Sail rotor forming die

Abstract

The utility model relates to the technical field of sail rotor manufacturing, and discloses a sail rotor forming die which comprises a variable-rigidity filling type core die provided with a core cavity, a filling unit used for guaranteeing the shape of the variable-rigidity filling type core die is arranged in the core cavity, and the variable-rigidity filling type core die is arranged in the filling unit. The variable-rigidity filling type core mold comprises a winding cylinder and two sealing heads connected to the two ends of the winding cylinder. According to the sail rotor forming mold, the rigidity of the variable-rigidity filling type core mold can be obviously changed by adjusting parameters such as the types, the number or the pressure of the filling units, so that the requirements of variable-rigidity filling type core molds with different sizes can be met; according to the manufacturing method, the variable-rigidity filling type core mold is prevented from flexural deformation exceeding a preset range in the winding process, it is guaranteed that the variable-rigidity filling type core mold has high dimensional accuracy, then the product quality is guaranteed, the sail rotor which is very large in size and of an integrated structure can be manufactured, and the production cost of the mold is low.

Description

Technical Field

[0001] The utility model relates to the field of sail rotor manufacturing, and more specifically, to a sail rotor forming mold. Background Art

[0002] A sail rotor is an innovative device that uses wind energy to propel ships. Through the power of wind, the sail rotor converts wind energy into power to propel the ship forward. Specifically, when the wind blows towards the sail rotor, the sail generates lateral thrust, which is converted into mechanical energy through the rotation of the rotor, thereby propelling the ship forward. There are various ways to form sail rotors, and fiber winding molding is one of the commonly used molding methods. The fiber winding molding process is to wind continuous fibers impregnated with resin onto a core mold according to a certain pattern. After stacking to a preset thickness, the fibers are cured and demolded, and then fine-processed to obtain a sail rotor that meets the requirements.

[0003] Due to the large size of the sail rotor (generally not less than 17m in length and not less than 2.8m in diameter), the size of the core mold is also correspondingly large. In order to ensure the dimensional accuracy of the core mold, the stiffness of the core mold must not be lower than the preset stiffness, so as to prevent the core mold from bending and deforming beyond the preset range during the winding process, thereby affecting the quality of the wound sail rotor. In order to increase the stiffness of the core mold to a sufficiently large value, the cost of existing sail rotor molding molds is often high. For some sail rotors that are very large and require an integrated structure, it is even impossible to manufacture molding molds that meet the requirements. Utility Model Content

[0004] The purpose of the utility model is to overcome the defects in the prior art and provide a sail rotor forming mold with low manufacturing cost and no flexural deformation beyond a preset range during the winding process.

[0005] To achieve the above-mentioned purpose, the technical solution of the present invention is to provide a sail rotor forming mold, including: a variable stiffness filling core mold, the variable stiffness filling core mold is provided with a core cavity, a filling unit is provided in the core cavity for ensuring the shape of the variable stiffness filling core mold, the variable stiffness filling core mold includes a winding tube and two heads connected to the two ends of the winding tube.

[0006] By using the sail rotor forming mold described in the utility model, the winding tube and the head form a variable stiffness filling core mold with a core cavity. By adjusting parameters such as the type, quantity or pressure of the filling unit, the stiffness of the variable stiffness filling core mold can be significantly changed to adapt to the needs of variable stiffness filling core molds of different sizes, prevent the variable stiffness filling core mold from flexural deformation beyond the preset range during the winding process, ensure that the variable stiffness filling core mold has high dimensional accuracy, and thus ensure the quality of the product, and can manufacture sail rotors with very large size and integrated structure. The structure of the sail rotor forming mold is simple and the production cost of the mold is low.

[0007] Preferably, the filling unit includes high-pressure gas and / or an adjustable inner support frame. Such a design can ensure that the variable stiffness filling core mold will not bend and deform beyond a preset range during the winding process.

[0008] Preferably, a two-way gas pipeline is provided on the sealing head, and the two-way gas pipeline is connected to the core cavity, and a valve is provided on the two-way gas pipeline. Such a design can facilitate the adjustment of the gas pressure in the core cavity.

[0009] Preferably, the end cap includes a cylindrical section and a hemispherical shell section, and the bidirectional gas pipeline is installed on the hemispherical shell section. Such a design is conducive to maintaining a stable gas pressure in the core cavity.

[0010] Preferably, a drive joint is connected to the outer side of the head, and the drive joint is located at the center of the outer surface of the head. Such a design can enable the winding machine to drive the variable stiffness filling core mold to rotate stably to complete the fiber winding.

[0011] Preferably, the bidirectional gas pipeline and the drive joint are both detachably connected to the sealing head. Such a design facilitates the reuse of the drive joint and the bidirectional gas pipeline, thereby reducing production costs.

[0012] Preferably, the adjustable inner support frame comprises a plurality of annular support portions spaced along the length of the winding drum, and axial rods connected to the annular support portions, wherein the length of the axial rods aligns with the length of the winding drum. This design can further enhance the deformation resistance of the variable stiffness filling core mold.

[0013] Preferably, a mark is provided on the axial rod, and the mark is the connection position between the annular support portion and the axial rod. Such a design can facilitate the assembly of the annular support portion and the axial rod.

[0014] Preferably, the annular support portion includes two support units, each comprising an arc ring that fits against the inner wall of the winding drum, an adjustment plate connected to the end of the arc ring, a first support rod fixedly connected to both ends of the arc ring, and a plurality of second support rods fixedly connected to the arc ring and the first support rods. The spacing between the two support units is adjusted by two adjustment units, and the adjustment units are mounted on the corresponding adjustment plates of the two support units. This design facilitates the installation of the annular support portion within the core cavity.

[0015] Preferably, the adjustment unit includes a threaded rod, a first nut, a second nut, a third nut, and a fourth nut. The threaded rod is movably connected to the adjustment plate. The first nut, the second nut, the third nut, and the fourth nut are all threadedly connected to the threaded rod. The first nut and the second nut are respectively attached to the two sides of one adjustment plate, and the third nut and the fourth nut are respectively attached to the two sides of the other corresponding adjustment plate. This design can accurately adjust the distance between the two support units.

[0016] The beneficial effects of the present invention are:

[0017] 1. By using the wind turbine rotor forming mold described in the present invention, the winding cylinder and the sealing head form a variable stiffness filling core mold with a core cavity. By adjusting parameters such as the type, number or pressure of the filling unit, the stiffness of the variable stiffness filling core mold can be significantly changed to meet the needs of variable stiffness filling core molds of different sizes, and the variable stiffness filling core mold is prevented from being flexed and deformed beyond a preset range during the winding process, thereby ensuring that the variable stiffness filling core mold has high dimensional accuracy, thereby ensuring the quality of the product, and being able to manufacture very large-sized, integrated wind turbine rotors. The wind turbine rotor forming mold has a simple structure and a low production cost.

[0018] 2. By providing the first support rod, it is possible to determine whether the assembly of the annular support portion meets the requirements by measuring the distance between the two corresponding first support rods, thereby improving the dimensional accuracy of the winding drum and further improving the quality of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the overall structure of the sail rotor forming mold;

[0020] Figure 2 It is a schematic cross-sectional view of the three-dimensional structure of a sail rotor forming mold;

[0021] Figure 3 It is a three-dimensional structural diagram of the head, two-way gas pipeline and drive joint;

[0022] Figure 4 yes Figure 3 A magnified view of the structure at center A;

[0023] Figure 5 is a partial schematic front cross-sectional view of a sail rotor forming mold;

[0024] Figure 6 1. It is a schematic diagram of the three-dimensional structure of the adjustable inner support frame;

[0025] Figure 7 2. It is a schematic diagram of the three-dimensional structure of the annular support portion;

[0026] Figure 8 is a schematic diagram of the three-dimensional structure of the support unit;

[0027] Figure 9 is a schematic cross-sectional view of a right side of a sail rotor forming die;

[0028] Figure 10 yes Figure 5 A magnified view of the structure at B in the middle;

[0029] Figure 11 is a schematic diagram of the three-dimensional structure of the winding machine and the sail rotor forming mold in Example 11;

[0030] Figure 12 is a side cross-sectional schematic diagram of the winding machine and the sail rotor forming mold in Example 11;

[0031] Figure 13 yes Figure 11 A magnified view of the structure at center C;

[0032] Figure 14 is a side cross-sectional schematic diagram of the sail rotor in implementation mode B of Example 11;

[0033] Figure 15 It is a schematic diagram of the three-dimensional structure of the sail rotor.

[0034] In the figure: 1. variable stiffness filling core mold; 2. core cavity; 3. adjustable inner support frame; 4. winding cylinder; 5. head; 6. two-way gas pipeline; 7. valve; 8. drive joint; 9. connecting pipe; 10. sealing ring; 11. annular support portion; 12. axial rod; 13. support unit; 14. arc ring; 15. adjustment plate; 16. first support rod; 17. second support rod; 18. adjustment unit; 19. threaded rod; 20. first nut; 21. second nut; 22. third Nut; 23. Fourth nut; 24. Connecting seat; 25. Frame; 26. Motor; 27. Winding claw; 28. Transmission assembly; 29. Bracket; 30. Immersion tank; 31. Combing plate; 32. Unwinding assembly; 33. Combing hole; 34. Guide roller; 35. Unwinding roller; 36. Fiber roll; 37. Cylindrical section; 38. Hemispherical shell section; 39. First basalt fiber layer; 40. Carbon fiber layer; 41. Second basalt fiber layer; 42. Main body; 43. Bottom edge portion. DETAILED DESCRIPTION

[0035] The subject matter described herein will now be discussed with reference to example embodiments. It should be understood that these embodiments are discussed to enable those skilled in the art to better understand and implement the subject matter described herein. The functions and arrangements of the elements discussed may be varied without departing from the scope of protection of this specification. Various examples may omit, substitute, or add various processes or components as needed. In addition, features described with respect to some examples may also be combined in other examples.

[0036] In order to better understand the present invention, Figures 1-15 A sail rotor forming mold of the utility model is described in detail.

[0037] Example 1:

[0038] like Figure 1 and Figure 2 As shown, a sail rotor forming mold includes: a variable stiffness filling type core mold 1, the variable stiffness filling type core mold 1 is provided with a core cavity 2, the core cavity 2 is provided with a filling unit for ensuring the shape of the variable stiffness filling type core mold 1, and the variable stiffness filling type core mold 1 includes a winding tube 4 and two heads 5 connected to the two ends of the winding tube 4.

[0039] It should be noted that by adjusting parameters such as the type, quantity or pressure of the filling unit, the stiffness of the variable stiffness filling core mold 1 can reach the preset stiffness, ensuring that the variable stiffness filling core mold 1 will not undergo flexural deformation beyond the preset range during the winding process.

[0040] In this embodiment, the material of the variable stiffness filling core mold 1 is fiberglass. During the winding process, the variable stiffness filling core mold 1 needs to be driven by a winding machine to rotate. By using a variable stiffness filling core mold 1 made of fiberglass, the weight of the variable stiffness filling core mold 1 can be reduced, and the overall working efficiency of the winding machine can be improved. In addition, the price of fiberglass is relatively low, which can reduce the manufacturing cost of the sail rotor forming mold.

[0041] By using the sail rotor forming mold described in the present invention, the winding tube 4 and the head 5 form a variable stiffness filling core mold 1 with a core cavity 2. By adjusting parameters such as the type, quantity or pressure of the filling unit, the stiffness of the variable stiffness filling core mold 1 can be significantly changed to adapt to the needs of variable stiffness filling core molds 1 of different sizes, and prevent the variable stiffness filling core mold 1 from undergoing flexural deformation beyond the preset range during the winding process, thereby ensuring that the variable stiffness filling core mold 1 has high dimensional accuracy, thereby ensuring the quality of the product. The material of the variable stiffness filling core mold 1 is fiberglass, and the manufactured sail rotor forming mold is not only light in weight but also has low production costs.

[0042] Example 2:

[0043] As an optimization of Example 1, Figure 2 As shown, the filling unit includes high-pressure gas and / or an adjustable inner support frame 3.

[0044] It should be noted that an appropriate amount of gas is filled into the core cavity 2 so that the gas pressure value in the core cavity 2 is within a preset pressure range. The high-pressure gas in the core cavity 2 can provide sufficient support for the variable stiffness filling type core mold 1, greatly improving the stiffness of the variable stiffness filling type core mold 1, and ensuring that the variable stiffness filling type core mold 1 does not undergo flexural deformation beyond a preset range during the winding process.

[0045] An adjustable inner support frame 3 is installed in the core cavity 2, and the support structure of the adjustable inner support frame 3 is dense and uniform. The adjustable inner support frame 3 can provide sufficient support for the variable stiffness filling type core mold 1, greatly improving the stiffness of the variable stiffness filling type core mold 1, and ensuring that the variable stiffness filling type core mold 1 does not flex beyond a preset range during the winding process;

[0046] In this embodiment, the core cavity 2 is filled with an appropriate amount of gas, and an adjustable internal support frame 3 is installed in the core cavity 2. The high-pressure gas in the core cavity 2 provides the main support for the variable stiffness filling core mold 1, and the adjustable internal support frame 3 provides auxiliary support for the variable stiffness filling core mold 1 and maintains the shape of the variable stiffness filling core mold 1. The high-pressure gas and the adjustable internal support frame 3 jointly ensure the accurate size of the variable stiffness filling core mold 1, thereby ensuring the quality of the product.

[0047] Example 3:

[0048] As an optimization of Example 2, Figure 1 and Figure 2 As shown, a two-way gas pipeline 6 is provided on the head 5 , and the two-way gas pipeline 6 is communicated with the core cavity 2 , and a valve 7 is provided on the two-way gas pipeline 6 .

[0049] It should be noted that by adjusting the opening and closing of the valve 7, it is possible to control whether to inflate or exhaust, and thus regulate the gas pressure in the core cavity 2, thereby ensuring that the gas pressure value in the core cavity 2 is within a preset pressure range (1-10 MPa), the variable stiffness filling core mold 1 will not over-expand, and will not flex beyond the preset range during the winding process. In addition, the bidirectional gas pipeline 6 is provided on the head 5 and will not affect the winding process.

[0050] Before installing the variable stiffness filling core mold 1 on the winding machine, open the valve 7, use the digital pressure pump to inflate the core cavity 2 of the variable stiffness filling core mold 1 through the two-way gas pipe 6, and observe the gas pressure value in the core cavity 2 through the display screen of the digital pressure pump until the gas pressure value in the core cavity 2 is within the preset pressure range, stop inflating and close the valve 7;

[0051] If the gas pressure in the core cavity 2 exceeds the preset pressure range due to over-inflation, the valve 7 can be opened again to release part of the gas in the core cavity 2 until the gas pressure in the core cavity 2 is within the preset pressure range, and then the valve 7 is closed;

[0052] When the valve 7 is closed, the variable stiffness filling core mold 1 is a closed structure, and the gas in the core cavity 2 cannot be discharged through the two-way gas pipe 6. The gas pressure value in the core cavity 2 is within the preset pressure range. The high-pressure gas in the core cavity 2 can provide sufficient support for the variable stiffness filling core mold 1 to prevent the variable stiffness filling core mold 1 from bending and deforming beyond the preset range during the winding process. The adjustable internal support frame 3 provides support for the variable stiffness filling core mold 1 while allowing the winding tube 4 to maintain a cylindrical shape, thereby ensuring that the size of the wound product is more accurate, and the variable stiffness filling core mold 1 will not over-expand due to the excessive gas pressure in the core cavity 2, affecting the dimensional accuracy of the winding tube 4.

[0053] In this embodiment, two bidirectional gas pipes 6 are provided on the two heads 5 at both ends of the winding tube 4 to facilitate the assembly line production of the heads 5. During inflation, air can be inflated into the core cavity 2 through the two bidirectional gas pipes 6, thereby improving the inflation efficiency and thus improving the production efficiency.

[0054] Example 4:

[0055] As an optimization of Example 3, Figure 1-Figure 3As shown, the head 5 includes a cylindrical barrel section 37 and a hemispherical shell section 38 , and the bidirectional gas pipeline 6 is installed on the hemispherical shell section 38 .

[0056] It should be noted that the cylindrical section 37 is compatible with both the winding tube 4 and the hemispherical shell section 38. The curvature radius of the hemispherical shell section 38 is equal at all locations, and the force is very uniform. When subjected to the same internal pressure, the wall thickness required for the head 5 is minimal, and the edge stress is relatively low and can be ignored. Therefore, no large stress concentration will occur at the edge of the head 5. The head 5 can effectively disperse and resist the internal pressure, thereby maintaining stable air pressure.

[0057] Since the length of the winding drum 4 is greater than the winding length of the fiber, even if the edge of the winding drum 4 or the head 5 is damaged, it is only necessary to cut and polish the edges of the winding drum 4 and the head 5, and the winding drum 4 and the head 5 can still be reused until the length of the winding drum 4 is less than the winding length of the fiber, or the hemispherical shell segment 38 of the head 5 is damaged, thereby improving the utilization rate of the winding drum 4 and the head 5, reducing the consumption of the winding drum 4 and the head 5, and reducing the production cost.

[0058] In this embodiment, the cylindrical section 37 is bonded to the winding tube 4 , and the thickness of the head 5 is consistent with that of the winding tube 4 , which is conducive to stable and firm bonding of the cylindrical section 37 and the winding tube 4 .

[0059] Example 5:

[0060] As an optimization of Example 4, Figure 1 and Figure 3 As shown, a drive joint 8 is connected to the outer side of the head 5 , and the drive joint 8 is located at the center of the outer surface of the head 5 .

[0061] It should be noted that the drive joint 8 is located at the center of the outer surface of the head 5. In other words, the axis of the drive joint 8 coincides with the axis of the head 5. The variable stiffness filling core mold 1 is driven and connected to the winding claw 27 of the winding machine through the drive joint 8. The winding machine drives the drive joint 8 to rotate, thereby driving the variable stiffness filling core mold 1 to rotate stably for fiber winding.

[0062] Example 6:

[0063] As an optimization of Example 5, Figure 3-Figure 5 As shown, the bidirectional gas pipeline 6 and the drive joint 8 are both detachably connected to the head 5 .

[0064] It should be noted that when demolding, it is necessary to open the valve 7 to release the high-pressure gas in the core cavity 2, cut off the head 5, and then reduce the distance between the two support units 13 so that the adjustable inner support frame 3 can be removed, thereby facilitating demolding. If the hemispherical shell segment 38 is damaged after cutting, the two-way gas pipeline 6 and the drive joint 8 can be removed and installed on a new head 5 for reuse. There is no need for each head 5 to be equipped with a two-way gas pipeline 6 and a drive joint 8, which reduces production costs.

[0065] In this embodiment, a connecting seat 24 is fixedly connected to the center of the outer surface of the head 5, the drive joint 8 is threadedly connected to the connecting seat 24, the head 5 is connected to a connecting pipe 9, the two-way gas pipeline 6 is threadedly connected to the connecting pipe 9, and the connection between the two-way gas pipeline 6 and the connecting pipe 9 is sealed by a sealing ring 10.

[0066] Example 7:

[0067] As an optimization of Example 6, Figure 5-Figure 6 As shown, the adjustable inner support frame 3 includes a plurality of annular support portions 11 spaced apart along the length direction of the winding drum 4 and an axial rod 12 connected to the annular support portions 11 , and the length direction of the axial rod 12 is consistent with the length direction of the winding drum 4 .

[0068] It should be noted that the annular structure of the annular support portion 11 can help the winding drum 4 maintain a cylindrical shape and ensure the dimensional accuracy of the winding drum 4. The axial rod 12 connects the multiple annular support portions 11 into a whole, which can further improve the deformation resistance of the variable stiffness filling core mold 1.

[0069] The annular support portion 11 is connected to the axial rod 12 by binding. For winding tubes 4 of different lengths, the spacing between the annular support portions 11 is different (the longer the winding tube 4 is, the smaller the spacing between the annular support portions 11 is). The binding connection method can facilitate the disassembly of the annular support portion 11 and the axial rod 12 and the adjustment of the spacing between the annular support portions 11.

[0070] In this embodiment, only one axial rod 12 is provided, and the support for the variable stiffness filling type core mold 1 is mainly provided by the high-pressure gas in the core cavity 2. The main function of the adjustable internal support frame 3 is to maintain the shape of the winding tube 4 and to assist in providing support for the variable stiffness filling type core mold 1.

[0071] Example 8:

[0072] As an optimization of Example 7, a mark is provided on the axial rod 12 , and the marked position is the connection position between the annular support portion 11 and the axial rod 12 .

[0073] It should be noted that the spacing between the annular support parts 11 is determined according to the design requirements, and marks are made on the axial rod 12 (such as drawing lines with a marker), and then the annular support parts 11 are tied to the marks on the axial rod 12. The position of the annular support parts 11 is accurately installed, and the assembly of the annular support parts 11 and the axial rod 12 is more convenient, thereby improving the assembly efficiency of the adjustable inner support frame 3.

[0074] Example 9:

[0075] As an optimization of Example 8, Figure 7-Figure 9 As shown, the annular support portion 11 includes two support units 13, the support unit 13 includes an arc ring 14 that fits against the inner wall of the winding tube 4, an adjustment plate 15 connected to the end of the arc ring 14, a first support rod 16 fixedly connected to both ends of the arc ring 14, and a plurality of second support rods 17 fixedly connected to the arc ring 14 and the first support rod 16. The spacing between the two support units 13 is adjusted by two adjustment units 18, and the adjustment units 18 are installed on the adjustment plates 15 corresponding to the two support units 13.

[0076] It should be noted that each support unit 13 is provided with two adjustment plates 15, that is, each annular support portion 11 is provided with four adjustment plates 15, and the two adjustment plates 15 of one support unit 13 cooperate with the two adjustment plates 15 of another support unit 13. The adjustment unit 18 adjusts the distance between the two support units 13 by adjusting the distance between the corresponding two adjustment plates 15;

[0077] To ensure that the winding drum 4 can maintain accurate dimensions, the outer diameter of the annular support portion 11 is consistent with the inner diameter of the winding drum 4. The distance between the two support units 13 is reduced by the adjustment unit 18, which makes it easier to place the annular support portion 11 into the core cavity 2. The adjustment unit 18 is then adjusted again to increase the distance between the two support units 13 until both arc rings 14 are in contact with the inner wall of the winding drum 4 and the two arc rings 14 form a standard annular structure.

[0078] To ensure that the two arc rings 14 form a standard circular ring structure, after the two adjustment units 18 are adjusted, it is necessary to ensure that the spacing between the corresponding two first support rods 16 meets the requirements. The spacing between the two first support rods 16 can be measured by the outer measuring claws of the vernier caliper. If it does not meet the requirements, the two adjustment units 18 can be fine-tuned until the spacing between the two first support rods 16 meets the requirements, and at this time, the two first support rods 16 are parallel.

[0079] In this embodiment, the length direction of the second support rod 17 is arranged along the radius direction of the circular arc ring 14 , and the second support rod 17 can better provide radial support for the circular arc ring 14 .

[0080] Example 10:

[0081] As an optimization of Example 9, Figure 5 、 Figure 7 and Figure 10 As shown, the adjusting unit 18 includes a threaded rod 19, a first nut 20, a second nut 21, a third nut 22 and a fourth nut 23. The threaded rod 19 is movably connected to the adjusting plate 15. The first nut 20, the second nut 21, the third nut 22 and the fourth nut 23 are all threadedly connected to the threaded rod 19. The first nut 20 and the second nut 21 are respectively attached to the two sides of one of the adjusting plates 15, and the third nut 22 and the fourth nut 23 are respectively attached to the two sides of the other corresponding adjusting plate 15.

[0082] It should be noted that a threaded rod 19 is movably connected to two adjustment plates 15 corresponding to the two support units 13. By adjusting the positions of the nuts (the first nut 20, the second nut 21, the third nut 22 and the fourth nut 23), the distance between the corresponding two adjustment plates 15 is adjusted, and then the distance between the two support units 13 is adjusted.

[0083] In this embodiment, the first nut 20, the second nut 21, the third nut 22 and the fourth nut 23 are arranged in sequence on the threaded rod 19. By adjusting the distance between the second nut 21 and the third nut 22, the distance between the corresponding two adjustment plates 15 can be controlled, and then the first nut 20 and the fourth nut 23 are tightened. The first nut 20 and the second nut 21 cooperate with the threaded rod 19 to jointly limit the position of one of the adjustment plates 15, and the third nut 22 and the fourth nut 23 cooperate with the threaded rod 19 to jointly limit the position of the other corresponding adjustment plate 15, thereby fixing the distance between the corresponding two adjustment plates 15, and then completing the adjustment of the distance between the two support units 13, that is, completing the adjustment of the size of the adjustable inner support frame 3.

[0084] Example 11:

[0085] A sail rotor forming process based on a sail rotor forming mold includes the following steps:

[0086] S1: Mold manufacturing, including the following steps:

[0087] S11: Making the glass fiber reinforced plastic flat plate and the end cap 5: According to the design requirements, the glass fiber reinforced plastic flat plate and the end cap 5 are made into semi-finished glass fiber reinforced plastic plates by using a mold, and then cutting and polishing them to obtain the glass fiber reinforced plastic flat plate and the end cap 5;

[0088] S12: Rolling the FRP flat plate and gluing the joints to form a winding drum 4. When rolling the plate, the FRP flat plate is rolled into a cylindrical shape with the joints of the winding drum 4 facing the ground. A worker enters the interior of the winding drum 4 and sticks the fiber cloth with resin to the inner wall of the winding drum 4, gluing the two ends of the FRP flat plate together.

[0089] S13: Install the adjustable inner support frame 3, first reduce the size of the adjustable inner support frame 3, place the adjustable inner support frame 3 into the winding cylinder 4, and then increase the adjustable inner support frame 3 to a preset size so that the adjustable inner support frame 3 fits tightly against the inner wall of the winding cylinder 4;

[0090] S14: Install the head 5 and bond the two heads 5 to the two ends of the winding tube 4 to form a sealed space;

[0091] S15: Fill the sealed space (core cavity 2) with an appropriate amount of gas, use a pressure air pump to inflate the sealed space, and observe the display screen of the pressure air pump to clearly understand the gas pressure in the variable stiffness filling core mold 1. When the gas pressure in the sealed space is within the preset pressure range, stop inflating.

[0092] After the mold is manufactured, it needs to be installed on the winding machine. Figure 11-13 As shown, the winding machine includes a frame 25, a motor 26, a winding claw 27, a transmission assembly 28, a bracket 29, an immersion tank 30, a combing plate 31 and an unwinding assembly 32. There are two frames 25 and two winding claws 27. The two winding claws 27 are rotatably mounted on the corresponding two frames 25 respectively. The motor 26 is fixedly mounted on one of the frames 25, and the motor 26 is driven and connected to one of the winding claws 27. The variable stiffness filling core mold 1 is installed between the two winding claws 27, and the axis of the variable stiffness filling core mold 1 coincides with the axis of the winding claw 27. The bracket 29 is arranged on the transmission assembly 28, the immersion tank 30 and the combing plate 31 are both mounted on the bracket 29, and the combing plate 31 is positioned On the side of the immersion tank 30 away from the variable stiffness filling core mold 1, a plurality of combing holes 33 are provided on the combing plate 31 to facilitate combing of the fibers. Each fiber passes through a combing hole 33 to prevent multiple fibers from being entangled with each other during the fiber winding process, thereby affecting the winding effect. The immersion tank 30 contains resin for impregnation, and a plurality of guide rollers 34 are provided in the immersion tank 30. The guide rollers 34 guide the fibers to ensure that the fibers passing through the combing holes 33 are impregnated with resin before winding. The two ends of the variable stiffness filling core mold 1 are fixed by two winding claws 27 to provide support for the variable stiffness filling core mold 1, thereby reducing the magnitude of flexural deformation of the variable stiffness filling core mold 1.

[0093] The unwinding assembly 32 is arranged on the side of the transmission assembly 28 away from the variable stiffness filling core mold 1. The unwinding assembly 32 is provided with an unwinding roller 35 and a tension control system. The unwinding roller 35 is mounted with a fiber roll 36. The tension control system can control the tension of the fiber during the fiber winding process.

[0094] During fiber winding, the motor 26 drives the winding claw 27 to rotate, thereby driving the variable stiffness filling core mold 1 to rotate, and then the fiber impregnated with resin is wound on the winding drum 4. Under the condition of controlling the tension, the fiber can be evenly wound on the winding drum 4 to ensure the quality and density of the winding, thereby ensuring the quality of the product; after the fiber is wound to a preset thickness and cured and demolded, it is finely processed to obtain a sail rotor with a length of 35m and an outer diameter of 5m.

[0095] S2: Add a demoulding unit, and cover the outer surface of the winding tube 4 with the demoulding unit. The covering of the demoulding unit includes the following embodiments:

[0096] Embodiment 1: At least one layer of polyester film is wound on the outer surface of the winding drum 4;

[0097] Embodiment 2: firstly, a proper amount of release agent is applied on the outer surface of the winding tube 4 , and then at least one layer of polyester film is wound on the outer surface of the winding tube 4 .

[0098] S3: Winding the fiber. The resin-impregnated fiber is wound around the outer layer of the demoulding unit in a spiral winding manner. The winding thickness is set to 9.4-23 mm. The winding length of the fiber is 37 m. The types of wound fibers include the following embodiments:

[0099] Implementation A: The wound fibers are all carbon fibers, forming a carbon fiber sail rotor;

[0100] Implementation method B: Figure 14 As shown, the wound fibers are basalt fiber, carbon fiber, and basalt fiber from the inside out, forming a first basalt fiber layer 39, a carbon fiber layer 40, and a second basalt fiber layer 41, respectively, to form a composite sail rotor.

[0101] S4: Curing and demoulding. After the wound fibers are cured, the sail rotor semi-finished product is obtained. The mold is removed from the winding machine and then disassembled to separate the sail rotor semi-finished product from the mold. The mold disassembly includes the following steps:

[0102] S41: Open the bidirectional gas pipe 6 on the head 5 to release the high-pressure gas in the variable-rigidity filling core mold 1;

[0103] S42: Cut off the ends 5;

[0104] S43: The adjustable inner support frame 3 is reduced in size and removed from the winding drum 4;

[0105] S44: Pull the winding drum 4 inward to deform it, so as to separate the winding drum 4 from the semi-finished sail rotor product.

[0106] S5: Finishing, including cutting, grinding and polishing. Cut 1m inward at each end of the sail rotor semi-finished product to obtain a 35m long sail rotor semi-finished product. Then grind and polish the cut sail rotor semi-finished product, and paint the polished surface of the sail rotor.

[0107] like Figure 15 As shown, the outer diameter of the resulting sail rotor is 5m, the length is 35m, the thickness of the main part 42 of the sail rotor is 9.4mm, the thickness of the bottom edge part 43 of the sail rotor is 23mm, and the length of the bottom edge part 43 in the axial direction of the sail rotor is 70mm.

[0108] The above describes an embodiment of the utility model in conjunction with the accompanying drawings, but this embodiment is not limited to the above-mentioned specific implementation methods. The above-mentioned specific implementation methods are merely illustrative and not restrictive. Under the guidance of this embodiment, ordinary technicians in this field can also make many forms without departing from the purpose of this embodiment and the scope of protection of the claims, all of which are protected by this embodiment.

Claims

1. A sail rotor forming mold, characterized in that: include: A variable rigidity filling type core mold (1) is provided with a core cavity (2), a filling unit for ensuring the shape of the variable rigidity filling type core mold (1) is provided in the core cavity (2), and the variable rigidity filling type core mold (1) comprises a winding drum (4) and two sealing heads (5) connected to both ends of the winding drum (4).

2. A sail rotor forming mold according to claim 1, characterized in that: The filling unit comprises high-pressure gas and / or an adjustable inner support frame (3).

3. The sail rotor forming mold according to claim 2, characterized in that: A bidirectional gas pipeline (6) is provided on the sealing head (5), and the bidirectional gas pipeline (6) is in communication with the core cavity (2), and a valve (7) is provided on the bidirectional gas pipeline (6).

4. The sail rotor forming mold according to claim 3, characterized in that: The end cap (5) comprises a cylindrical barrel section (37) and a hemispherical shell section (38), and the bidirectional gas pipeline (6) is installed on the hemispherical shell section (38).

5. The sail rotor forming mold according to claim 3, characterized in that: The outer side of the sealing head (5) is connected to a drive joint (8), and the drive joint (8) is located at the center of the outer surface of the sealing head (5).

6. The sail rotor forming mold according to claim 5, characterized in that: The bidirectional gas pipeline (6) and the drive joint (8) are both detachably connected to the sealing head (5).

7. The sail rotor forming mold according to claim 2, characterized in that: The adjustable inner support frame (3) comprises a plurality of annular support portions (11) spaced apart along the length direction of the winding drum (4), and an axial rod (12) connected to the annular support portions (11), wherein the length direction of the axial rod (12) is consistent with the length direction of the winding drum (4).

8. The sail rotor forming mold according to claim 7, characterized in that: A mark is provided on the axial rod (12), and the mark is the connection position between the annular support portion (11) and the axial rod (12).

9. The sail rotor forming mold according to claim 7, characterized in that: The annular support portion (11) includes two support units (13), each of the support units (13) including an arc ring (14) fitted with the inner wall of the winding drum (4), an adjustment plate (15) connected to the end of the arc ring (14), a first support rod (16) fixedly connected to both ends of the arc ring (14), and a plurality of second support rods (17) fixedly connected to the arc ring (14) and the first support rod (16). The spacing between the two support units (13) is adjusted by two adjustment units (18), and the adjustment units (18) are mounted on the adjustment plates (15) corresponding to the two support units (13).

10. The sail rotor forming mold according to claim 9, characterized in that: The adjusting unit (18) comprises a threaded rod (19), a first nut (20), a second nut (21), a third nut (22) and a fourth nut (23); the threaded rod (19) is movably connected to the adjusting plate (15); the first nut (20), the second nut (21), the third nut (22) and the fourth nut (23) are all threadedly connected to the threaded rod (19); the first nut (20) and the second nut (21) are respectively attached to two sides of one of the adjusting plates (15); the third nut (22) and the fourth nut (23) are respectively attached to two sides of another corresponding adjusting plate (15).

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