Multi-stage gradient flow guide integrally-formed wind power blade front channel filling device

Abstract

The utility model discloses a multistage gradient diversion integrally-formed wind power blade front channel pouring device which comprises a pouring mold, a pouring pipeline, a variable porosity diversion net and a heating unit, and the pouring pipeline, the variable porosity diversion net and the heating unit are all located in the pouring mold. The variable-porosity flow guide net is laid on the inner wall face of the pouring mold, the porosity of the variable-porosity flow guide net is gradually increased from 40% of a blade root area to 60% of a blade tip area in the length direction of a blade in a gradient mode, the heating unit is laid on the variable-porosity flow guide net, the pouring pipeline is arranged on the heating unit, and the variable-porosity flow guide net is arranged on the pouring mold. And the pipe diameter of the filling pipeline is gradually reduced from the root of the blade to the tail end of the blade. Through the synergistic effect of the variable-porosity flow guide net and the perfusion pipeline, uniform resin distribution of the blade is achieved; meanwhile, the curing time is shortened, and the production efficiency of the blade is further improved; the resin consumption is reduced, and the economic benefit is remarkable.

Description

TECHNICAL FIELD

[0001] The utility model relates to the field of wind power blade manufacturing technology, especially to a multistage gradient flow guide integrated forming wind power blade front channel filling device. BACKGROUND

[0002] The traditional integrated forming blade vacuum filling process has the following technical pain points:

[0003] 1. The unreasonable resin flow path design leads to dry spot defects (statistical data show that the industry average defect rate is > 2.5%).

[0004] 2. The fixed porosity of the flow guide medium leads to flow rate imbalance in thick section areas and thin wall areas.

[0005] 3. The existing spiral flow guide pipe layout causes more than 30% of the resin to be wasted.

[0006] In the production of a certain type of 68-meter blade through the integrated forming blade vacuum filling process, bubble aggregation was found in the root area. After dissection and analysis, it was found that the gradient permeation regulation was not achieved in the thickening area of the flow guide net. INVENTION CONTENTS

[0007] The utility model aims at overcoming the above-mentioned deficiencies of the prior art, and provides a multistage gradient flow guide integrated forming wind power blade front channel filling device.

[0008] The utility model is implemented through the following technical solutions:

[0009] A multistage gradient flow guide integrated forming wind power blade front channel filling device comprises a filling mold, a filling pipeline, a variable porosity flow guide net and a heating unit. The filling pipeline, the variable porosity flow guide net and the heating unit are located in the filling mold. The variable porosity flow guide net is laid on the inner wall surface of the filling mold, and the porosity of the variable porosity flow guide net gradually increases from 40% in the root area to 60% in the tip area along the length direction of the blade. The heating unit is laid on the variable porosity flow guide net, and the filling pipeline is arranged on the heating unit. The diameter of the filling pipeline gradually decreases from the root of the blade to the end of the blade.

[0010] Further, the multistage gradient flow guide integrated forming wind power blade front channel filling device further comprises a controller. The number of the heating units is multiple. The controller is electrically connected to the multiple heating units and is used to control the switching and output power of the heating units respectively, so that the temperature control range of the multiple heating units is 25-80℃.

[0011] Further, the controller controls the plurality of heating units to have gradient temperatures, and the gradient temperatures of the heating units are 65 DEG C from the root region to the tip region of the blade in a gradient decreasing manner.

[0012] Further, the perfusion pipeline is connected with an electromagnetic flow regulating valve, and the controller is electrically connected to the electromagnetic flow regulating valve.

[0013] Further, the variable porosity flow guide net is a three-layer composite structure, and the variable porosity flow guide net comprises an upper layer of oriented fiber cloth, a middle layer of nano-porous membrane and a lower layer of standard flow guide net connected in sequence.

[0014] Further, the fiber orientation of the upper layer of oriented fiber cloth forms an angle of ±10 DEG with the resin flow direction in the perfusion pipeline.

[0015] The pore diameter of the middle layer of nano-porous membrane is 5-20 mu m, and the porosity is 50%-70%.

[0016] The porosity of the lower layer of standard flow guide net is 40%-60%.

[0017] Further, the perfusion pipeline comprises a main pipeline and a plurality of branch pipelines, the main pipeline extends along the length direction of the perfusion mold, the pipe diameter of the main pipeline at the blade root is 60 mm, the pipe diameter of the main pipeline at the blade tip is 15 mm, and the plurality of branch pipelines are all communicated with the main pipeline and outwardly extend to adopt a bionic fractal tree structure.

[0018] Further, the perfusion pipeline further comprises an edge overflow compensation channel, the edge overflow compensation channel is located in the area of the perfusion mold far from the main pipeline and is communicated with the branch pipeline, and the width of the edge overflow compensation channel gradually changes from 3 mm at the blade root to 8 mm at the blade tip.

[0019] Further, the edge overflow compensation channel is filled with high-permeability flow guide felt with a porosity of 80%.

[0020] Further, the branching angle of the main pipeline and the plurality of branch pipelines is 30 DEG -75 DEG.

[0021] The beneficial effects of the utility model lie in:

[0022] This utility model relates to a multi-level gradient flow-guided integrated molding wind turbine blade pre-treatment injection device. The porosity of the variable porosity flow-guided net gradually increases from 40% at the blade root to 60% at the blade tip along the blade length direction. The diameter of the injection pipe gradually decreases from the blade root to the blade tip. Through the synergistic effect of the variable porosity flow-guided net and the injection pipe, uniform resin distribution is achieved on the blade. At the same time, a heating unit is laid on the variable porosity flow-guided net and used to heat the resin, which shortens the curing time and further improves the blade production efficiency. Moreover, resin consumption is reduced, resulting in significant economic benefits. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the multi-level gradient flow guiding integrated molding wind turbine blade front injection device according to an embodiment of the present invention.

[0024] Figure 2 This is a schematic diagram of the injection pipe according to an embodiment of the present utility model.

[0025] Figure 3 This is another schematic diagram of the injection pipe according to an embodiment of the present utility model.

[0026] Explanation of reference numerals in the attached figures:

[0027] Injection Pipeline 1

[0028] 11 Guanzhi Road

[0029] Branch pipe 12

[0030] Edge overflow compensation channel 13

[0031] Injection mold 2

[0032] Variable porosity flow guide net 3

[0033] Heating unit 4

[0034] 10 Resin Injection Molding Machine Detailed Implementation

[0035] The following description of the embodiments is with reference to the accompanying drawings, which illustrate specific embodiments in which the present invention can be implemented.

[0036] like Figure 1 , Figure 2 and Figure 3As shown, the embodiment discloses a multi-stage gradient flow integrated molding wind power blade front pouring device, which comprises a pouring pipeline 1, a pouring mold 2, a variable porosity flow guide net 3 and a heating unit 4. The pouring pipeline 1, the variable porosity flow guide net 3 and the heating unit 4 are all located in the pouring mold 2. The variable porosity flow guide net 3 is laid on the inner wall surface of the pouring mold 2, and the porosity of the variable porosity flow guide net 3 increases from 40% in the blade root area to 60% in the blade tip area along the length direction of the blade. The heating unit 4 is laid on the variable porosity flow guide net 3, and the pouring pipeline 1 is arranged on the heating unit 4. The pipe diameter of the pouring pipeline 1 gradually decreases from the blade root to the blade tip end.

[0037] The resin and the curing agent are conveyed into the pouring pipeline 1 by the resin injection molding machine 10, and the resin is injected into the pouring pipeline 1 through the pouring pipeline 1. The resin in the pouring pipeline 1 penetrates onto the underlying core material and cloth layer through the heating unit 4 and the variable porosity flow guide net 3, thereby realizing the integrated molding wind power blade production. The porosity of the variable porosity flow guide net 3 increases from 40% in the blade root area to 60% in the blade tip area along the length direction of the blade. The pipe diameter of the pouring pipeline 1 gradually decreases from the blade root to the blade tip end. Through the synergistic effect of the variable porosity flow guide net 3 and the pouring pipeline 1, the pouring rate is higher, and the resin of the blade is uniformly distributed. At the same time, the heating unit 4 is laid on the variable porosity flow guide net 3 and used for heating the resin, so that the curing time is shortened, and the production efficiency of the blade is further improved. The resin consumption is reduced, and the economic benefit is significant.

[0038] The multi-stage gradient flow integrated molding wind power blade front pouring device further comprises a controller. The number of the heating units 4 is multiple. The controller is electrically connected to the multiple heating units 4 and is used for respectively controlling the on-off and output power of the heating units 4, so that the temperature control range of the multiple heating units 4 is 25-80℃. The controller is used for respectively controlling the output power of the multiple heating units 4, so that the precise control is realized, and the use is very convenient.

[0039] Specifically, the heating unit 4 is divided into at least 10 independent temperature zones, and the area of each temperature zone is ≤2m 2 The thickness of the heating sheet of the heating unit 4 is 0.5mm, and the response time of the heating is ≤30s. The heating unit 4 is partitioned and arranged above the variable porosity flow guide net 3. The heating power of each partition is independently controllable, and the temperature control range is 25-80℃, and the precision is ±1.5℃. Preferably, the controller controls the multiple heating units 4 to be gradient temperature, and the gradient temperature of the heating unit 4 is 65℃ in the blade root area and decreases to 45℃ in the blade tip area.

[0040] The variable porosity flow guide net 3 is a three-layer composite structure. The variable porosity flow guide net 3 comprises an upper layer of oriented fiber cloth, a middle layer of nano-porous membrane and a lower layer of standard flow guide net which are connected in sequence, so that the flow guide speed is high, and the resin of the blade is uniformly distributed.

[0041] Specifically, the variable porosity flow guide net 3 can be composed of polyester fibers and glass fibers, with a grammage of 200-600 g / m 2 The porosity gradually increases from 40% in the blade root area to 60% in the blade tip area along the length direction of the blade. The grammage of the upper layer of oriented fiber cloth is 150 g / m 2 The fiber orientation of the upper layer of oriented fiber cloth is at an angle of ±10° with the resin flow direction in the infusion pipeline 1. The pore size of the middle layer of nanoporous membrane is 5-20 μm, and the porosity is 50%-70%. The grammage of the lower layer of standard flow guide net is 400 g / m 2 The porosity of the lower layer of standard flow guide net is 40%-60%.

[0042] The infusion pipeline 1 is connected with an electromagnetic flow regulating valve, and the controller is electrically connected to the electromagnetic flow regulating valve. By arranging the electromagnetic flow regulating valve on the infusion pipeline 1, the resin flow can be accurately controlled according to the infusion requirements of different parts. At the same time, the controller is used to control the opening and closing of the electromagnetic flow regulating valve and the opening degree, so as to realize accurate control and convenient use. The response time of the electromagnetic flow regulating valve connected to the infusion pipeline 1 is less than 50 ms, the flow regulating range of the electromagnetic flow regulating valve is 0.1-20 L / min, and the resin viscosity to be adapted is 300-500 cP (tested at 25°C).

[0043] The infusion pipeline 1 includes a main pipeline 11 and a plurality of branch pipelines 12. The main pipeline 11 extends along the length direction of the infusion mold 2, and the pipe diameter of the main pipeline 11 at the blade root is 60 mm, and the pipe diameter of the main pipeline 11 at the blade tip is 15 mm. The plurality of branch pipelines 12 are all communicated with the main pipeline 11 and are arranged to extend outward, so that the infusion pipeline 1 adopts a bionic fractal tree structure. The resin to be infused will flow into the main pipeline 11, and then will flow into the plurality of branch pipelines 12, and finally will be injected into the infusion mold 2. The infusion pipeline 1 forms a plurality of partitioned flow guide channels through the main pipeline 11 and the plurality of branch pipelines 12. These flow guide channels are optimized in layout according to the shape and structural characteristics of the blade, and gradually branch and extend to each part of the blade from the infusion inlet. At the same time, the flow guide speed is fast, the flow guide efficiency is higher, and the flow guide penetration effect is better, so the yield is high.

[0044] The diameter of the main pipeline 11 is 50 mm, the length is 300 mm, and the wall thickness is 5 mm. The diameter of the branch pipeline 12 is 15-30 mm, the length is 150-200 mm, and the wall thickness is 2-3 mm. The branching angle of the main pipeline 11 and the plurality of branch pipelines 12 is 30°-75°. The plurality of branch pipelines 12 are also communicated with each other to form branching, and the branching angle is also 30°-75°.

[0045] The perfusion pipeline 1 further comprises an edge overflow compensation channel 13 located in the perfusion mold 2 away from the main pipeline 11 and communicated with the branch pipeline 12, and the width of the edge overflow compensation channel 13 gradually changes from 3 mm at the root 3 to 8 mm at the tip 8. The excess resin is absorbed by the edge overflow compensation channel 13 in the curing stage, so as to reduce the resin consumption. Preferably, the edge overflow compensation channel 13 is filled with a high-permeability flow guide felt with a porosity of 80%.

[0046] In the dynamic perfusion control process of the multi-stage gradient flow guide integrally formed wind power blade front perfusion device of the embodiment, the following steps are included: step one, generating a layer thickness distribution map based on a three-dimensional blade model, and dividing perfusion priority areas; step two, monitoring the resin front position in real time through a pressure sensor and feeding back to a controller; step three, dynamically adjusting the opening and closing sequence of the glue injection port and the heating temperature of the heating unit 4, so that the resin flow rate difference is controlled within ±5%.

[0047] When manufacturing a certain type of 83-meter offshore wind power blade, the perfusion time of the traditional process is 8.5 hours, the resin consumption is 2150 kg, and the ultrasonic detection defect rate is 2.1%. The perfusion time of the multi-stage gradient flow guide integrally formed wind power blade front perfusion device of the embodiment is 5.2 hours, which is reduced by 39%, the resin consumption is 1980 kg, which is reduced by 8%, and the ultrasonic detection defect rate is 0.3%.

[0048] When manufacturing a mountain type low-density blade, the multi-stage gradient flow guide integrally formed wind power blade front perfusion device of the embodiment solves the flow lagging problem in high-altitude low-pressure environment by adjusting the porosity gradient (45%→65%) of the variable porosity flow guide net 3, and the product passes the GL certification. Beneficial effects: the defect rate is reduced to below 0.5% (industry breakthrough), the material utilization rate is increased by more than 12%, suitable for 5MW-15MW different specification blade production line modification; realizing ±2% resin distribution uniformity of large size parts (length>80m), significant economic benefits: single blade production cost is reduced by about 78,000 yuan (estimated data).

[0049] When manufacturing a 72-meter onshore wind power blade in a high-humidity environment, the process conditions are: environmental humidity 85%, epoxy resin viscosity 420 cP (25℃), and the weight of the flow guide net is selected as 400 g / m 2 (leaf root)-250g / m 2(leaf tip). Optimization measures: add hydrophobic modified nanoporous membrane (contact angle > 120°) in the middle layer of the variable porosity flow guide net 3; set gradient temperature for the heating unit 4: 65℃ in the root area → 45℃ in the tip area, accelerate resin defoaming. Effect: in the environment with humidity > 80%, the complete pouring time is stabilized at 5.8h, and the bubble content is < 0.15vol%.

[0050] In conclusion, the multi-stage gradient flow integrated molding wind power blade front pouring device of the embodiment is especially suitable for 5-15MW offshore wind power blade manufacturing, and can realize uniform resin distribution of large-size blades (> 80m) by the synergistic effect of the variable porosity flow guide net 3 and the pouring pipeline 1, in combination with the heating unit 4 (±1.5℃ temperature control) and the dynamic pouring algorithm, and solve the problem of dry spot defects caused by uneven resin flow in the traditional process.

[0051] The above only discloses preferred embodiments of the utility model, and of course cannot limit the scope of the utility model, so equivalent changes made according to the utility model claims still belong to the scope covered by the utility model.

Claims

1. A multi-stage gradient flow guiding integrated molding wind turbine blade front-end injection device, characterized in that, It includes an injection mold, an injection pipe, a variable porosity guide net, and a heating unit. The injection pipe, the variable porosity guide net, and the heating unit are all located inside the injection mold. The variable porosity guide net is laid on the inner wall of the injection mold, and the porosity of the variable porosity guide net gradually increases from 40% in the blade root region to 60% in the blade tip region along the blade length direction. The heating unit is laid on the variable porosity guide net, and the injection pipe is set on the heating unit. The diameter of the injection pipe gradually decreases from the blade root to the blade tip.

2. The multi-stage gradient flow guiding integrated molding wind turbine blade front-end injection device as described in claim 1, characterized in that, The multi-level gradient flow integrated molding wind turbine blade front injection device also includes a controller. The number of heating units is multiple. The controller is electrically connected to multiple heating units and is used to control the switching and output power of the heating units respectively, so that the temperature control range of the multiple heating units is 25-80℃.

3. The multi-stage gradient flow guiding integrated molding wind turbine blade pre-treatment injection device as described in claim 2, characterized in that, The controller controls multiple heating units to operate at a gradient temperature, with the gradient temperature of the heating units decreasing from 65°C at the leaf root region to 45°C at the leaf tip region.

4. The multi-stage gradient flow guiding integrated molding wind turbine blade front-end injection device as described in claim 2, characterized in that, An electromagnetic flow regulating valve is connected to the injection pipeline, and the controller is electrically connected to the electromagnetic flow regulating valve.

5. The multi-stage gradient flow guiding integrated molding wind turbine blade pre-treatment injection device as described in claim 1, characterized in that, The variable porosity flow guide net is a three-layer composite structure, comprising an upper layer of oriented fiber cloth, a middle layer of nanoporous membrane, and a lower layer of standard flow guide net connected in sequence.

6. The multi-stage gradient flow guiding integrated molding wind turbine blade pre-treatment injection device as described in claim 5, characterized in that, The fiber orientation of the upper oriented fiber cloth forms an angle of ±10° with the resin flow direction in the injection pipe; The pore size of the middle layer nanoporous membrane is 5-20 μm, and the porosity is 50%-70%. The porosity of the lower standard flow guide mesh is 40%-60%.

7. The multi-stage gradient flow guiding integrated molding wind turbine blade front-end injection device as described in claim 1, characterized in that, The injection pipeline includes a main pipeline and multiple branch pipelines. The main pipeline extends along the length of the injection mold, and the diameter of the main pipeline located at the root of the blade is 60 mm, while the diameter of the main pipeline located at the end of the blade is 15 mm. The multiple branch pipelines are all connected to the main pipeline and extend outward, so that the injection pipeline adopts a biomimetic fractal tree structure.

8. The multi-stage gradient flow guiding integrated molding wind turbine blade pre-treatment injection device as described in claim 7, characterized in that, The injection pipeline also includes an edge overflow compensation channel, which is located in the injection mold in an area away from the main pipeline and connected to the branch pipeline. The width of the edge overflow compensation channel gradually changes from 3mm at the blade root to 8mm at the blade tip.

9. The multi-stage gradient flow guiding integrated molding wind turbine blade pre-treatment injection device as described in claim 8, characterized in that, The edge overflow compensation channel is filled with a high-permeability flow guiding felt with a porosity of 80%.

10. The multi-stage gradient flow guiding integrated molding wind turbine blade front-end injection device as described in claim 7, characterized in that, The bifurcation angle between the main pipeline and the multiple branch pipelines is 30°-75°.

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