CN109203516B - Manufacturing method of wind power blade - Google Patents
Manufacturing method of wind power blade Download PDFInfo
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- CN109203516B CN109203516B CN201811274791.1A CN201811274791A CN109203516B CN 109203516 B CN109203516 B CN 109203516B CN 201811274791 A CN201811274791 A CN 201811274791A CN 109203516 B CN109203516 B CN 109203516B
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- side shell
- rear edge
- bonding flange
- bonding
- pressure side
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/36—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- B29L2031/082—Blades, e.g. for helicopters
Abstract
The invention discloses a manufacturing method of a wind power blade, which comprises the following steps: laying a rear edge bonding flange at the rear edge of the shell mold according to the sequence of glass fiber cloth-core material-glass fiber cloth, and obtaining the rear edge bonding flange by adopting a vacuum infusion process; carrying out shell laying in a shell mold, and bonding and combining the rear edge bonding flange at the rear edge position of the shell mold with the shell laying through a vacuum infusion process to obtain a shell with the rear edge bonding flange; bonding the rear edge of the shell with the rear edge bonding flange with the rear edge of the shell without the rear edge bonding flange; according to the method, the shell with the front edge bonding flange is obtained, and the front edge of the suction side shell is bonded with the front edge of the pressure side shell to obtain the wind power blade. According to the invention, the bonding flange prefabricated part is obtained firstly, and then the bonding flange prefabricated part and the shell layer are formed together through a vacuum pouring process to obtain the shell with the bonding flange, the bonding flange is prefabricated and formed in advance, the bonding angle cavity is more conformal, the defects are identified in advance, and the quality risk is reduced.
Description
Technical Field
The invention belongs to the technical field of wind power blades, and particularly relates to a manufacturing method of a wind power blade.
Background
With the coming of new energy equity times, in the development of the trend of large-size wind power blades, low cost and high reliability become design and manufacturing keys. At present, the structure of a wind power blade generally comprises a blade suction side shell, a blade pressure side shell and a web plate, wherein the wind power blade is produced in the production process, a crossbeam and a web plate prefabricated part are usually manufactured firstly and respectively, then the crossbeam prefabricated part and the shell layer are used for manufacturing the suction side shell and the pressure side shell together, after the shell is manufactured, the web plate prefabricated part is adhered to the crossbeams of the suction side shell and the pressure side shell by using adhesive glue, adhesive flanges for adhering and assembling a die are paved at the front edge and the rear edge of the suction side shell and the pressure side shell, and then the adhesive flanges are cured and molded, and the suction side shell and the pressure side shell are adhered together by using structure glue to obtain the wind power blade.
In the method, the front edge bonding flange and the rear edge bonding flange are layered together with a shell material in the preparation process, the problems of over-thick bonding glue layer or low bonding strength are easily caused in the later bonding process, the using amount of bonding glue is large, the curing time of the bonding glue is long, and the wind power blade is heavy in weight, poor in quality, high in cost and low in efficiency; and the mold closing gap of the shell is unstable, so that the faults such as rear edge cracking and the like occur in the operation process of the wind power blade, the molding efficiency of the blade is influenced, and the burden of after-sale service is also increased.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a manufacturing method of a wind power blade.
The invention provides a manufacturing method of a wind power blade, which comprises the following steps:
1) laying a rear edge bonding flange at the rear edge of a suction side shell or a pressure side shell mold according to the sequence of glass fiber cloth-core material-glass fiber cloth, laying a vacuum system on the laid rear edge bonding flange, vacuum-pouring resin until the resin completely soaks the laid layer, heating and curing, and demolding to obtain the rear edge bonding flange;
2) carrying out shell layer laying in a suction side shell or a pressure side shell mould, and bonding and combining a rear edge bonding flange with a shell layer at the rear edge position of the suction side shell or the pressure side shell mould through a vacuum introduction molding process to obtain the suction side shell or the pressure side shell with the rear edge bonding flange;
3) bonding the rear edge of the suction side shell or the pressure side shell with the rear edge bonding flange with the rear edge of the pressure side shell or the suction side shell without the rear edge bonding flange;
4) and similarly, obtaining a suction side shell or a pressure side shell with a front edge bonding flange according to the method of the steps 1) to 3), and bonding the front edge of the suction side shell with the front edge of the pressure side shell to obtain the wind power blade.
Preferably, the pressure side shell or the suction side shell without the rear edge bonding flange in the step 3) is manufactured by a vacuum introduction molding process.
Preferably, the method for laying the vacuum system in the step 1) comprises the following steps: and a circle of sealant is stuck at the edge of the bonding flange laying layer, demolding cloth is laid on the upper surface of the bonding flange laying layer, an upper surface flow guide net and an upper surface air exhaust bag are laid on the upper surface of the demolding cloth, then a sealed vacuum bag film is laid on the whole bonding flange mold, an injection hole and a vacuum exhaust hole in a molding mold cavity are arranged, and the vacuum degree is kept to be less than or equal to-0.098 Mpa by vacuumizing.
Preferably, the bonding method of the trailing edge of the suction side shell and the trailing edge of the pressure side shell in the step 3) is as follows: and (3) coating structural adhesive on the rear edge bonding flange, and bonding the rear edge of the suction side shell or the pressure side shell with the rear edge bonding flange with the rear edge of the pressure side shell or the suction side shell without the rear edge bonding flange through the structural adhesive.
Preferably, before the trailing edge of the suction side shell and the trailing edge of the pressure side shell are bonded in the step 3), two ends of the leading edge web and the trailing edge web are bonded to the suction side shell and the pressure side shell respectively.
Preferably, the method for bonding the leading edge of the suction side shell and the leading edge of the pressure side shell in the step 4) comprises the following steps: and (3) coating structural adhesive on the front edge bonding flange, and bonding the front edge of the suction side shell or the pressure side shell with the front edge bonding flange with the front edge of the pressure side shell or the suction side shell without the front edge bonding flange through the structural adhesive.
Preferably, the core material of step 1) is balsa wood, polyvinyl chloride or polyethylene terephthalate.
The two ends of the front edge web plate and the rear edge web plate are provided with flanges for bonding, structural adhesive is coated on the front edge web plate and the rear edge flange, and the two ends of the front edge web plate and the rear edge web plate are respectively bonded to the suction side shell and the pressure side shell through the structural adhesive.
Two ends of the front edge web plate and the rear edge web plate are bonded with a suction side girder on the suction side shell and a pressure side girder on the pressure side shell through structural glue.
According to the invention, in the step 1), the rear edge bonding flange laying is carried out at the rear edge position of the suction side shell or the pressure side shell mold according to the sequence of glass fiber cloth-core material-glass fiber cloth, the core material is completely wrapped by the glass fiber cloth, and the core material is not exposed.
The vacuum introduction molding process comprises the following steps: the technological principle is that a flexible vacuum bag film is used to cover and seal a reinforcing material preformed body on a single-sided rigid mould, the gas in a mould cavity is removed under vacuum negative pressure, the resin is used for impregnating fibers and fabrics thereof by utilizing the flowing and permeation of the resin, and the composite material member is obtained by curing and forming.
The present invention may also employ hand lay-up, die pressing or pultrusion processes instead of the vacuum infusion molding process.
At present, in the production process of a wind power blade, a girder and a web prefabricated part are usually manufactured respectively, then a suction side shell and a pressure side shell are manufactured jointly by the girder prefabricated part and a shell laying layer, after the shell is manufactured, the web prefabricated part is adhered to the girder of the suction side shell and the pressure side shell by using adhesive, adhesive flanges for adhering and closing the mold are laid on the front edge and the rear edge of the suction side shell and the pressure side shell, then the adhesive flanges are cured and formed, and the suction side shell and the pressure side shell are adhered together by using structural adhesive to obtain the wind power blade. In the method, the front edge bonding flange and the rear edge bonding flange are layered together with a shell material in the preparation process, the problems of over-thick bonding glue layer or low bonding strength are easily caused in the later bonding process, the using amount of bonding glue is large, the curing time of the bonding glue is long, and the wind power blade is heavy in weight, poor in quality, high in cost and low in efficiency; and the mold closing gap of the shell is unstable, so that the faults such as rear edge cracking and the like occur in the operation process of the wind power blade, the molding efficiency of the blade is influenced, and the burden of after-sale service is also increased.
The invention firstly obtains a prefabricated member of a rear edge bonding flange and a front edge bonding flange, and then the prefabricated member and a layer of a suction side shell or a pressure side shell are formed together through a vacuum infusion process to obtain the suction side shell or the pressure side shell with the bonding flange, the rear edge of the suction side shell or the pressure side shell with the rear edge bonding flange is bonded with the rear edge of the pressure side shell or the suction side shell without the rear edge bonding flange through structural adhesive, similarly, the front edge of the suction side shell or the pressure side shell with the front edge bonding flange is bonded with the front edge of the pressure side shell or the suction side shell without the front edge bonding flange through the structural adhesive, so that the suction side shell and the pressure side shell are realized, 4-medium combination modes can be provided, namely, the front edge and the rear edge of the suction side shell are respectively provided with the front edge bonding flange and the rear edge bonding flange, and the pressure side shell; the front edge and the rear edge of the pressure side shell are respectively provided with a front edge bonding flange and a rear edge bonding flange, and the suction side shell is not provided with a bonding flange; the front edge of the suction side shell is provided with a front edge bonding flange, and the rear edge of the pressure side shell is provided with a rear edge bonding flange; fourthly, the rear edge of the suction side shell is provided with a rear edge bonding flange, and the front edge of the pressure side shell is provided with a front edge bonding flange.
By adopting the method, the bonding flange is prefabricated and molded to obtain the free-form bonding flange, the defects are identified in advance, the quality risk is reduced, the problem of rework and repair in the original production process is solved, and the manufacturing precision and the strength of the product are improved. The shape of the bonding surface is visible, so that the field organization efficiency can be improved, the drawing can be perfected at any time, and the design optimization of a new product is facilitated; the thickness of the adhesive layer is controlled more finely, the adhesive strength is improved, and the using amount of structural adhesive is reduced; and the prefabricated bonding flange that obtains further spreads the layer with the casing and jointly moulds through the vacuum infusion technology, rather than gluing through the structure, can reduce the quantity that the structure glued, avoids appearing shaping defects such as fold and bubble, has saved bonding flange and the time of casing bonding solidification, has strengthened the bonding strength that casing and structure glued, in blade production process, has alleviateed wind-powered electricity generation blade's weight, has reduced wind-powered electricity generation blade manufacturing cost, promotion product quality and production efficiency.
The invention has the beneficial effects that:
1. according to the invention, the prefabricated parts of the rear edge bonding flange and the front edge bonding flange are obtained firstly, and then the prefabricated parts and the suction side shell or the pressure side shell are formed together through a vacuum pouring process to obtain the suction side shell or the pressure side shell with the bonding flanges, the bonding flanges are prefabricated and formed in advance, the bonding angle cavity is more conformal, the defects are identified in advance, and the quality risk is reduced.
2. According to the invention, the obtained prefabricated bonding flange and the shell layer are further molded together through a vacuum infusion process instead of being bonded through structural adhesive, so that the using amount of the structural adhesive can be reduced, the molding defects such as folds, bubbles and the like are avoided, the bonding curing time of the bonding flange and the shell is saved, the bonding strength of the shell and the structural adhesive is enhanced, the weight of the wind power blade is reduced, the production cost of the wind power blade is reduced, and the product quality and the production efficiency are improved in the blade production process.
3. The bonding flange obtained by the method has the advantages that the thickness of the bonding glue layer is controlled more finely, the bonding strength is improved, and the using amount of structural glue is reduced.
4. The manufacturing method is simple, the production efficiency is high, and the material use cost and the like in the production process are reduced.
Drawings
FIG. 1 is a schematic structural view of a trailing edge bonding flange of the present invention.
FIG. 2 is a schematic structural view of the rear edge bonding flange and the shell after bonding.
FIG. 3 is a schematic structural view of a suction side shell or pressure side shell mold trailing edge cavity of the present invention.
Wherein, 1 rear edge bonding flange, 2 structural adhesive, 3 suction edge/pressure edge shell, 11 glass fiber cloth and 12 core materials.
Detailed Description
The following examples are presented to further illustrate the embodiments of the present invention and are not intended to limit the invention thereto.
As shown in fig. 1-2, the rear edge bonding flange 1 manufactured by the present invention includes a glass fiber cloth 11 and a core material 12, and the glass fiber cloth 11 completely wraps the core material 12 to prevent the core material 12 from being exposed. As shown in fig. 2, the rear edge of the suction side shell/pressure side shell 3 with the rear edge bonding flange 1 is bonded with the rear edge of the pressure side shell/suction side shell 3 without the rear edge bonding flange by the structural adhesive 2.
The trailing edge bonding flange 1 according to the invention is formed in the trailing edge of a suction side shell or a pressure side shell mould as shown in fig. 3 by means of a vacuum infusion process.
The suction side shell or the pressure side shell mold can also adopt an arc cavity mold, such as a lower blade shell mold and an upper blade shell mold shown in the patent application number CN 201510858687.7.
Example 1
1) Laying a rear edge bonding flange at the rear edge position of a suction side shell or a pressure side shell mold according to the sequence of glass fiber cloth-core material-glass fiber cloth, sticking a circle of sealant at the edge of the laid rear edge bonding flange, laying demolding cloth on the upper surface of the laid bonding flange, laying an upper surface flow guide net and an upper surface air exhaust bag on the upper surface of the demolding cloth, laying a sealed vacuum bag film on the whole bonding flange mold, arranging an adhesive injection port and a vacuum exhaust port in a molding mold cavity, vacuumizing to keep the vacuum degree less than or equal to-0.098 MPa, vacuum-injecting epoxy resin until the resin completely infiltrates the laid layer, heating, curing and demolding to obtain a rear edge bonding flange;
2) firstly, respectively manufacturing a suction side girder, a pressure side girder, a front edge web plate and a rear edge web plate by adopting a vacuum introduction molding process, laying upper glass fiber cloth, a suction side/pressure side crossbeam, a sandwich and lower glass fiber cloth in sequence in a suction side shell/pressure side shell mould, after the shell laying is finished, placing a rear edge bonding flange at the rear edge of a suction side shell/pressure side shell mould, then building a vacuum system by the whole shell layer, arranging an injection port and a vacuum extraction port in the molding mold cavity, vacuumizing to ensure that the vacuum degree is less than or equal to-0.098 Mpa and the vacuum negative pressure can be maintained for not less than 30min, then injecting the epoxy resin into the molding die cavity through the glue injection port by utilizing vacuum negative pressure to impregnate the preformed body, after the preformed body is completely impregnated by the resin system, heating and curing, and demolding to obtain a suction side shell/pressure side shell with a rear edge bonding flange;
3) respectively bonding two ends of a front edge web plate and a rear edge web plate to a suction side shell and a pressure side shell, smearing structural adhesive on a rear edge bonding flange, and bonding the rear edge of the suction side shell/the pressure side shell with the rear edge bonding flange with the rear edge of the pressure side shell/the suction side shell without the rear edge bonding flange through the structural adhesive;
4) and similarly, according to the method of the steps 1) to 3), obtaining a suction side shell/pressure side shell with a front edge bonding flange, and bonding the front edge of the suction side shell with the front edge of the pressure side shell to obtain the wind power blade.
Comparative example 1
1) Firstly, respectively manufacturing a suction side crossbeam, a pressure side crossbeam, a front edge web and a rear edge web by adopting a vacuum introduction molding process, sequentially paving upper glass fiber cloth, the suction side/pressure side crossbeam, a sandwich and lower glass fiber cloth in a suction side shell/pressure side shell mold, after shell paving is finished, carrying out rear edge bonding flange paving on the rear edge of the suction side shell/pressure side shell mold according to the sequence of the glass fiber cloth, a core material and the glass fiber cloth, then establishing a vacuum system for the whole shell paving, arranging a glue injection port and a vacuum extraction port in a molding mold cavity, vacuumizing to ensure that the vacuum degree is less than or equal to-0.098 Mpa and the vacuum negative pressure is not less than 30min, then injecting epoxy resin into the molding mold cavity through the glue injection port by utilizing the vacuum negative pressure to dip the preform, heating and curing after the resin system completely dips the preform, obtaining a suction side shell/a pressure side shell with a rear edge bonding flange after demoulding;
2) respectively bonding two ends of a front edge web plate and a rear edge web plate to a suction side shell and a pressure side shell, smearing structural adhesive on a rear edge bonding flange, and bonding the rear edge of the suction side shell/the pressure side shell with the rear edge bonding flange with the rear edge of the pressure side shell/the suction side shell without the rear edge bonding flange through the structural adhesive;
3) and similarly, according to the method of the steps 1) to 2), obtaining a suction side shell/pressure side shell with a front edge bonding flange, and bonding the front edge of the suction side shell with the front edge of the pressure side shell to obtain the wind power blade.
Through research, the method in the embodiment 1 is adopted, firstly, the prefabricated parts of the rear edge bonding flange and the front edge bonding flange are obtained, and then the prefabricated parts and the paving layer of the suction side shell or the pressure side shell are formed through the vacuum infusion process, so that the suction side shell or the pressure side shell with the bonding flange are obtained.
Claims (5)
1. A manufacturing method of a wind power blade is characterized by comprising the following steps:
1) laying a rear edge bonding flange at the rear edge of a suction side shell or a pressure side shell mold according to the sequence of glass fiber cloth-core material-glass fiber cloth, laying a vacuum system on the laid rear edge bonding flange, vacuum-pouring resin until the resin completely soaks the laid layer, heating and curing, and demolding to obtain the rear edge bonding flange;
2) carrying out shell layer laying in a suction side shell or a pressure side shell mould, and bonding and combining a rear edge bonding flange with a shell layer at the rear edge position of the suction side shell or the pressure side shell mould through a vacuum introduction molding process to obtain the suction side shell or the pressure side shell with the rear edge bonding flange;
3) bonding the rear edge of the suction side shell or the pressure side shell with the rear edge bonding flange with the rear edge of the pressure side shell or the suction side shell without the rear edge bonding flange;
4) similarly, according to the method of the steps 1) to 3), obtaining a suction side shell or a pressure side shell with a front edge bonding flange, and bonding the front edge of the suction side shell with the front edge of the pressure side shell to obtain the wind power blade;
the method for laying the vacuum system in the step 1) comprises the following steps: a circle of sealant is stuck at the edge of the bonding flange laying layer, demolding cloth is laid on the upper surface of the bonding flange laying layer, an upper surface flow guide net and an upper surface air exhaust bag are laid on the upper surface of the demolding cloth, then a sealed vacuum bag film is laid on the whole bonding flange mold, an adhesive injection port and a vacuum exhaust port in a molding mold cavity are arranged, and the vacuum degree is maintained to be less than or equal to-0.098 Mpa by vacuumizing;
step 3) the bonding method of the rear edge of the suction side shell and the rear edge of the pressure side shell comprises the following steps: and (3) coating structural adhesive on the rear edge bonding flange, and bonding the rear edge of the suction side shell or the pressure side shell with the rear edge bonding flange with the rear edge of the pressure side shell or the suction side shell without the rear edge bonding flange through the structural adhesive.
2. The method for manufacturing the wind turbine blade as claimed in claim 1, wherein the pressure side shell or the suction side shell without the rear edge bonding flange in the step 3) is manufactured by a vacuum induction molding process.
3. The method for manufacturing the wind power blade according to claim 1 or 2, wherein in step 3), before the rear edge of the suction side shell and the rear edge of the pressure side shell are bonded, two ends of a front edge web and a rear edge web are bonded to the suction side shell and the pressure side shell respectively.
4. The manufacturing method of the wind power blade as claimed in claim 1 or 2, wherein the method for bonding the front edge of the suction side shell and the front edge of the pressure side shell in the step 4) comprises the following steps: and (3) coating structural adhesive on the front edge bonding flange, and bonding the front edge of the suction side shell or the pressure side shell with the front edge bonding flange with the front edge of the pressure side shell or the suction side shell without the front edge bonding flange through the structural adhesive.
5. The method for manufacturing the wind power blade according to claim 1, wherein the core material in the step 1) is basha wood, polyvinyl chloride or polyethylene terephthalate.
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CN111186145B (en) * | 2019-12-28 | 2022-04-08 | 中材科技(萍乡)风电叶片有限公司 | Wind power blade die assembly method |
CN113787740B (en) * | 2021-09-26 | 2023-09-19 | 沈阳工业大学 | Wind turbine blade trailing edge reinforcement repairing method |
CN116039124B (en) * | 2023-04-03 | 2023-06-13 | 新创碳谷集团有限公司 | Integral molding tool and molding process for rear edge of modularized segmented blade |
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JP2002137307A (en) * | 2000-11-02 | 2002-05-14 | Toray Ind Inc | Blade structure of windmill made of fiber-reinforced resin |
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CN103042700B (en) * | 2012-12-27 | 2014-10-29 | 中国科学院工程热物理研究所 | Integrated forming method and device for segmented blade |
CN103144312A (en) * | 2013-03-28 | 2013-06-12 | 重庆通用工业(集团)有限责任公司 | Outside reinforcing, vacuum filling and heat curing molding process on front edge and back edge of blade |
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WO2010037762A1 (en) * | 2008-09-30 | 2010-04-08 | Vestas Wind Systems A/S | A method of making a wind turbine blade |
CN105952580A (en) * | 2016-05-24 | 2016-09-21 | 白银中科宇能科技有限公司 | Wind power blade and manufacturing technology thereof |
CN107618192A (en) * | 2017-09-28 | 2018-01-23 | 国电联合动力技术有限公司 | A kind of wind power generation unit blade bonding angle and preparation method thereof |
CN107559155A (en) * | 2017-10-16 | 2018-01-09 | 国电联合动力技术有限公司 | A kind of wind generator set blade and its laying adhesive method and Wind turbines |
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