Spraying repairing method for surface of wind power blade
Through the synchronous spraying technology of plasma jet and atomized coating slurry, the problem of erosion of wind power blades in harsh environments is solved, and rapid and environmentally friendly in-situ repair is achieved, improving the repair effect and safety.
Patent Information
- Application Number
- CN202510458156.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-11
- Publication Date
- 2025-06-06
AI Technical Summary
When wind power blades operate for a long time in harsh sea environments, they are prone to erosion problems such as sand holes, pits, cracks, and drilling, resulting in loss of surface materials of the blades, reducing aerodynamic performance, and possibly damaging the internal structure. Existing repair methods such as high temperature curing and ultraviolet curing have problems such as high energy consumption, poor environmental protection and difficult operation.
Synchronous spraying technology of plasma jet and atomized coating slurry is used to impact the activated coating slurry and blade surfaces through high-energy examples in air plasma jets, promoting the recombination of chemical bonds, thereby achieving rapid in-situ repair. This method does not require large equipment, is easy to operate flexibly, and cures the resin efficiently at room temperature or low temperature conditions.
The film curing rate and the interface bonding strength between the film and the blade are improved, efficient in-situ repair of the blade is achieved, energy consumption is reduced, and the hazards of high-temperature curing and ultraviolet curing are avoided, which meets environmental protection requirements.
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Figure CN120094822A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of coating, and in particular to a method for spraying and repairing the surface of a wind turbine blade. Background Art
[0002] As the core component of wind turbines, wind turbine blades are subjected to continuous effects such as rain erosion, light and heat aging, and salt spray erosion when operating in harsh marine environments for a long time. After 2 to 3 years, sand holes, pits, cracks, and gouges will appear on the leading edge surface of the blades. Leading edge erosion will lead to the loss of material on the blade surface, leaving a rough surface, reducing the overall aerodynamic performance of the blades, and even causing the internal structure to absorb water and be damaged, thereby reducing material performance.
[0003] Currently, the main methods for repairing non-structural damage to blades are resin injection and patching, which rely on high temperature or UV curing. High temperature curing consumes a lot of energy, has low efficiency, and is difficult to repair in situ. In addition, UV curing relies on photoinitiators or thermal initiators, the material storage conditions are harsh, and UV radiation is harmful to the human body, and the coating has poor bonding performance with the substrate. Summary of the invention
[0004] In order to solve the above technical problems, the present application proposes a spray repair method for the surface of a wind turbine blade, which is energy-saving, environmentally friendly, simple to operate, and can achieve efficient in-situ repair of the blade, and is beneficial to improving the interface bonding strength.
[0005] A spraying repair method for the surface of a wind turbine blade comprises the following steps: placing a coating slurry in a syringe; introducing air into a main channel of a plasma jet spray gun through an air compressor, and adjusting the parameters of the plasma jet spray gun to stably spray a plasma jet; connecting the syringe to the plasma jet spray gun through an atomizing nozzle; atomizing the coating slurry through the syringe through the atomizing nozzle to form droplets, and then injecting the droplets into the plasma jet spray gun, after the droplets are stably sprayed out with the plasma jet, spraying the plasma jet spray gun toward a to-be-repaired area on the surface of a wind turbine blade and moving the plasma jet spray gun so that the droplets are deposited on the surface of the wind turbine blade to form a film layer; and curing the film layer to achieve the repair of the surface of the wind turbine blade.
[0006] In some embodiments of the present application, when air is introduced into the main channel of the plasma jet spray gun through the air compressor, the flow rate of the air is controlled to be 1 L / min to 4 L / min.
[0007] In some embodiments of the present application, the diameter of the nozzle of the plasma jet spray gun at the outlet is 1 mm to 4 mm.
[0008] In some embodiments of the present application, the syringe is a digital syringe pump.
[0009] In some embodiments of the present application, the flow rate of the coating slurry when injected into the plasma jet spray gun through the syringe is 0.5 mL / min to 2 mL / min.
[0010] In some embodiments of the present application, when the plasma jet spray gun is sprayed and moved toward the area to be repaired on the surface of the wind turbine blade, the vertical distance between the outlet of the nozzle of the plasma jet spray gun and the area to be repaired on the surface of the wind turbine blade is 7 mm to 13 mm.
[0011] In some embodiments of the present application, the moving speed of the plasma jet spray gun when spraying and moving toward the area to be repaired on the surface of the wind turbine blade is 0.1 mm / s to 1 mm / s.
[0012] The spray repair method for the surface of wind turbine blades of the present application utilizes the impact of high-energy examples in the air plasma jet to effectively activate the coating slurry and the surface of the wind turbine blades, promote the breaking of old chemical bonds and the generation of new chemical bonds to achieve chemical bond reorganization, which is beneficial to improve the film curing rate and the interface bonding strength between the film layer and the blade. The above method adopts plasma jet and atomized coating slurry synchronous spraying technology, which is convenient for rapid in-situ repair, does not need to rely on large equipment, and is convenient for flexible operation. Furthermore, compared with the traditional coating and curing method, the plasma jet in the above method can efficiently cure the resin at room temperature or low temperature conditions, thereby reducing energy consumption, avoiding the high energy consumption of high-temperature curing and the harm caused by ultraviolet curing, and is more in line with environmental protection requirements. BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Figure 1 This is a schematic structural diagram of a spray repair device according to one embodiment of the present application.
[0014] Figure 2 A schematic flow chart of a method for spraying and repairing the surface of a wind turbine blade according to an embodiment of the present application. DETAILED DESCRIPTION
[0015] The technical solution of the present application will be clearly and completely described below in conjunction with specific embodiments. Obviously, the described implementation methods are only part of the implementation methods of the present application, rather than all of the implementation methods. Based on the implementation methods in the present application, all other implementation methods obtained by ordinary technicians in the field without making creative work are within the scope of protection of the present application.
[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art to which this application belongs. The names of the technical means used in the specification of this application are only for the purpose of describing specific embodiments and are not intended to limit this application.
[0017] In the absence of conflict, the following embodiments and features in the embodiments may be combined with each other, and the sequence of steps may be adjusted with each other.
[0018] See also Figure 1 The present application provides a method for spraying and repairing the surface of a wind turbine blade, which can be operated by, but not limited to, a spraying and repairing device 100. Figure 1 As shown, the spray repair device 100 includes a plasma jet spray gun 10, an air compressor 20 and an injector 30. The air compressor 20 is connected to the main channel of the plasma jet spray gun 10, and is used to introduce air into the main channel of the plasma jet spray gun 10, and the flow rate of the introduced air can be controlled by, but not limited to, rotor flow quantum. The injector 30 is used to store materials (such as coating slurry). In some embodiments, the injector 30 can be, but not limited to, a digital injection pump, so as to accurately control the injection amount of the material. The main channel of the plasma jet spray gun 10 is connected to the atomizing nozzle 41 on the side, and the atomizing nozzle 41 is connected to the injector 30 through a liquid inlet pipe 43, so that the material stored in the injector 30 is passed to the atomizing nozzle 41 through the liquid inlet pipe 43, and enters the main channel of the plasma jet spray gun 10 after being atomized by the atomizing nozzle 41.
[0019] In some embodiments, the diameter of the nozzle of the plasma jet spray gun 10 at the outlet may be 1 mm to 4 mm, and further, may be 2 mm. If the diameter of the nozzle of the plasma jet spray gun 10 at the outlet is too large, it is easy to cause the plasma jet temperature to be too high to damage the sample surface or the injected coating slurry to overheat and cause quality change, and if the diameter of the nozzle of the plasma jet spray gun 10 at the outlet is too small, the nozzle is easy to be blocked.
[0020] Please refer to Figure 2 The above-mentioned spraying repair method for the surface of a wind turbine blade comprises the following steps: Step S1 : placing the coating slurry in the syringe 30 .
[0021] The coating slurry can be prepared by, but is not limited to, the following method: mixing the resin and the curing agent, stirring them evenly to form a mixture, and degassing the mixture to obtain the coating slurry.
[0022] Specifically, in some embodiments, the stirring may be performed by, but not limited to, a magnetic stirrer, and the degassing may be performed by, but not limited to, immersing the mixture in an ultrasonic cleaner for degassing.
[0023] Step S2, air is introduced into the main channel of the plasma jet spray gun 10 through the air compressor 20, and the parameters of the plasma jet spray gun 10 are adjusted to stably spray the plasma jet.
[0024] In some embodiments, when the air compressor 20 introduces air into the main channel of the plasma jet spray gun 10, the air flow rate can be controlled to be 1L / min to 4L / min. Further, the air flow rate can be controlled to be 2L / min. By controlling the flow rate of the introduced air, it is possible to avoid the stability of the plasma jet being affected by an excessively high flow rate, and to avoid the inability of the plasma jet to be ejected due to an excessively low flow rate.
[0025] Specifically, the high-voltage end of the discharge area inside the plasma jet spray gun 10 is a metal electrode (such as a stainless steel spiral electrode), the metal electrode is connected to an external power supply (such as a CTP-2000K low-temperature plasma experimental power supply), the grounding hole of the plasma jet spray gun 10 is connected to the power ground wire, and the power output power is controlled until arc discharge occurs inside the plasma jet spray gun 10, and the generated plasma is ejected with the air.
[0026] Step S3 , connecting the injector 30 to the plasma jet spray gun 10 through the atomizing nozzle 41 .
[0027] In step S4, the coating slurry is atomized through the injector 30 and the atomizing nozzle 41 to form droplets, which are then injected into the plasma jet spray gun 10. After the droplets are stably ejected with the plasma jet, the plasma jet spray gun 10 is sprayed toward the area to be repaired on the surface of the wind turbine blade 200 and the plasma jet spray gun 10 is moved so that the droplets are deposited on the surface of the wind turbine blade 200 to form a film layer.
[0028] In some embodiments, the flow rate of the coating slurry when injected into the plasma jet spray gun 10 through the injector 30 can be 0.5 mL / min to 2 mL / min, and further, can be 1 mL / min. By controlling the flow rate of the coating slurry injection, the risk of clogging the plasma jet outlet is reduced while ensuring the repair speed.
[0029] In some embodiments, when the plasma jet spray gun 10 is sprayed and moved toward the area to be repaired on the surface of the wind turbine blade 200, the vertical distance between the outlet of the nozzle of the plasma jet spray gun 10 and the area to be repaired on the surface of the wind turbine blade 200 may be 7 mm to 13 mm, and further, may be 10 mm. If the distance is too far, the plasma jet does not fully contact the surface of the wind turbine blade 200, and the repair effect is not good. If the distance is too close, the plasma jet is easy to damage the surface of the wind turbine blade 200.
[0030] In some embodiments, the moving speed of the plasma jet spray gun 10 when spraying and moving toward the area to be repaired on the surface of the wind turbine blade 200 is 0.1 mm / s to 1 mm / s, and further, can be 0.5 mm / s. By controlling the moving speed, the plasma jet wind turbine blade 200 surface is fully contacted and the droplets formed by the coating slurry can be fully deposited on the surface of the wind turbine blade 200 to form a complete film layer.
[0031] In some embodiments, before the plasma jet spray gun 10 is sprayed toward the area to be repaired on the surface of the wind turbine blade 200, a step of pre-treating the surface of the wind turbine blade 200 may be included. Specifically, the surface of the wind turbine blade 200 may be polished by, but not limited to, sandpaper to improve the surface roughness and uniformity, and avoid stress concentration at the bonding point between the subsequent film layer and the surface of the wind turbine blade 200.
[0032] Step S5 , curing the film layer to repair the surface of the wind turbine blade 200 .
[0033] In some embodiments, the curing of the film layer is achieved by leaving the wind turbine blade 200 formed with the film layer to stand still, wherein standing still is beneficial to maintaining the leveling and shape of the film layer.
[0034] The spray repair method for the surface of wind turbine blades of the present application utilizes the impact of high-energy examples in the air plasma jet to effectively activate the coating slurry and the surface of the wind turbine blades, promote the breaking of old chemical bonds and the generation of new chemical bonds to achieve chemical bond reorganization, which is beneficial to improve the film curing rate and the interface bonding strength between the film layer and the blade. The above method adopts plasma jet and atomized coating slurry synchronous spraying technology, which is convenient for rapid in-situ repair, does not need to rely on large equipment, and is convenient for flexible operation. Furthermore, compared with the traditional coating and curing method, the plasma jet in the above method can efficiently cure the resin at room temperature or low temperature conditions, thereby reducing energy consumption, avoiding the high energy consumption of high-temperature curing and the harm caused by ultraviolet curing, and is more in line with environmental protection requirements.
[0035] Below, the present invention is further described by examples and comparative examples.
[0036] Example 1 The surface of the wind turbine blade was polished with 400-mesh sandpaper, and five polished wind turbine blades were taken as samples. The LT-5089 A room temperature hand-laid epoxy resin produced by Huibo New Materials was fully mixed with the corresponding LT-5089 B curing agent at a mass ratio of 100:30 and stirred evenly using a magnetic stirrer. The stirred mixture was immersed in an ultrasonic cleaner for degassing and placed in a syringe. The syringe was connected to a plasma jet spray gun, wherein the diameter of the nozzle outlet of the plasma jet spray gun was 2 mm. Air was introduced into the main channel of the plasma jet spray gun through an air compressor, and the air flow rate was 2L / min, and the parameters of the plasma jet spray gun were adjusted to spray a plasma jet with a stable morphology. The coating slurry was atomized by a syringe through an atomizing nozzle to form droplets and then injected into the plasma jet spray gun to make it enter the plasma discharge area inside the plasma jet spray gun, wherein the coating slurry was injected into the plasma jet spray gun through a syringe at a flow rate of 1mL / min. The plasma activation of the droplets in the plasma discharge area increases the surface polarity and active groups, and some functional groups on the surface of the droplets are cleaved or rearranged. After the droplets are stably ejected with the plasma jet, the outlet of the nozzle of the plasma jet spray gun is kept at a vertical distance of 10 mm from the area to be repaired on the surface of the wind turbine blade, and the plasma jet spray gun is sprayed toward the area to be repaired on the surface of the wind turbine blade and moved at a rate of 0.5 mm / s to allow the droplets to deposit on the surface of the wind turbine blade to form a film layer. After the film layer fills the area to be repaired on the surface of the wind turbine blade, the wind turbine blade is left to stand for 24 hours to complete the repair.
[0037] Comparative Example 1 The surface of the wind turbine blade was polished using 400-grit sandpaper, and five polished wind turbine blades were taken as samples. The difference between Comparative Example 1 and Example 1 is that the plasma power supply is turned off during the spraying process, ensuring that the only difference between Example 1 and Comparative Example 1 is whether it is exposed to the plasma source.
[0038] The adhesion strength of the film layer of the wind turbine blades repaired in Example 1 and Comparative Example 1 was tested by a pull-out test. The average adhesion strength of the five repaired samples in Example 1 was increased by more than 20% compared with the average adhesion strength of the five repaired samples in Comparative Example 1.
[0039] Among them, pull-off test: refer to "GB / T 5210-2006 Paint and varnish pull-off adhesion test"
[57] The cured coating was subjected to a pull-out test. First, a test column with a diameter of 20 mm was bonded to the surface of the repaired wind turbine blade sample with epoxy AB glue, and the epoxy AB glue was left to stand for more than 24 hours to completely cure; then a cutter was used to cut along the periphery of the test column until the substrate was exposed, so as to facilitate the separation of the film layer from the wind turbine blade substrate. Finally, the sample and its surface test column were fixed in a customized fixture. The bottom fixture was used to fix the sample, and the upper movable fixture ensured that the tensile force was evenly applied to the bonding area between the test column and the film layer. The CMT6104 microcomputer-controlled electronic universal testing machine was used to apply tensile stress in a direction perpendicular to the sample surface, and the tensile speed was 0.5 mm / min. The maximum stress when the test column was pulled off was recorded as F, and σ=F / 314 was used to calculate the destructive strength of the surface coating of each sample. The unit of F was N, and the unit of σ was MPa.
[0040] In addition, for ordinary technicians in this field, various other corresponding changes and modifications can be made according to the technical concept of this application, and all these changes and modifications should fall within the protection scope of the claims of this application.
Claims
1. A method for spraying and repairing the surface of a wind turbine blade, comprising the following steps: placing the coating slurry in a syringe; Air is introduced into the main channel of the plasma jet spray gun through an air compressor, and the parameters of the plasma jet spray gun are adjusted to stably spray the plasma jet; Connecting the syringe to the plasma jet spray gun through an atomizing nozzle; The coating slurry is atomized through the syringe and the atomizing nozzle to form droplets, and then injected into the plasma jet spray gun, and after the droplets are stably ejected with the plasma jet, the plasma jet spray gun is sprayed toward the area to be repaired on the surface of the wind turbine blade and the plasma jet spray gun is moved to allow the droplets to be deposited on the surface of the wind turbine blade to form a film layer; The film layer is cured to repair the surface of the wind turbine blade.
2. The spray repair method for the surface of a wind turbine blade according to claim 1, characterized in that: When air is introduced into the main channel of the plasma jet spray gun through the air compressor, the flow rate of the air is controlled to be 1 L / min to 4 L / min.
3. The spray repair method for the surface of a wind turbine blade according to claim 1, characterized in that: The diameter of the nozzle of the plasma jet spray gun at the outlet is 1 mm to 4 mm.
4. The spray repair method for the surface of a wind turbine blade according to claim 1, characterized in that: The syringe is a digital syringe pump.
5. The spray repair method for the surface of a wind turbine blade according to claim 4, characterized in that: The coating slurry is injected into the plasma jet spray gun through the syringe at a flow rate of 0.5 mL / min to 2 mL / min.
6. The spray repair method for the surface of a wind turbine blade according to claim 1, characterized in that: When the plasma jet spray gun is sprayed and moved toward the area to be repaired on the surface of the wind turbine blade, the vertical distance between the outlet of the nozzle of the plasma jet spray gun and the area to be repaired on the surface of the wind turbine blade is 7 mm to 13 mm.
7. The spray repair method for the surface of a wind turbine blade according to claim 6, characterized in that: The moving speed of the plasma jet spray gun when spraying and moving toward the area to be repaired on the surface of the wind turbine blade is 0.1 mm / s to 1 mm / s.