LIGHTWEIGHT SPAR CAP WITH CONCAVE STRUCTURE FOR WIND TURBINE BLADE AND MANUFACTURING METHOD THEREOF, SPAR CAP STRUCTURE COMBINATION, WIND TURBINE BLADE AND MANUFACTURING METHOD THEREOF

Abstract

The present disclosure provides a lightweight spar cap with a concave structure for a wind turbine blade and a manufacturing method thereof, a wind turbine blade and a manufacturing method thereof. The lightweight spar cap is groove-shaped as a whole, and includes supporting portions located on two wings of the lightweight spar cap and an intermediate connecting portion connecting the two supporting portions. The manufacturing method of the lightweight spar cap includes laying a reinforcing body of the intermediate connecting portion and a supporting material of the supporting portion, and performing resin infusion. By comprehensively considering multiple factors, the present disclosure reduces the weight of the wind turbine blade, improves the material utilization of the wind turbine blade, and realizes a lightweight wind turbine blade.

Claims

1. A lightweight spar cap with a concave structure for a wind turbine blade, wherein the lightweight spar cap is groove-shaped as a whole, and comprises supporting portions (32) located on two wings of the lightweight spar cap and an intermediate connecting portion (36) connecting the two supporting portions (32); one splicing surface formed by connecting the supporting portion (32) and the intermediate connecting portion (36) is an integral plane; the shape of the integral plane is configured to be consistent with an inner side of an upper shell (1) or a lower shell (2) of the wind turbine blade for abutting; the other splicing surface formed by connecting the supporting portion (32) and the intermediate connecting portion (36) is a groove-shaped discontinuous plane; a positioning groove (34) formed by the groove-shaped discontinuous plane is configured to be consistent with an end of a web (5) of the wind turbine blade for abutting and nesting.

2. The lightweight spar cap with a concave structure for a wind turbine blade according to claim 1, wherein a cross section of the intermediate connecting portion (36) is in a trapezoidal shape; a reinforcing body of the intermediate connecting portion is formed by sequentially superimposing multiple layers of reinforcing fiber cloths from an upper base to a lower base of a trapezoid; a cross section of the reinforcing body formed by superimposing the reinforcing fiber cloths presents a trapezoidal shape.

3. The lightweight spar cap with a concave structure for a wind turbine blade according to claim 2, wherein the reinforcing fiber cloths are carbon fiber cloths, and the reinforcing body is formed by laying the carbon fiber cloths with equal widths in staggered layers so as to present the trapezoidal cross section.

4. The lightweight spar cap with a concave structure for a wind turbine blade according to claim 1, wherein a thickness of the supporting portion (32) is greater than that of the intermediate connecting portion (36), and the supporting portion wraps a lateral side of the intermediate connecting portion (36) into an inverted trapezoidal groove.

5. The lightweight spar cap with a concave structure for a wind turbine blade according to claim 2, wherein an inclined surface (37) is provided at an outer corner of the supporting portion (32).

6. The lightweight spar cap with a concave structure for a wind turbine blade according to claim 1, wherein the supporting portion (32) adopts a reinforcing material composed of one or more from the group consisting of balsa, polyvinyl chloride (PVC), polyethylene terephthalate (PET) and high-density polyethylene (HPE); the supporting portion (32) and the intermediate connecting portion (36) are integrally molded by resin infusion.

7. A method for manufacturing a lightweight spar cap with a concave structure for a wind turbine blade, comprising the following steps: step 1: laying a reinforcing material of an intermediate connecting portion (36) on a spar cap mold, such that a reinforcing body of the intermediate connecting portion (36) presents a trapezoidal shape, and a lower base of a trapezoidal reinforcing body abuts against a surface of the spar cap mold; step 2: placing a reinforcing material of a supporting portion (32) on both sides of the reinforcing body of the intermediate connecting portion (36), such that the reinforcing material of the supporting portion (32) wraps a trapezoidal lateral side of the reinforcing body to form a positioning groove (34) that is able to match with an end of a web (5) of a wind turbine blade later, thereby obtaining a composite body of reinforcing materials; and step 3: subjecting the composite body of reinforcing materials obtained in the above step to an integral resin infusion process, to finally obtain the lightweight spar cap for the wind turbine blade.

8. The method for manufacturing the lightweight spar cap with a concave structure for a wind turbine blade according to claim 7, wherein the laying the reinforcing material of the intermediate connecting portion (36) specifically comprises: laying carbon fiber cloth layers (91) with equal widths in a staggered manner, wherein each carbon fiber cloth layer has a size of L; a first layer has a distance of D from a left end (33) of the spar cap mold, a second layer has a distance of D+L from the left end (33) of the spar cap mold, and so on, until an N-th layer has a distance of D from a right end (35) of the spar cap mold.

9-11. (canceled)

12. A lightweight wind turbine blade, comprising an upper shell (1), a lower shell (2), a web (5) and two lightweight spar caps for the wind turbine blade, wherein the lightweight spar caps for the wind turbine blade are concave spar caps, and the two concave spar caps comprise a pressure surface lightweight spar cap (3) and a suction surface lightweight spar cap (4): a longitudinal positioning structure is provided on one side of each of the pressure surface lightweight spar cap (3) and the suction surface lightweight spar cap (4); double ends of the web (5) are respectively connected with the positioning structures of the pressure surface lightweight spar cap (3) and the suction surface lightweight spar cap (4) through a positioning matching structure, and are fixedly connected with the pressure surface lightweight spar cap (3) and the suction surface lightweight spar cap (4) as a whole, to form a lightweight spar cap structure combination; and one end of the lightweight spar cap structure combination for the wind turbine blade is connected with the upper shell (1), and the other end thereof is connected with the lower shell (2); the lightweight spar cap structure combination for the wind turbine blade is fixedly connected with the upper shell (1) and the lower shell (2) as a whole; double ends of the upper shell (1) and the lower shell (2) are correspondingly connected to form a leading edge (6) and a trailing edge (7) respectively.

13. The lightweight wind turbine blade according to claim 12, wherein a trailing edge web (8) is provided in a trailing edge chamber defined by the web (5) and the trailing edge (7).

14. The lightweight wind turbine blade according to claim 13, wherein a starting point (61) of the trailing edge web (8) along a length direction of the blade is provided in a region that contributes 12% to 15% to a total length of the blade from a blade root (63), and an end point (62) of the trailing edge web (8) along the length direction of the blade is provided in a region that contributes 57% to 60% to the total length of the blade from the blade root (63); a height of the trailing edge web (8) is smaller than that of the web (5), and the trailing edge web is substantially parallel to the web (5).

15. The lightweight wind turbine blade according to claim 12, wherein the upper shell (1) and the lower shell (2) are made of a compressive and shear resistant composite material; the composite material comprises a core material and glass fiber fabrics (86) adhered on upper and lower surfaces of the core material; the core material uses a sandwich panel (9) as a support; a path is formed in the sandwich panel (9) to place a fiber bundle; a vertical fiber column (81), a diagonal fiber column (82), a longitudinal fiber rib (83) and a transverse fiber rib (84) are formed in the sandwich panel (9) by a dipping process; the diagonal fiber column (82), the longitudinal fiber rib (83) and the transverse fiber rib (84) form a lattice type fence (85) that is vertically and horizontally interwoven and integrally bonded in the sandwich panel (9); the glass fiber fabrics (86) adhered on the upper and lower surfaces of the sandwich panel (9) are bonded with the vertical fiber column (81) and the lattice type fence (85) to form an integral structure.

16. The lightweight wind turbine blade according to claim 15, wherein the sandwich panel (9) is made of any one or more from the group consisting of balsa, PVC, PET and HPE; the glass fiber fabric (86) is made of a carbon fiber-glass fiber composite material, which is a hybrid design of a carbon fiber and a glass fiber in a mass ratio of (10-90):(10-90).

17. The lightweight wind turbine blade according to claim 12, wherein the lightweight wind turbine blade further comprises a lightning protection system; the lightning protection system comprises a carbon fiber cloth layer (91) wrapping a surface of the upper shell (1) and/or the lower shell (2), at least one layer of metal belt (93) and a down conductor (96) that is connected with a wind turbine lightning protection system; the carbon fiber cloth layer (91) conducts a lightning current to the metal belt (93); the metal belt (93) is connected with the down conductor (96) through a wire.

18. The lightweight wind turbine blade according to claim 17, wherein the carbon fiber cloth layer (91) conducts the lightning current to the at least one layer of metal belt (93) through at least one additional carbon fiber cloth layer (92); a width of the carbon fiber cloth layer (91) depends on a lightning current carrying capacity of a carbon fiber material, and a minimum requirement is that the lightning current passes through the carbon fiber cloth layer (91) without damaging the carbon fiber cloth layer (91).

19. The lightweight wind turbine blade according to claim 18, wherein there are multiple additional carbon fiber cloth layers (92) and multiple layers of metal belts (93); the multiple additional carbon fiber cloth layers (92) and the multiple layers of metal belts (93) are alternately arranged, such that the lightning is dispersed to the multiple layers of metal belts (93) through the multiple additional carbon fiber cloth layers (92) and is finally conducted to the down conductor (96); a superimposed area of each additional carbon fiber cloth layer (92) is the same, and each additional carbon fiber cloth layer (92) completely wraps the metal belt (93).(93) are alternately arranged, such that the lightning is dispersed to the multiple layers of metal belts (93) through the multiple additional carbon fiber cloth layer (92) and is finally conducted to the down conductor (96); a superimposed area of each additional carbon fiber cloth layer (92) is the same, and each additional carbon fiber cloth layer (92) completely covers the metal belt (93).

20. The lightweight wind turbine blade according to claim 17, wherein the carbon fiber cloth layer (91) is laid from a blade tip to the blade root (63); a connection point of the metal belt (93) and the carbon fiber cloth layer (91) along the length direction of the blade is located in a region that contributes 30% to the total length of the wind turbine blade from the blade root (63), and is connected with the blade by integral infusion.

21. The lightweight wind turbine blade according to claim 17, wherein the metal belt (93) passes through the blade shell and extends into the blade chamber to be twisted into a strand, and is connected with the wire through a doubling device (95); upper and lower wires are connected with the down conductor (96) through a wire doubling device (94); the down conductor (96) is connected with the wind turbine lightning protection system at the blade root (63).

22. A method for manufacturing a lightweight wind turbine blade, comprising the following steps: step 1: respectively fixedly connecting a pressure surface lightweight spar cap (3) and a suction surface lightweight spar cap (4), which are respectively provided with a positioning groove (34), with an upper shell (1) and a lower shell (2) as a whole; step 2: placing the suction surface lightweight spar cap (4) fixedly connected with the lower shell (2) as a whole upwards, and applying a structural glue to the positioning groove (34) of the lower shell (2); lifting a web (5) onto the suction surface lightweight spar cap (4), and inserting a lower base plate (52) of the web (5) into the positioning groove (34) coated with the structural glue to realize the positioning and fixing of the web (5) on the suction surface lightweight spar cap (4); and step 3: applying a structural glue to an outer surface of an upper base plate (51) of the web (5), lifting the upper shell (1) together with the pressure surface lightweight spar cap (3) fixed with the upper shell (1) above the web (5), lowering the upper shell (1) and the pressure surface lightweight spar cap (3), inserting the upper base plate (51) of the web (5) into the positioning groove (34) of the pressure surface lightweight spar cap (3), and fixedly connecting the web (5) with the pressure surface lightweight spar cap (3) through the applied structural glue.

23. A lightweight spar cap structure combination for the lightweight wind turbine blade according to claim 12, wherein the positioning structure and the positioning matching structure adopt a groove matching positioning mode; one of the positioning structure and the positioning matching structure is configured as a positioning groove (34), and the other thereof is configured as an insert that fits with the positioning groove (34); and the groove matching positioning mode is any one of the following: the positioning groove (34) is a trapezoidal groove respectively provided on the pressure surface lightweight spar cap (3) and the suction surface lightweight spar cap (4), and the insert is an upper base plate (51) and a lower base plate (52) which are respectively provided at double ends of the web (5) and matched with the trapezoidal groove; or the positioning groove (34) is a V-shaped groove respectively provided on the pressure surface lightweight spar cap (3) and the suction surface lightweight spar cap (4), and the insert is a positioning rib respectively provided at double ends of the web (5).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0061] To describe the technical solutions in the embodiments of the present disclosure or in the prior art more clearly, the following briefly describes the accompanying drawings required for describing the embodiments or the prior art. Apparently, the accompanying drawings in the following description merely show some embodiments of the present disclosure, and a person of ordinary skill in the art may still derive other accompanying drawings from these accompanying drawings without creative efforts.

[0062] FIG. 1 is an overall external view of a wind turbine blade.

[0063] FIG. 2 is a cross-sectional view of a lightweight spar cap.

[0064] FIG. 3 is a schematic diagram of reinforcing fiber cloths laid on the lightweight spar cap.

[0065] FIG. 4 is a cross-sectional view of a lightweight spar cap of Embodiment 1 connected with a blade shell.

[0066] FIG. 5 is a cross-sectional view of a web of Embodiment 1.

[0067] FIG. 6 is a cross-sectional view of a lightweight spar cap structure combination of Embodiment 1 assembled with a wind turbine blade shell.

[0068] FIG. 7 is a cross-sectional view of a lightning protection system of the wind turbine blade of Embodiment 1.

[0069] FIG. 8 is a lateral external view of a wind turbine blade of Embodiment 1.

[0070] FIG. 9 is a connection diagram of a carbon fiber cloth layer and a down conductor in Embodiment 1.

[0071] FIG. 10 is a diagram of a connection section of a carbon fiber cloth layer and a metal belt in Embodiment 1.

[0072] FIG. 11 is a cross-sectional view of a wind turbine blade of Embodiment 2.

[0073] FIG. 12 is a schematic diagram of a trailing edge web on a side of the wind turbine blade in Embodiment 2.

[0074] FIG. 13 is a cross-sectional view of a lightweight spar cap of Embodiment 3 connected with a wind turbine blade shell.

[0075] FIG. 14 is a cross-sectional view of a web of Embodiment 3.

[0076] FIG. 15 is a cross-sectional view of a lightweight spar cap structure combination of Embodiment 3 assembled with a wind turbine blade shell.

[0077] FIG. 16 is a schematic diagram of a compressive panel.

[0078] FIG. 17 is a schematic diagram of a fiber structure inside the panel.

[0079] Reference Numerals: 1. upper shell; 2. lower shell; 3. pressure surface lightweight spar cap; 4. suction surface lightweight spar cap; 5. web; 6. leading edge; 7. trailing edge; 8. trailing edge web; 9. sandwich panel; 31. upper positioning groove; 41. lower positioning grove; 32. supporting portion; 33. left end of spar cap mold; 34. positioning groove; 35. right end of spar cap mold; 36. intermediate connecting portion; 37. inclined surface; 51. upper base plate; 52. lower base plate; 53. upper positioning rib; 54. lower positioning rib; 61. starting point; 62. end point; 63. blade root; 81. vertical fiber column; 82. diagonal fiber column; 83. longitudinal fiber rib; 84. transverse fiber rib; 85. lattice type fence; 86. glass fiber fabric; 91. carbon fiber cloth layer; 92. additional carbon fiber cloth layer; 93. metal belt; 94. wire doubling device; 95. doubling device; 96. down conductor.

DETAILED DESCRIPTION

[0080] In order to facilitate the understanding of the present disclosure, the present disclosure is described in detail below in conjunction with the accompanying drawings of the specification and the preferred embodiments, but the protection scope of the present disclosure is not limited to the following specific embodiments.

[0081] Unless otherwise defined, all professional terms used in the following have the same meaning as commonly understood by those skilled in the art. The terms used herein are only intended for the purpose of describing the specific embodiments, rather than to limit the protection scope of the present disclosure.

[0082] Unless otherwise specified, the various raw materials, reagents, instruments and devices used in the present disclosure may be purchased from the market or may be manufactured by using existing methods.

Embodiment 1

[0083] The present disclosure provides a lightweight spar cap for a wind turbine blade. As shown in FIGS. 1 to 10, the lightweight spar cap is groove-shaped as a whole, and includes supporting portions 32 located on two wings of lightweight spar cap and an intermediate connecting portion 36 connecting the two supporting portions 32.

[0084] One splicing surface formed by connecting supporting portion 32 and the intermediate connecting portion 36 is an integral plane. The shape of the integral plane is configured to be consistent with an inner side of an upper shell 1 or a lower shell 2 of the wind turbine blade for abutting.

[0085] The other splicing surface formed by connecting supporting portion 32 and the intermediate connecting portion 36 is a groove-shaped discontinuous plane. A positioning groove 34 formed by the groove-shaped discontinuous plane is configured to be consistent with an end of a web 5 of the wind turbine blade for abutting and nesting.

[0086] A cross section of the intermediate connecting portion 36 is in a trapezoidal shape. A reinforcing body of the intermediate connecting portion is formed by sequentially superimposing multiple layers of reinforcing fiber cloths from a trapezoidal upper base to a lower base. The cross section of the reinforcing body formed by superimposing the reinforcing fiber cloths finally presents a trapezoidal shape. The reinforcing fiber cloth is a carbon fiber cloth layer, and the carbon fiber cloth layers with equal widths are laid in a staggered manner to form the trapezoidal reinforcing body (shown in FIG. 3). The supporting portion 32 adopts a reinforcing material composed of one or more from the group consisting of balsa, polyvinyl chloride (PVC), polyethylene terephthalate (PET) and high-density polyethylene (HPE). A thickness of the supporting portion is greater than that of the intermediate connecting portion 36, and the supporting portion wraps a lateral side of the intermediate connecting portion 36 into an inverted trapezoidal groove (i.e. a positioning groove 34). The supporting portion 32 and the intermediate connecting portion 36 are integrally molded by resin infusion.

[0087] An inclined surface 37 is provided at an outer corner of the supporting portion 32, and the inclined surface 37 is kept substantially parallel to the trapezoidal lateral side of the intermediate connecting portion 36. The inclined surface can form a smooth transition with the core material structure of the blade shell beside the spar cap in the height direction so as to avoid the formation of thickness steps.

[0088] In this embodiment, a method for manufacturing the lightweight spar cap for a wind turbine blade includes:

[0089] (1) Clean a spar cap mold, provide a diversion system on a surface of the spar cap mold, and continuously heat the mold.

[0090] (2) Lay carbon fiber cloths of equal widths in a staggered manner on a lower surface of the spar cap mold, as shown in FIG. 3, where each carbon fiber cloth layer has a size of 10 mm; a first layer has a distance of D, that is, 150 mm, from a left end 33 of the spar cap mold, a second layer has a distance of D+L, that is, 160 mm, from the left end 33 of the spar cap mold, and so on, until an eleventh layer has a distance of D, that is, 150 mm, from a right end 35 of the spar cap mold. In this way, the intermediate connecting portion 36 is formed into a trapezoidal laid structure, which has trapezoidal chamfers on two ends and a trapezoidal lower base abutting against the lower surface of the spar cap mold.

[0091] (3) Lay a reinforcing material of the supporting portion 32 on both sides of the reinforcing body of the intermediate connecting portion 36, such that the reinforcing material of the supporting portion 32 wraps the trapezoidal lateral side of the reinforcing body of the intermediate connecting portion 36 to form the positioning groove 34 that is able to match with an upper base plate 51 and a lower base plate 52 on double ends of the web 5 of the wind turbine blade later, thereby obtaining a composite body of reinforcing materials, where the positioning groove specifically includes an upper positioning groove 31 and a lower positioning groove 41.

[0092] There is a small gap between an inner shaped surface of the positioning groove 34 and upper and lower end surfaces of the web 5, such that the web 5 can be placed in the upper positioning groove 31 and the lower positioning groove 41 and a structural glue can be retained in this small gap. During and after assembly, the upper base plate 51 and the lower base plate 52 are respectively located in the upper positioning groove 31 and the lower positioning groove 41 and are fixed by the structural glue applied in advance.

[0093] (4) Provide a diversion system on an upper surface of the lightweight spar cap with the laid cloth layers, lay on the upper surface of the spar cap mold, and provide an air extraction system.

[0094] (5) Exert a vacuum pressure of the air extraction system to introduce a resin, control a heating temperature of the mold, and perform curing.

[0095] (6) Stop heating to complete the curing and shaping, demold and trim, to obtain the lightweight spar cap for a wind turbine blade.

[0096] In this embodiment, a lightweight spar cap structure combination for a wind turbine blade includes a web 5 and two lightweight spar caps for the wind turbine blade. The lightweight spar caps for the wind turbine blade are concave spar caps, and the two concave spar caps include a pressure surface lightweight spar cap 3 and a suction surface lightweight spar cap 4.

[0097] A longitudinal positioning structure is provided on one side of each of the pressure surface lightweight spar cap 3 and the suction surface lightweight spar cap 4. Double ends of the web 5 are respectively connected with the positioning structures of the pressure surface lightweight spar cap 3 and the suction surface lightweight spar cap 4 through a positioning matching structure, and are fixedly connected with the pressure surface lightweight spar cap 3 and the suction surface lightweight spar cap 4 as a whole.

[0098] As shown in FIG. 4, in this embodiment, the positioning structure and the positioning matching structure adopt a groove matching positioning mode. Specifically, the positioning structure is configured as a positioning groove 34, and the positioning matching structure is configured as an insert that fits with the positioning groove 34.

[0099] The positioning groove 34 is a trapezoidal groove respectively provided on the pressure surface lightweight spar cap 3 and the suction surface lightweight spar cap 4, and the insert is a base plate. In this embodiment, the base plate includes the upper base plate 51 and the lower base plate 52 which are respectively provided at double ends of the web 5. As shown in FIG. 5, the web 5 is I-shaped, and includes the upper base plate 51 and the lower base plate 52 that are located on upper and lower ends and matched with the trapezoidal groove.

[0100] As shown in FIG. 6, the pressure surface lightweight spar cap 3 is provided with an upper positioning groove 31, and the suction surface lightweight spar cap is provided with a lower positioning groove 41. An inner shaped surface of the upper positioning groove 31 and an inner shaped surface of the lower positioning groove 41 are matched with shaped surfaces of the upper base plate 51 and the lower base plate 52 respectively. The upper base plate 51 and the lower base plate 52 are respectively located in the upper positioning groove 31 of the pressure surface lightweight spar cap 3 and the lower positioning groove 41 of the suction surface lightweight spar cap 4.

Embodiment 2

[0101] The present disclosure further provides a lightweight wind turbine blade. The lightweight wind turbine blade includes an upper shell 1, a lower shell 2 and the lightweight spar cap structure combination. One end of the lightweight spar cap structure combination for the wind turbine blade is connected with the upper shell 1, and the other end thereof is connected with the lower shell 2. The lightweight spar cap structure combination for the wind turbine blade is fixedly connected with the upper shell 1 and the lower shell 2 as a whole. The lightweight spar cap structure combination of the wind turbine blade in this embodiment is substantially the same as that of Embodiment 1, except that there are two lightweight spar cap structure combinations provided in this embodiment. Specifically, as shown in FIG. 11, butt joints on both sides of the upper shell 1 and the lower shell 2 respectively form the leading edge 6 and the trailing edge 7 of the wind turbine blade. Among the two lightweight spar cap structure combinations of the wind turbine blade, one lightweight spar cap structure combination for the wind turbine blade is exactly the same as that in Embodiment 1, which includes a web 5 and two lightweight spar caps described in Embodiment 1; a trailing edge web 8 is further provided in a trailing edge chamber formed by the web 5 and the trailing edge 7. The structure and composition of the trailing edge web 8 are substantially the same as the lightweight spar cap structure combination for the wind turbine blade in Embodiment 1, except that the height and shape are slightly different. As shown in FIG. 12, a starting point 61 of the trailing edge web 8 along a length direction of the blade is provided in a region that contributes 12% to 15% to a total length of the blade from a blade root 63, and an end point 62 of the trailing edge web 8 along the length direction of the blade is provided in a region that contributes 57% to 60% to the total length of the blade from the blade root 63. A height of the trailing edge web is smaller than that of the web 5, and the trailing edge web is substantially parallel to the web 5.

Embodiment 3

[0102] The present disclosure provides another lightweight spar cap for a wind turbine blade. As shown in FIGS. 13 to 15, the overall structure, material and manufacturing method of the lightweight spar cap are the same as those in Embodiments 1 and 2, except that the lightweight spar cap is provided with a V-shaped groove.

[0103] As shown in FIGS. 13 to 15, in this embodiment, a lightweight spar cap structure combination includes a web 5 and two lightweight spar caps as described in the above embodiment. The lightweight spar caps for the wind turbine blade are concave spar caps, and the two concave spar caps include a pressure surface lightweight spar cap 3 and a suction surface lightweight spar cap 4. A longitudinal positioning structure is provided on one side of each of the pressure surface lightweight spar cap 3 and the suction surface lightweight spar cap 4. Double ends of the web 5 are respectively connected with the positioning structures of the pressure surface lightweight spar cap 3 and the suction surface lightweight spar cap 4 through a positioning matching structure, and are fixedly connected with the pressure surface lightweight spar cap 3 and the suction surface lightweight spar cap 4 as a whole.

[0104] The positioning structure and the positioning matching structure adopt a groove matching positioning mode. Specifically, the positioning structure is configured as a positioning groove 34, and the positioning matching structure is configured as an insert that fits with the positioning groove 34.

[0105] The positioning groove 34 is a V-shaped groove respectively provided on the pressure surface lightweight spar cap 3 and the suction surface lightweight spar cap 4, and the insert is a positioning rib respectively provided at double ends of the web 5. The web 5 is I-shaped, and includes the upper base plate 51 and the lower base plate 52 that are located on upper and lower ends and matched with the trapezoidal groove. The upper base plate 51 and the lower base plate 52 are respectively provided with a positioning rib.

[0106] An upper top surface of the upper base plate 51 and a lower bottom surface of the lower base plate 52 are respectively provided with a longitudinal upper positioning rib 53 and a lower positioning rib 54. An inner shaped surface of the upper positioning groove 31 and an inner shaped surface of the lower positioning groove 41 are matched with outer shaped surfaces of the upper positioning rib 53 and the lower positioning rib 54 respectively. The upper positioning rib 53 of the upper base plate 51 of the I-shaped web 5 is provided in the upper positioning groove 31 of the pressure surface lightweight spar cap 3. The lower positioning rib 54 of the lower base plate 52 of the I-shaped web 5 is provided in the lower positioning groove 41 of the suction surface lightweight spar cap 4.

[0107] The present disclosure further provides a lightweight wind turbine blade. As shown in FIG. 15, the lightweight wind turbine blade includes an upper shell 1, a lower shell 2 and the lightweight spar cap structure combination as described in the above embodiment. One end of the lightweight spar cap structure combination for the wind turbine blade is connected with the upper shell 1, and the other end thereof is connected with the lower shell 2. The lightweight spar cap structure combination for the wind turbine blade is fixedly connected with the upper shell 1 and the lower shell 2 as a whole.

[0108] The manufacturing method of the lightweight spar cap for the wind turbine blade in this embodiment is substantially the same as that of Embodiment 1, except that the shape of the groove is slightly different.

[0109] In the above embodiments, the upper shell 1 and the lower shell 2 of the wind turbine blade use a compressive and shear resistant composite material that is able to withstand multi-directional pressure and shear force. The composite material includes a core material and glass fiber fabrics 86 adhered on upper and lower surfaces of the core material. The core material uses a sandwich panel 9 as a support. A path is formed in the sandwich panel to place a fiber bundle. A vertical fiber column 81, a diagonal fiber column 82, a longitudinal fiber rib 83 and a transverse fiber rib 84 are formed in the sandwich panel 9 by a dipping process. The diagonal fiber column 82, the longitudinal fiber rib 83 and the transverse fiber rib 84 form a lattice type fence 85 that is vertically and horizontally interwoven and integrally bonded in the sandwich panel 9. The glass fiber fabrics 86 are adhered on the upper and lower surfaces of the sandwich panel 9 before dipping, and the glass fiber fabrics 86 are bonded with the vertical fiber column 81 and the lattice type fence 85 to form an integral structure.

[0110] The vertical fiber column 81 directly resists a positive pressure exerted on the sandwich panel 9 in the structure. In addition to the positive pressure, the pressure exerted on the panel also includes other pressure in various directions. Therefore, the diagonal fiber column 82 is provided in the structure. The longitudinal fiber rib 83 and the transverse fiber rib 84 bond with all the diagonal fiber columns 82 to an integral frame through a glue. They enhance the stability of each diagonal fiber column 82 in case of pressure, and significantly enhance the compressive performance of the sandwich panel 9 against pressure in all directions. The longitudinal fiber rib 83 and the transverse fiber rib 84 also significantly enhance the tensile performance of the sandwich panel 9 in the horizontal direction. As shown in FIG. 17, the lattice type fence 85 is actually only a description of a part of the mechanical overall structure constructed in the sandwich panel 9.

[0111] As shown in FIGS. 16 and 17, the diagonal fiber column 82, the longitudinal fiber rib 83 and the transverse fiber rib 84 form a lattice type fence 85 that is vertically and horizontally interwoven and integrally bonded in the sandwich panel 9. That is, two transversely adjacent diagonal fiber columns 82 in the sandwich panel 9 are bonded to two sides of the longitudinal fiber rib 83 in an X shape, and two longitudinally adjacent diagonal fiber columns 82 in the sandwich panel 9 are bonded to two sides of the transverse fiber rib 84 in an X shape. Meanwhile, the adjacent longitudinal fiber rib 83 and transverse fiber rib 84 are bonded together.

[0112] To form the path to place the fiber bundle, multiple orthogonal longitudinal slits and transverse slits are equally spaced on the sandwich panel, and the sandwich panel is divided into a number of sandwich squares connected at the bottom. A vertical hole is drilled downward on the sandwich square, and diagonal holes are drilled downward along front, left, back and right sides of the sandwich square respectively.

[0113] The sandwich panel 9 used is composed of any one or more of balsa, PVC, PET and HPE. These materials are easy to cut and perforate, and various frames may be built in the panel for support. In addition, these materials are light in weight, and after being constructed into a compressive integral structure, they are sufficient to become qualified sandwich materials for the root region of the wind turbine blade shell. The glass fiber fabric is made of a carbon fiber-glass fiber composite material, which is a hybrid design of a carbon fiber and a glass fiber in a mass ratio of (10-90):(10-90).

[0114] The vertical fiber column 81, the diagonal fiber column 82, the longitudinal fiber rib 83 and the transverse fiber rib 84 are formed in the panel. The diagonal fiber column 82, the longitudinal fiber rib 83 and the transverse fiber rib 84 form a lattice type fence 85 that is vertically and horizontally interwoven and integrally bonded in the sandwich panel. The glass fiber fabrics 86 on the upper and lower surfaces are bonded with the vertical fiber column 81 and the lattice type fence 85 to form an integral frame. All of the above processes are completed by one-time dipping. Specifically, holes and slits are provided in the sandwich panel 9 to place the fiber bundles, adhere the glass fiber fabrics 86 and implement dipping and curing to form the integral structure.

[0115] The wind turbine blade of the above embodiments further includes a lightweight lightning protection system.

[0116] As shown in FIG. 7, the lightning protection system adopts a carbon fiber cloth layer. The lightning protection system is composed of a carbon fiber cloth layer 91 wrapping a surface of the upper shell 1 and the lower shell 2, a metal belt 93, a down conductor 96 that is connected with a wind turbine lightning protection system, a doubling device 95 and a wire doubling device 94. The carbon fiber cloth layer 91 conducts a lightning current to the metal belt 93. The metal belt 93 is connected with the down conductor 96 through a wire.

[0117] As shown in FIG. 8, in a wind turbine blade, the upper shell 1 and the lower shell 2 are provided with the wind turbine blade lightning protection system of this embodiment. The carbon fiber cloth layer 91 covers outer surfaces of the upper shell 1 and the lower shell 2, and is laid from a blade tip to a blade root. A width of the carbon fiber cloth layer 91 depends on a lightning current carrying capacity of a carbon fiber material, and a minimum requirement is that the lightning current passes through the carbon fiber cloth layer 91 without damaging the carbon fiber cloth layer. The carbon fiber cloth layer 91 plays a dual role of structural bearing and lightning current conduction in the wind turbine blade of this embodiment.

[0118] As shown in FIG. 8, the carbon fiber cloth layer 91 and the metal belt 93 are connected with the blade by integral infusion. A connection point of the metal belt and the carbon fiber cloth along the length direction of the blade is located in a region that contributes 30% to the total length of the wind turbine blade from the blade root. As shown in FIGS. 7 and 10, in a position near the blade root, the carbon fiber cloth layer 91 conducts the lightning current to two layers of metal belts 93 through two additional carbon fiber cloth layers 92. The carbon fiber cloth layer 91 is superimposed with an additional carbon fiber cloth layer 92. Each carbon fiber cloth layer 92 is alternately superimposed with each layer of metal belt 93, with the same superimposed area at each layer. The carbon fiber cloth layer 91 and the additional carbon fiber cloth layer 92 completely cover the metal belt 93. The ability of the superimposed carbon fiber cloth layers to pass current reaches a lightning current standard of 200 KA. The lightning is dispersed to the multiple layers of metal belts 93 through the multiple additional carbon fiber cloth layer 92 and is finally conducted to the down conductor 96. The multilayer alternate superimposed design of the additional carbon fiber cloth layers 92 and metal belts 93 reduces the sudden change of resistance from the carbon fiber cloth layers 91 to the metal belts 93. When the lightning current is conducted from the carbon fiber cloth layer 91 to the down conductor 96, this design reduces the damage of the lightning current to the carbon fiber near the carbon fiber cloth layer.

[0119] Specifically, the carbon fiber cloth layer 91 is connected to the surface of the blade shell by integral infusion. During the infusion process, the carbon fiber cloth layer 91 is laid on the mold, and the resin is then infused, such that the resin and the inner side of the carbon fiber cloth layer 91 form an integral structure. The outer side of the carbon fiber cloth layer 91 is not wrapped with the resin, and is exposed to conduct lightning.

[0120] As shown in FIG. 9, the metal belt 93 passes through the upper shell 1 and the lower shell 2 and extends into the blade chamber to be twisted into a strand, and is connected with the wire through a doubling device 95. Upper and lower wires are connected with the down conductor 96 through a wire doubling device 94. The down conductor 96 is connected with the wind turbine lightning protection system at the blade root.

[0121] The carbon fiber cloth layer is laid on the surface of the shell through infusion for air termination. It expands the air termination area, improves the air termination efficiency, and guides the lightning to the down conductor at the blade root.

[0122] In this embodiment, a method for manufacturing the lightweight wind turbine blade includes: assemble the upper shell 1, the lower shell 2, the pressure surface lightweight spar cap 3, the suction surface lightweight spar cap 4 and the web 5 as a whole. Specifically:

[0123] (1) Respectively fixedly connect a pressure surface lightweight spar cap 3 and a suction surface lightweight spar cap 4, which are respectively provided with a positioning groove, with an upper shell 1 and a lower shell 2 as a whole.

[0124] (2) Place the suction surface lightweight spar cap 4 fixedly connected with the lower shell 2 as a whole upwards, and apply a structural glue to the positioning groove 34 of the suction surface lightweight spar cap 4; lift a web 5 onto the suction surface lightweight spar cap 4, and insert a lower base plate 52 of the web 5 into the positioning groove 34 coated with the structural glue to realize the positioning and fixing of the web 5 on the suction surface lightweight spar cap 4.

[0125] (3) Apply a structural glue to a lower bonding surface 21 and an outer surface of an upper base plate 51 of the web 5, lift the upper shell 1 together with the pressure surface lightweight spar cap 3 fixed with the upper shell 1 above the web 5, lower the upper shell 1 and the pressure surface lightweight spar cap 3, insert the upper base plate 51 of the web 5 into the positioning groove 34 of the pressure surface lightweight spar cap 3, and bind an upper bonding surface 11 of the upper shell 1 with the lower bonding surface 21 of the lower shell 2 until the structural glue is condensed.