大型海上风电叶片关键技术及创新研究海上叶片技术挑战Longer Blade Demanding for Innovative Technologies材料科学 Material Science•高模量 High stiffness •轻质 Low weight •性能稳定 Robust •耐腐蚀及紫外线 Anti-erosion/UV气动设计 Aerodynamics•高叶尖速 High tip speed ratio •高雷诺数 High Reynolds # •粗糙度敏感性低 Dirt Airfoil •气弹稳定性 Aeroelastic flutter •失速余量 Stall margin •载荷控制 Load control•气动效率 Performance结构设计 Structural Design•高可靠性 High reliability •后缘梁设计TE UD•三明治结构稳定性•大厚度主梁帽 Thick Spar Cap •叶根设计 Root connection工艺设计 Mfg Process •部件预制 Prefabrication •大厚度梁帽制作 Thicker Spar cap •防雷金属网灌注 Coppermesh application 防护设计 LPS & Anti-erosion•碳材料防雷 LPS for carbon •前缘防护 LE protection价格因子/重量因子 Cost & Weight factors0.0%20.0%40.0%60.0%80.0% 100.0%120.0%0.0%50.0% 100.0% 150.0% 200.0% 250.0%300.0% 350.0% 400.0% 常规玻纤布大克重玻纤布拉挤玻纤片材碳纤灌注 碳纤预浸料碳纤拉挤片材单位模量价格因子重量因子价格因子 重量因子玻纤织物 Glass Fabrics•编织过程产生微观褶皱 Micro-waviness due to weaving•衬纱和捆绑纱是产生起始疲劳裂纹的原因 stitching yarn & cross fibersinitiate cracksSource： Journal of Composite Materials 0(0) 1–17碳玻混织物 Hybrid FabricsMismatch of Thermal coefficientsGlass 5~6x10^-6/度 Carbon -0.5~-1 /度 Thermal-induced Residual stress 防雷解决方案玻纤 Glass碳纤 Carbon混编织物 hybrid fabrics收缩膨胀内应力 residual stress织物混铺 hybrid laminate玻纤层 Glass碳纤层 Carbon 玻纤层 Glass 类似的问题碳纤布 Carbon Fabrics找不同What’s the difference?碳预浸料Carbon Prepreg•粘性导致容易褶皱 easy to have wrinkles•层间气泡 air bubble between layers•需要无损检测 demand accurate UT scan•气动设计考虑叶片扩展需求 Segmented tooling design •提高模具利用率，降低成本 Reduce tooling cost•叶片系列扩展设计Blade family design •模具共用率超过60%Thin airfoils from 60+m•叶尖薄翼型设计 Thin airfoils at tip •提升叶片效率 •Cp_max=0.486•粗糙度敏感性低，发电性能更好。
Low surface roughness sensitivity, higher power performanceSpan Relative thickness [%] [%] 70 21 90 18稳态性能：额定功率：6.0MW ； 最大Cp ：0.486； 最优TSR ：10.8； 最优变桨角：0度；锯齿尾缘降噪Serration to Reduce NoiseDesign to implementationVG aerodynamic simulation发电性能提升 Vortex Generator to Enhance Power GenerationFlow separationX=0.13X=0.14X=0.15X=0.17X=0.18X=0.19X=0.23X=0.25-551015200.00.40.81.21.62.02.4 baselineVGs locate 20% chord lengthC la airfoil thickness=40%叶片结构设计 Structural Design碳纤维的应用，与玻纤相比可以降低约30%的叶片质量，降低整机综合成本Carbon enables weight reduction of 30%针对碳纤专门开发的树脂体系Customized Epoxy resin system for carbon专门设计的主梁模具Customized spar cap mould system缩短叶片成型周期Reduced blade manufacturing cycle time降低一体成型工艺难度Pre-fabricated components to reduce processdifficauties and risks叶根预制 Prefabricated Root专门设计的叶根预制件模具Special designed mould system for prefab rootproduction缩短叶片成型周期Decrease the time for whole blade production降低一体成型工艺难度Making the blade production process easier腹板设计 Spar Web Design小腹板提高摆振刚度Mini_web increase edgewise stiffness分段式腹板预制件Modular prefabricated shear webs根据实际合模情况优化腹板几何参数Shear web profiling through dry mould closing缩短叶片成型周期Reduced production cycle time降低一体成型工艺难度Enhanced manufacturability主梁预制 Prefabricated Spar Cap进行多次碳纤维主梁灌注试验，（完成160层碳纤维灌注）研究解决了碳纤维主梁灌成型产品的缺陷Massive careful designed basicdevelopment were done in advance of theprototype production;在样片试制阶段，实现CGI83.6碳纤维主梁产品一次灌注成功，通过UT检查，0缺陷Resulting in a perfect spar cap product after being inspected by UT method28 碳纤维梁帽 Carbon Spar Cap丰富的碳纤维灌注及预浸料制作叶片梁帽经验Rich experience with Carbon prepreg and carbon fabrics infusion for spar cap碳纤维梁帽 Carbon Spar Cap缺陷波形正常波形褶皱问题改善后金属网预制 Prefabricated copper wire mesh 进行多次铜网灌注工艺试验，彻底解决预制铜网灌注气泡问题Resolve the air bubble issue in the metal meshCGI83.6 叶片试制过程中，铜网灌注良好，没有明显气泡 Good quality of metal mesh31 叶根及后缘UD预制 Prefabrication of TE UD and Root提高模具利用效率 Improved efficiency of mould usage提高了灌注质量Enhanced laminate quality减少质量风险Reduced quality riskTE bond line profiling Shear web bond line profiling 腹板粘接 High Quality Bonding腹板压型Profiling for better bonding thickness 随型性粘结胶施加工装提高了效率和减低材料浪费Bonding paste applicator to improve efficiency/quality and reduce material waste工装设备 Tooling & Equipment模内走台工装，避免人员在布层上走动，提高了铺层质量Walking board in the root section facilitates the fabrics lay up, nowalking on top of finished layups;叶片最大弦长超过4m，工装解决了在陡峭的曲面上铺层的难题With a maximum chord length of over 4m, this tooling is quite useful especiallyin steep areas叶片防护技术 Offshore Blade Erosion Protection 海上叶片涂层要求Offshore Blade Coating Requirements高湿度High humidity高盐雾Salt air紫外照射强Strong UV radiation高低温循环Rapid temp. changes暴雨Heavy rain高叶尖速度High tip velocity海上金属零件防护Corrosion protection for receptors耐腐蚀性能 Corrosion resistance抗电性 Electrical erosion resistance 腐蚀防护系统 Corrosion protection system防雷系统测试 Lightning Protection Design and Testing初始先导附着试验 Initial leader attachment电流注入试验Arc entry 扫掠通道附着试验Swept channel attachment初始先导附着试验 Initial leader attachment test 确认试验件可能被雷电附着的位置以及可能的沿非导电材料表面或穿透非导电材料的击穿路径;扫掠通道附着试验 Swept channel attachment test 确认非导电材料表面可能的击穿位置、闪络路径或者保护装置的性能；电流注入试验 Arc entry test确认因雷电附着于叶片以及雷电能量从附着点注入造成的直接效应损伤；非导电表面电流试验 Non-conductive surfaces test 确认在接闪系统接闪后雷电通道扫掠过非导电表面的影响。