LARGE-SIZE WIND POWER BLADE HAVING MULTI-BEAM STRUCTURE AND MANUFACTURING METHOD THEREFOR

Abstract

A large-size wind power blade with a multi-beam structure and its manufacturing method, wherein the blade adopts a hollow layout structure and comprises a blade skin suction edge, a blade skin pressure edge, a main load-carrying structure crossbeam and anti-shearing webs, wherein the blade skin suction edge and the blade skin pressure edge are combined to form a cavity structure having a streamlined cross section, wherein a support structure formed by the combination of the main load-carrying structure crossbeam and the anti-shearing web is located in the cavity. Both the blade skin suction edge and the blade skin pressure edge adopt a multi-segment combined structure, wherein the multiple segments are connected to the side surface of the main load-carrying structure crossbeam to integrally form the blade skin suction edge and the skin pressure edge. Under the premise of ensuring the structural rigidity and strength, the anti-bending capability as well as the stability of the blade of the present invention is increased. With the use of high modulus carbon fiber laxer, the weight of the blade is reduced, the load of the blade, especially the fatigue load, is reduced is reduced.

Claims

1. A large-size wind power blade with a multi-beam structure, wherein the blade adopts a hollow layout structure and comprises a blade skin suction edge, a blade skin pressure edge, a main load-carrying structure crossbeam and anti-shearing webs, wherein the blade skin suction edge and the blade skin pressure edge are combined to form a cavity structure having a streamlined cross section, wherein a support structure formed by the combination of the main load-carrying structure crossbeam and the anti-shearing web is located in the cavity, characterized in that both the blade skin suction edge and the blade skin pressure edge adopt a multi-segment combined structure, wherein the multiple segments are connected to the side surface of the main load-carrying structure crossbeam to integrally form the blade skin suction edge and the skin pressure edge.

2. The large-size wind power blade with a multi-beam structure according to claim 1, characterized in that the main load-carrying structure cross beam is composed of four blade crossbeams, wherein the blade skin suction edge is provided with a first blade crossbeam and a second blade crossbeam, and the blade skin pressure edge is provided with a third blade crossbeam and a fourth blade crossbeam, and the four blade crossbeams are laterally connected with the blade skin suction edge and the blade skin pressure edge, so that the four blade crossbeams become part of the blade skin suction edge and the blade skin pressure edge.

3. The large-size wind power blade with a multi-beam structure according to claim 2, characterized in that the connection between the four blade crossbeams and the blade skin suction edge as well as the blade skin pressure edge is cohesive connection, wherein the two sides of each of the four blade crossbeams are connected with the sides of the blade skin suction edge and the blade skin pressure edge respectively via uniform cross section and through resin adhesive.

4. The large-size wind power blade with a multi-beam structure according to claim 3, characterized in that the multi-segment combined structure is that the blade skin suction edge and the blade skin pressure edge are divided into three segments respectively, which are the front sections of the blade skin suction edge and the blade skin pressure edge, the middle sections between the crossbeams, and the tail sections of the blade skin suction edge and the blade skin pressure edge.

5. The large-size wind power blade with a multi-beam structure according to claim 1, characterized in that the tail sections of the blade skin suction edge and the blade skin pressure edge are provided with trailing edge force bearing structure trabeculae respectively, wherein the trailing edge force bearing structure trabeculae are connected with the middle segment of the tail sections of the blade skin suction edge and the blade skin pressure edge respectively to form part of the tail sections of the blade skin suction edge and the blade skin pressure edge.

6. The large-size wind power blade with a multi-beam structure according to claim 5, characterized in that the trailing edge force bearing structure trabeculae are cohesively connected with the blade skin suction edge and the blade skin pressure edge, wherein the two sides of the trailing edge force bearing structure trabeculae are connected with the sides of the tail sections of the blade skin suction edge and the blade skin pressure edge via glue respectively.

7. A method to manufacture the large-size wind power blade with a multi-beam structure according to claim 1, using multi-beam hollow structure to make the blades, providing a plurality of main load-carrying structure crossbeams in the blade skin suction edge and the blade skin pressure edge which are supported by the anti-shearing web, so that a wind power blade with cavity structure whose cross section is streamline is formed, characterized in that both the blade skin suction edge and the blade skin pressure edge adopt a multi-segment combined structure, wherein the blade skin suction edge and the blade skin pressure edge are divided into a plurality of segments and are manufactured separately, and the segments adhesively connected with the main load-carrying structure crossbeams from the side respectively, so that the blade skin suction edge and the blade skin pressure edge with multiple segments are formed.

8. The method to manufacture the large-size wind power blade with a multi-beam structure according to claim 7, characterized in that the main load-carrying structure cross beam is composed of four blade crossbeams, wherein the blade skin suction edge is provided with a first blade crossbeam and a second blade crossbeam, and the blade skin pressure edge is provided with a third blade crossbeam and a fourth blade crossbeam, and the tail sections of the blade skin suction edge and the blade skin pressure edge are provided with trailing edge force bearing structure trabeculae respectively, wherein the four blade crossbeams are laterally connected with the blade skin suction edge and the blade skin pressure edge, so that the four blade crossbeams become part of the blade skin suction edge and the blade skin pressure edge, and the four blade crossbeams are first manufactured and are cohesively connected with the anti-shearing web to form a “” form crossbeam, the crossbeam is then placed in the positioning equipment and is laid and infused together with the blade skin suction edge and the blade skin pressure edge, and epoxy resin is used as infusion resin to realize solidification via vacuum infusion.

9. The method to manufacture the large-size wind power blade with a multi-beam structure according to claim 8, characterized in that the tail sections of the blade skin suction edge and the blade skin pressure edge are provided with trailing edge force bearing structure trabeculae respectively, wherein the trailing edge force bearing structure trabeculae are connected with the middle segment of the tail sections of the blade skin suction edge and the blade skin pressure edge respectively to form part of the tail sections of the blade skin suction edge and the blade skin pressure edge.

10. The method to manufacture the large-size wind power blade with a multi-beam structure according to claim 6, characterized in that the four blade crossbeams and the trailing edge force bearing structure trabeculae are laid with carbon fiber layer and solidified, wherein the surface density of carbon fiber cloth is smaller than the surface density of the glass fiber cloth, and epoxy resin is used as infusion resin to realize solidification via vacuum infusion.

Description

FIGURES

[0025] FIG. 1 shows the cross section of the blade of the present invention.

[0026] FIG. 2 shows the structure along the blade of the present invention (suction edge).

[0027] FIG. 3 shows the structure along the blade of the present invention (pressure edge).

IN THE FIGURES

[0028] 1. Suction edge close to the front edge crossbeam; 2. Suction edge close to the trailing edge crossbeam; 3. Suction edge close to trailing edge trabeculae; 4. Pressure edge close to front edge crossbeam; 5. Pressure edge close to trailing edge crossbeam; 6. Pressure edge close to trailing edge trabeculae; 7. Front edge web plate; 8. Trailing edge web plate; 9. Section between crossbeams of the suction edge; 10. Section between crossbeams of the pressure edge; 11. Blade skin suction edge; 12. Blade skin pressure edge.

EMBODIMENTS

[0029] The present invention is further illustrated with the following figures and embodiments.

[0030] FIG. 1 shows the cross section of the blade of the present invention. FIG. 2 and FIG. 3 show the structure along the blade shell of the present invention.

[0031] A large-size wind power blade with a multi-beam structure, wherein the blade adopts a hollow layout structure and comprises a blade skin suction edge (11), a blade skin pressure edge (12), a main load-carrying structure crossbeam (1, 2, 4, 5) and anti-shearing web (7,8), trailing edge force bearing structure trabeculae (3, 6). The main load-carrying structure cross beam (1, 2, 4, 5) is composed of four blade crossbeams. The width of the blade structure crossbeam is 0.31 m, and the total length of the crossbeam is 52.51 m. The crossbeam is provided with one-way carbon fiber layer, namely 0° fiber is identical with the central line of the crossbeam. The surface density of the carbon fiber cloth is 600 g/m.sup.2.

[0032] The sections 9 between the suction edge crossbeams and the sections 10 between the pressure edge crossbeams are provided with sandwich structure, wherein the width of the sandwich is 0.20 m. The sandwich is made of carbon fiber cloth and the thickness of the sandwich is optimum determined by stability calculation according to the blade load.

[0033] In the current embodiment, in order to reduce the weight of the blade, the four blade crossbeams of the blade skin suction edge and the blade skin pressure edge are laid with carbon fiber layer and solidified, wherein the surface density of carbon fiber cloth is smaller than the surface density of the glass fiber cloth. In a preferred embodiment, the surface density of the carbon fiber cloth is 600 g/m.sup.2, and the surface density of the glass fiber cloth is 1215 g/m.sup.2. Preferably, epoxy resin is used as infusion resin to realize solidification via vacuum infusion.

[0034] In comparison with the usage of sole glass fiber cloth in state of the art, the present invention replaces the glass fiber of the crossbeams with the carbon fiber cloth which has a smaller surface density, so that the weight of the blade is reduced significantly.

[0035] In the present invention, the blade crossbeams are first manufactured. The anti-shearing web plate is cohesively connected in the middle position of the inner surface of the blade structure crossbeam. The crossbeam is then placed in the positioning equipment. In the positioning equipment, the sandwich structure, the skin and the crossbeams are laid and infused together. The blade skin suction edge and the blade skin pressure edge form multi-segment combination structure, wherein the multiple segments are connected to the side surface of the main load-carrying structure crossbeam to integrally form the blade skin suction edge and the skin pressure edge, and are combined with the blade structure crossbeam and the anti-shearing web, so that a wind power blade with cavity structure whose cross section is streamline is formed.

[0036] With the same wind field level, the characteristics of the blade of the current invention is compared with the characteristics of the blade in the state of the art, as shown in FIG. 1. The suction edge crossbeam and the pressure edge crossbeam of the state of the art are both infused with glass fiber/epoxy resin.

TABLE-US-00001 Blade of the Blade in state of the art current invention Blade length/m 57.7 57.7 Wind field level IEC 3A IEC 3A Generated output 3.0 MW 3.0 MW quantity/kg 17443 13748 Mass center/m 17.40 15.50 One order flap/Hz 0.56 0.67 One order lag motion/Hz 0.98 1.17 Blade root limit load/KNm 16730 15408 Blade root fatigue load/ 7498 6591 KNm

[0037] As shown in FIG. 1, the one order flag and the one order lag motion of the blade of the present invention are significantly bigger than those of the blade of the state of the art. In addition, the blade root limit load and blade root fatigue load of the blade of the present invention are lower than those of the blade of the state of the art. This means that the load produced by the blade of the current invention is very small, which improves the safety of the whole machine.

[0038] From the above examples, the current invention is related with a method to manufacture the large-size wind power blade with a multi-beam structure as well as the wind power blade, using multi-beam hollow structure to make the blades, providing a plurality of main load-carrying structure crossbeams in the blade skin suction edge and the blade skin pressure edge which are supported by the anti-shearing web, so that a wind power blade with cavity structure whose cross section is streamline is formed, characterized in that both the blade skin suction edge and the blade skin pressure edge adopt a multi-segment combined structure, wherein the blade skin suction edge and the blade skin pressure edge are divided into a plurality of segments and are manufactured separately, and the segments adhesively connected with the main load-carrying structure crossbeams from the side respectively, so that the blade skin suction edge and the blade skin pressure edge with multiple segments are formed.

[0039] Further, the main load-carrying structure cross beam is composed of four blade crossbeams, wherein the blade skin suction edge is provided with a first blade crossbeam and a second blade crossbeam, and the blade skin pressure edge is provided with a third blade crossbeam and a fourth blade crossbeam, and the tail sections of the blade skin suction edge and the blade skin pressure edge are provided with trailing edge force bearing structure trabeculae respectively, wherein the four blade crossbeams are laterally connected with the blade skin suction edge and the blade skin pressure edge, so that the four blade crossbeams become part of the blade skin suction edge and the blade skin pressure edge, and the four blade crossbeams are first manufactured and are cohesively connected with the anti-shearing web to form a “” form crossbeam, the crossbeam is then placed in the positioning equipment and is laid and infused together with the blade skin suction edge and the blade skin pressure edge, and epoxy resin is used as infusion resin to realize solidification via vacuum infusion.

[0040] Further, the tail sections of the blade skin suction edge and the blade skin pressure edge are provided with trailing edge force bearing structure trabeculae respectively, wherein the trailing edge force bearing structure trabeculae are connected with the middle segment of the tail sections of the blade skin suction edge and the blade skin pressure edge respectively to form part of the tail sections of the blade skin suction edge and the blade skin pressure edge.

[0041] Further, the trailing edge force bearing structure trabeculae are cohesively connected with the blade skin suction edge and the blade skin pressure edge, wherein the two sides of the trailing edge force bearing structure trabeculae are connected with the sides of the tail sections of the blade skin suction edge and the blade skin pressure edge via glue respectively.

[0042] Further, the four blade crossbeams and the trailing edge force bearing structure trabeculae are laid with carbon fiber layer and solidified, wherein the surface density of carbon fiber cloth is smaller than the surface density of the glass fiber cloth, and epoxy resin is used as infusion resin to realize solidification via vacuum infusion.

[0043] A large-size wind power blade with a multi-beam structure, wherein the blade adopts a hollow layout structure and comprises a blade skin suction edge, a blade skin pressure edge, a main load-carrying structure crossbeam and an anti-shearing web, wherein the blade skin suction edge and the blade skin pressure edge are combined to form a cavity structure having a streamlined cross section, wherein a support structure formed by the combination of the main load-carrying structure crossbeam and the anti-shearing web is located in the cavity, characterized in that both the blade skin suction edge and the blade skin pressure edge adopt a multi-segment combined structure, wherein the multiple segments are connected to the side surface of the main load-carrying structure crossbeam to integrally form the blade skin suction edge and the skin pressure edge.

[0044] Further, the main load-carrying structure cross beam is composed of four blade crossbeams, wherein the blade skin suction edge is provided with a first blade crossbeam and a second blade crossbeam, and the blade skin pressure edge is provided with a third blade crossbeam and a fourth blade crossbeam, and the four blade crossbeams are laterally connected with the blade skin suction edge and the blade skin pressure edge, so that the four blade crossbeams become part of the blade skin suction edge and the blade skin pressure edge.

[0045] Further, the connection between the four blade crossbeams and the blade skin suction edge as well as the blade skin pressure edge is cohesive connection, wherein the two sides of each of the four blade crossbeams are connected with the sides of the blade skin suction edge and the blade skin pressure edge respectively via uniform cross section and through resin adhesive. That is to say, the profiles of the blade skin suction edge and the blade skin pressure edge close to the blade crossbeams are the same as the profiles of the blade crossbeams, and form a bell mouth shaped opening of the blade skin suction edge and the blade skin pressure edge, in order to ensure a stable cohesive connection between the blade crossbeam and the blade skin suction edge as well as the blade skin pressure edge.

[0046] Further, the multi-segment combined structure is that the blade skin suction edge and the blade skin pressure edge are divided into three segments respectively, which are the front sections of the blade skin suction edge and the blade skin pressure edge, the middle sections between the crossbeams, and the tail sections of the blade skin suction edge and the blade skin pressure edge.

[0047] Further, the sections between the crossbeams are provided with sandwich structure, wherein the thickness of the sandwich is optimum determined by stability calculation according to the blade load.

[0048] Further, the anti-shearing web plates are placed in the middle part of the blade crossbeam corresponding with the blade skin suction edge and the blade skin pressure edge, so that the four blade crossbeams form two “” shaped supporting crossbeams.

[0049] The tail sections of the blade skin suction edge and the blade skin pressure edge are provided with trailing edge force bearing structure trabeculae respectively, wherein the trailing edge force bearing structure trabeculae are connected with the middle segment of the tail sections of the blade skin suction edge and the blade skin pressure edge respectively to form part of the tail sections of the blade skin suction edge and the blade skin pressure edge.

[0050] The large-size wind power blade with a multi-beam structure according to claim 5, characterized in that the trailing edge force bearing structure trabeculae are cohesively connected with the blade skin suction edge and the blade skin pressure edge, wherein the two sides of the trailing edge force bearing structure trabeculae are connected with the sides of the tail sections of the blade skin suction edge and the blade skin pressure edge via glue respectively.

[0051] Further, the four blade crossbeams and the trailing edge force bearing structure trabeculae are laid with carbon fiber layer and solidified, wherein the surface density of carbon fiber cloth is smaller than the surface density of the glass fiber cloth.

[0052] In comparison with the state of the art, the advantages of the present invention are: the present invention provides a blade manufacture method as well as its structure, wherein the multi-segment skin is connected with the profiles of the blade crossbeams. In this way, the force bearing condition of the skin can be changed efficiently, the width of the crossbeam is reduced, and the layer thickness of the blade crossbeam is increased. According to the different force carrying condition, different skin for different segment is made. Sandwich structure is used in the section between crossbeams, in order to increase the stability of the whole blade structure. Under the premise of ensuring the structural rigidity and strength, the weight of the blade is reduced, the frequency of the blade is increases and the load of the blade is decreased. In addition, the problem of instability caused by the high strength and high modulus material is solved. The present invention is suitable for the manufacture of large size and elongated wind power blade, which significantly reduces the weight as well as the load of the blade.