Production process of cabin cover of wind power generator

Abstract

The invention provides a wind power generator cabin cover production process, and relates to the field of wind power generator cabin cover molding, and the wind power generator cabin cover production process comprises the following steps: spraying a gel coat on a production mold, and curing to form a gel coat layer; auxiliary parts are arranged in the production mold; the arranged production mold is covered with a vacuum bag film and sealed; the space in the vacuum bag film is vacuumized through a flow guide pipe; a molding injection material is injected into the production mold through a glue injection guide pipe; after glue injection is finished, the extraction opening and the glue injection opening are blocked, and a vacuum environment is kept for curing; the vacuum degree is regulated and controlled in stages based on molding injection material parameters; after curing is completed, the vacuum bag film is removed; and taking out the formed cabin cover of the wind power generator from the production mold. The process requirements of different stages can be met by regulating and controlling the vacuum degree in stages, and the quality of the formed cabin cover of the wind power generator is guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of wind turbine nacelle forming technology, in particular to a wind turbine nacelle production process. BACKGROUND

[0002] Wind power generation is currently a very important power generation technology, and a wind turbine generally includes a tower, a blade, a hub and a nacelle cover. The nacelle cover is arranged at the top of the generator set and protects the wind turbine. The reliability of the wind turbine nacelle cover determines the stability and service life of the wind turbine.

[0003] The existing wind turbine nacelle production process, such as CN110778465B, a wind turbine nacelle manufacturing process, and CN104589665B, a wind turbine nacelle cover one-step forming process, both disclose that the pressure value of the vacuum system during injection is kept at -0.09±0.005MPa. However, the process does not disclose the staged pressure regulation during the injection and curing process, which cannot dynamically adjust the pressure according to the different process requirements at different stages, and the production quality of the wind turbine nacelle cover may be unqualified due to the mismatch of the pressure. SUMMARY

[0004] The present application provides a wind turbine nacelle production process to solve the technical problems in the background art.

[0005] To solve the above technical problems, the present application discloses a wind turbine nacelle production process, comprising:

[0006] Step S1: spraying glue on the production mold and curing to form a glue layer;

[0007] Step S2: arranging auxiliary components in the production mold;

[0008] Step S3: covering the production mold with a vacuum bag film after the arrangement in step S2 and sealing;

[0009] Step S4: performing a vacuum operation on the space in the vacuum bag film through a flow guide pipe;

[0010] Step S5: injecting a molding injection material into the production mold through an injection pipe; after the injection is completed, the air outlet and the injection port are blocked, and the vacuum environment is maintained for curing;

[0011] In step S5, the vacuum degree is regulated in stages based on the parameters of the molding injection material;

[0012] Step S6: after curing is completed, the vacuum bag film is removed;

[0013] Step S7: taking out the molded wind turbine nacelle from the production mold.

[0014] Preferably, it further comprises step S8: corner polishing and inner gel coating spraying are performed on the shaped wind turbine nacelle.

[0015] Preferably, the auxiliary components comprise embedded parts and reinforcing materials, and the reinforcing materials comprise glass cloth and reinforcing ribs.

[0016] Preferably, the vacuum operation is performed to a pressure of -0.08 to -0.1 MPa.

[0017] Preferably, the wet gel film thickness in step S1 is 0.5 to 0.8 mm.

[0018] Preferably, before step S5, the batch of the to-be-applied injection material further comprises the following steps based on the batch of the to-be-applied injection material:

[0019] Step S051: obtaining a control gel time and a control curing time of the to-be-applied injection material;

[0020] Step S052: collecting an actual injection viscosity and an actual pH of the to-be-applied injection material;

[0021] Step S053: determining a viscosity-curing coupling characteristic factor based on the actual injection viscosity and a curing agent addition ratio of the to-be-applied injection material, correcting the control gel time based on the viscosity-curing coupling characteristic factor to obtain a corrected gel time;

[0022] Step S054: determining a predicted gel rate based on the corrected gel time, determining a gel rate deviation coefficient based on the predicted gel rate, and determining a pH deviation coefficient based on the actual pH of the to-be-applied injection material; correcting the control curing time based on the gel rate deviation coefficient and the pH deviation coefficient to obtain a corrected curing time;

[0023] Step S055: dividing the injection gel starting time to the curing process of the to-be-applied injection material into a first vacuum period, a second vacuum period, and a third vacuum period based on the corrected gel time and the corrected curing time;

[0024] Step S056: obtaining a target vacuum degree of the first vacuum period based on the viscosity deviation coefficient and a control vacuum degree of the first vacuum period; obtaining a target vacuum degree of the second vacuum period based on the pH deviation coefficient and a control vacuum degree of the second vacuum period; and obtaining a target vacuum degree of the third vacuum period based on the gel rate deviation coefficient and a control vacuum degree of the third vacuum period;

[0025] When the batch of the to-be-applied injection material performs step S05, the actual vacuum degree of the vacuum period is controlled to be the corresponding target vacuum degree.

[0026] Preferably, the first vacuum period is from the injection gel starting time to the injection gel completion time plus 0.5 times the corrected gel time.

[0027] Vacuum period two: "glue injection completion time + 0.5 times the modified gel time" to "glue injection completion time + 1.5 times the modified gel time";

[0028] Vacuum period three: "glue injection completion time + 1.5 times the modified gel time" to "glue injection completion time + modified curing time".

[0029] Preferably, the target glue injection speed of the batch injection material to be applied is determined before step S5 when the batch hatch cover to be produced is produced, and the glue injection is performed at the target glue injection speed when the batch hatch cover to be produced is produced.

[0030] Preferably, the target glue injection speed of the batch injection material to be applied includes:

[0031] Step S01: detecting the actual glue layer hardness, actual glue layer thickness, and actual glue layer temperature of the glue layer when the batch hatch cover to be produced is produced;

[0032] Step S02: detecting the actual viscosity and temperature of the batch injection material to be applied, and performing dimensionless processing on the actual glue layer hardness, actual glue layer thickness, and actual viscosity of the batch injection material to be applied to obtain a hardness coefficient, a thickness coefficient, and a viscosity coefficient, respectively, and determining a current "glue-substrate adaptation factor" based on the hardness coefficient, the thickness coefficient, and the viscosity coefficient;

[0033] Step S03: determining a current interface expansion stress characteristic factor based on the actual glue layer temperature, the temperature of the batch injection material to be applied, the thermal expansion coefficient of the glue, and the thermal expansion coefficient of the batch injection material to be applied;

[0034] Step S04: determining a target glue injection speed range corresponding to the current "glue-substrate adaptation factor" and the current interface expansion stress characteristic factor based on a "glue-substrate adaptation factor range-interface expansion stress characteristic factor range-infiltration section glue injection speed range" model;

[0035] Step S05: obtaining a comparison "single hatch cover production glue injection time-glue injection amount-glue injection speed" matrix of the batch injection material to be applied, and dividing the matrix into an infiltration section matrix, a filling section matrix, and a densification section matrix; and respectively determining an average glue injection speed and a glue injection speed fluctuation coefficient corresponding to the filling section matrix and the densification section matrix, determining a filling section target glue injection speed range based on the average glue injection speed and the glue injection speed fluctuation coefficient of the filling section, and determining a densification section target glue injection speed range based on the average glue injection speed and the glue injection speed fluctuation coefficient of the densification section.

[0036] The technical solutions of the present application will be further described in detail below with reference to the drawings and examples.

[0037] Compared with the prior art, the present application has the following beneficial effects:

[0038] Staged vacuum control adapts to the process requirements of different stages: In the injection stage, a reasonable vacuum level ensures the injection material fully fills the mold cavity, avoiding material shortages in dead zones; in the gel stage, given the rapid increase in material viscosity and the sharp decrease in fluidity, the vacuum level is adjusted individually to balance local shrinkage and prevent surface depressions and internal micro-cracks; in the curing stage, pressure is controlled according to the material's curing shrinkage pattern to reduce stress concentration and delamination, improving the uniformity and stability of the canopy structure. This reduces the defect rate in canopy production.

[0039] The configuration of the gelcoat wet film thickness (0.5-0.8 mm) and auxiliary components (embedded parts, reinforcing materials) was clarified, which not only ensured the surface quality of the hood (uniform gelcoat layer thickness), but also improved the structural strength of the hood through reinforcing materials, further optimizing the performance of the finished product. Attached Figure Description

[0040] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0041] Figure 1 This is a schematic diagram of the process of the present invention. Detailed Implementation

[0042] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0043] Furthermore, in this invention, the use of terms such as "first" and "second" is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit the invention. They are merely used to distinguish components or operations described using the same technical terms and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions and features of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If a combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0044] The present invention provides the following embodiments:

[0045] Example 1: This embodiment of the invention provides a manufacturing process for a wind turbine nacelle, such as... Figure 1 As shown, it includes:

[0046] Step S1: Apply gel coat to the production mold and allow it to cure to form a gel coat layer;

[0047] Step S2: Arrange auxiliary components inside the production mold;

[0048] Step S3: Cover the production mold arranged in step S2 with a vacuum bag film and seal it;

[0049] Step S4: Vacuum the space inside the vacuum bag membrane through the guide tube;

[0050] Step S5: Inject molding material into the production mold through the injection tube; after injection, seal the air extraction port and injection port to maintain a vacuum environment for curing;

[0051] In step S5, the vacuum level is adjusted in stages based on the molding injection parameters;

[0052] Step S6: After curing is complete, remove the vacuum bag film;

[0053] Step S7: Remove the formed wind turbine nacelle cover from the production mold.

[0054] This also includes step S8: grinding the edges and corners of the formed wind turbine nacelle and spraying the inner layer of gel coat.

[0055] The auxiliary components include embedded parts, reinforcing materials, etc., and the reinforcing materials include fiberglass cloth and reinforcing ribs.

[0056] The vacuuming operation is performed to a pressure of -0.08 to -0.1 MPa.

[0057] In step S1, the wet gel coat film thickness is 0.5–0.8 mm.

[0058] In this embodiment, the production mold is a wind turbine nacelle molding mold;

[0059] In this embodiment, the molding injection material refers to a mixture of materials used to fill the mold and, after curing, form the main structure of the hood.

[0060] The beneficial effects of the above technical solution are as follows:

[0061] Staged vacuum control adapts to the process requirements of different stages: In the injection stage, a reasonable vacuum level ensures the injection material fully fills the mold cavity, avoiding material shortages in dead zones; in the gel stage, given the rapid increase in material viscosity and the sharp decrease in fluidity, the vacuum level is adjusted individually to balance local shrinkage and prevent surface depressions and internal micro-cracks; in the curing stage, pressure is controlled according to the material's curing shrinkage pattern to reduce stress concentration and delamination, improving the uniformity and stability of the canopy structure. This reduces the defect rate in canopy production.

[0062] The configuration of the gelcoat wet film thickness (0.5-0.8 mm) and auxiliary components (embedded parts, reinforcing materials) was clarified, which not only ensured the surface quality of the hood (uniform gelcoat layer thickness), but also improved the structural strength of the hood through reinforcing materials, further optimizing the performance of the finished product.

[0063] Example 2, based on Example 1, further includes the following before performing step S5 on the batch injection of materials to be applied:

[0064] Step S051: Obtain the control gel time and control curing time of the batch injection to be applied;

[0065] Step S052: Collect the actual injection viscosity and actual pH of the batch feed to be applied;

[0066] Step S053: Combine the actual injection viscosity and the curing agent addition ratio of the batch injection material to be applied, determine the viscosity-curing coupling characteristic factor, and correct the control gel time based on the viscosity-curing coupling characteristic factor to obtain the corrected gel time;

[0067] Step S054: Determine the predicted gel rate based on the corrected gel time, determine the gel rate deviation coefficient based on the predicted gel rate, and determine the pH deviation coefficient based on the actual pH of the batch to be injected; correct the control curing time based on the gel rate deviation coefficient and the pH deviation coefficient to obtain the corrected curing time.

[0068] Step S055: Based on the corrected gel time and corrected curing time, the process from the start of dispensing to the application batch dispensing and curing is divided into three vacuum periods: Vacuum Period 1, Vacuum Period 2, and Vacuum Period 3.

[0069] Step S056: Based on the viscosity deviation coefficient and the control vacuum degree of vacuum period one, obtain the target vacuum degree of vacuum period one (e.g., -0.09 to -0.1 MPa); based on the pH deviation coefficient and the control vacuum degree of vacuum period two, obtain the target vacuum degree of vacuum period two (e.g., -0.07 to -0.08 MPa); based on the gel rate deviation coefficient and the control vacuum degree of vacuum period three, obtain the target vacuum degree of vacuum period three (e.g., -0.08 to -0.09 MPa).

[0070] During the process development phase, for the molding injection material, based on the qualified production data of the chamber cover, a correlation model of "deviation type - deviation amplitude - vacuum degree adjustment coefficient" corresponding to three vacuum periods is preset:

[0071] Vacuum Period 1: Establish a correlation model between "viscosity deviation coefficient and vacuum adjustment coefficient";

[0072] Vacuum Period Two: Establish a correlation model between "pH deviation coefficient and vacuum adjustment coefficient";

[0073] Vacuum Period 3: Establish a correlation model between "gelation rate deviation coefficient and vacuum degree adjustment coefficient".

[0074] The association model can be a mapping table, which can be obtained as follows:

[0075] Data collection: Collect the "viscosity / pH / gel rate deviation values" and "corresponding vacuum adjustment coefficients" of all qualified production (which can be pilot production) of the same formula resin (molding injection material);

[0076] Correlation analysis: Correlation between deviation values ​​and vacuum adjustment values ​​is established one-to-one, and the optimal adjustment coefficients corresponding to different deviation amplitudes are statistically analyzed to form a preliminary mapping relationship.

[0077] The correlation model can also be a formula, which is obtained by fitting the collected "deviation value - vacuum degree adjustment coefficient" data.

[0078] The target vacuum level for the current vacuum period = the reference vacuum level for the current vacuum period × (1 + the corresponding vacuum level adjustment coefficient for the current vacuum period).

[0079] When performing the batch execution step S05 of the batch injection, the actual vacuum level during the vacuum period is controlled to be the corresponding target vacuum level.

[0080] Viscosity deviation coefficient = (actual injected viscosity of the batch to be applied - control viscosity of the batch to be applied) ÷ control viscosity of the batch to be applied;

[0081] Viscosity-curing coupling characteristic factor = viscosity deviation coefficient ÷ curing agent addition ratio in the batch to be applied;

[0082] Gel formation is the process by which resin changes from a "liquid and flowable" state to a "semi-solid and non-flowable" state. Viscosity affects the speed of gelation through the "resistance to the movement of resin molecules": the higher the viscosity, the greater the "initial resistance" to intermolecular cross-linking, and the slower the gelation rate. At the same time, the proportion of curing agent determines the "theoretical rate basis" of the cross-linking reaction, so it is necessary to consider the influence of the curing agent ratio and viscosity deviation.

[0083] A positive coupling factor results in a slower gelation rate than the standard case; conversely, a negative coupling factor results in a faster gelation rate.

[0084] Corrected gel time = Control gel time × (1 + "viscosity-curing coupling characteristic factor" × time correction coefficient 1);

[0085] The time correction factor is obtained by first conducting small-scale laboratory tests to measure the ratio of theoretical to measured gelation time under different conditions; then iteratively optimizing based on production data, or referring to industry-standard process data. The time correction factor ranges from 0.05 to 0.5 (0.05 to 0.2 for small deviations / simple structures; 0.2 to 0.3 for standard scenarios; and 0.3 to 0.5 for large deviations / thick structures).

[0086] Predicted gel rate = (viscosity of the feed to be applied in the gel state - actual injection viscosity of the feed to be applied in the gel state) ÷ corrected gel time;

[0087] Gel rate deviation coefficient = (predicted gel rate - control gel rate of the batch to be applied) ÷ control gel rate of the batch to be applied;

[0088] pH deviation coefficient = (Control pH of the batch to be applied - Actual pH of the batch to be applied) ÷ Control pH of the batch to be applied;

[0089] Corrected curing time = Control curing time × (1 + (pH deviation coefficient - gel rate deviation coefficient) × Time correction coefficient 2);

[0090] Curing time is a key parameter for the resin to change from a "gel state" to a "fully cured state". pH deviation affects the activity of the curing agent (and thus changes the curing rate; higher alkalinity → stronger curing agent activity → faster curing), while gel rate deviation reflects the difference in the rhythm of the early gelation process (for example, faster gel rate → earlier curing start → shorter actual curing time). Both together determine the suitability of the final curing time.

[0091] Time correction factor two: The ratio of theoretical to actual curing time measured in laboratory small-scale tests, fine-tuned based on production data or referenced from industry data. Value: 0.1~0.5 (0.05~0.2 for small deviations / simple structures; 0.2~0.3 for conventional scenarios; 0.3~0.5 for large deviations / complex structures).

[0092] Among them, vacuum period one: from the start of glue injection to "the time when glue injection is completed + 0.5 times the correction gel time";

[0093] Vacuum Period Two: From "Time of completion of glue injection + 0.5 times correction gel time" to "Time of completion of glue injection + 1.5 times correction gel time";

[0094] Vacuum Period Three: From "Time of completion of glue application + 1.5 times correction gel time" to "Time of completion of glue application + correction curing time".

[0095] In this embodiment, "control" refers to the set of parameters obtained by standard condition testing of the same type of molding injection material (with completely identical formula and model) under the qualified state of "the final molded hood performance meets the production indicators (such as strength, appearance, etc. meet the hood quality requirements)". (These parameters can come from qualified standard samples of this type of material and material parameters corresponding to qualified products produced in previous batches.)

[0096] Comparative gelation time: The time required for a similar material to transform from a liquid mixture to a non-flowing gel under standard conditions of "performance qualification" (it is the benchmark time to ensure that the gelation process of the material meets the qualification requirements).

[0097] Comparison curing time: The total time for the same type of material to transform from a liquid mixture to a solid structure under the standard condition of "performance qualified" (it is the benchmark time to ensure that the performance of the material meets the standard after curing).

[0098] Control gel rate: The benchmark value of gel rate of the same type of material under "performance qualified" condition (calculated as "(gel viscosity of the material under qualified condition - injection viscosity) ÷ control gel time", which is a reference scale for measuring whether the gelation rhythm of the material meets the qualified requirements).

[0099] Reference pH: The pH reference value of the same type of material under the standard conditions of "performance qualified" (it is a pH reference value to ensure the stability of the material reaction and the final performance meets the standard).

[0100] The vacuum level at each stage is the actual vacuum pressure corresponding to each stage (vacuum period one, vacuum period two, and vacuum period three) of the same type of molding injection material under the standard condition of "performance qualified".

[0101] "Standard conditions" refer to a uniform and stable environment and operating parameters in the laboratory that simulate the normal production scenario of the molding injection material. They typically include the following core elements: temperature conditions; pressure conditions; material state: the molding injection material is precisely proportioned and stirred evenly according to the formula requirements (stirring rate and duration are fixed, such as 1000r / min, stirring for 5 minutes); test container: a small standard sample mold (such as a fiberglass molding small test mold of uniform size) is used with the same material and shape as the actual production mold.

[0102] The beneficial effects of the above technical solution are as follows:

[0103] 1. Traditional processes typically use a fixed control time / vacuum degree to cover all batches, but the viscosity and pH of different batches of materials naturally fluctuate (e.g., due to differences in raw material batches and storage environments). This process uses a chain of actual viscosity → viscosity-curing coupling characteristic factors → correction of gel time, and actual pH + gel rate deviation → correction of curing time, allowing the core time parameters to directly anchor to the "true state of the current batch of materials," avoiding the problems of "geling too fast / too slow, or curing insufficient / over-curing" caused by "applying standard parameters to individual materials."

[0104] The vacuum level is more precisely controlled by dividing the vacuum period into three phases, each corresponding to a different "viscosity deviation coefficient, pH deviation coefficient, and gelation rate deviation coefficient" to correct the control vacuum level.

[0105] Vacuum Period 1 (Initial Gel Formation): The viscosity deviation coefficient is used to adapt the vacuum level, which more accurately solves the problem of "differences in the difficulty of degassing materials with different viscosities" (high-viscosity materials require higher vacuum levels for degassing, while low-viscosity materials should avoid excessive vacuuming to prevent material splashing).

[0106] Vacuum Period Two (Mid-Gel Process): The vacuum level is adapted using the pH deviation coefficient to match the differences in the crosslinking rate of the material during this stage (pH fluctuations can affect the activity of the curing agent, and adjusting the vacuum level accordingly can maintain the uniformity of crosslinking).

[0107] Vacuum Period Three (Cure Stage): The vacuum level is adapted using the gel rate deviation coefficient to ensure the stability of the material's morphology and properties during the curing process (avoiding uneven internal stress caused by curing rate fluctuations).

[0108] The division of the three vacuum periods, which are strongly tied to the time nodes and material stages, is not a "fixed duration," but rather based on "the completion time of glue application + a multiple of the gel / curing time": Period 1 covers the "gel initiation period," adapting to the initial needs of the material's transition from a liquid to a gel state (focusing on venting); Period 2 covers the "critical gel period," adapting to the stage with the fastest cross-linking rate of the material (focusing on maintaining the morphology); Period 3 covers the "curing and setting period," adapting to the stage of the material's transition from a gel state to a solid state (focusing on ensuring mechanical properties). This division ensures that the vacuum level of each period precisely matches the material's "physical / chemical state requirements," rather than "process time requirements."

[0109] If the viscosity of a certain batch of material is too high, the gelation time will be adjusted accordingly, and the duration of the three vacuum periods will also change dynamically in sync (for example, the first period is extended to adapt to the longer exhaust time of high-viscosity materials). There is no need to manually reset the process nodes, realizing a closed loop of "batch difference → automatic parameter adaptation → automatic process adjustment".

[0110] When changing batches using traditional processes, it is necessary to manually and repeatedly adjust parameters such as time and vacuum degree (and even conduct trial production of 1-2 batches). This process, through the logic of "actual parameters → automatic parameter correction", only requires collecting viscosity and pH when changing batches, and can automatically generate suitable parameters, reducing the debugging time from several hours to several minutes, while reducing material waste during trial production.

[0111] Example 3, based on Example 2, further includes:

[0112] Step S057: With time as the horizontal axis and vacuum degree as the vertical axis, construct an initial "time-vacuum degree polygon" based on the target vacuum degrees corresponding to vacuum period one, vacuum period two, and vacuum period three, and mark the transition time range from vacuum period one to vacuum period two and the transition time range from vacuum period two to vacuum period three (the duration interval of vacuum degree switching between adjacent periods can be 10 to 20 minutes).

[0113] Vacuum period one, vacuum period two, and vacuum period three are represented as horizontal plateau segments in the broken line;

[0114] Step S058: Determine the corresponding transition slope range based on each transition time range (the endpoints and time ranges are known, so the transition slope range can be calculated); divide each transition slope range into a first-level slope segment, a second-level slope segment, and a third-level slope segment;

[0115] The slope range of the transition curve is divided into three segments: the segment with the largest slope is the first-order slope segment; the segment with the smallest slope is the third-order slope segment; and the rest are the second-order slope segments.

[0116] Obtain the "time-control vacuum degree" curve of the batch of material to be applied (this curve comes from the actual production data of a typical qualified batch of the same type of material, including parameters such as the vacuum degree of each vacuum stable section and the slope of the transition between sections), and determine the average transition slope (average slope of the transition section) from vacuum period one to vacuum period two and the average transition slope from vacuum period two to vacuum period three of the "time-control vacuum degree".

[0117] For vacuum period one to vacuum period two, the average transition slope of the slope segment in which ...

[0118] The midpoint of the corresponding target slope segment is used as the corresponding transition slope to finally determine the "time-vacuum degree piecewise linear curve". The actual step S5 process is controlled based on the "time-vacuum degree piecewise linear curve".

[0119] The beneficial effects of the above technical solution are as follows:

[0120] By using "slope range calculation + comparison curve matching", the vacuum transition is transformed from "empirical parameter adjustment" to "data-driven segmented control", reducing the fluctuation range of the vacuum change rate and avoiding the flow disorder of adhesive caused by sudden changes in vacuum.

[0121] Example 4: Based on any one of Examples 1-3, before step S5, a process is performed to determine the target injection speed of the batch injection material to be applied (the injection material applied to the batch of ...

[0122] The process of determining the target injection speed for the batch to be applied includes:

[0123] Step S01: Detect the actual gel coat layer hardness, actual gel coat layer thickness, and actual gel coat layer temperature during the production of the batch of chamber covers to be produced;

[0124] Step S02: Detect the actual viscosity and temperature of the batch material to be applied, and perform dimensionless processing on the actual gel coat layer hardness, actual gel coat layer thickness, and actual viscosity of the batch material to be applied to obtain the hardness coefficient, thickness coefficient, and viscosity coefficient respectively. Determine the current "gel coat-matrix compatibility factor" based on the hardness coefficient, thickness coefficient, and viscosity coefficient.

[0125] Step S03: Based on the actual gel coat temperature, the temperature of the batch to be applied, the coefficient of thermal expansion of the gel coat, and the coefficient of thermal expansion of the batch to be applied, determine the current interface expansion stress characteristic factor.

[0126] Step S04: Based on the model of "gel coat-matrix compatibility factor range - interface expansion stress characteristic factor range - impregnation section injection speed range", determine the target injection speed range of the impregnation section corresponding to the current "gel coat-matrix compatibility factor" and the current interface expansion stress characteristic factor.

[0127] Step S05: Obtain the reference matrix of "single chamber production injection time - injection volume - injection speed" for the batch injection to be applied, and divide it into the impregnation section matrix, the filling section matrix, and the dense section matrix; and determine the average injection speed and injection speed fluctuation coefficient (standard deviation of the injection speed of the corresponding matrix ÷ average value of the injection speed of the corresponding matrix) for the filling section matrix and the dense section matrix respectively. Determine the target injection speed range for the filling section based on the average injection speed and injection speed fluctuation coefficient of the filling section; determine the target injection speed range for the dense section based on the average injection speed and injection speed fluctuation coefficient of the dense section.

[0128] Impregnation section (actual total glue volume is 0-25% of the required total glue volume): target glue injection speed range is 8-12 ml / s;

[0129] Filling section (actual total glue volume is 25% to 75% of the required total glue volume): target glue dispensing speed range is 5 to 7 ml / s;

[0130] Dense section (actual total glue volume is 75% to 100% of the required total glue volume): target glue injection speed range is 2 to 4 ml / s;

[0131] Hardness coefficient = Actual gelcoat layer hardness ÷ Reference gelcoat layer hardness;

[0132] Thickness factor = Actual gelcoat thickness ÷ Reference gelcoat thickness;

[0133] Viscosity coefficient = Actual viscosity of the batch to be used ÷ Reference viscosity of the batch to be used;

[0134] Gelcoat-matrix compatibility factor = (hardness coefficient × thickness coefficient) ÷ viscosity coefficient;

[0135] Among them, "hardness coefficient × thickness coefficient" reflects the load-bearing capacity of the gel coat, and viscosity coefficient reflects the "flow impact" of the injected material;

[0136] Essentially, it's about the matching state between "gel coat load-bearing capacity" and "injection material impact resistance";

[0137] Interface expansion stress characteristic factor = (actual temperature of the batch to be applied - actual temperature of the gel coat layer) × |coefficient of thermal expansion of gel coat - coefficient of thermal expansion of the batch to be applied|;

[0138] The larger the absolute value of the interfacial expansion stress characteristic factor, the more significant the difference in expansion / contraction deformation between the gel coat and the injected material due to temperature difference, the stronger the tensile / compressive stress at the interface, and the higher the risk of cracking and delamination.

[0139] The characteristic factor of interfacial expansion stress is close to 0: the temperature difference is small or the expansion coefficients are close, the interfacial deformation is synchronized, and the stress risk is low.

[0140] In this embodiment, the "control" refers to the set of parameters obtained by standard condition testing of the same type of molding injection material (with completely identical formula and model) under the qualified state of "the final molded hood performance meets the production indicators (such as strength, appearance, etc. meet the hood quality requirements)". The parameter set includes the test data of qualified standard samples of this type of material, the actual production parameters corresponding to multiple batches of qualified products in the past (taking the statistical interval value and typical mean value of each type of parameter in the qualified batches)); the parameter set includes the hardness of the control gel coat layer, the thickness of the control gel coat layer, and the matrix of "single hood production injection time-injection amount-injection speed".

[0141] The model “Gelcoat-substrate compatibility factor range - interfacial expansion stress characteristic factor range - impregnation section glue injection speed range” can be a mapping table;

[0142] Line element: Interval division of gel coat-matrix adaptation factor;

[0143] Column elements: Interval division of interfacial expansion stress characteristic factors;

[0144] Cell element: The range of injection speed under the corresponding working condition (the range of gel coat-substrate compatibility factor and the range of interface expansion stress characteristic factor).

[0145] First, based on the "reference parameters of qualified products", divide the factor intervals into rows / columns. Then, through the parameter statistics of qualified working conditions, fill in the injection speed range corresponding to each interval.

[0146] The "Comparison Matrix" is a separate correlation matrix of "glue injection time - glue injection volume - glue injection speed" established using actual production data from a specific "typical qualified batch" (the batch of canopies produced fully meets the quality indicators). Row dimension: glue injection stage (wetting stage, filling stage, densifying stage); Column dimension: 3 key process parameters (glue injection time range, glue injection volume range, glue injection speed range); Cell: The specific value / range of each key process parameter item corresponding to each "glue injection stage".

[0147] Step S05 specifically involves: first obtaining the average dispensing speed of the impregnation segment matrix, and then determining the target ratio;

[0148] Target ratio = Average injection speed of the impregnation section matrix ÷ Median of the target injection speed range of the impregnation section;

[0149] Target injection speed of the filling section = average injection speed of the filling section × ;

[0150] Target injection speed of the filling section = median target injection speed of the filling section × (1 ± injection speed fluctuation coefficient of the filling section);

[0151] Target injection speed in dense section = Average injection speed in dense section × ;

[0152] Target injection speed of dense section = median target injection speed of dense section × (1 ± injection speed fluctuation coefficient of dense section);

[0153] Correction coefficient one (values ​​range from 0.9 to 1.1) and correction coefficient two (values ​​range from 0.8 to 1) are obtained based on fitting (statistical regression fitting) of actual production process matching experiments / historical qualified data;

[0154] The beneficial effects of the above technical solution are as follows:

[0155] This scheme establishes a quantitative correlation mechanism between gel coat condition (hardness, thickness) and injected material properties (viscosity, temperature) through dimensionless characterization and multi-factor coupled calculation.

[0156] The product of hardness coefficient and thickness coefficient characterizes the "load-bearing and buffering comprehensive performance" of gelcoat. Combined with the quantification of flow impact by viscosity coefficient, a quantitative assessment of the mechanical compatibility between gelcoat and injection material is achieved.

[0157] By introducing the product of temperature difference and thermal expansion coefficient difference as the characteristic factor of interfacial thermal stress, the risk of interfacial thermo-mechanical coupling can be predicted in advance.

[0158] Ultimately, this allows for precise matching between the glue injection speed in the impregnation section and the mechanical compatibility and interfacial thermal stress state of the gel coat and substrate. This solves the empirical blind spot in the traditional process of matching "material properties - glue injection parameters", and reduces the dispersion coefficient of interfacial bonding strength.

[0159] The solution achieves layered quality risk control throughout the entire glue injection process through staged matrix decomposition and statistical fluctuation constraints.

[0160] The impregnation section adopts a factor-velocity mapping model to ensure the resin penetration rate into the fiber substrate and reduce the dry spot defect rate.

[0161] The speed range of the filling section and the dense section is determined based on the average speed and fluctuation coefficient of the comparison matrix, which increases the cavity filling rate and reduces the equivalent diameter of residual bubbles in the dense section, thus reducing the mechanical property loss rate.

[0162] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A manufacturing process for a wind turbine nacelle cover, characterized in that: include: Step S1: Apply gel coat to the production mold and allow it to cure to form a gel coat layer; Step S2: Arrange auxiliary components inside the production mold; Step S3: Cover the production mold arranged in step S2 with a vacuum bag film and seal it; Step S4: Vacuum the space inside the vacuum bag membrane through the guide tube; Step S5: Inject molding material into the production mold through the injection tube; after injection, seal the air extraction port and injection port to maintain a vacuum environment for curing; In step S5, the vacuum level is adjusted in stages based on the molding injection parameters; Step S6: After curing is complete, remove the vacuum bag film; Step S7: Remove the formed wind turbine nacelle cover from the production mold; Before step S5, which involves batch processing of the batch of materials to be applied, the following is also included: Step S051: Obtain the control gel time and control curing time of the batch injection to be applied; Step S052: Collect the actual injection viscosity and actual pH of the batch feed to be applied; Step S053: Combine the actual injection viscosity and the curing agent addition ratio of the batch injection material to be applied, determine the viscosity-curing coupling characteristic factor, and correct the control gel time based on the viscosity-curing coupling characteristic factor to obtain the corrected gel time; Step S054: Determine the predicted gel rate based on the corrected gel time, determine the gel rate deviation coefficient based on the predicted gel rate, and determine the pH deviation coefficient based on the actual pH of the batch to be injected; correct the control curing time based on the gel rate deviation coefficient and the pH deviation coefficient to obtain the corrected curing time. Step S055: Based on the corrected gel time and corrected curing time, the process from the start of dispensing to the application batch dispensing and curing is divided into three vacuum periods: Vacuum Period 1, Vacuum Period 2, and Vacuum Period 3. Step S056: Obtain the target vacuum level for vacuum period one based on the viscosity deviation coefficient and the control vacuum level for vacuum period one; obtain the target vacuum level for vacuum period two based on the pH deviation coefficient and the control vacuum level for vacuum period two; obtain the target vacuum level for vacuum period three based on the gel rate deviation coefficient and the control vacuum level for vacuum period three. When performing the batch execution step S05 of the batch injection, the actual vacuum level during the vacuum period is controlled to be the corresponding target vacuum level.

2. The manufacturing process for a wind turbine nacelle according to claim 1, characterized in that: It also includes step S8: grinding the edges and corners of the formed wind turbine nacelle and spraying the inner layer of gel coat.

3. The manufacturing process for a wind turbine nacelle according to claim 1, characterized in that: The auxiliary components include embedded parts and reinforcing materials, the reinforcing materials including fiberglass cloth and reinforcing ribs.

4. The manufacturing process for a wind turbine nacelle cover according to claim 1, characterized in that: The vacuuming operation is performed until the pressure is -0.08 to -0.1 MPa.

5. The manufacturing process for a wind turbine nacelle cover according to claim 1, characterized in that: In step S1, the wet film thickness of the gel coat is 0.5–0.8 mm.

6. The manufacturing process for a wind turbine nacelle cover according to claim 1, characterized in that: Vacuum Period 1: From the start of glue application to the completion of glue application + 0.5 times the correction gel time; Vacuum Period Two: from "Completion time of glue application + 0.5 times correction gel time" to "Completion time of glue application + 1.5 times correction gel time"; Vacuum Period 3: from "dip filling completion time + 1.5 times correction gel time" to "dip filling completion time + correction curing time".

7. The manufacturing process for a wind turbine nacelle according to claim 1, characterized in that: When the batch of chamber covers to be produced is being manufactured, the target injection speed for the batch to be applied is determined before step S5. During the production of the batch of chamber covers to be produced, the injection is performed at the target injection speed.

8. The manufacturing process for a wind turbine nacelle according to claim 7, characterized in that: The process of determining the target injection speed for the batch to be applied includes: Step S01: Detect the actual gel coat layer hardness, actual gel coat layer thickness, and actual gel coat layer temperature during the production of the batch of chamber covers to be produced; Step S02: Detect the actual viscosity and temperature of the batch material to be applied, and perform dimensionless processing on the actual gel coat layer hardness, actual gel coat layer thickness, and actual viscosity of the batch material to be applied to obtain the hardness coefficient, thickness coefficient, and viscosity coefficient respectively. Determine the current "gel coat-matrix compatibility factor" based on the hardness coefficient, thickness coefficient, and viscosity coefficient. Step S03: Based on the actual gel coat temperature, the temperature of the batch to be applied, the coefficient of thermal expansion of the gel coat, and the coefficient of thermal expansion of the batch to be applied, determine the current interface expansion stress characteristic factor. Step S04: Based on the model of "gel coat-matrix compatibility factor range - interface expansion stress characteristic factor range - impregnation section injection speed range", determine the target injection speed range of the impregnation section corresponding to the current "gel coat-matrix compatibility factor" and the current interface expansion stress characteristic factor. Step S05: Obtain the reference matrix of "single chamber production injection time - injection volume - injection speed" for the batch injection to be applied, and divide it into the impregnation section matrix, the filling section matrix, and the dense section matrix; and determine the average injection speed and injection speed fluctuation coefficient corresponding to the filling section matrix and the dense section matrix respectively. Based on the average injection speed and injection speed fluctuation coefficient of the filling section, determine the target injection speed range of the filling section; and based on the average injection speed and injection speed fluctuation coefficient of the dense section, determine the target injection speed range of the dense section.

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