CN108638541B

CN108638541B - Blade shell and web integrated forming method and blade forming method

Info

Publication number: CN108638541B
Application number: CN201810408747.9A
Authority: CN
Inventors: 朱加凯; 肖智龙; 陈威
Original assignee: Jiangsu Goldwind Science and Technology Co Ltd
Current assignee: Jiangsu Goldwind Science and Technology Co Ltd
Priority date: 2018-05-02
Filing date: 2018-05-02
Publication date: 2020-09-01
Anticipated expiration: 2038-05-02
Also published as: CN108638541A

Abstract

A method of forming a blade shell and web in one piece and a blade is disclosed. The method for integrally forming the blade shell and the web comprises the following steps: laying a web plate tool at a main beam on a blade shell laying layer on a blade shell mould; laying a web paving layer on one side of the web tool; and performing vacuum auxiliary resin infusion by taking the blade shell layer and the web plate layer as a whole. By the forming method provided by the invention, the dosage of the bonding angle during the forming of the blade can be obviously reduced, the weight of the blade is reduced, and the structural strength of the blade is improved.

Description

Blade shell and web integrated forming method and blade forming method

Technical Field

The invention relates to the field of wind power generation, in particular to a web plate used for forming a blade of a wind generating set and a method for manufacturing the blade.

Background

The main structure of the blade of the wind generating set is composed of a main beam, a web plate and a shell. The production process of the blade is divided into parts, and mainly comprises main beam production, web production, shell production, web and shell bonding, shell mold closing and post-treatment. The production die of the blade comprises a main beam die, a web die and a shell main die. Currently, the production of the blade is to preform the main beam and the web, then to produce two half shells, when producing the shell, to place the preformed main beam at a designated position, then to complete the production of the two half shells, then to bond the two webs to one of the half shells, and to bond the two half shells to the other half shell after fixing to form a whole blade.

When bonding the web, all use the bonding glue to bond in the upper and lower both sides of web, because blade inner space is narrow and small, reasons such as manual operation difficulty often can take place the position that needs the bonding and lack the phenomenon of bonding glue, perhaps the bonding glue quantity is too much, and the bonding glue that extrudes when leading to web and casing to bond is too much. If the bonding glue is lacked, the strength of the bonding position is insufficient, the blade shell is separated from the web, and even the quality accident of blade cracking or fracture occurs in severe cases. If too much adhesive glue is extruded, the blade rotates on a fan, the wind power vibrates the blade and the like, the extruded excessive adhesive glue is only adhered to the surface of the shell and is not subjected to the pressure of an upper layer, the excessive adhesive glue can be separated from the surface of the shell and fall into the blade after a long time, the falling adhesive glue can impact the blade at four places, and people are required to clean the blade inside, so that the blade is very dangerous and difficult to operate.

Disclosure of Invention

According to an embodiment of the invention, there is provided a method of integrally moulding a blade shell and a web, the method comprising: laying a web plate tool at a main beam on a blade shell laying layer on a blade shell mould; laying a web paving layer on one side of the web tool; and carrying out vacuum auxiliary resin infusion molding on the blade shell layer and the web plate layer as a whole.

Optionally, the web tool is vertical and frame-shaped, and includes a bottom beam attached to the main beam, a vertical beam vertically extending from the bottom beam, and a top beam fixed above the vertical beam.

Optionally, the web layup comprises a fiber layer including a vertical portion fixed relative to a vertical side of the web tooling, a horizontal portion overlapping the blade shell layup, and a flange portion overlapping the top of the web tooling.

Optionally, the fiber layer comprises a fiber cloth layer or a fiber board preformed by the fiber cloth layer and resin.

Optionally, before the web tool is laid, a piece of demolding cloth exceeding the preset length of the main beam is laid on the main beam, and after the web tool is laid and before the web laying layer is laid, the piece of demolding cloth on one side of the web tool is turned to be tightly attached to the web tool.

Optionally, the web plies are Z-shaped, S-shaped or C-shaped, the operation of laying the web plies comprising: laying a first cloth layer at one side of the web tool, wherein the first cloth layer comprises a vertical part tightly attached to the vertical side face of the web tool, a horizontal part lapped on the laying layer of the blade shell and a flanging part lapped on the top of the web tool; laying down a core material on vertical portions of the first cloth layer; and laying a second cloth layer on the core material, wherein the second cloth layer comprises a vertical part clung to the core material, a horizontal part lapped on the horizontal part of the first cloth layer and a flanging part lapped on the flanging part of the first cloth layer.

Optionally, after the web layer is laid, release cloth is laid on the front edge and the rear edge of the blade shell layer and the flanging part of the web layer, and then an isolation film is laid on the blade shell layer and the web layer.

Optionally, after the web laying layer is laid, a vacuum infusion system is laid on the blade shell laying layer and the web laying layer, wherein a draft tube is laid at a preset height of the web tool, a spiral tube is laid at the top of the web tool, and when resin is infused, the draft tube is opened when the front of the resin infused on the blade shell laying layer exceeds the draft tube laid at the preset height of the web tool.

Optionally, after forming, the web tooling is removed and the bottom of the formed web is reinforced.

Optionally, two web tools are laid on the blade shell layer, so that two webs are integrally formed on the blade shell.

There is also provided, in accordance with another embodiment of the present invention, a method of forming a blade, the method including: with the above method, a first web is integrally formed with the first blade shell on the first blade shell mold, and a second web is integrally formed with the second blade shell on the second blade shell mold; the first and second blade shell molds are closed and, when closed, the first web is bonded to the second blade shell and the second web is bonded to the first blade shell.

Optionally, the operation of closing the mold comprises: and coating adhesive glue on the top of the formed first web plate and coating adhesive glue on the top of the formed second web plate, or respectively coating adhesive glue on the positions of the adhesive web plates on the first blade shell and the second blade shell, then closing the dies, and carrying out heating and curing treatment.

There is also provided, in accordance with another embodiment of the present invention, a method of forming a blade, the method including: integrally forming two webs with the first blade shell on the first blade shell mould or with the second blade shell on the second blade shell mould by using the method; the first and second blade shell molds are closed, and the two webs are bonded to one of the first and second blade shells that is not integrally formed with a web during closing.

Optionally, the operation of closing the mold comprises: and coating adhesive glue on the tops of the two formed webs, or coating adhesive glue on the position of the adhesive web on one of the first blade shell and the second blade shell, which is not integrally formed with the web, and then closing the dies and carrying out heat curing treatment.

According to the blade and the web manufacturing method provided by the embodiment of the invention, the web can be integrally formed with the blade shell, and the web does not need to be manufactured separately and then laid on the blade shell. The glue consumption during the bonding of the web plates can be reduced, and the weight of the blade and the load requirement on the whole machine can be obviously reduced. In addition, through pouring into shaping blade and web integratively, can show the structural strength who improves between web and the blade casing to improve blade bulk strength, prolong life cycle.

Drawings

FIGS. 1-4 are schematic views of a blade upper shell integrally formed with a web according to an embodiment of the present invention;

FIG. 5 is an enlarged partial schematic view of FIG. 4;

FIG. 6 is a schematic view of a blade under shell integrally formed with a web according to an embodiment of the present invention;

FIG. 7 is a schematic view of a clamped condition according to an embodiment of the invention;

FIG. 8 is a block flow diagram of a blade forming process according to an embodiment of the present invention.

Description of reference numerals:

1: a blade upper shell mold; 2: shell layering on blades, 3: main beam, 4: leading edge web frock, 5: release fabric, 6: first fabric layer, 7: core material, 8: second fabric layer, 9: honeycomb duct, 10: separator, 11: flow guide net, 12: vacuum bag film, 13: lower blade shell mold, 14: main beam, 15: layer laying of a lower shell of the blade, 17: trailing edge web tooling, 18: trailing edge web layup, 19: profiled leading edge web, 191: cuff portion of leading edge web, 20: profiled trailing edge web, 201: a flange portion of the trailing edge web; 21: bonding position on blade lower shell, 22: bonding position on the shell on the blade, 23: trailing edge bond position, 24: a leading edge bond location.

Detailed Description

In order that those skilled in the art will better understand the present invention, specific embodiments thereof will be described in detail below with reference to the accompanying drawings.

Referring to fig. 1 to 8, a method of forming a blade according to an embodiment of the invention is shown, which employs a way that a blade shell is integrally formed with a web for manufacturing the blade. In general, when a blade is manufactured, an upper blade shell and a lower blade shell are manufactured by using an upper blade shell mold and a lower blade shell mold respectively, and webs on the blade can be respectively called a leading edge web and a trailing edge web or can be also called a first web and a second web together according to positions of the webs. In this way, during the production of the blade shell, a web is formed in each case integrally with the two shells, and then the two webs are bonded to the other blade shell in each case during the clamping. For example, in one embodiment, a first web may be integrally formed on the upper shell of the blade and a second web may be integrally formed on the lower shell of the blade, as shown in

additional steps

110 and 120 in FIG. 8, and then the first web may be bonded to the lower shell of the blade and the second web may be bonded to the upper shell of the blade by clamping the dies.

The method of forming the blade is specifically described below by way of example of integrally forming a leading edge web (or may be referred to as a first web) on an upper shell of the blade (or may be referred to as a first shell) and integrally forming a trailing edge web (or may be referred to as a second web) on a lower shell of the blade (or may be referred to as a second shell).

The blade upper shell mould (or first blade shell mould) 1 may be cleaned first, and then a release agent is applied on the surface of the mould 1, so that the blade is released after being formed. Then, two sealing tapes are pasted on the flange surfaces of the front edge and the rear edge of the mould 1, then, demoulding cloth is laid at the front edge and the rear edge of the mould 1, a part of the demoulding cloth is laid on the flange surface of the mould 1, and the rest part of the demoulding cloth is laid on the surface of the cavity of the mould 1. Then, outer skins are laid in the mould cavity, the number of which is determined by the blade structural design, and usually about 3 to 4 layers can be laid.

Then, a root reinforcement layer is laid at the position of the root of the blade shell to reinforce the strength of the root of the blade shell. And then placing the main beam 3 at a proper position in the middle of the blade, as shown in step 111 in fig. 8, wherein the specific position can be determined by the main beam tool. The main beam 3 may be a main beam component which is formed separately in advance, and of course, the main beam may also be formed integrally with the blade shell, that is, when the blade shell layer is laid, the main beam layer (including the glass fiber cloth layer and the core material, etc.) may be laid together. After the main beam 3 is laid, the accuracy of the laying position of the main beam can be verified by a quality worker, and if the accuracy does not meet the expected requirement, the position of the main beam needs to be finely adjusted to be placed at the accurate laying position so as to ensure the structural strength of the finally formed blade. After the main beam 3 is laid, blade core materials can be laid on two sides of the main beam 3 so that the blade shell and the main beam can be smoothly transited. After that, the trailing edge auxiliary beam can be laid at the trailing edge of the blade shell, for example, a single-shaft glass fiber cloth can be laid at the trailing edge of the blade shell to form the trailing edge auxiliary beam, and the length of the single-shaft glass fiber cloth can be 120mm and 170 mm. Then, the spar upper root reinforcement layer and the thickening layer are laid at the root of the blade shell, and an inner skin, the number of which may typically correspond to the number of outer skins, e.g. around 3 to 4, is laid on the spar 3, the core and the root thickening layer and thickening layer. Then, a release cloth 5 is laid on the main beam 3, and the edges at the front and rear edges of the release cloth 5 need to be more than about 120mm beyond the main beam 3. The various cloth layers, skins, cores, girders 3, etc. laid as described above may be collectively referred to as a blade upper shell lay-up 2.

Next, a leading edge web tooling (or may be referred to as a first web tooling) 4 is laid on the already laid girder 3, and as shown in step 112, the leading edge web tooling 4 may be on the left half of the girder 3, and may be about 5-15cm from the left edge of the girder 3. The leading edge web tooling 4 may be coated with a release agent prior to layup to facilitate release after the blade shell is formed. In an embodiment of the invention, the leading edge web tooling 4 may be substantially vertical frame-shaped and may include a bottom beam that mates with the main beam 3, which may mate with the blade upper shell layup, a vertical beam extending vertically upward from the bottom beam, and a top beam secured to the vertical beam, and the leading edge web may be profiled on the left vertical surface of the leading edge web tooling 4, so that the resulting profiled leading edge web is substantially S-shaped, as will be described in more detail below. Of course, by properly adjusting the position and size of the leading edge web tooling 4, a leading edge web can also be formed on the right vertical surface of the leading edge web tooling 4, and then the leading edge web can be substantially Z-shaped.

Thus, in general, the side surface of the leading edge web tooling 4 used to shape the web may match the shape of the leading edge web. In addition, the leading edge web tooling 4 may take any other suitable shape besides being frame-shaped. For example, if the left portion of the leading edge web tooling 4 is generally C-shaped with the opening to the left and a leading edge web is formed on the left side of the leading edge web tooling 4, the resulting formed leading edge web may be generally C-shaped.

In addition, in the present embodiment, since the leading edge web is formed on the blade upper shell, the leading edge web tool 4 is provided on the main beam 3 so as to be offset to the leading edge, and if the trailing edge web is formed on the blade upper shell, the trailing edge web is provided so as to be offset to the trailing edge. The location of the web tooling on the blade shell may be determined based on design requirements.

After the front edge web tool 4 is placed, the part, located on the left side of the front edge web tool 4, of the demolding cloth 5 laid on the main beam 3 in the front direction can be rightwards turned to be attached to the left side face of the front edge web tool 4, the demolding cloth 5 can be fixed to the left side face of the front edge web tool 4 through glue spraying, the demolding cloth covers the part between the front edge web tool 4 and the main beam 3 and the left side face of the front edge web tool 4, and accordingly demolding and later-period reinforcement operations are facilitated.

A leading edge web layup may then be laid down on the side of the leading edge web tooling 4 facing the leading edge (i.e., the left side as viewed in the figures), as shown at step 113. Accordingly, if the trailing edge web is integrally formed on the blade upper shell, the web plies can be laid on the side of the trailing edge web tooling facing the trailing edge.

The laid leading edge web plies may generally comprise materials such as fibre plies and core materials. For the fiber layer, a fiber cloth layer such as a glass fiber cloth layer may be specifically used or a fiber board preformed from the fiber cloth layer and a resin, for example, a carbon fiber board, a glass fiber board, a bamboo fiber board, or the like may be used. The fibre plies may be laid out in substantially three parts, namely a vertical part fixed relative to the vertical face of the left side of the leading edge web tooling 4, a horizontal part overlapping the blade upper shell layup and a cuff part overlapping the top of the leading edge web tooling 4.

Specifically, the step of laying up the leading edge web layup may generally comprise the following operations. A first cloth layer 6 is first laid on the left side of the leading edge web tooling 4 as shown in fig. 1. The first cloth layer 6 can be fixed on the left vertical surface of the front edge web tool 4 by glue spraying so as to prevent the first cloth layer from sliding downwards. The first cloth layer 6 may include a vertical portion 62 secured to the vertical face of the leading edge web tooling 4, a horizontal portion 63 (alternatively, the horizontal portion 63 may also be referred to as a cuff portion) that overlaps the blade upper shell layup (e.g., inner skin), and a cuff portion 61 that overlaps the top of the leading edge web tooling 4. Wherein, the length of the first cloth layer 6 lapped on the top of the blade upper shell laying layer and the front edge web tooling can be about 100-140 mm. The first cloth layer 6 may be a biaxial fiberglass cloth layer, and the specific number of layers may be determined according to the design requirements of the blade, for example, 3 to 4 layers of fiberglass cloth may be laid. Then, a core material 7 may be further laid on the first cloth layer 6, as shown in fig. 2, and the core material 7 may be made of PVC or balsa wood. The core material 7 may be substantially flush against the vertical portion 62 of the first fabric layer 6 and may be secured by means of a spray adhesive. Thereafter, laying of the second fabric layer 8 may be continued as shown in fig. 3. Similar to the first fabric layer 6, the second fabric layer 8 may generally include a horizontal portion 83 overlapping the horizontal portion 63 of the first fabric layer 6 (alternatively, the horizontal portion 83 may also be referred to as a cuff portion), a vertical portion 82 abutting the vertical portion 62 of the first fabric layer 6, and a cuff portion 81 overlapping the cuff portion 61 of the first fabric layer 6, and the second fabric layer 8 may be temporarily fixed by spraying glue. Similarly, the second fabric layer 8 may be a biaxial fiberglass fabric layer, and may be laid substantially in the range of 3 to 4 layers. In addition, in the above laying process, the fabric layer and the core material may be fixed by other means such as an adhesive tape, in addition to positioning the fabric layer by the spray glue.

To this end, the leading edge web plies may be substantially S-shaped. However, the invention is not so limited and may take other forms, for example, the leading edge web plies may also be Z-shaped or C-shaped, as previously described. The specific form of the web tool and the web paving layer laying can be determined according to the blade strength design requirement, the actual field production condition and other conditions.

Where the fibre plies are in the form of fibreboards in particular, the step of laying up the leading edge web layup may generally comprise the operations of: 1-2 layers of glass fiber cloth layers are firstly laid on the left side of the front edge web tool 4, the laying mode of the glass fiber cloth layers can be similar to that of the laid cloth layers, then the core materials and the fiber boards are continuously laid on the vertical parts of the glass fiber cloth layers, and finally 1-2 layers of glass fiber cloth layers are similarly laid on the fiber boards.

After the laying of the leading edge web plies is completed, release cloth may be laid at the leading and trailing edge positions of the blade at the web flanging portion, and the isolation film 10 may be laid on the release cloth and the already laid plies (including the blade upper shell ply and the leading edge web ply). Then, a flow guiding net 11 is laid on the separating film 10, that is, the separating film 10 and the flow guiding net 11 can cover the already laid blade upper shell layer and leading edge web layer. For the left vertical side of the leading edge web tooling 4, the isolation film 10 and the flow guide net 11 can be sewn and fixed on the core material 7 by using cotton threads or glass fiber threads to prevent the down sliding.

Then, the draft tube can be laid on the blade upper shell and the web tooling 4, wherein the draft tube 9 on the web tooling 4 can be laid on the left vertical surface at a position about 200 and 300mm away from the blade upper shell, as shown in fig. 4 and 5. Then, at 4 the superiors of leading edge web frock, can lay the spiral pipe to can use the pellicle parcel to live the spiral pipe, in order to prevent that resin from flowing into the spiral pipe when follow-up pouring resin, guarantee the normal clear of evacuation and pouring resin. Thereafter, the vacuum bag film 12 may be laid on all the laydown areas on the blade upper shell mold 1 (including the laydown areas of the blade upper shell and the leading edge web). That is, the leading edge web tooling 4 and the leading edge web laying layer are wrapped in the vacuum bag film 12 together with the blade upper shell and are placed in a vacuum environment together. Two layers of vacuum bag membranes 12 may be laid to ensure vacuum tightness of the laid area and prevent air leakage.

Then, a resin injection port can be manufactured, and the whole laying area is vacuumized until the vacuum degree in the laying area meets the injection requirement. The resin may then be poured, as shown in step 114. When resin is poured, the opening and closing sequence can be adjusted, the resin is poured into the layer spreading area of the shell on the blade at first, and when the resin front permeating on the layer spreading of the shell on the blade exceeds the flow guide pipe 9 on the layer spreading of the front edge web, the pouring port on the flow guide pipe 9 is opened to pour the resin into the layer spreading of the front edge web.

After the resin infusion is complete, a heat curing process may be performed, as shown in step 115. Specifically, the heater can be turned on, and the heating temperature can be adjusted, so that different areas can be heated to different degrees. For example, insulating cotton may be placed over the leading edge web layup to increase the rate of temperature rise in the web area and speed curing. Alternatively, a heating tunnel may additionally be provided at the leading edge web region, with a heat gun blowing hot air into the heating tunnel to accelerate curing of the leading edge web.

After the upper shell and the front edge web of the blade are integrally cured and molded, auxiliary materials on the surface, including a vacuum bag film, an isolation film, a flow guide net, a flow guide pipe and the like, can be torn off. The leading edge web tooling 4 can then be removed and the bottom of the profiled leading edge web, for example the lower left corner (i.e. the corner facing the leading edge of the blade), can be hand-taped. Specifically, 3 to 4 layers of biaxial fiberglass cloth can be used for reinforcement, the fiberglass cloth can cover the range of about 120mm wide of each of the front edge web and the blade upper shell, and the specific covering length can be determined according to factors such as the blade model, the strength requirement, the web length and the like. To this end, the blade upper shell and leading edge web are integrally formed.

When the blade upper shell and the leading edge web are integrally manufactured, the integral forming of the blade lower shell and the trailing edge web can be simultaneously carried out, and the specific operation is generally similar to the integral forming operation of the blade upper shell and the leading edge web. That is, the following steps may be mainly included in general: after the blade lower shell mold (or may be referred to as a second blade shell mold) 13 has laid down the blade lower shell layup 15 (including the spar 14) in a manner similar to the blade upper shell (as shown at step 121), a trailing edge web tooling (or may be referred to as a second web tooling) 17 may be placed on the spar 14 at a location offset to the trailing edge, as shown at step 122. The structure of the rear edge web tooling 17 is similar to that of the front edge web tooling 4, and can also be in a vertical frame shape. The trailing edge web plies 18 are then laid down on the side of the trailing edge web tooling 17 facing the trailing edge of the blade (i.e., the right side), as shown at step 123, and likewise, the trailing edge web plies 18 also generally comprise fiber layers and core materials, as shown in FIG. 6. The fiber layer may include a vertical portion 182 that is affixed to the right vertical face of the trailing edge web tooling 17, a horizontal portion 183 that overlaps the blade lower shell layup 15 (alternatively, the horizontal portion 183 may also be referred to as a cuff portion), and a cuff portion 181 that overlaps the top of the trailing edge web tooling 17, such that the entire trailing edge web layup 18 is generally Z-shaped after it is laid.

Specifically, a first cloth layer is laid on the right side of the trailing edge web tool 17, and the first cloth layer can be fixed on the right vertical surface of the trailing edge web tool 17 by using glue spraying. The first cloth layer may include a vertical portion that is secured to a vertical face of the trailing edge web tooling 17, a horizontal portion that overlaps the blade lower shell layup 15, and a cuff portion that overlaps the top of the trailing edge web tooling 17. The length of the first cloth layer overlapped on the tops of the blade lower shell laying layer 15 and the trailing edge web tooling 17 can be about 100-140mm generally. The first cloth layer can be a biaxial fiberglass cloth layer, and the specific number of layers can be determined according to the design requirements of the blade, for example, 3 to 4 layers of fiberglass cloth can be laid. A core material may then be laid over the first fabric layer, the core material being substantially flush against the vertical portion of the first fabric layer and being secured by the spray glue. Thereafter, laying of the second fabric layer may continue. Similar to the first cloth layer, the second cloth layer may substantially include a horizontal portion overlapping the horizontal portion of the first cloth layer, a vertical portion abutting the vertical portion of the first cloth layer, and a turned-up portion overlapping the turned-up portion of the first cloth layer 6, and the second cloth layer may be temporarily fixed by spraying glue. Similarly, the second fabric layer may be a biaxial fiberglass fabric layer, or may be laid substantially in the range of 3 to 4 layers.

Thereafter, vacuum infusion plies such as barrier films, flow-directing meshes, and the like may be similarly laid over the area where the blade lower shell plies 15 and trailing edge web plies 18 are laid, and then resin infusion and curing operations may be performed, as shown at

steps

124 and 125, which are similar to the operations performed when the blade upper shell and leading edge web are integrally formed, and will not be described in detail herein.

After the blade upper shell and leading edge web and blade lower shell and trailing edge web are integrally formed, a mold clamping operation may be performed, as shown at step 140 in fig. 7 and 8. Before clamping, adhesive glue may be applied to the blade upper shell and the blade lower shell at the trailing edge bond locations 23 and the leading edge bond locations 24, as shown at step 130. Meanwhile, the bonding glue can be coated on the flanging part 191 of the formed front edge web plate 19 and the flanging part 201 of the rear edge web plate 20, or the bonding glue can be coated on the position 22 of the blade upper shell body bonded with the rear edge web plate 20, and the bonding glue can be coated on the position 21 of the blade lower shell body bonded with the front edge web plate 19. After clamping the mold, the adhesive is cured by heat curing, as shown in step 150, so that the leading edge web 19 is bonded to the blade lower shell and the trailing edge web 20 is bonded to the blade upper shell.

And then demolding can be carried out to form the complete blade.

It should be noted that the present invention is not limited to the above embodiments, and the blade shell and the web may be integrally formed in other manners. For example, two webs may be integrally formed on one of the blade shells and then subsequently bonded to the other blade shell during mold clamping.

Specifically, two web tools may be laid on the first blade shell mold at predetermined positions on the main beam of the first blade shell laying layer, one of the web tools may be referred to as a leading edge web tool, and the other web tool may be referred to as a trailing edge web tool. The leading edge web tooling may be biased toward the leading edge on the spar and the trailing edge web tooling may be biased toward the trailing edge on the spar. The leading edge web plies and trailing edge web plies may then be laid down in a similar procedure to the above operation. And then the front edge web layer and the rear edge web layer are integrally formed with the first blade shell layer through vacuum assisted resin infusion molding, so that two webs are integrally molded on the first blade shell. Also, the two webs may be hand-lay reinforced at the point of engagement with the main beam after the forming operation.

When the two shell molds are closed, the top positions of the two webs can be coated with bonding glue, or the two positions of the bonding webs on the separately formed second blade shell are respectively coated with bonding glue, and the two webs are bonded to the second blade shell through closing the two shell molds.

In the above molding operation, the web is integrally molded with the blade shell by simultaneously laying the blade shell layup and the web layup on the blade shell mold. In addition, the web can be prefabricated in advance, the prefabricated web is placed on the blade shell laying layer, and cloth layers which are overlapped on the vertical side face of the web and the blade shell laying layer in a certain width mode are laid at the bottom of the web. And then, integrally paving layers of the web and the blade shell to carry out vacuum auxiliary resin infusion, and further integrally forming the web and the blade shell.

By the mode that the web and the blade shell are integrally formed, the glue consumption of half of the web bonding glue can be reduced, for example, for a 59-meter-long blade, the glue consumption can be reduced by about 150kg, and the cost of the bonding glue is reduced by about 7500 yuan. Because the use of the bonding glue is reduced, the weight of the blade can be effectively reduced, the requirement on the load of the whole machine is reduced, and the cleaning of the bonding glue in the later operation process can be reduced. In addition, compare in the use of bonding glue, the integration is filled and can effectually be reduced the bonding defect, promotes the structural quality of web and casing. Because web unilateral and casing integrated into one piece have increased the operating space of web, can paste the reinforcement by hand at the non-turn-ups side of blade web, promote the connection performance of blade web. Because single web preparation, can be convenient with web auxiliary fixtures installation or demolish.

Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents, and that such changes and modifications are intended to be within the scope of the invention.

Claims

1. A method of integrally forming a blade shell and a web, the method comprising:

laying a blade shell layer on a blade shell mould;

laying a web plate tool at a main beam on the blade shell laying layer;

paving a web plate laying layer on one side of the web plate tool, wherein the web plate laying layer is Z-shaped, S-shaped or C-shaped;

resin is poured into the blade shell layer and the web plate layer by utilizing a vacuum auxiliary resin pouring forming process so as to carry out vacuum auxiliary resin pouring and curing forming on the blade shell layer and the web plate layer as a whole,

wherein the operation of laying up the web layup comprises:

laying a first cloth layer at one side of the web tool, wherein the first cloth layer comprises a vertical part tightly attached to the vertical side face of the web tool, a horizontal part lapped on the laying layer of the blade shell and a flanging part lapped on the top of the web tool;

laying down a core material on vertical portions of the first cloth layer;

and laying a second cloth layer on the core material, wherein the second cloth layer comprises a vertical part clung to the core material, a horizontal part lapped on the horizontal part of the first cloth layer and a flanging part lapped on the flanging part of the first cloth layer.

2. The method of claim 1, wherein the web tooling is in the shape of a vertical frame and includes a bottom beam that abuts the main beam, a vertical beam that extends vertically from the bottom beam, and a top beam that is secured above the vertical beam.

3. The method of claim 1, wherein the web layup comprises a fiber layer including a vertical portion fixed relative to a vertical side of the web tooling, a horizontal portion overlapping the blade shell layup, and a cuff portion overlapping a top of the web tooling.

4. A method according to claim 3, wherein the fibre layer comprises a fibre cloth layer or a fibreboard pre-formed from a fibre cloth layer and resin.

5. The method of claim 1, wherein after the web plies are laid, release cloth is laid over the leading and trailing edges of the blade shell plies and the flange portions of the web plies, and then a release film is laid over the blade shell plies and the web plies.

6. The method of claim 1, wherein after the web layup is laid, a vacuum infusion system is laid over the blade shell layup and the web layup, wherein a draft tube is laid at a predetermined height of the web tooling and a spiral tube is laid at a top of the web tooling,

and when the resin is poured, opening the flow guide pipe when the front of the resin poured on the blade shell layer exceeds the flow guide pipe paved at the preset height of the web tool.

7. The method of claim 1, wherein after forming, the web tooling is removed and the bottom of the formed web is reinforced.

8. A method according to any of claims 1 to 7, wherein two web tooling is laid on the blade shell layup to integrally mould two webs on the blade shell.

9. A method of forming a blade, the method comprising:

using the method of any of claims 1 to 7, integrally moulding a first web on a first blade shell mould with a first blade shell and integrally moulding a second web on a second blade shell mould with a second blade shell;

the first and second blade shell molds are closed and, when closed, the first web is bonded to the second blade shell and the second web is bonded to the first blade shell.

10. The method of claim 9, wherein the operation of clamping the mold comprises: and coating adhesive glue on the top of the formed first web plate and coating adhesive glue on the top of the formed second web plate, or respectively coating adhesive glue on the positions of the adhesive web plates on the first blade shell and the second blade shell, then closing the dies, and carrying out heating and curing treatment.

11. A method of forming a blade, the method comprising:

using the method of claim 8, integrally forming two webs with the first blade shell on the first blade shell mold or with the second blade shell on the second blade shell mold;

the first and second blade shell molds are closed, and the two webs are bonded to one of the first and second blade shells that is not integrally formed with a web during closing.

12. The method of claim 11, wherein the operation of clamping the mold comprises: and coating adhesive glue on the tops of the two formed webs, or coating adhesive glue on the position of the adhesive web on one of the first blade shell and the second blade shell, which is not integrally formed with the web, and then closing the dies and carrying out heat curing treatment.