manufacturing, factors such as production processes or personnel operation frequently lead to defects affecting the structural strength, such as poor wetting of the interlayer fabric, dry yarn, and air bubbles, posing a threat to the safe and stable operation of the wind turbine. As a key component in the blade's load-bearing structure, the quality of the pultruded main beam directly affects the overall performance and service life of the blade. Therefore, reducing the number of interlayer defects in the pultruded main beam during the blade manufacturing stage is a crucial step in ensuring the safe and stable operation of the wind turbine.

[0003] The current industry standard for grouting the pultruded main beam area of ​​wind turbine blades involves laying the main beam underlayer, the main beam continuous felt, the pultruded main beam, the shell core material, the guide net, and the glue injection pipeline sequentially on the main mold during blade shell layering. After laying, a vacuum is established. During the installation of the pultruded main beam, the tooling is removed sequentially. When grouting the pultruded main beam area, the resin is preferentially injected through the injection line located at the rear edge. It impregnates the upper surface of the pultruded main beam along the guide net towards the front edge, and the lower surface along the continuous felt under the main beam towards the front edge. Between the layers of the pultruded main beam, the resin impregnates the interlayer fiberglass cloth through the gaps between the pultruded plates. Because the flow velocity of the resin on the continuous felt and guide net is much greater than the flow velocity on the interlayer fiberglass cloth of the pultruded plates, the resin on the upper and lower surfaces of the pultruded main beam will first flow into the pultruded plate joint. At this time, the fiberglass cloth on the side of the pultruded plate gap facing the rear edge of the blade has not yet been completely impregnated with resin. The resin at the pultruded plate gap surrounds the interlayer fiberglass cloth at the rear edge of the pultruded plate, forming a grouting defect. Figure 5 As shown. There is currently no repair method for this defect, and its impact on the blades has not been verified by wind farms. The risk of interlayer failure of the pultruded main beam is relatively high, which reduces the operational stability of the wind turbine blades.

[0004] Interlayer defects in pultruded main beams have long been a major problem plaguing the blade industry, and no systematic and effective solution has yet been found. Existing processes offer limited improvement in addressing interlayer defects in pultruded main beams for wind turbine blades, and cannot guarantee the safe and stable operation of wind turbine units. Summary of the Invention

[0005] The first objective of this invention is to provide a method for improving interlayer defects in the pultruded main beam of wind turbine blades, which can reduce the number of interlayer defects in the pultruded main beam and improve the blade forming quality.

[0006] The second objective of this invention is to provide a pultruded main beam obtained using the aforementioned method.

[0007] To achieve the first objective of this invention, the following technical solution is adopted:

[0008] A method for improving interlayer defects in pultruded main beams of wind turbine blades includes improving the process (1), whereby the side guards of the tensioning fixture are removed before the pultruded main beam is laid, and then it is hoisted and laid.

[0009] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, in the improved process (1), when the pultruded main beam is hoisted and laid, the tensioning fixture is removed after the pultruded main beam is hoisted to the shell mold.

[0010] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, in the improved process (1), the order of removing the tensioning fixtures is as follows: first, remove the tensioning fixtures between the blade root and the blade tip, and then remove the tensioning fixtures at the blade root and blade tip positions.

[0011] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, in the improved process (1), the order of removing the tensioning fixtures is as follows: the tensioning fixtures from the blade root to the blade tip are removed intermittently, while the tensioning fixtures at the blade root and blade tip are retained during the process; after the intermittent removal is completed, the tensioning fixtures at the blade root and blade tip are removed.

[0012] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, the method further includes an improved process (2): after the core material is laid, the shell mold is preheated.

[0013] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, in the improved process (2), after the second layer of vacuum bag film is tightened, an insulation layer is covered above the area of ​​the pultruded main beam.

[0014] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, the method further includes an improved process (3): when laying the auxiliary material, the guide net on the front edge of the pultruded main beam is disconnected in the chord direction, and VAP suction bags are covered at the disconnection position and the area on both sides thereon, so that one side of the VAP suction bag overlaps with the guide net side and the other side overlaps with the core material side.

[0015] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, in the improved process (3), the disconnection position of the guide net is located on the pultruded main beam at a position from the blade root to the blade tip, between L11.7m and L72m.

[0016] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, in the improved process (3), the guide net is broken by 150±10mm on the pultruded main beam in the chord direction and by 30±10mm on the core material side.

[0017] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, the method further includes an improved process (4), which increases the pumping force during the vacuum injection process of the shell mold.

[0018] The present invention relates to a method for improving interlayer defects in the pultruded main beam of wind turbine blades, wherein preferably, the extraction force is increased to a total extraction volume ≥ 1400 m³. 3 / h.

[0019] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, the method further includes an improved process (5). First, the arrangement of the injection pipelines on the PS and SS surfaces of the wind turbine blades is adjusted, including any one or more of the following: injection port arrangement, injection pipe disconnection position, injection pipe disconnection length, and injection pipe chordal distance from the edge. Then, any one or more of the following are adjusted: opening sequence, opening timing, and opening method of the injection valves at each injection port.

[0020] The present invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. Preferably, the method for opening the glue injection valve is as follows: first open 1 / 3 to 1 / 2, wait 10 to 30 minutes, and then fully open it.

[0021] To achieve the second objective of the present invention, a pultruded main beam obtained according to the foregoing method is also provided.

[0022] The beneficial effects of this invention are as follows:

[0023] This invention provides a method for improving interlayer defects in the pultruded main beam of wind turbine blades. By optimizing the layout of the flow guiding auxiliary materials and adjusting the timing and method of injection, the number of interlayer defects in the pultruded main beam of the blade is significantly reduced. At the same time, it does not cause significant changes or other problems to the injection whitening quality defects, the amount of injection resin, the total injection time, the blade mass distance, or the production efficiency.

[0024] Its advanced nature is reflected in the multiple optimization measures for interlayer defects in pultruded main beams. After actual production verification, it has significantly reduced the number of defects, and the number of defects per blade can be controlled to within 5, showing obvious advantages and significantly improving the stability of blade product quality. It effectively reduces the interlayer defect problem of pultruded main beams that is common in the original process, avoids a lot of repairs for defects in the later stage, and improves production efficiency. Moreover, it has not caused significant changes or other problems to the quality defects of blade injection whitening, injection resin dosage, total injection time, blade mass distance, and production efficiency, further proving the stability and high reliability of this solution. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the chordal cross-section of the pultruded main beam in one embodiment of the method for improving interlayer defects in the pultruded main beam of wind turbine blades according to the present invention.

[0026] Figure 2 yes Figure 1 Schematic diagram of the hoisting structure of the pultruded main beam;

[0027] Figure 3 yes Figure 1 Inner axial view of the PS and SS surfaces of the injection system - regarding the arrangement of the flow guide net, insulation layer, and VAP extraction bag;

[0028] Figure 4 yes Figure 1 Inner axial view of the PS and SS surfaces of the injection system - regarding the injection piping layout;

[0029] Figure 5 This is a schematic diagram illustrating the formation of injection defects at the gaps in pultruded plates in existing technology. Among them,

[0030] Figure 1-3 In the middle section, the shell mold is 1; the lower layer of the pultruded main beam is 2; the continuous felt is 3; the pultruded plate is 4; the interlayer fabric of the pultruded main beam is 5; the core material is 6; the upper layer of the pultruded main beam is 7; the release fabric is 8; the guide net is 9; the VAP vacuum bag is 10; the injection tube is 11; the pultruded main beam is 12; the tensioning fixture is 13; the lifting strap is 14; the lifting fixture is 15; and the observation port is 16.

[0031] Figure 4In the diagram, ring 1 represents the circumferential glue injection tube; shaft 1, shaft 2 (leading edge auxiliary pipe), shaft 3 (main pipe), shaft 4, shaft 5, and shaft 6 represent the axial glue injection tubes. Detailed Implementation

[0032] The technical solution and its effects of the present invention will be further described below with reference to specific embodiments / examples and accompanying drawings. The following embodiments / examples are only for illustrating the content of the present invention, and the invention is not limited to the following embodiments or examples. Simple modifications made to the present invention based on the concept of the present invention are all within the scope of protection claimed by the present invention.

[0033] like Figure 1-5 As shown, the present invention provides a method for improving interlayer defects of pultruded main beams for wind turbine blades, including an improved process (1). When laying the pultruded main beam 12, the side guard of the tensioning fixture 13 is removed first, and then it is hoisted and laid.

[0034] Those skilled in the art understand that during the hoisting and laying of the pultruded main beam 12, the resin needs to follow a complex path during its flow, such as entering the gap from the main channel, flowing through the fiberglass cloth, and flowing along the guide fibers. Resistance or poor flow can occur along these paths, potentially leading to defects such as dry or semi-dry yarn. Previously, the tensioning fixture 13 used during the hoisting and laying of the pultruded main beam 12 had a retaining edge, resulting in tight, gapless splicing between the sheets after the pultruded main beam 12 was hoisted to the shell template. This hindered the smooth flow of resin in the tangential direction, leading to interlayer defects. This invention improves the process by removing the retaining edge of the tensioning fixture 13 during the laying of the pultruded main beam 12, optimizing the hoisting and laying process, ensuring smooth flow of resin between sheets and in the tangential direction, effectively reducing the probability of interlayer defects, and improving the quality stability of the pultruded main beam 12.

[0035] In a preferred embodiment, in the improved process (1), when the pultruded main beam 12 is hoisted and laid, after the pultruded main beam 12 is hoisted to the shell mold 1, the tensioning fixture 13 is removed, which helps to further ensure the gap between the plates and the smooth flow of resin in the tangential direction, reduce the probability of interlayer defects in the pultruded main beam, and improve the quality stability of the pultruded main beam 12.

[0036] In a preferred embodiment, in the improved process (1), the order of removing the tensioning fixture 13 is as follows: first remove the tensioning fixture 13 between the blade root and the blade tip, and then remove the tensioning fixture 13 at the blade root and blade tip positions. This ensures both the smooth flow of the plate gap and the tangential resin flow, and also prevents the plate from spreading out during the removal of the tensioning fixture 13.

[0037] In a preferred embodiment, in the improved process (1), the order of removing the tensioning fixtures 13 is as follows: the tensioning fixtures 13 from the blade root to the blade tip are removed intermittently, while retaining the tensioning fixtures 13 at the blade root and blade tip positions during the process; after the intermittent removal is completed, the tensioning fixtures 13 at the blade root and blade tip positions are removed; preferably, the interval is one. That is, the tensioning fixtures 13 from the blade root to the blade tip position are removed according to the rule of leaving one and removing one, and the tensioning fixtures 13 at the blade root and blade tip positions are retained until the last removal. This order of removing the tensioning fixtures 13 can further ensure both the smooth flow of the gap between the plates and the tangential resin flow, and can also prevent the plates from spreading out during the removal of the tensioning fixtures 13.

[0038] In one embodiment, the method further includes an improved process (2), in which the shell mold 1 is preheated after the core material is laid.

[0039] Those skilled in the art understand that, in the original process, preheating of the shell mold 1 was only initiated before injection (using a mold temperature controller), resulting in insufficient preheating of the pultruded main beam area during injection, leading to inconsistent temperatures on the upper and lower surfaces. Consequently, the resin flow was uneven and insufficient, resulting in interlayer defects in the pultruded main beam. This invention, through process improvement (2), initiates preheating of the shell mold 1 immediately after the core material is laid. This helps ensure consistent temperatures on the upper and lower surfaces of the pultruded main beam area, improves the uniformity and sufficiency of resin flow, further enhances injection quality, and reduces interlayer defects in the pultruded main beam.

[0040] In one embodiment, in the improved process (2), after the second vacuum bag film is tightened, an insulation layer is covered above the area of ​​the pultruded main beam 12, thereby further improving the consistency of the upper and lower surface temperatures of the pultruded main beam area, improving the uniformity and sufficiency of resin flow, further improving the injection quality, and reducing the generation of interlayer defects in the pultruded main beam.

[0041] In one embodiment, the method further includes an improved process (3): when laying the auxiliary material, the guide net on the front edge of the pultruded main beam is disconnected in the chord direction, and VAP vacuum bags 10 are covered at the disconnection position and the area on both sides thereon, so that one side of the VAP vacuum bag 10 overlaps with the guide net side and the other side overlaps with the core material side.

[0042] Those skilled in the art understand that, during the arrangement of auxiliary materials, the original process involved laying a guide net across the entire pultruded main beam area, using a sealing strip at the leading edge to slow down the resin flow rate. The resin on the upper surface of the pultruded main beam flowed tangentially from the rear edge to the front edge through the guide net, while the interlayer resin flowed in the same direction through the interlayer biaxial guide cloth. Because the guide net on the upper surface served as a guiding medium, the injection speed was relatively faster than the interlayer resin flow speed. After the resin on the upper surface flowed to the leading edge of the main beam, it flowed to the rear edge through the interlayer guide cloth, ultimately creating a defect between the resin flowing through the original interlayer guide cloth. This invention improves process (3) by disconnecting the guide net at the front edge of the pultruded main beam in the chord direction during auxiliary material laying, thereby controlling the resin flow velocity difference between the upper and lower surfaces, slowing down the resin flow velocity on the upper surface, reducing the resin flow velocity difference between the upper and lower surfaces, and thus improving the uniformity and sufficiency of resin flow; and by covering the disconnected position of the guide net and the area on both sides of it with VAP vacuum bags 10, and making one side of the VAP vacuum bag 10 overlap with the guide net side and the other side overlap with the core material side, air is extracted from this area (the area covered by the VAP vacuum bag) to generate negative pressure. Using this negative pressure, the resin is drawn into the fiber layer through the pipeline, ensuring that the interlayer fabric of the pultruded main beam is fully impregnated with resin, reducing the risk of defects.

[0043] In one embodiment, in the improved process (3), the VAP vacuum bag 10 overlaps with both the guide net side and the core material side by 30±10mm.

[0044] In one embodiment, in the improved process (3), the VAP vacuum bag 10 is provided with observation ports 16 at intervals along the axial direction; preferably at intervals of 30 to 50 mm, such as 30 mm, 40 mm and 50 mm and any value and range within this range.

[0045] Those skilled in the art will understand that if the VAP extraction bag 10 is long enough to fully cover its area, then observation ports 16 can be set at intervals on it; if the VAP extraction bag 10 is short, with a length of 10±1m, then multiple VAP extraction bags 10 can be set at intervals along the axial direction, with the interval positions serving as observation ports 16.

[0046] Those skilled in the art will understand that the VAP vacuum bag 10 is a conventional VAP vacuum bag, for example, with a width of 300±30mm.

[0047] In one embodiment, in the improved process (3), the break point of the guide net is located on the pultruded main beam 12 at a distance of L11.7m to L72m from the blade root to the blade tip. That is, on the axial direction of the pultruded main beam 12 from the blade root to the blade tip, the starting point of the break point of the guide net is 11.7m and 72m away from the blade root, respectively. Those skilled in the art will understand that, on the axial direction, the blade root position of the pultruded main beam 12 is L0m, L11.7m refers to a position 1.7m away from the blade root, and L72m refers to a position 72m away from the blade root.

[0048] In one embodiment, in the improved process (3), the guide net is broken by 150±10mm on the pultruded main beam 12 in the chord direction and broken by 30±10mm on the core material side.

[0049] In one embodiment, the method further includes an improved process (4), wherein an additional suction device is added to the suction system to increase the suction force during the vacuum injection process of the shell mold 1; preferably, the suction force is increased to a total suction volume ≥ 1400m³. 3 / h.

[0050] Those skilled in the art will understand that, in this invention, the pumping device can be a vacuum pump.

[0051] Those skilled in the art will understand that, generally speaking, after interlayer flow occurs, the fiberglass cloth can reduce defect formation through capillary effect. However, if the suction volume of the suction system is insufficient during the injection process of the shell mold 1, this effect cannot be achieved. In the original process, the total suction volume of the suction system for the shell mold 1 was approximately 600 m³ / s. 3 The total pumping volume is too low (around / h), resulting in insufficient pumping force during injection and inability to fully drive resin flow, leading to interlayer defects in the pultruded main beam. This invention improves the process (4) by adding pumping equipment (such as a vacuum pump) to the pumping system, thereby increasing the pumping force of the pumping system to a total pumping volume ≥1400m³ during vacuum injection of the shell mold 1. 3 / h, ensuring that the resin flows fully and evenly during injection, reducing interlayer defects in the pultruded main beam.

[0052] In one embodiment, the method further includes improving the process (5). First, the arrangement of the injection pipelines on the PS and SS surfaces of the wind turbine blades is adjusted, including the arrangement of the injection ports, the disconnection position of the injection pipe, the disconnection length of the injection pipe, and the chordal distance of the injection pipe from the edge, or any one or more of these. Then, the opening sequence, opening timing, and opening method of the injection valves at each injection port are adjusted.

[0053] In one embodiment, the improved process (5) includes adjusting the position of the injection port and / or increasing the number of injection ports.

[0054] In one embodiment, the adjustment of the discontinuation position of the glue injection tube in the improved process (5) includes moving the discontinuation position of the glue injection tube along the direction from the leaf root to the leaf tip toward the nearest glue injection port, preferably moving it to a distance of 100±10m from the glue injection port.

[0055] In one embodiment, the adjustment of the dispensing tube disconnection length in the improved process (5) includes increasing the dispensing tube disconnection length.

[0056] In one embodiment, the adjustment of the chordal distance of the dispensing tube from the edge in the improved process (5) includes increasing or decreasing the chordal distance of the dispensing tube from the edge.

[0057] In one embodiment, in the improved process (5), the opening sequence of the glue injection valves at each glue injection port is as follows: first open the glue injection valve of the main pipeline, and then open the glue injection valve of the leading edge auxiliary pipeline.

[0058] In one embodiment, in the improved process (5), each glue injection valve of the main pipeline is opened sequentially at intervals from the blade root to the blade tip, preferably at intervals of 10-20 minutes.

[0059] In one embodiment, in the improved process (5), each injection valve of the leading edge sub-pipe is opened according to the distance of the adhesive liquid through the leading edge sub-pipe.

[0060] The opening times of the various injection valves on the leading edge secondary pipeline are independent of each other, and are only related to the distance the adhesive travels through the leading edge secondary pipeline at the corresponding position. For example, as shown in Table 1. For the leading edge secondary pipeline on the PS surface, injection valve 2-1 is opened only when the distance the adhesive travels through the leading edge secondary pipeline at the corresponding injection valve reaches 50cm. The same applies to the injection valves on other surfaces.

[0061] In one embodiment, in the improved process (5), the glue injection valves on the main pipeline of the PS surface are opened sequentially from the blade root to the blade tip; and / or, on the SS surface, the second glue injection valve on the main pipeline from the blade root to the blade tip is opened first, and the first glue injection valve from the blade root to the blade tip is opened after an interval of 20-40 minutes, and then the third glue injection valve to the last valve are opened sequentially from the blade root to the blade tip.

[0062] In one embodiment, the improved process (5) involves opening the glue injection valve as follows: first open it 1 / 3 to 1 / 2, wait 10 to 30 minutes, and then fully open it. The specific opening method for each step, including the opening degree and waiting time, can be adjusted within this range as needed.

[0063] The following uses the fabrication of a 95m wind turbine blade as an example to illustrate the arrangement of the injection pipelines for the PS and SS surfaces of the wind turbine blade in the improved process (5). Figure 4 As shown.

[0064] On the original wind turbine blade PS surface:

[0065] Leading-edge auxiliary pipeline: The glue injection pipe of the leading-edge side shaft 2 of the pultruded main beam is located at 2800-56000mm in the axial direction, and its distance from the leading edge of the pultruded main beam in the chord direction is 80-100mm; and the axial positions of 11500-11700mm, 19500-19700mm, 31500-31700mm, and 47500-47700mm are the glue injection pipe disconnection areas; glue injection port 2-1 is at 3200mm in the axial direction, glue injection port 2-2 is at 12000mm in the axial direction, glue injection port 2-3 is at 20000mm in the axial direction, glue injection port 2-4 is at 32000mm in the axial direction, and glue injection port 2-5 is at 48000mm in the axial direction;

[0066] Main pipeline: The adhesive injection pipes on the rear edge side shaft 3 of the pultruded main beam are located at axial positions from 1500 to 94500 mm. Specifically, at axial positions from 1500 to 85000 mm, the chord-direction distance from the rear edge of the pultruded main beam is 100 mm; at axial position 86000 mm, the chord-direction distance is 400 mm; at axial position 90000 mm, the chord-direction distance is 300 mm; and at axial position 93000 mm, the chord-direction distance is 100 mm. The adhesive injection pipes are laid according to their dimensions; and at axial position 11500 mm... The areas at ~11700mm, 31500~31700mm, 47500~47700mm, 59500~59700mm, and 71500~71700mm are the areas where the glue injection tube is disconnected; glue injection port 3-1 is at 2000mm in the axial direction, glue injection port 3-2 is at 12000mm in the axial direction, glue injection port 3-3 is at 20000mm in the axial direction, glue injection port 3-4 is at 32000mm in the axial direction, glue injection port 3-5 is at 48000mm in the axial direction, glue injection port 3-6 is at 60000mm in the axial direction, and glue injection port 3-7 is at 72000mm in the axial direction.

[0067] On the improved PS surface of the wind turbine blade:

[0068] Leading-edge auxiliary pipeline: The glue injection pipe of the leading-edge side shaft 2 of the pultruded main beam is located at 2800-56000mm in the axial direction, and its distance from the leading edge of the pultruded main beam in the chord direction is 80-100mm; and the axial positions of 11700-19000mm, 19700-19900mm, 31700-31900mm, and 47700-47900mm are the glue injection pipe disconnection areas; glue injection port 2-1 is at 3200mm in the axial direction, glue injection port 2-2 is at 12000mm in the axial direction, glue injection port 2-3 is at 20000mm in the axial direction, glue injection port 2-4 is at 32000mm in the axial direction, and glue injection port 2-5 is at 48000mm in the axial direction;

[0069] The improvement over the original is that the axial positions of 11700~19000mm, 19700~19900mm, 31700~31900mm, and 47700~47900mm are the discontinuation areas of the glue injection tube; the improvement lies in the adjustment of the discontinuation position of the glue injection tube.

[0070] Main pipeline: The adhesive injection pipes on the rear edge side shaft 3 of the pultruded main beam are located axially between 1500 and 94500 mm. Specifically, at 1500–85000 mm axially, the pipes are 100 mm from the rear edge of the pultruded main beam in the chordal direction; at 86000 mm axially, the pipes are 400 mm from the rear edge of the pultruded main beam in the chordal direction; at 90000 mm axially, the pipes are 300 mm from the rear edge of the pultruded main beam in the chordal direction; and at 93000 mm axially, the pipes are 100 mm from the rear edge of the pultruded main beam in the chordal direction. The adhesive injection pipes are laid according to their dimensions; and axially between 11800 and 11900 mm... The locations at m, 19800~19900mm, 31800~31900mm, 47800~47900mm, 59800~59000mm, and 71800~71900mm are the areas where the glue injection tube is disconnected; glue injection port 3-1 is at 2000mm in the axial direction, glue injection port 3-2 is at 12000mm in the axial direction, glue injection port 3-3 is at 20000mm in the axial direction, glue injection port 3-4 is at 32000mm in the axial direction, glue injection port 3-5 is at 48000mm in the axial direction, glue injection port 3-6 is at 60000mm in the axial direction, and glue injection port 3-7 is at 72000mm in the axial direction.

[0071] The improvement over the original is that the axial positions of 11800~11900mm, 19800~19900mm, 31800~31900mm, 47800~47900mm, 59800~59000mm, and 71800~71900mm are the areas where the glue injection tube is disconnected; the improvement also lies in the adjustment of the disconnection position and the disconnection length of the glue injection tube.

[0072] On the original wind turbine blade SS surface:

[0073] Leading-edge auxiliary pipeline: The glue injection pipe of the leading-edge side shaft 2 of the pultruded main beam is located at 2800-56000mm in the axial direction, and its distance from the leading edge of the pultruded main beam in the chord direction is 80-100mm; and the axial positions of 21500-21700mm and 37500-37700mm are the glue injection pipe disconnection areas; glue injection port 2-1 is at 3200mm in the axial direction, glue injection port 2-2 is at 12000mm in the axial direction, glue injection port 2-3 is at 22000mm in the axial direction, and glue injection port 2-4 is at 38000mm in the axial direction;

[0074] Main pipeline: The adhesive injection pipes on the rear edge side shaft 3 of the pultruded main beam are located at axial positions from 1500 to 94500 mm. Specifically, at axial positions from 1500 to 85000 mm, the chord-direction distance from the rear edge of the pultruded main beam is 100 mm; at axial position from 86000 mm, the chord-direction distance is 400 mm; at axial position from 90000 mm, the chord-direction distance is 300 mm; and at axial position from 93000 mm, the chord-direction distance is 100 mm. The adhesive injection pipes are laid according to their dimensions; and the axial distance is from 21500 to 21700 mm. The locations at m, 31500~31700mm, 42500~42700mm, 53500~53700mm, 67500~67700mm, and 77500~77700mm are the areas where the glue injection tube is disconnected; glue injection port 3-1 is at 2000mm axially, glue injection port 3-2 is at 12000mm axially, glue injection port 3-3 is at 22000mm axially, glue injection port 3-4 is at 32000mm axially, glue injection port 3-5 is at 43000mm axially, glue injection port 3-6 is at 54000mm axially, and glue injection port 3-7 is at 68000mm axially.

[0075] On the SS surface of the improved wind turbine blade:

[0076] Leading-edge auxiliary pipeline: The glue injection pipe of the leading-edge side shaft 2 of the pultruded main beam is located at 2800~28000mm, 3400~42500mm, and 48000~56000mm in the axial direction, and its distance from the leading edge of the pultruded main beam in the chord direction is 50~70mm; and the axial positions of 11700~11900mm and 21700~21900mm are the glue injection pipe disconnection areas; glue injection port 2-1 is at 3200mm in the axial direction, glue injection port 2-2 is at 12000mm in the axial direction, glue injection port 2-3 is at 22000mm in the axial direction, glue injection port 2-4 is at 38000mm in the axial direction, and glue injection port 2-5 is at 52000mm in the axial direction;

[0077] The improvements over the original are as follows: the glue injection tubes on the front edge side shaft 2 of the pultruded main beam are located at 2800-2800mm, 3400-42500mm, and 48000-56000mm in the axial direction, and their chordal distance from the front edge of the pultruded main beam is 50-70mm; and the glue injection tube disconnection areas are located at 11700-11900mm and 21700-21900mm in the axial direction; the newly added glue injection port 2-5 is located at 52000mm in the axial direction; the improvements are in the adjustment of the glue injection tube disconnection position, the glue injection port arrangement (new glue injection port), and the chordal distance of the glue injection tube from the edge;

[0078] Main pipeline: The adhesive injection pipes on the rear edge side shaft 3 of the pultruded main beam are located at axial positions of 1500–94500 mm. Specifically, at axial positions of 1500–85000 mm, the chord-direction distance from the rear edge of the pultruded main beam is 150 mm; at axial position of 86000 mm, the chord-direction distance is 400 mm; at axial position of 90000 mm, the chord-direction distance is 300 mm; and at axial position of 93000 mm, the chord-direction distance is 100 mm. The adhesive injection pipes are laid according to their dimensions. Furthermore, the axial positions at 2000–2100 mm, 21300–21400 mm, 27800–27900 mm, 34800–34900 mm, and 4280 mm are also specified. The areas at 0-42900mm, 51800-51900mm, 61800-61900mm, 71800-71900mm, and 81800-81900mm are the areas where the glue injection tube is disconnected; the glue injection port 3-1 is at 1700mm axially, the glue injection port 3-2 is at 12000mm axially, the glue injection port 3-3 is at 21500mm axially, the glue injection port 3-4 is at 28000mm axially, the glue injection port 3-5 is at 35000mm axially, the glue injection port 3-6 is at 43000mm axially, the glue injection port 3-7 is at 52000mm axially, the glue injection port 3-8 is at 62000mm axially, the glue injection port 3-9 is at 72000mm axially, and the glue injection port 3-10 is at 82000mm axially.

[0079] The improvement over the original is as follows: the injection tube on the rear edge side shaft 3 of the pultruded main beam is located axially at positions of 1500–94500 mm, specifically, at axial positions of 1500–85000 mm, it is 150 mm away from the rear edge of the pultruded main beam in the chord direction; and the axial positions at 2000–2100 mm, 21300–21400 mm, 27800–27900 mm, 34800–34900 mm, 42800–42900 mm, 51800–51900 mm, 61800–61900 mm, 71800–71900 mm, and 8180 mm... The 0-81900mm position is the discontinuation area of ​​the glue injection tube; glue injection port 3-3 is at 21500mm axially, glue injection port 3-4 is at 28000mm axially, glue injection port 3-5 is at 35000mm axially, glue injection port 3-6 is at 43000mm axially, glue injection port 3-7 is at 52000mm axially, glue injection port 3-8 is at 62000mm axially, glue injection port 3-9 is at 72000mm axially, and glue injection port 3-10 is at 82000mm axially; the improvement lies in the discontinuation position of the glue injection tube, the discontinuation length of the glue injection tube, the arrangement of the glue injection ports (adding glue injection ports), and the adjustment of the chordal distance of the glue injection tube from the edge.

[0080] The following uses the preparation of a 95m wind turbine blade as an example to explain the opening sequence and timing of the glue injection valves at each glue injection port in the improved process (5).

[0081] In the improved process (5), when vacuum injection is performed on the shell mold 1, after adjusting the injection pipeline arrangement of the PS surface and SS surface of the wind turbine blade, the opening sequence and opening time of the injection valve at each injection port are adjusted according to Table 1. In Table 1, main 1, main 2... main 7... main 10 refer to the injection valves on the main pipeline (shaft 3) in the direction from blade root to blade tip; 2-1, 2-2, 2-3, 2-4, 2-5 refer to the injection valves on the leading edge auxiliary pipeline (shaft 2) in the direction from blade root to blade tip.

[0082] Table 1. Opening sequence and timing of the glue injection valves at each injection port.

[0083]

[0084]

[0085] In this invention, during vacuum injection in the shell mold 1, the injection pipeline arrangement of the PS and SS surfaces of the blade is adjusted, as well as the opening sequence, opening timing and opening method of each injection valve are adjusted, thereby adjusting the injection scheme of the PS and SS surfaces of the wind turbine blade, so that the flow rate of the adhesive during vacuum injection is reduced and made as consistent as possible, thereby improving the uniformity and fullness of adhesive wetting.

[0086] The present invention also provides a pultruded main beam obtained according to the aforementioned method.

[0087] The present invention also provides a wind turbine blade obtained according to the aforementioned method.

[0088] This invention relates to a method for improving interlayer defects in the pultruded main beam of wind turbine blades. By optimizing the layout of the guiding auxiliary materials and adjusting the timing and method of injection, the number of interlayer defects in the pultruded main beam of the blade is significantly reduced. At the same time, it does not cause significant changes or other problems to the injection whitening quality defects, the amount of injection resin, the total injection time, the blade mass distance, or the production efficiency.

[0089] The present invention will be further illustrated below through examples and comparative examples.

[0090] Example 1 (S1)

[0091] like Figure 1-4 As shown, a method for improving interlayer defects of pultruded main beams for wind turbine blades is to improve the process (1). When laying the pultruded main beam 12, the side guard of the tensioning fixture 13 is removed first, and then it is hoisted and laid.

[0092] Furthermore, when the pultruded main beam 12 is hoisted and laid, after hoisting the pultruded main beam 12 to the shell mold 1, the tensioning fixture 13 is removed;

[0093] The order of removing the tensioning fixture 13 is as follows: tensioning fixtures 13 from the blade root to the blade tip are removed intermittently, while tensioning fixtures 13 at the blade root and blade tip are retained during the process; after the intermittent removal is completed, tensioning fixtures 13 at the blade root and blade tip are removed.

[0094] The pultruded main beam A1 was obtained.

[0095] Example 2 (S2)

[0096] The improvement of interlayer defects in the pultruded main beam of wind turbine blades according to Example 1 differs from Example 1 only in that:

[0097] Further process improvements were made (2). After the core material was laid, the shell mold was preheated.

[0098] The pultruded main beam A2 was obtained.

[0099] Example 3 (S3)

[0100] The improvement of interlayer defects in the pultruded main beam of wind turbine blades according to Example 1 differs from Example 1 only in that:

[0101] In addition, the process was improved (2). After the core material was laid, the shell mold was preheated. After the second layer of vacuum bag film was tightened, an insulation layer was covered on the area of ​​the pultruded main beam.

[0102] The pultruded main beam A3 was obtained.

[0103] Example 4 (S4)

[0104] The improvement of interlayer defects in the pultruded main beam of wind turbine blades according to Example 1 differs from Example 1 only in that:

[0105] In addition, the process was improved (3). When laying the auxiliary materials, the guide net on the front edge of the pultruded main beam was disconnected in the chord direction, and VAP vacuum bags were covered at the disconnection position and the area on both sides, so that one side of the VAP vacuum bag overlapped with the guide net side and the other side overlapped with the core material side.

[0106] In the axial direction, the break point of the guide net is located at L11.7m to L72m on the pultruded main beam from the blade root to the blade tip;

[0107] In the chord direction, the guide net is broken 150±10mm on the pultruded main beam and 30±10mm on the core material side;

[0108] The pultruded main beam A4 was obtained.

[0109] Example 5 (S5)

[0110] The improvement of interlayer defects in the pultruded main beam of wind turbine blades according to Example 1 differs from Example 1 only in that:

[0111] Furthermore, the process was improved (4). During the vacuum injection process of the shell mold, the pumping force was increased to a total pumping volume of 1400m³. 3 / h;

[0112] The pultruded main beam A5 was obtained.

[0113] Example 6 (S6)

[0114] The improvement of interlayer defects in the pultruded main beam of wind turbine blades according to Example 1 differs from Example 1 only in that:

[0115] Further process improvements were made (5);

[0116] First, adjust the arrangement of the injection pipes on the PS and SS surfaces of the wind turbine blades, including the arrangement of the injection ports, the disconnection position of the injection pipe, the disconnection length of the injection pipe, and the chordal distance of the injection pipe from the edge; among which,

[0117] On the PS surface of the wind turbine blade, ① on the main pipeline, the areas at axial positions of 11800~11900mm, 19800~19900mm, 31800~31900mm, 47800~47900mm, 59800~59000mm, and 71800~71900mm are designated as areas where the glue injection tubes are disconnected; ② on the leading edge auxiliary pipeline, the areas at axial positions of 11700~19000mm, 19700~19900mm, 31700~31900mm, and 47700~47900mm are designated as areas where the glue injection tubes are disconnected.

[0118] On the SS surface of the wind turbine blade, ① on the main pipeline, the glue injection pipe of the pultruded main beam rear edge side shaft 3 is located at axial position 1500-94500mm, where it is 150mm away from the chordal edge of the pultruded main beam at axial position 1500-85000mm; and the glue injection pipe is disconnected at axial positions 2000-2100mm, 21300-21400mm, 27800-27900mm, 34800-34900mm, 42800-42900mm, 51800-51900mm, 61800-61900mm, 71800-71900mm, and 81800-81900mm; adjust the glue injection port position, glue injection port 3-3 is at axial position 21500mm, and glue injection port 3-4 is at axial position 21500mm. ① Along the axial direction of 28000mm, injection port 3-5 is at 35000mm, injection port 3-6 is at 43000mm, injection port 3-7 is at 52000mm, injection port 3-8 is at 62000mm, injection port 3-9 is at 72000mm, and injection port 3-10 is at 82000mm; ② On the front-edge auxiliary pipe, the injection pipe of the pultruded main beam front-edge side shaft 2 is located at 2800~2800mm, 3400~42500mm, and 48000~56000mm in the axial direction, and its chord-direction distance from the front edge of the pultruded main beam is 60±10mm; and the axial positions of 11700~11900mm and 21700~21900mm are the injection pipe disconnection areas; an additional injection port is added at 52000mm in the axial direction;

[0119] Then, adjust the opening sequence, timing, and method of the glue injection valves at each injection port; as shown in Table 1 above.

[0120] The pultruded main beam A6 was obtained.

[0121] Example 7 (S7)

[0122] The improvement of interlayer defects in the pultruded main beam of wind turbine blades according to Example 1 differs from Example 1 only in that:

[0123] It also includes improved processes (2) as in Example 2, improved processes (2) as in Example 3, improved processes (3) as in Example 4, improved processes (4) as in Example 5, and improved processes (5) as in Example 6;

[0124] The pultruded main beam A7 was obtained.

[0125] Comparative Example 1 (D1)

[0126] The production of pultruded main beams for wind turbine blades using existing technologies includes:

[0127] When laying the pultruded main beam, the tensioning fixture is not removed from the side guards. After the pultruded main beam is hoisted to the shell mold, the tensioning fixture is removed in sequence from the blade root to the blade tip.

[0128] The mold temperature controller is turned on before vacuum filling, without preheating.

[0129] The pultruded main beam area is not covered with an insulation layer during grouting;

[0130] The leading edge guide net is not disconnected and is not covered by a VAP extraction bag;

[0131] The air extraction system has an extraction capacity of 600m³. 3 / h;

[0132] The injection pipeline layout is as follows:

[0133] On the PS surface of wind turbine blades:

[0134] Leading-edge auxiliary pipeline: The glue injection pipe of the leading-edge side shaft 2 of the pultruded main beam is located at 2800-56000mm in the axial direction, and its distance from the leading edge of the pultruded main beam in the chord direction is 80-100mm; and the axial positions of 11500-11700mm, 19500-19700mm, 31500-31700mm, and 47500-47700mm are the glue injection pipe disconnection areas; glue injection port 2-1 is at 3200mm in the axial direction, glue injection port 2-2 is at 12000mm in the axial direction, glue injection port 2-3 is at 20000mm in the axial direction, glue injection port 2-4 is at 32000mm in the axial direction, and glue injection port 2-5 is at 48000mm in the axial direction;

[0135] Main pipeline: The adhesive injection pipes on the rear edge side shaft 3 of the pultruded main beam are located at axial positions from 1500 to 94500 mm. Specifically, at axial positions from 1500 to 85000 mm, the chord-direction distance from the rear edge of the pultruded main beam is 100 mm; at axial position 86000 mm, the chord-direction distance is 400 mm; at axial position 90000 mm, the chord-direction distance is 300 mm; and at axial position 93000 mm, the chord-direction distance is 100 mm. The adhesive injection pipes are laid according to their dimensions; and at axial position 11500 mm... The areas at ~11700mm, 31500~31700mm, 47500~47700mm, 59500~59700mm, and 71500~71700mm are the areas where the glue injection tube is disconnected; glue injection port 3-1 is at 2000mm in the axial direction, glue injection port 3-2 is at 12000mm in the axial direction, glue injection port 3-3 is at 20000mm in the axial direction, glue injection port 3-4 is at 32000mm in the axial direction, glue injection port 3-5 is at 48000mm in the axial direction, glue injection port 3-6 is at 60000mm in the axial direction, and glue injection port 3-7 is at 72000mm in the axial direction.

[0136] On the SS surface of the wind turbine blade:

[0137] Leading-edge auxiliary pipeline: The glue injection pipe of the leading-edge side shaft 2 of the pultruded main beam is located at 2800-56000mm in the axial direction, and its distance from the leading edge of the pultruded main beam in the chord direction is 80-100mm; and the axial positions of 21500-21700mm and 37500-37700mm are the glue injection pipe disconnection areas; glue injection port 2-1 is at 3200mm in the axial direction, glue injection port 2-2 is at 12000mm in the axial direction, glue injection port 2-3 is at 22000mm in the axial direction, and glue injection port 2-4 is at 38000mm in the axial direction;

[0138] Main pipeline: The adhesive injection pipes on the rear edge side shaft 3 of the pultruded main beam are located at axial positions from 1500 to 94500 mm. Specifically, at axial positions from 1500 to 85000 mm, the chord-direction distance from the rear edge of the pultruded main beam is 100 mm; at axial position from 86000 mm, the chord-direction distance is 400 mm; at axial position from 90000 mm, the chord-direction distance is 300 mm; and at axial position from 93000 mm, the chord-direction distance is 100 mm. The adhesive injection pipes are laid according to their dimensions; and the axial distance is from 21500 to 21700 mm. The locations m, 31500~31700mm, 42500~42700mm, 53500~53700mm, 67500~67700mm, and 77500~77700mm are the areas where the glue injection tube is disconnected; the glue injection port 3-1 is at 2000mm in the axial direction, the glue injection port 3-2 is at 12000mm in the axial direction, the glue injection port 3-3 is at 22000mm in the axial direction, the glue injection port 3-4 is at 32000mm in the axial direction, the glue injection port 3-5 is at 43000mm in the axial direction, the glue injection port 3-6 is at 54000mm in the axial direction, and the glue injection port 3-7 is at 68000mm in the axial direction;

[0139] Opening time: Open each glue injection valve in sequence from the blade root to the blade tip, and open the valve when the glue flows axially to the glue injection port;

[0140] Activation method: Open all at once;

[0141] The pultruded main beam A1' was obtained.

[0142] result

[0143] Interlayer defects were determined by non-destructive testing of the pultruded main beam A1-7 obtained in Examples 1-7 (S1-7) and the pultruded main beam A1' obtained in Comparative Example 1 (D1). The results are shown in Table 2.

[0144] Table 2 Results of interlaminar defect determination for pultruded main beams A1-7 and A1'

[0145]

[0146]

[0147] According to the results in Table 2:

[0148] The pultruded main beam obtained by the method of the present invention for improving interlayer defects of pultruded main beams for wind turbine blades can control the number of interlayer defects to within 5, which is significantly reduced compared to 90+ in the prior art, thus improving its quality.

[0149] The method of the present invention for improving interlayer defects in the pultruded main beam of wind turbine blades does not significantly change the quality defects such as whitening during injection, the amount of injection resin, the total injection time, the blade mass distance, and the production efficiency compared to the prior art. The method of the present invention for improving interlayer defects in the pultruded main beam of wind turbine blades does not cause other negative impacts while improving the interlayer defects.

[0150] Although the present invention has been described in detail through the preferred embodiments described above, it should be understood that the above description should not be considered as limiting the invention. Those skilled in the art will understand that modifications and adjustments can be made to the invention based on the teachings of this specification. These modifications and adjustments should also be within the scope defined by the claims of the present invention.

Claims

1. A method for improving interlayer defects in the pultruded main beam of wind turbine blades, characterized in that, The method includes an improved process (1): when laying the pultruded main beam, the side guards of the tensioning fixture are removed first, and then it is hoisted and laid. In the improved process (1), when the pultruded main beam is hoisted and laid, the tensioning fixture is removed after the pultruded main beam is hoisted to the shell mold; In the improved process (1), the order of removing the tensioning fixture is to first remove the tensioning fixture between the blade root and the blade tip, and then remove the tensioning fixture between the blade root and the blade tip. Specifically, the tensioning fixtures from the blade root to the blade tip are removed in intervals, while the tensioning fixtures at the blade root and the blade tip are retained during the process. After the intervals are removed, remove the tensioning fixtures at the blade root and blade tip positions; The method also includes an improved process (3). When laying the auxiliary material, the guide net on the front edge of the pultruded main beam is disconnected in the chord direction, and VAP vacuum bags are covered at the disconnection position and the area on both sides, so that one side of the VAP vacuum bag overlaps with the guide net side and the other side overlaps with the core material side. In the improved process (3), the break point of the guide net is located on the pultruded main beam at a distance of 11.7m to 72m from the blade root in the direction from the blade root to the blade tip; In the improved process (3), in the chord direction, the guide net is broken by 150±10 mm on the pultruded main beam and by 30±10 mm on the core material side.

2. The method according to claim 1, characterized in that, The method also includes an improved process (2): after the core material is laid, the shell mold is preheated.

3. The method according to claim 2, characterized in that, In the improved process (2), after the second layer of vacuum bag film is tightened, an insulation layer is covered above the area of ​​the pultruded main beam.

4. The method according to any one of claims 1-3, characterized in that, The method also includes improving the process (4) by increasing the pumping force during the vacuum injection process of the shell mold.

5. The method according to claim 4, characterized in that, In the improved process (4), the pumping force is increased to a total pumping volume ≥1400 m³. 3 / h.

6. The method according to any one of claims 1-3 and 5, characterized in that, The method also includes process improvement (5). First, adjust the arrangement of the injection pipelines on the PS and SS surfaces of the wind turbine blades, including the arrangement of the injection ports, the disconnection position of the injection pipe, the disconnection length of the injection pipe, and the chordal distance of the injection pipe from the edge; then, adjust the opening sequence, opening timing, and opening method of the injection valves at each injection port.

7. The method according to claim 6, characterized in that, In the improved process (5), the opening method of the glue injection valve is as follows: first open 1 / 3 to 1 / 2, wait 10 to 30 minutes, and then open it completely.

8. A pultruded main beam obtained by the method according to any one of claims 1-7.

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