Molding method of wind power blade, wind power blade and wind generating set

Abstract

The invention discloses a forming method of a wind power blade, the wind power blade and a wind generating set, and the forming method of the wind power blade comprises the steps that a blade mold is provided, and the blade mold is provided with a cavity and a noise reduction groove which communicate with each other; a reinforcing layer is laid on the inner wall of the cavity, so that the reinforcing layer is embedded into the noise reduction groove; injecting resin into the reinforcing layer; the resin injected into the reinforcing layer is cured to obtain a blade semi-finished product, the blade semi-finished product comprises a blade body and a noise reduction convex part arranged on the blade body, the blade body is formed in the cavity, and the noise reduction convex part is formed in the noise reduction groove; the blade semi-finished product is shaped to obtain the wind power blade, the wind power blade comprises a blade body and noise reduction sawteeth arranged on the blade body, the noise reduction sawteeth are formed by shaping the noise reduction convex parts, and the blade body is formed by shaping the blade body. According to the embodiment of the invention, the problem that a noise reduction accessory in the related technology is easy to fall off can be solved, and the reliability of the formed wind power blade and the wind generating set applying the wind power blade is ensured.

Description

Technical Field

[0001] This application relates to the field of wind power generation technology, and in particular to a method for forming a wind turbine blade, a wind turbine blade, and a wind turbine generator set. Background Technology

[0002] As the capacity of individual wind turbine generators increases, the required blades become longer. This leads to increased radiated noise from the blades. Related technologies address this by attaching noise-reducing accessories to the blades to alter airflow characteristics, thereby reducing aerodynamic noise.

[0003] However, the wind turbine blades formed by the molding method of the blade with noise reduction accessories in the related technology are at risk of the noise reduction accessories falling off, which affects the reliability of the wind turbine blades and the wind turbine generators they are used in. Summary of the Invention

[0004] This application provides a method for forming a wind turbine blade, a wind turbine blade, and a wind turbine generator set, which can solve the problem of noise reduction accessories easily falling off in related technologies and ensure the reliability of the formed wind turbine blade and the wind turbine generator set it is used in.

[0005] On one hand, this application provides a method for forming a wind turbine blade, comprising: providing a blade mold having a cavity and a noise reduction groove, the noise reduction groove being connected to the cavity; laying a reinforcing layer on the inner wall of the cavity, such that the reinforcing layer is embedded in the noise reduction groove to fill the noise reduction groove; injecting resin into the reinforcing layer, the resin impregnating the reinforcing layer; curing the resin injected into the reinforcing layer to obtain a blade semi-finished product, the blade semi-finished product comprising a blade body and a noise reduction protrusion disposed on the blade body, the blade body being formed in the cavity, the noise reduction protrusion being formed in the noise reduction groove, the resin layer of the noise reduction protrusion and the resin layer of the blade body being an integral structure; shaping the blade semi-finished product to obtain a wind turbine blade, the wind turbine blade comprising a blade body and a noise reduction serration disposed on the blade body, the noise reduction serration being formed by shaping the noise reduction protrusion, and the blade body being formed by shaping the blade body.

[0006] In some embodiments, the reinforcing layer includes an outer fiber cloth, a core material, and an inner fiber cloth. The step of laying the reinforcing layer on the inner wall of the cavity so that the reinforcing layer is embedded in the noise reduction groove includes: laying the outer fiber cloth on the inner wall of the cavity so that a portion of the structure of the outer fiber cloth is embedded in the noise reduction groove to fill the noise reduction groove; placing the core material inside the outer fiber cloth; and laying the inner fiber cloth inside the core material.

[0007] In some embodiments, the step of laying the inner fiber cloth on the inner side of the core material includes: laying the inner fiber cloth on the inner side of the core material, and the inner fiber cloth extending to the inner side of the portion of the outer fiber cloth located within the noise reduction groove; or, laying the inner fiber cloth on the inner side of the core material, the inner fiber cloth extending to the inner side of the outer fiber cloth, and terminating on the inner side of the portion of the outer fiber cloth located outside the noise reduction groove.

[0008] In some embodiments, the outer fiber cloth includes noise-reducing fiber cloth and blade fiber cloth. At least one layer of noise-reducing fiber cloth includes a filling portion and an extension portion connected to each other. The shape of the filling portion is adapted to the shape of the noise-reducing groove. The step of laying the outer fiber cloth of the reinforcing layer on the inner wall of the cavity, such that a part of the structure of the outer fiber cloth is embedded in the noise-reducing groove to fill the noise-reducing groove, includes: alternately laying the noise-reducing fiber cloth and the blade fiber cloth, the blade fiber cloth being laid on the inner wall of the cavity, the filling portion being laid in the noise-reducing groove and filling the noise-reducing groove, the extension portion extending into the cavity, and the extension portion being sandwiched between two adjacent layers of blade fiber cloth.

[0009] In some embodiments, a blade mold is provided, the blade mold including a cavity and a noise reduction groove, the noise reduction groove being connected to the cavity, the step of which includes: providing a base mold including a cavity; making positioning marks on the inner wall of the cavity according to a preset noise reduction position of the wind turbine blade; and machining a noise reduction groove at the positioning marks according to a preset noise reduction shape.

[0010] In some embodiments, the blade mold includes a first mold and a second mold, the cavity includes a first forming groove and a second forming groove, the first forming groove is disposed on the first mold, the second forming groove is disposed on the second mold, and the noise reduction groove is disposed on the first mold and / or the second mold; the blade semi-finished product includes a first housing formed in the first mold and a second housing formed in the second mold, and the step of removing the blade semi-finished product from the blade mold includes: removing the first housing from the first mold, removing the second housing from the second mold; and closing the first housing and the second housing to obtain the blade semi-finished product.

[0011] In some embodiments, the noise reduction groove is a strip-shaped groove, used to shape the blade semi-finished product to obtain a wind turbine blade. The wind turbine blade includes a blade body and noise reduction serrations disposed on the blade body. The noise reduction serrations are formed by shaping the noise reduction protrusion. The step of shaping the blade body from the blade body includes: obtaining tooth profile parameters of a preset noise reduction shape; drawing a cutting line on the noise reduction protrusion according to the tooth profile parameters; cutting the noise reduction protrusion along the cutting line; and grinding the cut noise reduction protrusion to obtain noise reduction serrations; and / or, the noise reduction groove is a tooth-shaped groove, used to shape the blade semi-finished product to obtain a wind turbine blade. The wind turbine blade includes a blade body and noise reduction serrations disposed on the blade body. The noise reduction serrations are formed by shaping the noise reduction protrusion. The step of shaping the blade body from the blade body includes: obtaining deviation parameters between the noise reduction protrusion and the preset noise reduction shape; and grinding the noise reduction protrusion according to the deviation parameters to obtain noise reduction serrations.

[0012] On the other hand, this application provides a wind turbine blade, including: a blade body, including a skin, the skin including a skin fiber layer and a skin resin layer, the skin fiber layer being disposed within the skin resin layer; and noise-reducing serrations, including a noise-reducing fiber layer and a noise-reducing resin layer, the noise-reducing fiber layer being disposed within the noise-reducing resin layer, the noise-reducing resin layer and the skin resin layer being an integral structure.

[0013] In some embodiments, the skin fiber layer includes an outer fiber layer and an inner fiber layer, the outer fiber layer being disposed outside the inner fiber layer, the outer fiber layer and the noise-reducing fiber layer being an integral structure, and the inner fiber layer and the noise-reducing fiber layer being separate structures; or, the noise-reducing fiber layer includes a noise-reducing outer layer and a noise-reducing inner layer, the outer noise-reducing outer layer being disposed outside the inner noise-reducing inner layer, the outer fiber layer and the noise-reducing outer layer being an integral structure, and the inner fiber layer and the noise-reducing inner layer being an integral structure; or, the skin fiber layer and the noise-reducing fiber layer being separate structures.

[0014] In another aspect, embodiments of this application provide a wind turbine generator set, including the wind turbine blades provided above.

[0015] This application provides a method for molding a wind turbine blade. A blade mold with interconnected cavities and noise-reducing grooves is provided. A reinforcing layer is laid on the inner wall of the cavity and embedded in the noise-reducing grooves. The reinforcing layer is impregnated with resin, and then the resin injected into the reinforcing layer is cured. The blade semi-finished product is removed from the blade mold and shaped to obtain the wind turbine blade. The noise-reducing protrusions and the blade body are integrally molded. The noise-reducing protrusions are shaped into noise-reducing serrations, and the blade body is shaped into the blade body. This allows the resin layer of the noise-reducing serrations and the resin layer of the blade body to be formed in the same curing step, improving the interlayer bonding between the resin layer of the noise-reducing serrations and the resin layer of the blade body, and increasing the connection strength between the noise-reducing serrations and the blade body. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a flowchart illustrating a method for forming wind turbine blades according to some embodiments of this application; Figure 2 The flowchart shows steps S310 to S360 of the wind turbine blade forming method according to some embodiments of this application. Figure 3 This is a flowchart of step S200 of a method for forming wind turbine blades according to some embodiments of this application; Figure 4 This is a schematic diagram of step S231 of the wind turbine blade forming method of some embodiments of this application; Figure 5 This is a schematic diagram of step S232 of the wind turbine blade forming method according to some embodiments of this application; Figure 6 This is a schematic diagram of step S214 of the wind turbine blade forming method according to some embodiments of this application; Figure 7 This is a schematic diagram of step S214 of the wind turbine blade forming method in some other embodiments of this application; Figure 8 It shows Figure 7 Sectional view at point AA; Figure 9 This is a flowchart of step S100 of a method for forming wind turbine blades according to some embodiments of this application; Figure 10 This is a flowchart of step S600 of a method for forming wind turbine blades according to some embodiments of this application; Figure 11 This is a flowchart of step S700 of a method for forming wind turbine blades according to some embodiments of this application; Figure 12 A flowchart of step S700 of a method for forming wind turbine blades according to other embodiments of this application; Figure 13 A flowchart of step S700 of a method for forming wind turbine blades according to some embodiments of this application; Figure 14 This is a schematic diagram of the structure of a wind turbine blade in some embodiments of this application, where the outer fiber layer and the noise-reducing fiber layer are an integral structure and the inner fiber layer and the noise-reducing fiber layer are separate structures. Figure 15This is a schematic diagram of the structure of a wind turbine blade in some embodiments of this application, in which the fiber outer layer and the noise reduction outer layer are an integral structure and the fiber inner layer and the noise reduction inner layer are an integral structure. Figure 16 This is a schematic diagram of the structure of a wind turbine blade in some other embodiments of this application, in which the fiber outer layer and the noise reduction outer layer are an integral structure and the fiber inner layer and the noise reduction inner layer are an integral structure. Figure 17 This is a schematic diagram of the structure of a wind turbine blade in some embodiments of this application, where the skin fiber layer and the noise reduction fiber layer are separate structures. Figure 18 This is a schematic diagram of the forming method of wind turbine blades in related technologies; Figure 19 This is a schematic diagram of the structure of laying noise-reducing fiber cloth in the wind turbine blade forming method of some embodiments of this application; Figure 20 This is a schematic diagram of the structure of laying a first reinforcing ridge and a second reinforcing ridge in a noise reduction groove in a method for forming wind turbine blades according to some embodiments of this application. Figure 21 This is a schematic diagram of the structure of the noise reduction sawtooth in some embodiments of this application; The above-mentioned figures include the following explanations of reference numerals: 1. Wind turbine blades; 2. Blades; 3. Noise reduction accessories; 4. Adhesive; 10. Blade mold; 11. Cavity; 12. Noise reduction groove; 121. First groove section; 122. Second groove section; 20. Reinforcing layer; 21. Outer fiber cloth; 211. Noise-reducing fiber cloth; 2111. Filling portion; 2112. Extension portion; 2113. Fiberglass cloth layer; 2114. Reinforcing rib layer; 2115. First reinforcing rib; 2116. Second reinforcing rib; 212. Blade fiber cloth; 22. Core material; 23. Inner fiber cloth; 24. First reinforcing rib; 25. Second reinforcing rib; 311. Skin fiber layer; 3111. Fiber outer layer; 3112. Fiber inner layer; 3113. Blade core material; 32. Noise-reducing serrations; 321. Noise-reducing fiber layer; 3211. Noise-reducing outer layer; 3212. Noise-reducing inner layer; 322. Connecting section; 323. Toothed section; D. Depth of the noise reduction groove; X, length direction; Y, width direction. Detailed Implementation

[0018] The features and exemplary embodiments of various aspects of this application will be described in detail below. To make the objectives, technical solutions, and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain this application and not to limit it. For those skilled in the art, this application can be implemented without some of these specific details. The following description of the embodiments is merely to provide a better understanding of this application by illustrating examples.

[0019] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus that includes said element.

[0020] like Figure 18 As shown, currently, for large-megawatt wind turbine generators, the noise mainly comes from the aerodynamic noise of the wind turbine blades 1. In related technologies, noise reduction accessories 3 are bonded to the blades 2 to change the airflow characteristics, thereby reducing the generation of aerodynamic noise.

[0021] The inventors have noticed that when using adhesive 4 to install the noise reduction accessory 3, there is a problem of limited adhesive strength during wind turbine operation: (1) Long-term alternating stress may cause the adhesive at the bonding joint to gradually fail, which will reduce the bonding strength between the noise reduction accessory 3 and the blade 2, and may even cause it to fall off. Once the noise reduction accessory 3 falls off, it will not only lose its function of improving the performance of the blade 2, but may also damage other components of the wind turbine generator. (2) The performance of the adhesive at the bonding point will be affected by environmental factors, such as ultraviolet radiation and humidity changes. During long-term outdoor operation, the adhesive is prone to aging and embrittlement, reducing the bonding effect. Especially in high temperature, high humidity or low temperature environments, the performance of the adhesive deteriorates faster, further shortening the effective service life of the noise reduction accessory 3. (3) If there is a problem with the bonding, the expired glue needs to be cleaned first, the bonding surface needs to be retreated, and then the bonding operation can be carried out. This requires professional equipment and technicians, and the effect after repair is often difficult to reach the performance level of the initial installation.

[0022] Furthermore, in the relevant technologies, the installation of the noise reduction accessory 3 is carried out after the blade 2 is demolded. The blade 2 surface is cleaned, polished, and coated with adhesive before the noise reduction accessory 3 is installed. This makes the installation process of the noise reduction accessory 3 complex, the operation time of personnel is long, and the post-processing cycle of the wind turbine blade 1 is also correspondingly longer.

[0023] To address the problems of the prior art, this application provides a method for forming a wind turbine blade, a wind turbine blade, and a wind turbine generator set. The method for forming a wind turbine blade provided in this application will be described first.

[0024] like Figures 1 to 17 As shown in the figure, this application provides a method for forming a wind turbine blade, including the following steps: S100. A blade mold 10 is provided. The blade mold 10 has a cavity 11 and a noise reduction groove 12, and the noise reduction groove 12 is connected to the cavity 11.

[0025] In the process of forming wind turbine blades using blade mold 10, cavity 11 provides forming space for blade body and noise reduction groove 12 provides forming space for noise reduction protrusion. Since cavity 11 and noise reduction groove 12 are connected, the blade body and noise reduction protrusion can be integrally formed in the same forming process.

[0026] Optionally, the blade mold 10 and the cavity 11 may have at least the following two structural forms: (1) The blade mold 10 is an integral mold, that is, the blade mold 10 is an integral structure, and the cavity 11 is also a complete cavity set on the blade mold 10. The blade mold 10 is provided with a cavity opening that communicates with the cavity 11. The cavity opening provides an operating channel and space for operations such as laying the reinforcing layer 20 and injecting resin. The reinforcing layer 20 is laid on the inner wall of the cavity 11, and then resin is injected into the reinforcing layer 20 and cured, thereby obtaining a blade semi-finished product formed in the cavity 11. (2) The blade mold 10 is a split mold. The blade mold 10 includes a first mold and a second mold that are set separately. The cavity 11 includes a first forming groove and a second forming groove. The first forming groove is set on the first mold and the second forming groove is set on the second mold. The noise reduction groove 12 can be set on the first mold and connected to the first forming groove. The noise reduction groove 12 can also be set on the second mold and connected to the second forming groove. The first mold and the second mold can both be provided with noise reduction grooves 12.

[0027] Optionally, the noise reduction groove 12 may have at least the following two structural forms. In some optional embodiments, the noise reduction groove 12 may include a strip-shaped groove extending along a predetermined extension direction of the noise reduction saw teeth. Of course, in some embodiments, the noise reduction groove 12 may also include a plurality of grooves spaced apart along the predetermined extension direction of the noise reduction saw teeth.

[0028] S200, The reinforcing layer 20 is laid on the inner wall of the cavity 11 so that the reinforcing layer 20 is embedded in the noise reduction groove 12 to fill the noise reduction groove 12.

[0029] Optionally, the reinforcing layer 20 includes at least a fiber cloth and may also include a core material 22. When laying the reinforcing layer 20, the fiber cloth is embedded in the noise reduction groove 12 to fill the noise reduction groove 12 with the fiber cloth.

[0030] Optionally, when the blade mold 10 is an integral mold, the blade mold 10 is provided with a cavity opening that communicates with the cavity 11. A reinforcing layer 20 is laid on the inner wall of the cavity 11 through the cavity opening, wherein the cavity opening provides an operating channel for laying the reinforcing layer 20. When the blade mold 10 is a split mold, the cavity 11 includes a first forming groove and a second forming groove. The first forming groove is disposed on the first mold, and the second forming groove is disposed on the second mold. A reinforcing layer 20 is laid on the groove walls of the first forming groove and the groove walls of the second forming groove, respectively.

[0031] In step S200, since the reinforcing layer 20 is laid on the inner wall of the cavity 11 and embedded in the noise reduction groove 12, the reinforcing layer 20 is used as the reinforcing material of the wind turbine blade, so that the reinforcing layer 20 can optimize the mechanical properties of the blade body and the noise reduction protrusion, and improve the strength and stiffness of the blade body and the noise reduction protrusion.

[0032] S400, Resin is injected into the reinforcing layer 20, and the reinforcing layer 20 is impregnated with resin.

[0033] In step S400, resin is injected into the reinforcing layer 20 to impregnate the reinforcing layer 20, thereby improving the adhesion between the resin and the reinforcing layer 20 and enhancing the integrity, density, and strength of the blade body and the noise-reducing protrusion. Furthermore, the resin protects the fibers of the reinforcing layer 20 from environmental erosion, such as ultraviolet radiation, rainwater, and salt spray, thus improving the durability of the wind turbine blade.

[0034] S500, the resin injected into the reinforcing layer 20 is cured to obtain a blade semi-finished product. The blade semi-finished product includes a blade body and a noise reduction protrusion disposed on the blade body. The blade body is formed in the cavity 11, and the noise reduction protrusion is formed in the noise reduction groove 12. The resin layer of the noise reduction protrusion and the resin layer of the blade body are an integral structure.

[0035] In step S500, the resin changes from a liquid to a solid state, thereby forming a solid resin layer. The reinforcing layer 20 is then encapsulated within the resin layer, and the reinforcing layer 20 is tightly bonded to the resin layer, forming a robust composite material structure. The noise-reducing protrusion and the blade body are integrally formed.

[0036] It should be noted that in step S500, the substances injected into the reinforcing layer 20 include, but are not limited to, resin. In addition to resin, additives that improve the performance of the resin may also be included, such as curing agents such as polyetheramine and acid anhydride curing agents used to accelerate the curing process of the resin, diluents used to reduce the viscosity of the resin, and stabilizers such as antioxidants and light stabilizers used to improve the durability of the leaves.

[0037] S600, Remove the semi-finished blade from the blade mold 10.

[0038] S700. The blade semi-finished product is shaped to obtain a wind turbine blade. The wind turbine blade includes a blade body and noise reduction serrations set on the blade body. The noise reduction serrations are obtained by shaping the noise reduction protrusions. The blade body is obtained by shaping the blade body.

[0039] In the S700, by shaping the semi-finished blades, excess resin and fibers can be removed, the noise-reducing protrusions can be shaped into noise-reducing serrations, and the blade body can be shaped into the blade body. This ensures that the surfaces of the noise-reducing serrations and the blade body are smooth, thereby reducing the aerodynamic drag of the wind turbine blades.

[0040] The wind turbine blade forming method provided in this embodiment enables the noise reduction protrusion and the blade body to be integrally formed. The noise reduction protrusion is shaped into noise reduction serrations, and the blade body is shaped into the blade body. This allows the resin layer of the noise reduction serrations and the resin layer of the blade body to be formed in the same curing step, improving the interlayer bonding between the resin layer of the noise reduction serrations and the resin layer of the blade body, and improving the connection strength between the noise reduction serrations and the blade body. The theoretical lifespan of the noise reduction serrations is consistent with the lifespan of the blade body.

[0041] Furthermore, since the noise reduction protrusion and the blade body are integrally formed, there is no need to prefabricate noise reduction accessories. After obtaining the blade semi-finished product, only the blade semi-finished product needs to be shaped to obtain the wind turbine blade. There is no need to install noise reduction accessories, which simplifies the process flow of wind turbine blades, saves manpower and material resources, and improves turnover efficiency.

[0042] Furthermore, during long-term outdoor operation, the noise-reducing saw teeth and the connection points between them and the blade body are less prone to aging and embrittlement, thus improving weather resistance. This is especially true in high-temperature, high-humidity, or low-temperature environments, further extending the effective service life of the noise-reducing saw teeth.

[0043] Moreover, the noise reduction saw teeth can be repaired in the same way as the blade body. The repair can be completed by simply grinding and laying up the blade, making the post-repair process simple.

[0044] Optionally, such as Figure 2 As shown, after step S200 and before step S400, the method for forming wind turbine blades further includes the following steps: S310. A release agent is placed on the inner wall of the cavity 11, and a release cloth is laid on the inner surface of the reinforcing layer 20.

[0045] In step S310, by setting a release agent and a release cloth, the subsequent demolding operation is facilitated.

[0046] S320. Lay a flow guiding medium on the inside of the release cloth and release agent.

[0047] In step S320, the guiding medium may include a guiding mesh or a separating membrane. The function of the guiding medium is to guide the resin to permeate uniformly into the reinforcing layer 20 under vacuum pressure, ensuring that the resin can fully wet the reinforcing layer 20 and avoiding the generation of bubbles and voids.

[0048] S330. Install the glue injection system, place the glue injection port at the predetermined location, and connect the glue injection pipeline.

[0049] S340. After completing the installation of the dispensing system, lay a vacuum bag film above the flow medium and the dispensing port to form a vacuum system for the dispensing system.

[0050] In step S340, sealing strips are used to bond the edges of the vacuum bag film.

[0051] S350, Inspect and test the entire vacuum system.

[0052] In step S350, a vacuum is drawn through the dispensing port and the vacuum pump is disconnected to check whether the dispensing system can maintain the set vacuum level, so as to ensure that there is no air leakage during the dispensing process.

[0053] S360. Preheat the blade mold 10 and the reinforcing layer 20 until they reach the preheating temperature.

[0054] In step S360, the preheating temperature is typically determined based on the resin's curing requirements and process parameters.

[0055] like Figures 3 to 6 As shown, in some embodiments, step S200 includes: S210. Lay the outer fiber cloth 21 on the inner wall of the cavity 11, so that part of the structure of the outer fiber cloth 21 is embedded in the noise reduction groove 12 to fill the noise reduction groove 12.

[0056] Optionally, laying the outer fiber cloth 21 on the inner wall of the cavity 11 means that the outer fiber cloth 21 covers the inner wall of the cavity 11.

[0057] S220. Place the core material 22 inside the outer fiber cloth 21.

[0058] Optionally, placing the core material 22 inside the outer fiber cloth 21 means laying the core material 22 at intervals on the side of the outer fiber cloth 21 away from the blade mold 10.

[0059] S230. Lay the inner fiber cloth 23 on the inside of the core material 22.

[0060] Optionally, laying the inner fiber cloth 23 on the inside of the core material 22 means covering the side of the core material 22 away from the outer fiber cloth 21 with the inner fiber cloth 23, so that the outer fiber cloth 21 and the inner fiber cloth 23 sandwich the core material 22 in the middle.

[0061] Optionally, both the core material 22 and the inner fiber cloth 23 are located outside the noise reduction groove 12.

[0062] By sequentially laying out the outer fiber cloth 21, the core material 22, and the inner fiber cloth 23, the formed wind turbine blade can directly or indirectly contact the air through the outer fiber cloth 21, which can protect the inner core material 22 and inner fiber cloth 23 from environmental erosion, such as ultraviolet rays, rainwater, and salt spray. The core material 22 (such as PVC foam and PET foam) has good chemical resistance and weather resistance, and can maintain its performance for a long time in harsh environments. The inner fiber cloth 23 can provide additional support to prevent the core material 22 from deforming or being damaged during long-term operation.

[0063] The outer fiber cloth 21 and the inner fiber cloth 23 can be selected from glass fiber fabric or carbon fiber fabric according to the design requirements of the wind turbine blade.

[0064] By using the above steps S210 to S230 to lay the reinforcing layer 20, the resin layer of the noise-reducing serrations of the formed wind turbine blade and the resin layer of the blade body are integrated into one structure, which improves the interlayer bonding between the resin layer of the noise-reducing serrations and the resin layer of the blade body, improves the connection strength between the noise-reducing serrations and the blade body and the service life of the wind turbine blade, and eliminates the need for prefabrication and installation of noise-reducing accessories, thus simplifying the manufacturing process of wind turbine blades.

[0065] like Figure 4 As shown, in some embodiments, step S230 includes: S231. The inner fiber cloth 23 is laid on the inner side of the core material 22, and the inner fiber cloth 23 extends to the inner side of the portion of the outer fiber cloth 21 located in the noise reduction groove 12.

[0066] In some optional embodiments of this application, the inner fiber cloth 23 extends to the inner side of the portion of the outer fiber cloth 21 located in the noise reduction groove 12, such that the inner fiber cloth 23 and the outer fiber cloth 21 together constitute the outer fiber layer 3111 of the blade body and the noise reduction fiber layer of the noise reduction protrusion, thereby making the noise reduction fiber layer and the outer fiber layer 3111 integrally formed by the inner fiber cloth 23 and the outer fiber cloth 21, improving the connection strength between the noise reduction protrusion and the blade body.

[0067] like Figure 5 As shown, in some embodiments, step S230 includes: S232, The inner fiber cloth 23 is laid on the inner side of the core material 22, the inner fiber cloth 23 extends to the inner side of the outer fiber cloth 21, and terminates on the inner side of the portion of the outer fiber cloth 21 located outside the noise reduction groove 12.

[0068] In some optional embodiments of this application, the inner fiber cloth 23 extends to the inner side of the outer fiber cloth 21, which enhances the interlayer bonding strength between the outer fiber cloth 21 and the inner fiber cloth 23 after resin infusion. Since the inner fiber cloth 23 terminates on the inner side of the portion of the outer fiber cloth 21 located outside the noise reduction groove 12, the outer fiber cloth 21 constitutes the fiber layer of the blade body and the fiber layer of the noise reduction protrusion, while the inner fiber cloth 23 only constitutes the fiber layer of the blade body.

[0069] like Figures 6 to 8 As shown, in some embodiments, the outer fiber cloth 21 includes a noise-reducing fiber cloth 211 and a blade fiber cloth 212. At least one layer of noise-reducing fiber cloth 211 includes a filling portion 2111 and an extension portion 2112 connected to each other. The shape of the filling portion 2111 is adapted to the shape of the noise-reducing groove 12. Step S210 includes: alternately laying the noise-reducing fiber cloth 211 and the blade fiber cloth 212. The blade fiber cloth 212 is laid on the inner wall of the cavity 11. The filling portion 2111 is laid in the noise-reducing groove 12 and fills the noise-reducing groove 12. The extension portion 2112 extends into the cavity 11 and is sandwiched between two adjacent layers of blade fiber cloth 212.

[0070] like Figure 19 As shown, in some embodiments, the noise-reducing fiber cloth 211 includes a fiberglass cloth layer 2113 and a reinforcing rib layer 2114. When laying the noise-reducing fiber cloth 211, the fiberglass cloth layer 2113 is laid first, and then the reinforcing rib layer 2114 is laid. The reinforcing rib layer 2114 includes a plurality of first reinforcing ribs 2115 and a plurality of second reinforcing ribs 2116. The plurality of first reinforcing ribs 2115 are arranged in parallel, and the plurality of second reinforcing ribs 2116 are arranged in parallel. The first reinforcing ribs 2115 and the second reinforcing ribs 2116 are arranged at an angle to form a grid-like "skeleton support" to improve the torsional and bending resistance of the tooth body (especially suitable for thin-walled tooth bodies).

[0071] like Figure 19As shown, in some embodiments, the thickness of the first reinforcing rib 2115 is between 0.3 mm and 0.5 mm, and the thickness of the second reinforcing rib 2116 is between 0.3 mm and 0.5 mm. The first reinforcing rib 2115 extends along the length direction X, and the second reinforcing rib 2116 extends along the width direction Y.

[0072] In some optional embodiments of this application, during the sequential laying of noise-reducing fiber cloth 211 and blade fiber cloth 212, at least one layer of noise-reducing fiber cloth 211 is laid in the noise-reducing groove 12 and extends into the cavity 11 through the opening. Specifically, the filling part 2111 is laid in the noise-reducing groove 12 and fills the noise-reducing groove 12, and the extension part 2112 extends into the cavity 11. The extension part 2112 is sandwiched between two adjacent layers of blade fiber cloth 212, so that at least one layer of noise-reducing fiber cloth 211 and blade fiber cloth 212 are stacked alternately. The filling part 2111 constitutes the fiber layer of the noise-reducing protrusion, and the extension part 2112 and the blade fiber cloth 212 constitute the fiber layer of the blade body. Since the filling part 2111 and the extension part 2112 belong to the same layer of noise-reducing fiber cloth 211, the interlayer bonding area between the finally formed noise-reducing serration and the blade body is increased, and the structural strength of the connection part between the noise-reducing protrusion and the blade body is increased.

[0073] It should be noted that, compared with the technical solution of bonding the noise-reducing serrations to the blade body in related technologies, this embodiment alternately lays the noise-reducing fiber cloth and the blade fiber cloth, so that the extension and the blade fiber cloth 212 are stacked in an alternating manner. This can increase the structural strength of the connection between the noise-reducing protrusion and the blade body, while also having the advantage of easy connection operation. Specifically, in step S400, resin is injected into the reinforcing layer and the reinforcing layer is impregnated, thereby improving the density between the noise-reducing fiber cloth 211 and the blade fiber cloth 212 and avoiding the generation of cavities and air bubbles at the connection between the noise-reducing protrusion and the blade body.

[0074] Specifically, the extensions 2112 of the noise-reducing fiber cloth 211 of different layers can be sandwiched between the same two adjacent layers of blade fiber cloth 212, or they can be sandwiched between different two adjacent layers of blade fiber cloth 212.

[0075] like Figure 8 As shown, in some embodiments, in step S100, the depth D of the noise reduction groove is between 12mm and 17mm, and in step S700, the noise reduction protrusion is shaped into noise reduction serrations, the thickness of which is between 10mm and 15mm.

[0076] like Figure 20 and Figure 21As shown, the noise reduction groove 12 includes a first groove segment 121 and a second groove segment 122 arranged and connected in sequence along the width direction Y. The noise reduction serration 32 includes a connecting segment 322 formed in the first groove segment 121 and a toothed segment 323 formed in the second groove segment 122. The connecting segment 322 is stacked on the outer surface of the blade body, and the toothed segment 323 is connected to the connecting segment 322. The connecting segment 322 is the weakest part of the noise reduction serration 32 and is prone to delamination and detachment due to repeated stress. The structural design enhances the bonding strength.

[0077] In some optional embodiments of this application, the depth of the first groove 121 increases segment by segment along the width direction Y from the first groove 121 toward the second groove 122, so that the bottom of the first groove 121 forms a "multi-level bearing surface", and the force on the toothed segment 323 is transferred to the blade body layer by layer through the stepped connecting segment 322, so as to avoid the single interface of the connecting segment 322 being overloaded.

[0078] In some embodiments, along the width direction Y, the bottom of the first groove segment 121 forms a bearing surface every 1 mm to 2 mm, and there is a depth difference of 0.5 mm between two adjacent bearing surfaces.

[0079] In some optional embodiments of this application, the depth of the first groove segment 121 gradually increases in the direction from the first groove segment 121 toward the second groove segment 122 along the width direction Y, so that the stress is evenly distributed along the slope (similar to the stress logic of a "bridge approach"), reducing the risk of interface peeling.

[0080] In some embodiments, the angle between the bottom of the first groove segment 121 and the depth of the noise reduction groove is between 60° and 75°, and the dimension of the first groove segment 121 in the width direction Y is between 5mm and 8mm.

[0081] In some embodiments, in the direction from the first groove segment 121 toward the second groove segment 122 along the width direction Y, the dimensions of the second groove segment 122 gradually decrease in both the length direction X and the depth direction. This can disperse the impact / shear force borne by the toothed segment 323 to the blade body and prevent the connection between the connecting segment 322 and the toothed segment 323 from breaking due to the "neck effect".

[0082] In some embodiments, the dimension of the toothed segment 323 facing the connecting segment 322 in the length direction X is a, and the dimension of the toothed segment 323 away from the connecting segment 322 in the length direction X is b, 1.5≤a / b≤2, for example, 5mm≤a≤6mm, b=3mm.

[0083] In some embodiments, the dimension of the toothed segment 323 facing the connecting segment 322 in the depth direction of the noise reduction groove is c, and the dimension of the toothed segment 323 away from the connecting segment 322 in the depth direction X of the noise reduction groove is d, 1.5≤c / d≤2, for example, c=2mm, d=1mm.

[0084] In some embodiments, the edges of the connecting segment 322 are rounded with a radius of ≥1.5mm to replace right angles or acute angles, thereby eliminating stress concentration points and reducing crack initiation from the source.

[0085] In some embodiments, the end of the toothed segment 323 that is away from the connecting segment 322 is rounded, and the chamfer angle of the end of the toothed segment 323 that is away from the connecting segment 322 in the thickness direction is between 50° and 60°, so as to avoid the end of the toothed segment 323 that is away from the connecting segment 322 being too sharp and cracking due to excessive local stress, thereby enhancing the impact resistance of the tooth tip.

[0086] In some embodiments, such as Figure 20 As shown, the reinforcing layer 20 also includes a first reinforcing rib 24 and a second reinforcing rib 25. Before step S210, step S200 further includes: laying the first reinforcing rib 24 along the length direction X in the first groove segment 121 and laying the second reinforcing rib 25 along the width direction Y in the second groove segment 122 to form a "rib effect", which improves the overall bending rigidity of the sawtooth body (especially for slender teeth), enhances the overall lateral bending resistance of the sawtooth, and especially resists the "fan-shaped deformation" caused by centrifugal force when rotating at high speed, reduces local stress overload caused by deformation, reduces stress concentration, and improves bending resistance.

[0087] In some embodiments, the second reinforcing ridge 25 has a dimension between 0.5 mm and 1 mm in the depth direction of the noise reduction groove 12.

[0088] In some embodiments, the angle between the second reinforcing rib 25 and the length direction X is between 30° and 45°.

[0089] In some embodiments, the dimension of the first reinforcing ridge 24 in the depth direction of the noise reduction groove 12 is between 2 mm and 3 mm, and the dimension of the first reinforcing ridge 24 in the width direction Y of the noise reduction groove 12 is between 1 mm and 2 mm.

[0090] In some optional embodiments of this application, by forming noise-reducing serrations within the noise-reducing groove 12, the thickness of the final formed noise-reducing serrations can be increased by increasing the depth of the noise-reducing groove 12. Compared to the related technologies that bond noise-reducing serrations to the blade body, the related technologies require handling the noise-reducing serrations to be bonded, bonding and positioning the noise-reducing serrations, and controlling the bonding quality, which makes the noise-reducing serrations in the related technologies tend to adopt a lightweight design. However, this embodiment does not require handling the noise-reducing serrations to be bonded, bonding and positioning the noise-reducing serrations, or controlling the bonding quality, so this embodiment can enhance the strength of the noise-reducing serrations by using noise-reducing serrations with a larger thickness, and avoid the noise-reducing serrations falling off and being damaged during operation.

[0091] like Figure 9 As shown, in some embodiments, step S100 includes: S110. Provide a basic mold, which includes a cavity 11; S120. Positioning marks are made on the inner wall of cavity 11 according to the preset noise reduction position of the wind turbine blade; S130. At the positioning mark, process the noise reduction groove 12 according to the preset shape of the noise reduction saw teeth.

[0092] In some optional embodiments of this application, by processing the base mold, a blade mold 10 with interconnected noise reduction grooves 12 and cavities 11 is obtained, without the need to re-mold and process the blade mold 10, thereby reducing the cost of obtaining a blade mold 10 with interconnected noise reduction grooves 12 and cavities 11.

[0093] It should be noted that the preset noise reduction position of the wind turbine blade refers to the location of the noise reduction serrations on the blade body during the design of the wind turbine blade. The preset shape of the noise reduction serrations refers to the shape of the noise reduction serrations designed during the design of the wind turbine blade.

[0094] The preset shape of the noise reduction sawtooth includes the length of the noise reduction sawtooth, the tooth shape of the noise reduction sawtooth, and the thickness of the noise reduction sawtooth.

[0095] For example, step S130 includes at least the following two embodiments: (1) Based on the projection of the preset shape at the positioning mark, determine the area to be milled. The area to be milled is surrounded outside the projection. The area to be milled is a long strip-shaped area extending along the preset extension direction. Mill the area to be milled to obtain the noise reduction groove 12. The noise reduction groove 12 includes a strip-shaped groove extending along the preset extension direction of the noise reduction sawtooth. (2) Based on the projection of the preset shape at the positioning mark, determine the area to be milled. The area to be milled is surrounded outside the projection. The outline of the area to be milled is consistent with the outline of the preset shape. A machining allowance is reserved between the area to be milled and the projection. The area to be milled is milled to obtain the noise reduction groove 12. The noise reduction groove 12 includes multiple toothed grooves arranged at intervals along the preset extension direction of the noise reduction saw teeth.

[0096] It should be noted that, in some embodiments, in step S120, the preset noise reduction position of the wind turbine blade includes at least one of the trailing edge, leading edge, and blade tip of the wind turbine blade.

[0097] It should be noted that the preset extension direction is the blade span direction from the tip of the wind turbine blade to the root of the wind turbine blade.

[0098] Currently, for large-megawatt wind turbine generators, noise mainly comes from the aerodynamic noise at the trailing edge of the turbulent boundary layer. Therefore, in some optional embodiments of this application, the preset noise reduction position of the wind turbine blade includes the trailing edge of the wind turbine blade.

[0099] Optionally, the preset shape includes, but is not limited to, a flat triangular sawtooth, which includes multiple triangular toothed plates. When the flat triangular sawtooth is set on the trailing edge of the wind turbine blade, the multiple triangular toothed plates are arranged along the chordal direction of the trailing edge of the wind turbine blade.

[0100] like Figure 5 As shown, in some embodiments, the blade mold 10 includes a first mold and a second mold, the cavity 11 includes a first forming groove and a second forming groove, the first forming groove is disposed on the first mold, the second forming groove is disposed on the second mold, and the noise reduction groove 12 is disposed on the first mold and / or the second mold. Step S600 includes: S610. Remove the first housing from the first mold and remove the second housing from the second mold; S620. The first housing and the second housing are molded together to obtain a blade semi-finished product with noise reduction protrusions.

[0101] In some optional embodiments of this application, a first mold is used to form a first housing, and a second mold is used to form a second housing. The first housing and the second housing are then removed and the molds are closed to obtain a blade semi-finished product. This gives the blade semi-finished product the advantage of high flexibility in molding.

[0102] Optionally, different preset noise reduction positions result in different preset shapes of noise reduction serrations, causing the position of the noise reduction groove 12 on the cavity 11 to change, thereby resulting in the noise reduction groove 12 being disposed on the first mold and / or the second mold. This gives the first housing and / or the second housing a noise reduction protrusion.

[0103] It should be noted that the noise reduction groove 12 is disposed on the first mold and / or the second mold, including but not limited to the following three embodiments: (1) The noise reduction groove 12 is set on the first mold; (2) The noise reduction groove 12 is set on the second mold; (3) The noise reduction groove 12 is set on the first mold and the second mold.

[0104] like Figure 6 As shown, in some embodiments, the noise reduction groove 12 is a strip-shaped groove, and step S700 includes: S711. Draw cutting lines on the noise reduction protrusion according to the preset shape; S712. Cut the noise reduction protrusion along the cutting line; S713. Grind the cut noise-reducing protrusions to obtain noise-reducing saw teeth.

[0105] In some optional embodiments of this application, the noise reduction groove 12 is a strip-shaped groove, and the noise reduction protrusion is a strip-shaped structure. In step S700, the noise reduction protrusion can be cut according to different preset shapes to obtain noise reduction serrations of different preset shapes. This allows the same blade mold 10 to be used to form noise reduction serrations of different preset shapes, facilitating general production.

[0106] Optionally, a cutting line is drawn on the noise reduction protrusion according to the preset shape. The cutting line needs to be drawn according to the projection contour projected onto the noise reduction protrusion according to the preset shape. The cutting line needs to be set outside the projection contour, and a grinding allowance is reserved between the cutting line and the projection contour.

[0107] like Figure 7 As shown, in some embodiments, the noise reduction groove 12 is a toothed groove, and the step S700 of shaping the blade semi-finished product to obtain the wind turbine blade includes: S714. Obtain the deviation parameter between the noise reduction protrusion and the preset shape; S715. Grind the noise reduction protrusion according to the deviation parameters to obtain noise reduction saw teeth.

[0108] Optionally, obtaining the deviation parameters between the noise-reducing protrusion and the preset shape requires comparing the contour of the noise-reducing protrusion with the contour of the preset shape. The noise-reducing protrusion has a deviation portion that extends beyond the preset shape. The deviation parameters include the positional parameters of the deviation portion on the noise-reducing protrusion and the dimensional parameters of the deviation portion. The noise-reducing protrusion is then polished according to the deviation parameters, that is, the deviation portion is polished away.

[0109] In some optional embodiments of this application, the noise reduction groove 12 is a toothed groove and the noise reduction protrusion is a toothed structure. In step S700, the shaping steps of the noise reduction protrusion can be simplified, the forming efficiency is high, and it is convenient for mass production.

[0110] Optionally, such as Figure 7 and Figure 8 As shown, in some embodiments, the noise reduction groove 12 is a toothed groove, which includes multiple three-dimensional triangular grooves. The final formed noise reduction sawtooth includes multiple tooth bodies, which are three-dimensional triangular bodies, increasing the stability and strength of the noise reduction sawtooth and preventing the noise reduction sawtooth from delamination or damage after operation.

[0111] like Figure 8 As shown, in some embodiments, step S700 of shaping the blade semi-finished product to obtain the wind turbine blade includes: S710. Grind the semi-finished blades; S720: Apply a coating to the polished blade semi-finished product to obtain a wind turbine blade.

[0112] In some optional embodiments of this application, grinding can remove excess resin and fiber from the blade semi-finished product. Applying a coating to the ground blade semi-finished product can improve the weather resistance and corrosion resistance of the wind turbine blade. The coating can prevent environmental factors such as ultraviolet rays, rainwater, and salt spray from corroding the wind turbine blade and reduce maintenance costs.

[0113] Using cutting equipment such as a cutting machine, the edges of the serrated tail edge that has been cast are cut and polished, and then painted with rollers to complete the production of the serrated tail edge.

[0114] like Figures 12 to 15 As shown, another embodiment of this application provides a wind turbine blade, which includes a blade body and noise-reducing serrations 32. The blade body includes a skin, which includes a skin fiber layer 311 and a skin resin layer. The skin fiber layer 311 is disposed within the skin resin layer. The noise-reducing serrations 32 include a noise-reducing fiber layer 321 and a noise-reducing resin layer. The noise-reducing fiber layer 321 is disposed within the noise-reducing resin layer. The noise-reducing resin layer and the skin resin layer are an integral structure.

[0115] The wind turbine blade provided in this embodiment, because the noise-reducing resin layer and the skin resin layer are an integral structure, improves the interlayer bonding between the resin layer of the noise-reducing serration 32 and the resin layer of the skin, and enhances the connection strength between the noise-reducing serration 32 and the skin. Furthermore, no prefabrication of noise-reducing accessories is required, and after obtaining the blade semi-finished product with the noise-reducing serration 32, only shaping of the blade semi-finished product is needed to obtain the wind turbine blade; no noise-reducing accessories need to be installed, simplifying the wind turbine blade manufacturing process.

[0116] like Figure 12As shown, in some embodiments, the skin fiber layer 311 includes an outer fiber layer 3111 and an inner fiber layer 3112. The outer fiber layer 3111 is disposed outside the inner fiber layer 3112. The outer fiber layer 3111 and the noise reduction fiber layer 321 are an integral structure, while the inner fiber layer 3112 and the noise reduction fiber layer 321 are separate structures.

[0117] In some optional embodiments of this application, the outer fiber layer 3111 and the noise-reducing fiber layer 321 are an integral structure. Optionally, the noise-reducing fiber layer 321 and the outer fiber layer 3111 are formed from the same piece of fiber cloth to improve the connection strength between the noise-reducing saw teeth 32 and the skin.

[0118] like Figure 13 and Figure 14 As shown, in some embodiments, the skin fiber layer 311 includes an outer fiber layer 3111 and an inner fiber layer 3112, with the outer fiber layer 3111 disposed outside the inner fiber layer 3112. The noise-reducing fiber layer 321 includes a noise-reducing outer layer 3211 and a noise-reducing inner layer 3212, with the outer noise-reducing outer layer 3211 disposed outside the inner noise-reducing inner layer 3212. The outer fiber layer 3111 and the noise-reducing outer layer 3211 are an integral structure, and the inner fiber layer 3112 and the noise-reducing inner layer 3212 are an integral structure.

[0119] In some optional embodiments of this application, the outer fiber layer 3111 and the noise reduction outer layer 3211 are integral structures. Optionally, the noise reduction fiber layer 321 and the noise reduction outer layer 3211 are formed from the same piece of fiber cloth. The inner fiber layer 3112 and the noise reduction inner layer 3212 are integral structures. Optionally, the noise reduction fiber layer 321 and the noise reduction inner layer 3212 are formed from the same piece of fiber cloth, thereby improving the connection strength between the noise reduction serrations 32 and the skin.

[0120] like Figure 15 As shown, in some embodiments, the skin fiber layer 311 and the noise reduction fiber layer 321 are separate structures.

[0121] like Figures 12 to 15 As shown, in some embodiments, the skin fiber layer 311 further includes a blade core material 3113 disposed between the outer fiber layer 3111 and the inner fiber layer 3112.

[0122] In some optional embodiments of this application, the skin fiber layer 311 and the noise reduction fiber layer 321 are separate structures. Optionally, the fiber cloth used for the skin fiber layer 311 and the noise reduction fiber layer 321 is not the same piece of fiber cloth. During the use of the wind turbine blade, if the noise reduction sawtooth 32 needs to be repaired, the damage to the skin fiber layer 311 and the damage to the blade body can be reduced.

[0123] In some embodiments, at least one noise-reducing fiber layer 321 extends between two adjacent skin fiber layers 311, thereby causing at least one noise-reducing fiber layer 321 and skin fiber layer 311 to be stacked alternately, increasing the bonding area between the noise-reducing fiber layer 321 and skin fiber layer 311, and increasing the structural strength of the connection between the noise-reducing serration 32 and the blade body.

[0124] Specifically, the noise reduction fiber layer 321 of different layers extends between the same two adjacent skin fiber layers 311, or it can extend between different two adjacent skin fiber layers 311.

[0125] In some embodiments, the thickness of the noise-reducing saw teeth 32 is between 10 mm and 15 mm. This increases the thickness and strength of the noise-reducing saw teeth, preventing them from falling off or being damaged during operation.

[0126] In some embodiments, such as Figure 21 As shown, the noise-reducing sawtooth 32 includes a connecting segment 322 and a toothed segment 323 arranged and connected sequentially in the direction extending from the blade body. The connecting segment 322 is stacked on the outer surface of the blade body, and the toothed segment 323 is connected to the connecting segment 322. The connecting segment 322 is the weakest part of the noise-reducing sawtooth 32 and is prone to delamination and detachment due to repeated stress. The structural design enhances the bonding strength.

[0127] In some optional embodiments of this application, the thickness of the connecting segment 322 increases segment by segment along the width direction Y from the connecting segment 322 toward the toothed segment 323, so that the side of the connecting segment 322 away from the blade body forms a "multi-level bearing surface", which transfers the force on the toothed segment 323 to the blade body layer by layer, avoiding overload of a single interface.

[0128] In some embodiments, along the width direction Y, the side of the connecting segment 322 facing away from the blade body forms a bearing surface every 1 mm to 2 mm, and there is a depth difference of 0.5 mm between two adjacent bearing surfaces.

[0129] In some optional embodiments of this application, the thickness of the connecting segment 322 gradually increases in the direction from the connecting segment 322 toward the toothed segment 323 along the width direction Y, so that the stress is evenly distributed along the slope (similar to the stress logic of a "bridge approach"), reducing the risk of interface peeling.

[0130] In some embodiments, the angle between the side of the connecting segment 322 away from the blade body and the depth of the noise-reducing serration is between 60° and 75°, and the dimension of the connecting segment 322 in the width direction Y is between 5 mm and 8 mm.

[0131] In some embodiments, in the direction from the connecting section 322 toward the toothed section 323 along the width direction Y, the dimensions and thickness of the toothed section 323 in the length direction X gradually decrease, which can disperse the impact / shear force borne by the toothed section 323 to the blade body and prevent the connection between the connecting section 322 and the toothed section 323 from breaking due to the "neck effect".

[0132] In some embodiments, the dimension of the toothed segment 323 facing the connecting segment 322 in the length direction X is a, and the dimension of the toothed segment 323 away from the connecting segment 322 in the length direction X is b, 1.5≤a / b≤2, for example, 5mm≤a≤6mm, b=3mm.

[0133] In some embodiments, the thickness of the toothed segment 323 at the end facing the connecting segment 322 is c, and the thickness of the toothed segment 323 at the end away from the connecting segment 322 is d, where 1.5 ≤ c / d ≤ 2, for example, c = 2 mm, d = 1 mm.

[0134] In some embodiments, the edges of the connecting segment 322 are rounded with a radius of ≥1.5mm to replace right angles or acute angles, thereby eliminating stress concentration points and reducing crack initiation from the source.

[0135] In some embodiments, the end of the toothed segment 323 that is away from the connecting segment 322 is rounded, and the chamfer angle of the end of the toothed segment 323 that is away from the connecting segment 322 in the thickness direction is between 50° and 60°, so as to avoid the end of the toothed segment 323 that is away from the connecting segment 322 being too sharp and cracking due to excessive local stress, thereby enhancing the impact resistance of the tooth tip.

[0136] In some embodiments, such as Figure 21 As shown, a first reinforcing rib 24 is embedded on the side of the connecting section 322 away from the blade body, and a second reinforcing rib 25 is embedded on the side of the toothed section 323 away from the blade body, forming a "rib effect" to improve the overall bending rigidity of the sawtooth body (especially for slender teeth), enhance the overall lateral bending resistance of the sawtooth, and especially resist the "fan-shaped deformation" caused by centrifugal force when rotating at high speed, reduce local stress overload caused by deformation, reduce stress concentration, and improve bending resistance.

[0137] In some embodiments, the thickness of the second reinforcing ridge 25 is between 0.5 mm and 1 mm.

[0138] In some embodiments, the angle between the second reinforcing rib 25 and the length direction X is between 30° and 45°.

[0139] In some embodiments, the thickness dimension of the first reinforcing ridge 24 is between 2 mm and 3 mm, and the dimension of the first reinforcing ridge 24 in the width direction Y of the noise reduction groove 12 is between 1 mm and 2 mm.

[0140] In some embodiments, the noise-reducing saw teeth include multiple tooth bodies in the form of three-dimensional triangular bodies, which increases the stability and strength of the noise-reducing saw teeth and avoids delamination or damage to the noise-reducing saw teeth after operation.

[0141] Another embodiment of this application provides a wind turbine generator set, including the wind turbine blades described above. Applying the wind turbine generator set provided in this embodiment also improves the interlayer bonding between the resin layer of the noise-reducing protrusion and the resin layer of the skin, as the noise-reducing resin layer and the skin resin layer are an integral structure, thereby increasing the connection strength between the noise-reducing protrusion and the skin. Furthermore, no prefabrication of noise-reducing accessories is required, and after obtaining the blade semi-finished product with noise-reducing protrusions, only shaping of the blade semi-finished product is needed to obtain the wind turbine blade, eliminating the need for noise-reducing accessories and simplifying the wind turbine blade manufacturing process.

[0142] It should be noted that the wind turbine generator set provided in this application has the beneficial effects of the wind turbine blades in any of the aforementioned embodiments. For details, please refer to the aforementioned description of the beneficial effects of the wind turbine blades. This application will not repeat the description.

[0143] While the embodiments disclosed in this application are as described above, the content is merely for the purpose of facilitating understanding of this application and is not intended to limit the invention. Any person skilled in the art to which this application pertains may make any modifications and changes in form and detail of the implementation without departing from the spirit and scope disclosed in this application; however, the scope of protection of this application shall still be determined by the scope defined in the appended claims.

[0144] The above description is merely a specific embodiment of this application. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, substitutions for other connection methods described above can be made by referring to the corresponding processes in the foregoing method embodiments, and will not be repeated here. It should be understood that the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application.

Claims

1. A method for forming a wind turbine blade, characterized in that, include: A blade mold is provided, the blade mold having a cavity and a noise reduction groove, the noise reduction groove being connected to the cavity; The reinforcing layer is laid on the inner wall of the cavity, so that the reinforcing layer is embedded in the noise reduction groove to fill the noise reduction groove; Resin is injected into the reinforcing layer, and the resin impregnates the reinforcing layer; The resin injected into the reinforcing layer is cured to obtain a blade semi-finished product. The blade semi-finished product includes a blade body and a noise-reducing protrusion disposed on the blade body. The blade body is formed in the cavity, and the noise-reducing protrusion is formed in the noise-reducing groove. The resin layer of the noise-reducing protrusion and the resin layer of the blade body are an integral structure. Remove the semi-finished blade from the blade mold; The semi-finished blade is shaped to obtain a wind turbine blade. The wind turbine blade includes a blade body and noise-reducing serrations disposed on the blade body. The noise-reducing serrations are formed by shaping the noise-reducing protrusions. The blade body is formed by shaping the blade body.

2. The molding method according to claim 1, characterized in that, The reinforcing layer includes an outer fiber cloth, a core material, and an inner fiber cloth. The step of laying the reinforcing layer on the inner wall of the cavity so that the reinforcing layer is embedded in the noise reduction groove includes: The outer fiber cloth is laid on the inner wall of the cavity, so that part of the structure of the outer fiber cloth is embedded in the noise reduction groove to fill the noise reduction groove; The core material is placed inside the outer fiber cloth; The inner fiber cloth is laid on the inside of the core material.

3. The molding method according to claim 2, characterized in that, The step of laying the inner fiber cloth on the inner side of the core material includes: The inner fiber cloth is laid on the inner side of the core material, and the inner fiber cloth extends to the inner side of the portion of the outer fiber cloth located within the noise reduction groove; or, The inner fiber cloth is laid on the inner side of the core material, the inner fiber cloth extends to the inner side of the outer fiber cloth, and terminates on the inner side of the portion of the outer fiber cloth located outside the noise reduction groove.

4. The molding method according to claim 2, characterized in that, The outer fiber cloth includes noise-reducing fiber cloth and blade fiber cloth. At least one layer of the noise-reducing fiber cloth includes a connected filling portion and an extension portion. The shape of the filling portion is adapted to the shape of the noise-reducing groove. The step of laying the outer fiber cloth on the inner wall of the cavity, such that a portion of the structure of the outer fiber cloth is embedded in the noise-reducing groove to fill the noise-reducing groove, includes: The noise-reducing fiber cloth and the blade fiber cloth are laid alternately. The blade fiber cloth is laid on the inner wall of the cavity. The filling part is laid in the noise-reducing groove and fills the noise-reducing groove. The extension part extends into the cavity and is sandwiched between two adjacent layers of blade fiber cloth.

5. The molding method according to claim 1, characterized in that, The step of providing a blade mold, the blade mold including a cavity and a noise reduction groove, wherein the noise reduction groove is connected to the cavity, includes: A basic mold is provided, the basic mold including the cavity; Positioning marks are made on the inner wall of the cavity according to the preset noise reduction position of the wind turbine blade; At the positioning mark, the noise reduction groove is machined according to the preset shape of the noise reduction saw teeth.

6. The molding method according to claim 5, characterized in that, The blade mold includes a first mold and a second mold, and the cavity includes a first forming groove and a second forming groove. The first forming groove is disposed on the first mold, and the second forming groove is disposed on the second mold. The noise reduction groove is disposed on the first mold and / or the second mold. The blade semi-finished product includes a first shell formed in the first mold and a second shell formed in the second mold. The step of removing the blade semi-finished product from the blade mold includes: Remove the first housing from the first mold, and remove the second housing from the second mold; The first housing and the second housing are molded together to obtain the blade semi-finished product.

7. The molding method according to claim 5, characterized in that, The noise reduction groove is a strip-shaped groove. The step of shaping the semi-finished blade to obtain a wind turbine blade includes a blade body and noise reduction serrations disposed on the blade body. The noise reduction serrations are formed by shaping the noise reduction protrusions. The step of shaping the blade body from the blade body includes: Draw cutting lines on the noise reduction protrusion according to the preset shape; The noise-reducing protrusion is cut along the cutting line; The cut noise-reducing protrusions are polished to obtain the noise-reducing saw teeth; and / or, The noise reduction groove is a toothed groove. The step of shaping the semi-finished blade to obtain a wind turbine blade, the wind turbine blade including a blade body and noise reduction serrations disposed on the blade body, the noise reduction serrations being formed by shaping the noise reduction protrusions, and the step of shaping the blade body from the blade body including: Obtain the deviation parameter between the noise reduction protrusion and the preset shape; The noise-reducing protrusion is polished according to the deviation parameters to obtain the noise-reducing sawtooth.

8. A wind turbine blade, characterized in that, include: The blade body includes a skin, the skin including a skin fiber layer and a skin resin layer, the skin fiber layer being disposed within the skin resin layer; The noise-reducing saw teeth include a noise-reducing fiber layer and a noise-reducing resin layer. The noise-reducing fiber layer is disposed within the noise-reducing resin layer, and the noise-reducing resin layer and the skin resin layer are an integral structure.

9. The wind turbine blade according to claim 8, characterized in that, The skin fiber layer includes an outer fiber layer and an inner fiber layer, with the outer fiber layer disposed outside the inner fiber layer. The outer fiber layer and the noise-reducing fiber layer are an integral structure, while the inner fiber layer and the noise-reducing fiber layer are separate structures. or, The noise-reducing fiber layer includes a noise-reducing outer layer and a noise-reducing inner layer. The noise-reducing outer layer is disposed outside the noise-reducing inner layer. The fiber outer layer and the noise-reducing outer layer are an integral structure, and the fiber inner layer and the noise-reducing inner layer are an integral structure; or... The skin fiber layer and the noise reduction fiber layer are separate structures.

10. A wind turbine generator set, characterized in that, Includes the wind turbine blade as described in claim 8 or 9.

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