阅读说明：本技术 一种全生命周期内不报废的模块化风电叶片及其制造方法 (Modular wind power blade not to be scrapped in full life cycle and manufacturing method thereof ) 是由 张平 王建博 高猛 白高宇 于 2019-09-27 设计创作，主要内容包括：本发明公开了一种全生命周期内不报废的模块化风电叶片及其制造方法,包括迎风面壳体、背风面壳体和腹板,所述背风面壳体包括背风面后缘UD、背风面主梁和背风面壳体结构,所述迎风面壳体包括迎风面后缘UD、迎风面主梁和迎风面壳体结构；所述迎风面后缘UD、背风面后缘UD、背风面主梁和背风面壳体结构通过一体灌注成型,构成叶片背风面壳体；所述腹板为箱式,并垂直设于背风面主梁上,该腹板与叶片背风面壳体通过一体灌注成型；所述迎风面主梁设于腹板顶部,两者通过一体灌注成型；所述迎风面壳体结构设于迎风面主梁的两侧,包括多个形状大小不同的模块化壳体结构。本发明通过模块化设计实现叶片全生命周期不报废的目的。(The invention discloses a modular wind power blade which is not scrapped in a full life cycle and a manufacturing method thereof, wherein the modular wind power blade comprises a windward shell, a leeward shell and a web plate, wherein the leeward shell comprises a leeward trailing edge UD, a leeward main beam and a leeward shell structure; the windward side rear edge UD, the leeward side main beam and the leeward side shell structure are integrally formed by pouring to form a blade leeward side shell; the web plate is box-shaped and is vertically arranged on the leeward side main beam, and the web plate and the blade leeward side shell are integrally formed by pouring; the windward main beam is arranged at the top of the web plate and is integrally formed by pouring; the windward side shell structure is arranged on two sides of the windward side main beam and comprises a plurality of modularized shell structures with different shapes and sizes. The invention realizes the purpose of no scrapping of the blade in the whole life cycle through the modular design.)

1. A modular wind power blade which is not scrapped in a full life cycle comprises a windward shell, a leeward shell and a web plate, wherein the leeward shell comprises a leeward trailing edge UD, a leeward main beam and a leeward shell structure; the method is characterized in that: the windward side rear edge UD is connected with the leeward side rear edge UD, and the windward side rear edge UD, the leeward side main beam and the leeward side shell structure are integrally formed by pouring to form a blade leeward side shell; the web plate is box-shaped and is vertically arranged on the leeward side main beam, and the web plate and the blade leeward side shell are integrally formed by pouring; the windward main beam is arranged at the top of the web plate and integrally formed by pouring, and the leeward shell, the web plate and the windward main beam of the blade jointly form a main structure of the blade; the wind-facing shell structure is arranged on two sides of the wind-facing main beam and comprises a plurality of modular shell structures with different shapes and sizes, the modular shell structures are sequentially arranged along the direction from the blade root to the blade tip of the blade, the shape and the size of each modular shell structure are adaptive to the respective installation positions of the modular shell structures, one end of each modular shell structure is positioned and bonded through a bonding flange at the edge of the top of the web plate, and the other end of each modular shell structure is bonded to the edge of the main structure of the blade.

2. A method of manufacturing a modular wind blade that is not scrapped during its full life cycle of claim 1, comprising the steps of:

1) connecting a windward trailing edge UD with a leeward trailing edge UD, wherein the windward trailing edge UD, the leeward trailing edge UD, a leeward main beam and a leeward shell structure are integrally formed by pouring to form a blade leeward shell, and the windward trailing edge UD and the leeward trailing edge UD are integrally formed by pouring to eliminate the risk of bonding failure of two key components;

2) vertically arranging a box-type web plate on a leeward side main beam, integrally pouring and molding the web plate and a blade leeward side shell, wherein two sides of the top of the web plate are provided with bonding flanges, and the height positioning of the bonding flanges on the web plate depends on the thickness and the pneumatic appearance of the blade;

3) the windward main beam is arranged at the top of the web plate and integrally formed by pouring, and the leeward shell, the web plate and the windward main beam of the blade jointly form a main structure of the blade;

4) according to the requirements of the blade structure and the pneumatic appearance profile, the windward shell structures on two sides of the original windward main beam are split along the direction from the blade root to the blade tip of the blade to manufacture a plurality of modular shell structures, one end of each modular shell structure is positioned and bonded through a bonding flange at the edge of the top of a web plate, and the other end of each modular shell structure is bonded to the edge of the main blade structure;

5) the splicing region of the modular shell structure is spliced and reinforced according to requirements.

Technical Field

The invention relates to the technical field of blade structures and processes of wind generating sets, in particular to a modular wind power blade which is not scrapped in a full life cycle and a manufacturing method thereof.

Background

The conventional method for forming the blade shell integrally comprises the following steps: respectively manufacturing a half shell of an SS leeward side and a half shell of a PS windward side, and then adhering one surface of a web plate on the half shell of the SS side or the half shell of the PS side; and finally, respectively coating structural adhesive on the front edge and the rear edge of a certain shell surface and the bonding area of the web plate to bond the half shells. The method has the defects that the bonding quality of the surface of the main beam, the bonding quality of the UD area of the rear edge, the verticality and the bonding quality of the web directly influence the service life of the blade in the die assembly process of the blade. And because the length of the blade is very long, the internal cavity of the middle and rear parts of the blade is small, important regions such as a web region, a girder region, a trailing edge UD region and the like can not be maintained almost once the defects exist (the extreme maintenance condition can also cause larger bearing structure damage to seriously affect the quality of the blade), and most of the blade is discarded. The defect degree of the important region of the blade is light, or the defect which cannot be found in time is not found due to the rigorous objective conditions of the tip region of the blade in the mold closing process. And the condition that the blade is scrapped and replaced due to the fact that the blade cannot be maintained when the wind field is operated for several years and the defect degree is deepened often exists.

In addition, because the SS surface and the PS surface of the traditional blade structure are half shells of an integrally formed structure, the blade has the conditions of local shell bulging, layering, cracking, structural adhesive bonding failure and the like in the running process of a wind field. The whole can not be maintained, so that the whole can be scrapped.

Meanwhile, in order to improve the quality of the blade and reduce the rejection rate, manufacturers often need the investment of high-quality personnel, high-precision equipment investment, high-quality material selection, more reasonable design, higher-quality management and better manufacturing environment. However, the manufacture of blades is currently also labor intensive and relies on manual operations. There are several tens of processes from the raw material to the shipment. The traditional blade structure and the implementation method are difficult to guarantee that each blade can not be replaced in the whole life cycle. In addition, factors which cannot be avoided, such as differences of wind conditions of different machine positions of a wind field, evaluation errors of wind resources, values and actual differences of material performance during design, stability of raw materials, stability of equipment, transportation damage, control strategies of the whole machine, environmental influences and the like, are also difficult to avoid problems of preventing the safety of the blades from reaching 100% in the whole process.

In view of the above practical situation, the design safety of the blade is the prerequisite. Aiming at the damage type of the wind field blade, the defect transfer is realized through technical innovation, the defect which cannot be maintained originally is changed into a maintainable (only maintained) or a local module is replaceable, and therefore the blade is not scrapped (except extreme weather and accidents) in the whole life cycle.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provide a modular wind power blade which is not scrapped in the whole life cycle and a manufacturing method thereof.

In order to achieve the purpose, the technical scheme provided by the invention is as follows: a modular wind power blade which is not scrapped in a full life cycle comprises a windward shell, a leeward shell and a web plate, wherein the leeward shell comprises a leeward trailing edge UD, a leeward main beam and a leeward shell structure; the windward side rear edge UD is connected with the leeward side rear edge UD, and the windward side rear edge UD, the leeward side main beam and the leeward side shell structure are integrally formed by pouring to form a blade leeward side shell; the web plate is box-shaped and is vertically arranged on the leeward side main beam, and the web plate and the blade leeward side shell are integrally formed by pouring; the windward main beam is arranged at the top of the web plate and integrally formed by pouring, and the leeward shell, the web plate and the windward main beam of the blade jointly form a main structure of the blade; the wind-facing shell structure is arranged on two sides of the wind-facing main beam and comprises a plurality of modular shell structures with different shapes and sizes, the modular shell structures are sequentially arranged along the direction from the blade root to the blade tip of the blade, the shape and the size of each modular shell structure are adaptive to the respective installation positions of the modular shell structures, one end of each modular shell structure is positioned and bonded through a bonding flange at the edge of the top of the web plate, and the other end of each modular shell structure is bonded to the edge of the main structure of the blade.

A manufacturing method of a modular wind power blade which is not scrapped in a full life cycle comprises the following steps:

1) connecting a windward trailing edge UD with a leeward trailing edge UD, wherein the windward trailing edge UD, the leeward trailing edge UD, a leeward main beam and a leeward shell structure are integrally formed by pouring to form a blade leeward shell, and the windward trailing edge UD and the leeward trailing edge UD are integrally formed by pouring to eliminate the risk of bonding failure of two key components;

2) vertically arranging a box-type web plate on a leeward side main beam, integrally pouring and molding the web plate and a blade leeward side shell, wherein two sides of the top of the web plate are provided with bonding flanges, and the height positioning of the bonding flanges on the web plate depends on the thickness and the pneumatic appearance of the blade;

3) the windward main beam is arranged at the top of the web plate and integrally formed by pouring, and the leeward shell, the web plate and the windward main beam of the blade jointly form a main structure of the blade;

4) according to the requirements of the blade structure and the pneumatic appearance profile, the windward shell structures on two sides of the original windward main beam are split along the direction from the blade root to the blade tip of the blade to manufacture a plurality of modular shell structures, one end of each modular shell structure is positioned and bonded through a bonding flange at the edge of the top of a web plate, and the other end of each modular shell structure is bonded to the edge of the main blade structure;

5) the splicing region of the modular shell structure is spliced and reinforced according to requirements.

Compared with the prior art, the invention has the following advantages and beneficial effects:

1. the invention is not influenced by the size of the windward shell, and batch production is realized in actual production by splitting the windward shell into a plurality of modular shell structures; meanwhile, the size of the modular shell structure is relatively small, and the modular shell structure is easy to form; the assembly in a wind field and the modular replacement can be realized subsequently; the blade transportation cost and the fan operation and maintenance cost are saved.

2. According to the invention, important areas of the blade, such as the blade root, the main beam, the trailing edge, the web plate and the like, are organically integrated, so that the stability and controllability of the quality of key parts are realized. Structural adjustment is carried out through the position that will originally have fatal failure mode and probably lead to whole condemned, makes the defect follow the discovery of being difficult to detect, discovers unable maintenance, and the unable proof quality of maintenance becomes the defect detectable, but slight maintenance, but severe modularization change, and blade main structure in-process is not influenced, realizes the not condemned notion of blade full life cycle through partial structure modularization.

3. The invention reduces the influence of damage and scrapping of the blade on the safety of the whole machine in the operation process of the whole machine, reduces the cost loss caused by scrapping of the blade, greatly reduces the maintenance cost, and is more convenient and quicker to maintain, maintain and replace the blade.

Drawings

Fig. 1 is a schematic structural view of a blade leeward side shell of the present invention.

Fig. 2 is a schematic structural diagram of a main structure of a blade of the invention.

Fig. 3 is a schematic structural view of the modular housing structure of the present invention.

Fig. 4 is a schematic view of the overall structure of the present invention.

Detailed Description

The present invention will be further described with reference to the following specific examples.

As shown in fig. 1 to 4, the modular wind turbine blade that is not scrapped in the full life cycle according to the present embodiment includes a windward shell, a leeward shell and a web 301, where the leeward shell includes a leeward trailing edge UD 101, a leeward main beam 102 and a leeward shell structure 103, and the windward shell includes a windward trailing edge UD 201, a windward main beam 202 and a windward shell structure; the windward side rear edge UD 201 is connected with the leeward side rear edge UD 101, and the windward side rear edge UD 201, the leeward side rear edge UD 101, the leeward side main beam 102 and the leeward side shell structure 103 are integrally formed by pouring to form a blade leeward side shell; the web plate 301 is box-shaped and is vertically arranged on the leeward side main beam 102, and the web plate 301 and the blade leeward side shell are integrally formed by pouring; the windward main beam 202 is arranged at the top of the web plate 301, and the windward main beam 202 and the web plate 301 are integrally formed by pouring, and a main structure of the blade is formed by the leeward shell of the blade, the web plate 202 and the windward main beam 202; the windward side shell structure is arranged on two sides of a windward side main beam 202 and comprises a plurality of modularized shell structures 203 with different shapes and sizes, the plurality of modularized shell structures 203 are sequentially arranged along the direction from the blade root to the blade tip of the blade, the shape and the size of each modularized shell structure 203 are suitable for the respective installation position of each modularized shell structure, wherein one end of each modularized shell structure 203 is positioned and bonded through a bonding flange 302 on the top edge of a web plate 301, and the other end of each modularized shell structure 203 is bonded to the edge of a main structure of the blade.

The manufacturing method of the modular wind power blade which is not scrapped in the full life cycle comprises the following steps:

1) the windward side rear edge UD 201 is connected with the leeward side rear edge UD 101, the windward side rear edge UD 201, the leeward side rear edge UD 101, the leeward side main beam 102 and the leeward side shell structure 103 are integrally formed through pouring to form a blade leeward side shell, and the windward side rear edge UD 201 and the leeward side rear edge UD 101 are integrally formed into a whole through pouring, so that the bonding failure risk of two key components is eliminated, and the quality is more reliable.

2) Vertically arranging a box-type web plate 301 on the leeward side main beam 102, integrally pouring and molding the web plate 301 and the leeward side shell of the blade, wherein bonding flanges 302 are arranged on two sides of the top of the web plate 301, and the height of the bonding flanges 302 on the web plate 301 is determined by the thickness and the aerodynamic shape of the blade;

the web 301 and the leeward side girder 102 do not adopt the traditional bonding mode, the risk of bonding failure of the traditional web 301 and the leeward side girder 102 area is avoided, and the web 301 of the embodiment is positioned without the interference of other parts (the perpendicularity of the web 301 in the narrow space of the tip of the blade can not be controlled due to the existence of a windward side shell in the tip area of the web 301 in the traditional mode), so that the positioning of the web 301 is more accurate, the perpendicularity in the whole full size is accurate, and the quality of the blade main structure forming process is controllable.

3) The windward main beam 202 is arranged at the top of the web plate 301 and integrally formed by pouring, and the leeward shell of the blade, the web plate 301 and the windward main beam 202 jointly form a main structure of the blade; in the area of the lobe and the tip of the lobe, the cavity is small, and the bonding thickness and quality of the web plate 301 and the main beam 202 on the windward side are not controllable. Compared with a bonding mode, the integrated pouring forming mode has the advantages of controllable quality and reliable performance.

4) According to the requirements of blade structure and aerodynamic appearance profile, the windward shell structures on two sides of the original windward main beam 202 are split along the direction from the blade root to the blade tip of the blade to manufacture a plurality of modular shell structures 203, one end of each modular shell structure 203 is positioned and bonded through a bonding flange 302 on the top edge of a web 301, and the other end of each modular shell structure is bonded to the edge of the main structure of the blade;

by splitting the windward side shell into the windward side rear edge UD 201, the windward side main beam 202 and the plurality of modular shell structures 203, the windward side shell is not influenced by the overall size of the whole windward side shell and can be manufactured in batches according to needs. Each modular housing structure 203 is relatively small in size and easy to form. The assembly in a wind field and the modularized replacement can be realized subsequently, so that the transportation cost of the blades and the operation and maintenance cost of the fan are saved;

5) the splicing area of the modular shell structure 203 is reinforced by splicing seams according to requirements.

According to the embodiment, the windward shell is split into the windward trailing edge UD 201, the windward main beam 202 and the plurality of modularized shell structures 203, the defect degree is reduced through modularized forming and modularized bonding, and the defect spreading is prevented. More importantly, all original fatal risk points which are included between the blade shell and the shell and cannot be avoided, discovered and maintained are transferred to the modular shell structure 203, so that the modular shell structure becomes a conventional risk point which can be maintained and partially replaced. Meanwhile, the main structure of the blade is independently formed, the structure is stable, the performance is reliable, and if quality problems occur in the whole life cycle, only the modularized shell structure 203 needs to be maintained and replaced, so that the whole life cycle of the blade is not scrapped, the risk of operation of the whole machine is effectively reduced, the operation and maintenance cost is reduced, and the production efficiency of the blade is improved.

The above-mentioned embodiments are merely preferred embodiments of the present invention, and the scope of the present invention is not limited thereto, so that variations based on the shape and principle of the present invention should be covered within the scope of the present invention.