Sail rotor structure

Abstract

The invention relates to the technical field of sail rotors, and discloses a sail rotor structure which comprises a structural layer, the structural layer comprises a plurality of continuous winding layers, each winding layer comprises one-way cloth and yarn sheets, and fibers of the yarn sheets and fibers of the one-way cloth are arranged in a crossed mode. According to the sail rotor structure, the yarn sheets and the one-way cloth are annularly wound to manufacture the structural layer, the winding process is convenient, the production efficiency of the sail rotor structure is improved, the sail rotor structure with the large axial size can be formed at a time through winding forming, the strength of all parts of the sail rotor structure is uniform, and the service life of the sail rotor structure is prolonged. The sail rotor structure facilitates uniform load dispersion, avoids generation of concentrated stress, prolongs the service life of the sail rotor structure, and is flat and attractive in appearance.

Description

Technical Field

[0001] This invention relates to the field of sail rotor technology, and more specifically, to a sail rotor structure. Background Technology

[0002] A wind turbine rotor is a vertical axis wind propulsion device based on aerodynamic principles. Its core is to drive a vertical cylinder (rotor) to rotate by an electric motor. It uses the Magnus effect (the pressure difference caused by the difference in airflow speed on both sides of the rotating body) to generate lateral thrust, which propels the ship forward, thus helping ships save energy and reduce emissions.

[0003] Chinese Patent CN218315613U discloses a Magnus rotor sail barrel wall structure, the wall of which includes a winding layer and a bundle layer, with the bundle layer located between the two winding layers. The bundle layer is formed by several strips and / or sheets arranged in parallel circumferential directions. The winding layer includes a circumferential winding layer, a helical winding layer, or an alternating circumferential and helical winding layer. Both the circumferential and helical winding layers are made of continuous fiber impregnated with resin. The projections of the strips and sheets along the axial direction of the Magnus rotor sail barrel wall are rectangular. The bundle layer is inconvenient to lay on the inner winding layer, resulting in low rotor production efficiency and limited axial dimensions. For sail rotors with large axial dimensions, multiple rotor units need to be manufactured and then spliced ​​together. However, the splicing point is a weak point of the sail rotor. To ensure the strength of the splicing point, a noticeable protrusion is formed, affecting the aesthetics of the rotor. Summary of the Invention

[0004] The purpose of this invention is to overcome the defects in the prior art and provide a sail rotor structure formed by circumferential winding of gauze and unidirectional fabric.

[0005] To achieve the above objectives, the technical solution of the present invention is to provide a sail rotor structure, comprising: a structural layer, the structural layer comprising multiple continuous winding layers, the winding layer comprising unidirectional fabric and yarn, wherein the fibers of the yarn and the fibers of the unidirectional fabric are arranged crosswise.

[0006] Preferably, the winding layer is formed by sequentially winding the unidirectional fabric and the yarn in a circumferential direction. This design allows the unidirectional fabric winding layer to provide axial strength, while the yarn winding layer provides circumferential strength, thus ensuring the structural layer's strength in both the axial and circumferential directions.

[0007] Preferably, the winding layer is formed by overlapping the unidirectional fabric and the yarn sheet and then winding them circumferentially. During winding, the yarn sheet is located outside the unidirectional fabric. The overlapping of the unidirectional fabric and the yarn sheet forms a composite material. The yarn sheet comprises multiple rows of tightly arranged yarns, and the fiber length direction of the unidirectional fabric is perpendicular to the fiber length direction of the yarn. This design allows the unidirectional fabric and yarn sheet of the same winding layer to overlap, resulting in a denser fiber arrangement in the structural layer.

[0008] Preferably, adjacent winding layers are cross-wound, and the winding angle of the composite material remains constant. This design helps to optimize stress distribution and make the stress on the sail rotor more uniform.

[0009] Preferably, the composite material of two adjacent winding layers has the same winding angle. This design improves the overall symmetry of the structural layers, thereby enabling the wound sail rotor to achieve optimal mechanical properties and structural strength.

[0010] Preferably, the width of the unidirectional fabric is B, and the circumferential spacing of the composite material in the same winding layer is x, where B = 2x + y, and the value of y ranges from 20mm ≤ y ≤ 40mm. This design helps to improve the axial strength of the winding layer and the structural layer.

[0011] Preferably, in the same winding layer, the projections of two unidirectional turns spaced one turn apart on the axial symmetry plane of the structural layer overlap. The winding layer forms a protrusion in the overlapping area, and the protrusions of adjacent winding layers are staggered. This design avoids the cumulative effect of protrusions on the winding of the composite material.

[0012] Preferably, the width b of the yarn sheet is greater than or equal to x. This design helps to ensure the strength of the winding layer and facilitates the uniform winding and forming of the yarn sheet.

[0013] Preferably, the width of the yarn sheet is b=x. This design minimizes the thickness of the protrusion, thus facilitating the uniform winding and forming of the composite material.

[0014] Preferably, the sail rotor structure further includes a base felt layer, which is formed by circumferentially winding the yarn sheets. The base felt layer and the structural layer are wound sequentially from the inside out. This design helps improve the flatness of the inner ring of the sail rotor.

[0015] Preferably, the sail rotor structure further includes a thickening layer, which is formed by circumferentially winding the yarn sheet. The base felt layer, the structural layer, and the thickening layer are wound sequentially from the inside out. This design helps improve the flatness and aesthetics of the outer ring of the sail rotor.

[0016] The beneficial effects of this invention are as follows: By using the sail rotor structure of the present invention, the structural layer is manufactured by circumferential winding of yarn and unidirectional fabric. The winding process is convenient and improves the production efficiency of the sail rotor structure. Furthermore, the sail rotor structure with a large axial dimension can be formed in one step through winding molding. Moreover, the strength of each part of the sail rotor structure is uniform, which is conducive to the uniform distribution of load, avoids the generation of concentrated stress, and improves the service life of the sail rotor structure. In addition, the surface of the sail rotor structure is flat and beautiful. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the sail rotor; Figure 2 This is a top side cross-sectional view of the reinforcing layer (the winding layer is formed by sequentially winding unidirectional fabric and yarn in a circular manner). Figure 3 This is a schematic diagram of the winding method of the first winding layer in Example 5 (the winding layer is formed by overlapping unidirectional fabric and yarn and then winding it in a circumferential direction. The dotted line in the figure represents the yarn hidden under the unidirectional fabric, and the arrow in the figure indicates the direction of the composite material in the axial direction). Figure 4 This is a schematic diagram of the winding method of the second winding layer in Example 5 (the dotted line in the figure represents the yarn hidden under the unidirectional fabric, and the arrow in the figure indicates the direction of the composite material in the axial direction). Figure 5 This is a schematic diagram of the top front cross-section of the first winding layer in Embodiment 5; Figure 6 This is a schematic diagram of the top front view sectional view of the second winding layer in Example 5 (after the bottom layer is flattened in one direction).

[0018] In the diagram: 1. Structural layer; 10. Wrapping layer; 11. Unidirectional fabric wrapping layer; 12. Yarn wrapping layer; 13. Composite material; 141. Unidirectional fabric; 151. Yarn; 161. Protrusion; 2. Base felt layer; 3. Thickened layer. Detailed Implementation

[0019] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed to enable those skilled in the art to better understand and implement the subject matter described herein. Changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0020] To better understand this invention, the following is combined with... Figures 1-6A detailed description of a sail rotor structure according to the present invention is provided.

[0021] Example 1: like Figures 1-6 As shown, a sail rotor structure includes: a structural layer 1, which includes multiple continuous winding layers 10, the winding layers 10 including unidirectional fabric 141 and yarn 151, the fibers of the yarn 151 and the fibers of the unidirectional fabric 141 being cross-arranged.

[0022] It should be noted that the cross arrangement of the fibers of the yarn sheet 151 and the fibers of the unidirectional fabric 141 means that the length direction of the fibers of the yarn sheet 151 and the length direction of the fibers of the unidirectional fabric 141 are arranged at an angle. The yarn sheets 151 are bonded together with each other, the yarn sheet 151 is bonded to the unidirectional fabric 141, and the unidirectional fabric 141 is bonded to each other with resin. The unidirectional fabric 141 can also be replaced with a multi-axis fabric. The fibers of the yarn sheet 151 can be at least one of the fiber materials such as glass fiber or carbon fiber, and the fibers of the unidirectional fabric 141 can also be at least one of the fiber materials such as glass fiber or carbon fiber.

[0023] In this embodiment, the inner diameter of the sail rotor is 5m and the length is 35m. The unidirectional cloth 141 and the yarn sheet 151 are both wound in a circumferential manner, thereby improving the production efficiency of the sail rotor structure. Moreover, the structural layers of the sail rotor are integrally formed without splicing, resulting in better mechanical properties and aesthetics.

[0024] By using the sail rotor structure of the present invention, the structural layer is manufactured by circumferential winding of yarn sheet 151 and unidirectional cloth 141. The winding process is convenient and improves the production efficiency of the sail rotor structure. Furthermore, the sail rotor structure with a large axial dimension can be formed in one step by winding molding. Moreover, the strength of each part of the sail rotor structure is uniform, which is conducive to uniformly distributing the load, avoiding the generation of concentrated stress, improving the service life of the sail rotor structure, and the surface of the sail rotor structure is flat and beautiful.

[0025] Example 2: As an optimization of Example 1, such as Figure 2 As shown, the winding layer 10 is formed by sequentially winding unidirectional fabric 141 and yarn sheet 151 in a circumferential manner.

[0026] It should be noted that when the winding layer 10 is formed by sequentially winding the unidirectional fabric 141 and the yarn sheet 151 in a circumferential manner, when winding each layer of winding layer 10, it is preferable to first wind the unidirectional fabric 141 in a circumferential manner to form a unidirectional fabric winding layer 11, and then wind the yarn sheet 151 in a circumferential manner around the outer ring of the unidirectional fabric winding layer 11 to form a yarn sheet winding layer 12, thereby completing the winding formation of the winding layer 10. The unidirectional fabric winding layer 11 can provide axial strength, and the yarn sheet winding layer 12 can provide circumferential strength, thereby ensuring the strength of the structural layer 1 in both the axial and circumferential directions. The fiber length of the unidirectional fabric 141 extends along its own width direction. The strength of the unidirectional fabric 141 in its own length direction is relatively small. During the winding process of the unidirectional fabric 141, the tightness of the winding is limited. If the unidirectional fabric 141 is stretched too tightly, it is easy to break. However, during the winding process of the yarn sheet 151, the yarn sheet 151 can compress the unidirectional fabric 141, reduce the porosity existing in the winding process of the unidirectional fabric 141, and squeeze out the air or air bubbles in the inner layer material, reducing the probability of porosity defects, making the fiber arrangement of the structural layer 1 more compact, thereby improving the strength and quality of the structural layer 1.

[0027] Example 3: As an optimization of Example 1, such as Figure 3 and Figure 4 As shown, the winding layer 10 is formed by overlapping unidirectional fabric 141 and yarn sheet 151 and then winding it in a circumferential direction. During winding, the yarn sheet 151 is located outside the unidirectional fabric 141. The unidirectional fabric 141 and the yarn sheet 151 are overlapped to form a composite material 13. The yarn sheet 151 includes multiple single-row tightly arranged yarns. The fiber length direction of the unidirectional fabric 141 is perpendicular to the fiber length direction of the yarn. The two adjacent winding layers 10 are cross-wound, and the winding angle of the composite material 13 of the two adjacent winding layers 10 is the same.

[0028] It should be noted that when the winding layer 10 is formed by circumferentially winding the unidirectional fabric 141 and the yarn 151 together, the unidirectional fabric 141 and the yarn 151 are stacked to form the composite material 13, and the composite material 13 is circumferentially wound to form the winding layer 10. During the winding process, the yarn 151 of the composite material 13 that is wound on the mandrel is located on the side of the unidirectional fabric 141 away from the mandrel. When stacked, one edge of the yarn 151 can coincide with one edge of the unidirectional fabric 141, or the edge of the yarn 151 can have a certain distance from one edge of the unidirectional fabric 141. The fiber length direction of the yarn is the same as the fiber length direction of the yarn sheet 151. The length direction of the unidirectional fabric 141, the length direction of the yarn, and the length direction of the composite material 13 are consistent. The yarn mainly provides circumferential strength for the sail rotor, and the unidirectional fabric 141 mainly provides axial strength for the sail rotor, thereby ensuring the overall strength of the sail rotor. The unidirectional fabric 141 and yarn sheet 151 are overlapped and wound in a circular direction. Multiple tightly arranged yarns form the yarn sheet 151. During the winding process, the multiple yarns of the yarn sheet 151 compress the unidirectional fabric 141, resulting in a better compression effect. Figure 6In the same winding layer 10, the unidirectional fabric 141 and yarn 151 overlap each other, the fiber arrangement of the structural layer 1 is more compact, and there is no delamination. The proportion of fiber in the structural layer 1 is also higher, the proportion of resin is lower, and the overall strength of the structural layer 1 is also higher. In addition, during the winding process of the structural layer 1, there is no alternation between the two winding materials, unidirectional fabric 141 and yarn 151, which can further improve the production efficiency of the sail rotor. The sail rotor is manufactured by circumferential winding, and the winding length is greater than the length of the sail rotor. Finally, the ends are cut to obtain the sail rotor of the required length. The winding angle of the composite material 13 is the winding angle of the unidirectional fabric 141 and the yarn 151. During the winding process, the composite material 13 formed by the overlapping of the unidirectional fabric 141 and the yarn 151 is reciprocated and wound. Taking the cross section of one end of the mandrel as a reference, the circumferential winding direction of the composite material 13 remains unchanged (always clockwise or always counterclockwise). The cross-winding design helps to optimize stress distribution and make the wind turbine rotor more uniformly stressed. By setting the winding angle of the composite material 13 of two adjacent winding layers 10 to be the same, the overall symmetry of the structural layer 1 can be improved, which helps to further optimize stress distribution and further improve the uniformity of stress on the wind turbine rotor, so that the wind turbine rotor can achieve the best mechanical properties and structural strength.

[0029] In this embodiment, the yarn is impregnated with resin. During the winding process, excess resin on the yarn permeates the unidirectional fabric 141, thereby ensuring the bonding strength between yarn sheets 151, between yarn sheets 151 and unidirectional fabric 141, and between unidirectional fabrics 141. The unidirectional fabric 141 is not impregnated with resin alone; otherwise, the unidirectional fabric 141 is prone to breakage. Furthermore, if the unidirectional fabric 141 is impregnated with resin, due to the low strength of the unidirectional fabric 141 in its own length direction, the excess resin cannot be filtered out and reused, resulting in resin waste. Moreover, a large amount of resin on the unidirectional fabric 141 will lead to an increase in the resin content in the sail rotor, thereby reducing the strength of the sail rotor. In actual production, an appropriate amount of resin can be sprayed after the unidirectional fabric 141 is wound, depending on the site conditions, to ensure that the unidirectional fabric 141 is permeated with resin.

[0030] Example 4: As an optimization of Example 3, such as Figure 5 and Figure 6 As shown, the width of the unidirectional fabric 141 is B, and the circumferential spacing of the composite material 13 in the same winding layer 10 is x, and B = 2x + y, the value range of y is: 20mm ≤ y ≤ 40mm. In the same winding layer 10, the projections of two turns of unidirectional fabric 141 spaced one turn on the axial symmetry plane of the structural layer 1 have an overlapping area. The winding layer 10 forms a protrusion 161 in the overlapping area, and the protrusions 161 of adjacent winding layers 10 are staggered.

[0031] It should be noted that the circumferential spacing of composite material 13 refers to the winding spacing of composite material 13, that is, the distance that the guide head moves when the mandrel rotates one revolution. The unidirectional fabric 141 and the yarn 151 are both circumferentially wound on the outside of the mandrel. The mandrel rotates on its own, and the guide head drives the unidirectional fabric 141 and the yarn 151 to move along the mandrel axis, thereby performing the circumferential winding of composite material 13. By designing the width of the unidirectional fabric 141 to be greater than twice the pitch of the composite material 13, that is, the width of the unidirectional fabric 141 is greater than twice its own pitch, during the winding process, two turns of the unidirectional fabric 141 with a one-turn gap form an overlap (the overlap is not in direct contact, but only indicates that the projections on the axial symmetry plane of the structural layer 1 have an overlapping area). For example, the third turn of the unidirectional fabric 141 overlaps with the first turn of the unidirectional fabric 141 and the fifth turn of the unidirectional fabric 141 (the projections of the third turn of the unidirectional fabric 141 and the first turn of the unidirectional fabric 141 on the axial symmetry plane of the structural layer 1 have an overlapping area, and the projections of the third turn of the unidirectional fabric 141 and the fifth turn of the unidirectional fabric 141 on the axial symmetry plane of the structural layer 1 also have an overlapping area), and the width of the overlap is 20mm-40mm, which is beneficial to improving the axial strength of the winding layer 10 and the structural layer 1. The overlapping area is the area where the edge is located. By designing the staggered arrangement of the protrusions 161 of the two adjacent winding layers 10, the cumulative effect of the protrusions 161 on the winding of the composite material 13 can be avoided, thus making the thickness of the structural layer 1 and the overall structure more uniform. y refers to the width of the overlap of the two turns of unidirectional fabric 141 with a one-turn gap in the same winding layer 10.

[0032] Example 5: As an optimization of Example 4, such as Figure 3 and Figure 4 As shown, the width b of the yarn piece 151 is greater than or equal to x; Preferably, the width of the yarn 151 is b=x, and at this time, the winding angle of the composite material 13 is α=180 / π·arccos(b / (π·D)); Where D is the inner diameter of the sail rotor structure.

[0033] It should be noted that the yarn sheet 151 is formed by multiple yarns arranged in a single row. If the width of the yarn sheet 151 is less than the circumferential spacing of the composite material 13, that is, the width of the yarn sheet 151 is less than its own circumferential spacing, the yarn sheet 151 cannot achieve full coverage of the circumference of the winding layer 10 in the same winding layer 10. The circumferential strength and axial strength of the winding layer 10 and the structural layer 1 will be reduced. By designing the width of the yarn sheet 151 to be no less than the circumferential spacing of the composite material 13, it is beneficial to ensure the circumferential strength of the winding layer 10 and to ensure the uniform winding and forming of the yarn sheet 151.

[0034] The width of the yarn sheet 151 is preferably equal to the circumferential spacing of the composite material 13. That is, the width of the yarn sheet 151 is equal to the circumferential spacing of the yarn sheet 151. After one layer of winding layer 10 is wound, the height of the protrusion 161 is equal to the thickness of the unidirectional fabric 141. The thickness of the unidirectional fabric 141 is also less than the thickness of the yarn sheet 151, thereby minimizing the thickness of the protrusion 161, which is beneficial to the uniform winding and forming of the composite material 13.

[0035] In this embodiment, one edge of the yarn sheet 151 coincides with one edge of the unidirectional fabric 141.

[0036] Example 6: As an optimization of Example 5, such as Figure 1 As shown, the wind turbine rotor structure also includes a bottom felt layer 2, which is formed by circumferential winding of yarn sheet 151. The bottom felt layer 2 and the structural layer 1 are wound sequentially from the inside to the outside. The sail rotor structure also includes a thickened layer 3, which is formed by circumferential winding of yarn sheet 151. The bottom felt layer 2, the structural layer 1 and the thickened layer 3 are wound sequentially from the inside to the outside.

[0037] It should be noted that the winding angle of the yarn 151 of the bottom felt layer 2 is the same as the winding angle of the composite material 13 of the structural layer 1. Since the innermost layer of the structural layer 1 is a unidirectional fabric 141 layer, if the innermost layer of the structural layer 1 is used as the innermost layer of the sail rotor, the flatness of the inner ring of the sail rotor will be poor. By first winding one or two layers of bottom felt layer 2 on the mandrel as the innermost layer of the sail rotor, it is beneficial to improve the flatness of the inner ring of the sail rotor. The winding angle of the yarn 151 of the thickened layer 3 is the same as that of the composite material 13 of the structural layer 1. Due to the presence of the protrusion 161, after the structural layer 1 is wound, a thickened layer 3 of a certain thickness is wound on the outside of the structural layer 1. When winding the thickened layer 3, several layers of yarn 151 can be wound on the recessed areas on both sides of the protrusion on the outer ring of the structural layer 1 to level them. After the thickened layer 3 is wound, it is polished to make the outer surface of the thickened layer 3 flat, thereby improving the flatness and aesthetics of the outer ring of the sail rotor. By setting the base felt layer and the thickened layer, the overall flatness and aesthetics of the sail rotor are improved.

[0038] The embodiments of the invention have been described above with reference to the accompanying drawings. However, the embodiments are not limited to the specific implementation methods described above. The specific implementation methods described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the embodiments without departing from the spirit of the embodiments and the scope of protection of the claims, and all of these forms are within the protection scope of the embodiments.

Claims

1. A sail rotor structure, characterized in that, include: The structural layer (1) includes multiple continuous winding layers (10), the winding layer (10) includes a unidirectional fabric (141) and a yarn (151), the fibers of the yarn (151) are interwoven with the fibers of the unidirectional fabric (141).

2. The sail rotor structure according to claim 1, characterized in that, The winding layer (10) is formed by sequentially winding the unidirectional fabric (141) and the yarn (151) in a circumferential manner.

3. The sail rotor structure according to claim 1, characterized in that, The winding layer (10) is formed by overlapping the unidirectional fabric (141) and the yarn sheet (151) and then circumferentially winding it. During winding, the yarn sheet (151) is located outside the unidirectional fabric (141). The unidirectional fabric (141) and the yarn sheet (151) are overlapped to form a composite material (13). The yarn sheet (151) includes multiple single-row tightly arranged yarns. The fiber length direction of the unidirectional fabric (141) is perpendicular to the fiber length direction of the yarn.

4. The sail rotor structure according to claim 3, characterized in that, The two adjacent winding layers (10) are cross-wound.

5. A sail rotor structure according to claim 4, characterized in that, The composite material (13) of two adjacent winding layers (10) has the same winding angle.

6. A sail rotor structure according to claim 5, characterized in that, The width of the unidirectional fabric (141) is B. In the same winding layer (10), the circumferential spacing of the composite material (13) is x, and B = 2x + y, where the value of y is 20mm ≤ y ≤ 40mm.

7. A sail rotor structure according to claim 6, characterized in that, In the same winding layer (10), the projections of two turns of unidirectional fabric (141) spaced one turn on the axial symmetry plane of the structural layer (1) have an overlapping area, and the winding layer (10) forms a protrusion (161) in the overlapping area, with the protrusions (161) of two adjacent winding layers (10) being staggered.

8. A sail rotor structure according to claim 7, characterized in that, The width b of the yarn piece (151) is greater than or equal to x.

9. A sail rotor structure according to claim 8, characterized in that, The width of the yarn piece (151) is b=x.

10. A sail rotor structure according to claim 3, characterized in that, The sail rotor structure also includes a bottom felt layer (2), which is formed by circumferentially winding the yarn sheet (151). The bottom felt layer (2) and the structural layer (1) are wound sequentially from the inside out.

11. A sail rotor structure according to claim 10, characterized in that, The sail rotor structure also includes a thickened layer (3), which is formed by circumferentially winding the yarn sheet (151). The bottom felt layer (2), the structural layer (1) and the thickened layer (3) are wound sequentially from the inside out.

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