A large thermoplastic wind turbine blade automatic tape laying molding process based on hot pressing welding

Abstract

The application provides a large thermoplastic wind power blade automatic tape laying forming process based on hot pressure welding. Rare earth modified basalt fiber reinforced rare earth modified thermoplastic polyarylate prepreg tape is laid on the surface of a blade mold according to a set layering scheme by using a multi-axis tape laying robot, a rare earth modified thermoplastic resin gradient density core material and a rare earth modified melamine polymer skin film are synchronously embedded to form a preformed layering structure; after a high-temperature-resistant vacuum bag film is covered, vacuum is drawn and interlayer air gaps are discharged, then the mold is sent into a hot pressure forming equipment, pressure is maintained at 200-350 DEG C + / - 5 DEG C, 1.5-3 MPa + / - 0.2 MPa for 10 + / - 1 minutes, molecular chain interdiffusion of interface resin is promoted to form a seamless welded interface without a glue layer; finally, gradient cooling is performed at a speed of less than or equal to 5 DEG C / min to 70-90 DEG C or below to demold. The process can establish a precise welding parameter window for the whole thermoplastic material system, realize seamless welding between layers by relying on molecular chain interdiffusion, completely get rid of the dependence on secondary gluing, and significantly improve the structural interface bonding strength.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology for large composite material components, and in particular to an automated tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding. Background Technology

[0002] Currently, wind turbine blades of 100 meters and above generally adopt a molding process using thermosetting epoxy resin combined with vacuum infusion or prepreg molding. This type of process has many significant drawbacks: curing a single blade requires 24 to 72 hours, and the long curing cycle limits production capacity; after the resin cures, it forms an irreversible cross-linked structure, making it difficult to repair damaged blades and impossible to recycle after retirement, facing increasingly stringent environmental restrictions; the skin, main beam, and core material need to be assembled by secondary adhesive bonding, and the structural forming is highly dependent on the adhesive bonding process, with the adhesive interface becoming a major high-risk area for overall structural failure; in addition, thermosetting prepregs need to be stored at low temperatures, and the curing process must be started immediately after laying, which not only makes automation difficult but also limits the space for online adjustments during the production process.

[0003] Although there has been some research and exploration in the industry on the automatic tape laying process of thermoplastic composites, there are still three major bottlenecks in the engineering application of large-size blades: the temperature-pressure-time parameter window for adapting to the RE-ATSP / RE-2DPA-1 material system has not yet been established, and the welding process parameters are vaguely defined; the uniformity of temperature and pressure distribution during the hot pressing process of blades with a length of more than 100 meters is difficult to guarantee, and the size effect can easily cause the welding strength dispersion coefficient to be greater than 15%, making it difficult to control product consistency; at the same time, there is a lack of an effective online quality feedback mechanism, making it impossible to monitor the process and degree of interdiffusion of interfacial molecular chains in real time, resulting in a low yield of finished products.

[0004] Of particular note is the lack of a mature molding process for the RE-BF / RE-ATSP / RE-2DPA-1 all-thermoplastic material system. The optimal welding parameter window of 300℃, 2MPa, and 10 minutes, which combines high efficiency and high reliability, has not been clearly defined. Furthermore, the process has not been closed-loop controlled by integrating infrared thermal imaging and ultrasonic impedance online monitoring technologies. Therefore, there is an urgent need to develop a high-precision, high-efficiency, and intelligent automatic thermoplastic tape laying molding process for 100-meter-class wind turbine blades. Summary of the Invention

[0005] The present invention aims to solve at least one of the technical problems existing in the prior art or related art.

[0006] Therefore, the purpose of this invention is to provide an automatic tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding, which can effectively solve the problem of uneven temperature and pressure distribution during the hot pressing process of large blades of 100 meters or more, significantly reduce the dispersion of welding strength, and ensure the performance consistency throughout the entire blade length.

[0007] To achieve the above objectives, the present invention provides an automated tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding, comprising the following steps:

[0008] Step S1, Automatic tape laying: Using a multi-axis tape laying robot, the rare earth modified basalt fiber reinforced rare earth modified thermoplastic polyarylate prepreg tape is laid on the surface of the blade mold according to the set layup scheme. During the laying process, the rare earth modified thermoplastic resin gradient density core material and the rare earth modified melamine polymer skin film are embedded simultaneously to form a prefabricated layup structure.

[0009] Step S2, overall encapsulation: Cover the surface of the prefabricated layered structure with a high-temperature resistant vacuum bag film, evacuate to the target vacuum level, and remove interlayer air to eliminate air gaps;

[0010] Step S3, integrated hot press welding: The encapsulated mold is sent into a hot press molding equipment and held at a welding temperature of 200-350℃±5℃ and a welding pressure of 1.5-3MPa±0.2MPa for 10±1 minutes to allow the rare earth modified thermoplastic resin and rare earth modified melamine polymer at the layup interface to undergo molecular chain interdiffusion, forming a seamless welding interface without adhesive layer.

[0011] Step S4, Gradient Cooling Demolding: After hot pressing welding is completed, the blade is subjected to gradient cooling at a rate of ≤5℃ / min. After the temperature drops to below 70-90℃, the blade is demolded to obtain the finished thermoplastic wind turbine blade.

[0012] In the above technical solution, preferably, in step S3, the hot pressing molding equipment is equipped with a zoned temperature control system and a zoned pressure feedback system; for blade molds with a length greater than 100 meters, several independent temperature control and pressure control zones are divided along the blade length direction, and each zone independently adjusts the heating power and output pressure so that the temperature uniformity deviation of the entire blade area is controlled within ±3℃.

[0013] In any of the above technical solutions, preferably, during the hot pressing process in step S3, the temperature field distribution data of the entire surface of the blade is collected in real time by an infrared thermal imager; when the deviation between the measured temperature of any temperature control zone and the set welding temperature exceeds ±3℃, the control system automatically adjusts the heating power of the corresponding zone to correct the temperature deviation to within the range of ±3℃.

[0014] In any of the above technical solutions, preferably, during the hot pressing process in step S3, the acoustic impedance signal of the interlayer interface is collected in real time by an ultrasonic impedance probe embedded inside the mold; when the change rate of the interface acoustic impedance is less than 5-7%, it is determined that the molecular chain interdiffusion process is completed and the interface welding reaches the target strength.

[0015] In any of the above technical solutions, preferably, in step S1, the width of the rare earth modified basalt fiber reinforced rare earth modified thermoplastic polyarylate prepreg tape is 300-400mm and the single layer thickness is 0.15-0.3mm; the layup scheme adopts a [0 / ±45 / 90] symmetrical layup structure.

[0016] In any of the above technical solutions, preferably, in step S1, the multi-axis tape laying robot is a six-axis linkage tape laying robot, and the prepreg tape laying speed is 1-5m / min.

[0017] In any of the above technical solutions, preferably, in step S2, the vacuum degree after vacuuming is ≤9kPa, and this vacuum degree is maintained throughout the hot-press welding process to avoid interlayer air bubbles from affecting the welding quality.

[0018] In any of the above technical solutions, preferably, in step S4, the gradient cooling rate is 3-6℃ / min, and the overall temperature difference of the blade along the length direction during the cooling process does not exceed 4-7℃, so as to reduce the residual stress of molding and ensure that the overall stiffness deviation of the blade is less than 2%.

[0019] Compared with existing technologies, the advantages of the automatic tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding provided by this invention are as follows: It can establish a precise hot-press welding parameter window for the rare-earth modified basalt fiber reinforced rare-earth modified thermoplastic polyarylate all-thermoplastic material system, achieving seamless interlayer welding through interfacial molecular chain interdiffusion, completely eliminating the reliance on secondary adhesive bonding processes, and significantly improving the bonding strength of the structural interface; it can effectively solve the problem of uneven temperature and pressure distribution during the hot-pressing process of large-sized blades (hundreds of meters and above), greatly reducing the dispersion of welding strength and ensuring the overall blade length... It achieves consistent performance across the range; integrates online quality monitoring and closed-loop process control mechanisms to perceive the interface welding process and molecular interdiffusion in real time, enabling non-destructive quality control throughout the entire process and steadily improving the yield of finished products; it can significantly reduce the overall blade forming cycle, breaking through the production capacity bottleneck of traditional thermosetting processes, while endowing the blades with repairable and recyclable characteristics, meeting the development requirements of green manufacturing in offshore wind power; it can adapt to the automated and intelligent mass production of 100-meter to 150-meter class all-thermoplastic offshore wind turbine blades, providing reliable process support for the efficient manufacturing of deep-sea wind power equipment. Attached Figure Description

[0020] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0021] Figure 1 A flowchart illustrating the automated tape laying and molding process for large thermoplastic wind turbine blades according to an embodiment of the present invention is shown. Detailed Implementation

[0022] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0023] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0024] like Figure 1 As shown, the automated tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding according to an embodiment of the present invention includes the following steps:

[0025] Step S1, Automatic tape laying: Using a multi-axis tape laying robot, the rare earth modified basalt fiber reinforced rare earth modified thermoplastic polyarylate prepreg tape is laid on the surface of the blade mold according to the set layup scheme. During the laying process, the rare earth modified thermoplastic resin gradient density core material and the rare earth modified melamine polymer skin film are embedded simultaneously to form a prefabricated layup structure.

[0026] Step S2, overall encapsulation: Cover the surface of the prefabricated layered structure with a high-temperature resistant vacuum bag film, evacuate to the target vacuum level, and remove interlayer air to eliminate air gaps;

[0027] Step S3, integrated hot press welding: The encapsulated mold is sent into the hot press molding equipment and held under pressure for 10±1 minutes at a welding temperature of 300℃±5℃ and a welding pressure of 2MPa±0.2MPa, so that the rare earth modified thermoplastic resin and the rare earth modified melamine polymer at the layup interface undergo molecular chain interdiffusion to form a seamless welding interface without adhesive layer.

[0028] Step S4, Gradient Cooling Demolding: After hot pressing welding is completed, the blade is subjected to gradient cooling at a rate of ≤5℃ / min. After the temperature drops to below 80℃, the blade is demolded to obtain the finished thermoplastic wind turbine blade.

[0029] In this embodiment, a precise process window consisting of a welding temperature of 300℃±5℃, a welding pressure of 2MPa±0.2MPa, and a holding time of 10±1 minutes is used to drive the rare earth modified thermoplastic resin and rare earth modified melamine polymer at the layup interface to achieve sufficient molecular chain interdiffusion, forming a homogeneous welded bond structure without adhesive layer or interface pores. The interface welding strength can reach more than 95% of the base material strength, and the welding strength dispersion coefficient throughout the entire blade range can be controlled at around 3.2%, which is significantly better than the interface performance of traditional secondary adhesive bonding process, eliminating the hidden danger of the adhesive interface as a high-risk area for failure from the structural root.

[0030] The entire process, through automated tape laying and molding, vacuum sealing and degassing, integrated hot-press welding, and gradient cooling demolding, can reduce the overall molding cycle of a single 100-meter-class thermoplastic wind turbine blade to less than 8 hours. Compared to the traditional thermosetting epoxy resin vacuum infusion process, this increases production efficiency by more than 90%, significantly breaking through the capacity bottleneck of existing processes. Simultaneously, the gentle gradient cooling process at ≤5℃ / min effectively reduces the internal temperature gradient and residual molding stress of the blade, ensuring dimensional accuracy and overall stiffness uniformity after demolding. The overall stiffness deviation of the blade can be controlled within 2%.

[0031] In addition, the all-thermoplastic material system combined with the adhesive-free welding molding method gives the blades the green attributes of being repairable during service and recyclable after retirement, while avoiding the volatile organic compound emissions and environmental risks caused by the use of adhesives, making it suitable for the high-performance, long-life and green low-carbon manufacturing requirements of large offshore wind turbine blades.

[0032] In the above embodiments, preferably, in step S3, the hot pressing molding equipment is equipped with a zoned temperature control system and a zoned pressure feedback system; for blade molds with a length greater than 100 meters, several independent temperature control and pressure control zones are divided along the blade length direction, and each zone independently adjusts the heating power and output pressure so that the temperature uniformity deviation of the entire blade area is controlled within ±3℃.

[0033] In this embodiment, the size effect of large blades can be effectively offset by the independent control of zones, which solves the problems of temperature drop and uneven pressure distribution along the blade. This ensures that the entire area of ​​the blade from the root to the tip is within a stable welding process window, greatly reduces the dispersion of welding strength, ensures the consistency of the structural performance of the entire blade, and avoids defects such as under-welding or over-welding in local areas.

[0034] In any of the above embodiments, preferably, during the hot pressing process in step S3, the temperature field distribution data of the entire surface of the blade is collected in real time by an infrared thermal imager; when the deviation between the measured temperature of any temperature control zone and the set welding temperature exceeds ±3℃, the control system automatically adjusts the heating power of the corresponding zone to correct the temperature deviation to within ±3℃.

[0035] In this embodiment, by utilizing the global temperature sensing and closed-loop control mechanism of infrared thermal imaging, temperature fluctuations during the hot pressing process can be dynamically and in real time corrected, further improving the uniformity and stability of the blade temperature field, avoiding the influence of temperature deviation on the interdiffusion of resin molecular chains, providing a precise temperature control basis for stable welding interface quality, while reducing the workload of manual temperature calibration and improving the level of process automation.

[0036] In any of the above embodiments, preferably, during the hot pressing process in step S3, the acoustic impedance signal of the interlayer interface is collected in real time by an ultrasonic impedance probe embedded inside the mold; when the change rate of the interface acoustic impedance is less than 5%, it is determined that the molecular chain interdiffusion process is completed and the interface welding reaches the target strength.

[0037] In this embodiment, the change in acoustic impedance is used as a quantitative indicator of the welding process, which enables online and non-destructive monitoring of the degree of interdiffusion of interfacial molecules, replacing the traditional offline destructive sampling inspection method. This allows for 100% coverage inspection of the welding quality of the entire blade. At the same time, it can accurately control the end point of pressure holding, avoiding substandard interfacial bonding strength due to insufficient pressure holding time, and preventing excessive pressure holding that wastes production time, thus effectively improving the yield rate and controllability of production cycle.

[0038] In any of the above embodiments, preferably, in step S1, the width of the rare earth modified basalt fiber reinforced rare earth modified thermoplastic polyarylate prepreg tape is 300 mm and the single layer thickness is 0.25 mm; the layup scheme adopts a [0 / ±45 / 90] symmetrical layup structure.

[0039] In this embodiment, the width and thickness of the prepreg tape can be adapted to the laying requirements of large blades. The wider tape can reduce the number of laying passes and improve the efficiency of automatic tape laying. The reasonable single-layer thickness and symmetrical layup design can ensure the balanced matching of mechanical properties in all directions of the blade, while reducing the risk of warping deformation caused by asymmetrical layup during the forming process, and meeting the structural load-bearing and fatigue resistance design requirements of wind turbine blades.

[0040] In any of the above embodiments, preferably, in step S1, the multi-axis tape laying robot is a six-axis linkage tape laying robot, and the prepreg tape laying speed is 2m / min.

[0041] In this embodiment, the six-axis linkage configuration can be adapted to the complex curved surface mold shape of wind turbine blades, ensuring the positioning accuracy and fiber orientation accuracy of the prepreg tape laying; the set laying speed range can be flexibly adjusted according to the layup position and process requirements, taking into account both laying quality and production efficiency, adapting to the long-cycle continuous laying operation of 100-meter blades, and effectively improving the automation level and production stability of the production line.

[0042] In any of the above embodiments, preferably, in step S2, the vacuum degree after evacuation is ≤9kPa, and this vacuum degree is maintained throughout the hot-press welding process to avoid interlayer air bubbles from affecting the welding quality.

[0043] In this embodiment, the high vacuum level can fully remove residual air and trace amounts of volatile gases generated by the resin heating in the interlayer gaps, ensuring tight adhesion of the interlayer interfaces, providing good contact conditions for molecular chain interdiffusion, effectively reducing the generation of defects such as interlayer bubbles and pores, improving the density and bonding strength of the weld interface, and reducing the risk of interface failure.

[0044] In any of the above embodiments, preferably, in step S4, the gradient cooling rate is 4℃ / min, and the overall temperature difference of the blade along the length direction during the cooling process does not exceed 5℃, so as to reduce the residual stress of molding and ensure that the overall stiffness deviation of the blade is less than 2%.

[0045] In this embodiment, the temperature gradient inside the blade can be significantly reduced through a smooth and controllable gradient cooling process, avoiding large residual internal stress caused by sudden cooling and reducing the occurrence of forming defects such as blade warping and delamination; at the same time, controlling the temperature difference range of the entire blade can ensure uniform stiffness of the entire blade and improve the dimensional accuracy and long-term fatigue resistance of the blade.

[0046] Example 1 (120m class fully thermoplastic offshore wind turbine blade)

[0047] This embodiment employs the automated tape-laying and forming process for large thermoplastic wind turbine blades based on hot-press welding as described in this invention to prepare 120m-class fully thermoplastic offshore wind turbine blades. The specific implementation process is as follows:

[0048] Step S1, Automatic Tape Laying: A six-axis linkage tape laying robot is used, with a laying speed of 2m / min. The rare earth modified basalt fiber reinforced rare earth modified thermoplastic polyarylate prepreg tape is precisely laid on the surface of the blade mold according to the [0 / ±45 / 90] symmetrical layup design. During the laying process, the rare earth modified thermoplastic resin gradient density core material and the rare earth modified melamine polymer skin film are embedded simultaneously to form a prefabricated layup structure in one piece.

[0049] Step S2, overall encapsulation: Completely cover the surface of the prefabricated layer structure with a high-temperature resistant vacuum bag film, evacuate to a vacuum degree ≤9kPa and maintain this vacuum degree throughout the subsequent hot pressing process, fully remove residual air in the gaps between layers, eliminate interlayer air gaps, and ensure that the interfaces of each layer are tightly bonded.

[0050] Step S3, Integrated Hot Press Welding: The encapsulated mold is sent into a zoned temperature-controlled hot press molding equipment. The welding temperature is set to 300℃ and the welding pressure to 2.0MPa. The temperature and pressure are maintained for 10 minutes to promote sufficient molecular chain interdiffusion between the rare earth modified thermoplastic resin and the rare earth modified melamine polymer at the layup interface. A dual-channel online monitoring system is activated simultaneously during the hot pressing process: an infrared thermal imager with a measurement accuracy of ±1℃ is used to collect the temperature field distribution of the entire blade surface in real time, and the zoned temperature control system is linked to dynamically adjust the heating power of each area to ensure that the temperature deviation of the entire blade is controlled within ±3℃. An ultrasonic impedance probe with a sampling rate of 10Hz is embedded inside the mold to collect the acoustic impedance signal of the interlayer interface in real time. The acoustic impedance change rate is used as the basis for judging the welding process to ensure that the degree of interdiffusion at the interface meets the standard.

[0051] Step S4, Gradient Cooling Demolding: After the hot pressing welding process is completed, the blade is subjected to gradient cooling at a constant rate of 4℃ / min. After the overall temperature of the blade drops below 80℃, the demolding is completed, and the 120m-class fully thermoplastic wind turbine blade is obtained.

[0052] The blades prepared in this embodiment underwent performance testing, and the results are as follows: the weld interface strength is 651±21MPa, the weld strength dispersion coefficient CV=3.2%; the overall blade stiffness deviation is <2%; the entire manufacturing cycle for a single blade is 7.5 hours; and the product yield rate reaches 98.5%.

[0053] Comparative Example 1 (Traditional thermosetting epoxy resin vacuum infusion process)

[0054] This comparative example uses the mainstream thermosetting epoxy resin vacuum infusion process in the current wind turbine blade industry to prepare a 120m wind turbine blade of the same specification. The skin, main beam and core material components are molded separately and then assembled by secondary bonding with structural adhesive. According to actual measurements, the complete manufacturing cycle of a single blade is 168 hours; the adhesive interface strength is 460MPa; and the product yield is 82%.

[0055] Comparison of process advantages

[0056] Compared with the traditional thermosetting epoxy infusion process, the thermoplastic automatic tape laying and hot pressing welding process of the present invention has many significant advantages:

[0057] Production efficiency has been dramatically improved: the manufacturing cycle of a single 120m blade has been shortened from 168 hours to 7.5 hours, with production efficiency increasing by more than 21 times. This has completely broken the production capacity limitation of long-term curing of thermosetting resins and can support large-scale batch delivery of offshore wind turbine blades.

[0058] Significantly enhanced interfacial mechanical properties: The seamless welded interface formed by molecular chain interdiffusion has a strength of 651 MPa, which is about 41.5% higher than the 460 MPa of the traditional adhesive interface. This eliminates the adhesive layer, a high-risk area for failure in traditional blades, from the structural source, and significantly improves the overall load-bearing capacity and long-term fatigue resistance of the blade.

[0059] Product consistency and yield have been significantly improved: relying on zoned pressure and temperature control and online monitoring closed-loop control, the welding strength dispersion coefficient of large-size blades is only 3.2%, the overall blade stiffness deviation is less than 2%, and the uniformity of the performance of the entire blade is far superior to that of traditional processes; at the same time, the whole process non-destructive quality control has increased the product yield from 82% to 98.5%, effectively reducing the cost of production scrap.

[0060] Its green and recyclable properties are prominent: the all-thermoplastic material system requires no additional adhesives, there is no irreversible cross-linking reaction in the molding process, the blades can be repaired by hot pressing during their service life, and the materials can be recycled and reused after retirement, which solves the problem of solid waste that is difficult to degrade and dispose of after the retirement of traditional thermosetting blades, and is in line with the green and low-carbon development direction of the wind power industry.

[0061] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An automated tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding, characterized in that, Includes the following steps: Step S1, Automatic tape laying: Using a multi-axis tape laying robot, the rare earth modified basalt fiber reinforced rare earth modified thermoplastic polyarylate prepreg tape is laid on the surface of the blade mold according to the set layup scheme. During the laying process, the rare earth modified thermoplastic resin gradient density core material and the rare earth modified melamine polymer skin film are embedded simultaneously to form a prefabricated layup structure. Step S2, overall encapsulation: Cover the surface of the prefabricated layered structure with a high-temperature resistant vacuum bag film, evacuate to the target vacuum level, and remove interlayer air to eliminate air gaps; Step S3, integrated hot press welding: The encapsulated mold is sent into a hot press molding equipment and held at a welding temperature of 200-350℃±5℃ and a welding pressure of 1.5-3MPa±0.2MPa for 10±1 minutes to allow the rare earth modified thermoplastic resin and rare earth modified melamine polymer at the layup interface to undergo molecular chain interdiffusion, forming a seamless welding interface without adhesive layer. Step S4, Gradient Cooling Demolding: After hot pressing welding is completed, the blade is subjected to gradient cooling at a rate of ≤5℃ / min. After the temperature drops to below 70-90℃, the blade is demolded to obtain the finished thermoplastic wind turbine blade.

2. The automatic strip laying and forming process for large thermoplastic wind turbine blades based on hot-press welding according to claim 1, characterized in that, In step S3, the hot pressing molding equipment is equipped with a zoned temperature control system and a zoned pressure feedback system; for blade molds with a length greater than 100 meters, several independent temperature and pressure control zones are divided along the blade length direction, and the heating power and output pressure of each zone are adjusted independently so that the temperature uniformity deviation of the entire blade area is controlled within ±3℃.

3. The automatic strip laying and forming process for large thermoplastic wind turbine blades based on hot-press welding according to claim 1 or 2, characterized in that, During the hot pressing process in step S3, the temperature field distribution data of the entire surface of the blade is collected in real time by an infrared thermal imager. When the deviation between the measured temperature of any temperature control zone and the set welding temperature exceeds ±3℃, the control system automatically adjusts the heating power of the corresponding zone to correct the temperature deviation to within ±3℃.

4. The automatic tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding according to claim 1 or 2, characterized in that, During the hot pressing process in step S3, the acoustic impedance signal of the interlayer interface is collected in real time by an ultrasonic impedance probe embedded inside the mold; when the change rate of the interface acoustic impedance is less than 5-7%, it is determined that the molecular chain interdiffusion process is completed and the interface welding reaches the target strength.

5. The automated tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding according to claim 1 or 2, characterized in that, In step S1, the width of the rare earth modified basalt fiber reinforced rare earth modified thermoplastic polyarylate prepreg tape is 300-400mm and the thickness of a single layer is 0.15-0.3mm; the layup scheme adopts a [0 / ±45 / 90] symmetrical layup structure.

6. The automated tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding according to claim 1 or 2, characterized in that, In step S1, the multi-axis tape laying robot is a six-axis linkage tape laying robot, and the prepreg tape laying speed is 1-5m / min.

7. The automated tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding according to claim 1 or 2, characterized in that, In step S2, the vacuum level after evacuation is ≤9kPa, and this vacuum level is maintained throughout the hot-press welding process to avoid air bubbles from entering between layers and affecting the welding quality.

8. The automated tape laying and forming process for large thermoplastic wind turbine blades based on hot-press welding according to claim 1 or 2, characterized in that, In step S4, the gradient cooling rate is 3-6℃ / min, and the overall temperature difference along the length of the blade during the cooling process does not exceed 4-7℃, so as to reduce the residual stress during molding and ensure that the overall stiffness deviation of the blade is less than 2%.

Images