Offshore wind turbine blade surface salt spray wash protection assembly

Abstract

The present application relates to a kind of offshore wind turbine blade surface salt fog scouring protection assembly, the profile of base is matched with the airfoil surface of wind turbine blade and is fixed on wind turbine blade;Protection module is detachably installed on the outer side of base;Protection module includes modular shell, porous permeation layer opened in modular shell, and micropore is opened in the outer side of modular shell and connected with porous permeation layer;Fluid distribution system is used to transport anti-salt fog protection fluid to porous permeation layer;The base, protection module and fluid distribution system provided by the present application, combined with passive physical protection of high hardness, corrosion-resistant material, and active chemical protection of dynamic liquid film isolation, the protection effect is far more than single coating or edge scheme, realizes on-demand, accurate active protection, avoids the waste of protection fluid, and can automatically respond according to environmental changes.It effectively slows down the corrosion and wear rate of blade leading edge, significantly prolongs the overall service life of wind turbine blade.

Description

Technical Field

[0001] This invention relates to the field of wind power generation technology, and more specifically to a protective component for the surface of offshore wind turbine blades against salt spray erosion. Background Technology

[0002] Offshore wind power has developed rapidly due to its abundant resources and lack of land occupation. As the core component for capturing wind energy, wind turbine blades are exposed to harsh environments of high salt spray, high humidity, and high wind speeds for extended periods. Their leading edges are directly subjected to the intense erosion of salt spray particles, water droplets, and sand carried by high-speed airflow, making them highly susceptible to corrosion, wear, and coating peeling. This not only reduces the aerodynamic efficiency of the blades and affects power generation, but in severe cases, it can also cause structural damage to the blades, leading to significant safety hazards and maintenance costs.

[0003] Currently, the main protective measures for the leading edge of blades include: 1) Apply a corrosion-resistant and wear-resistant protective coating to the blade surface, but such coatings are prone to failure under long-term scouring and require frequent maintenance; 2) Although attaching or covering the leading edge of the blade with metal (such as titanium alloy) improves wear resistance, the thermal expansion coefficients of the metal and the composite matrix are different, which makes it easy to delaminate under temperature changes and cannot actively cope with the continuous corrosion of salt spray. 3) Adding an air filtration system inside the wind turbine nacelle can only protect the equipment inside the nacelle, but it cannot protect the exposed blades. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a salt spray erosion protection component for the surface of offshore wind turbine blades to solve the aforementioned problems.

[0005] This invention provides the following technical solution: A protective assembly for preventing salt spray erosion on the surface of offshore wind turbine blades, comprising: A base, the outline of which matches the airfoil surface of the wind turbine blade, for attaching and fixing to the wind turbine blade; The protective module is detachably mounted on the outer side of the base to cover and protect the leading edge area of ​​the wind turbine blades; The protective module includes a modular shell and a porous permeable layer inside the modular shell. The outer side of the modular shell has micropores that are connected to the porous permeable layer. A fluid distribution system is used to deliver anti-salt spray protective fluid to the porous permeable layer.

[0006] Preferably, the base includes a base body, an installation track extending along the length of the base body, and an internal flow channel embedded inside the base body. The fluid distribution system is connected to the porous permeable layer through the internal flow channel. The inner wall of the internal flow channel is provided with a flexible sealing gasket to prevent moisture and salt spray from penetrating into the bonding interface.

[0007] Preferably, a connecting block is provided on the inner side of the modular housing, and the connecting block slides into the mounting track of the base.

[0008] Preferably, the outer surface of the modular housing is coated with a superhydrophobic self-cleaning coating.

[0009] Preferably, the front end of the modular housing forms a sharp windward edge.

[0010] Preferably, the fluid distribution system includes: The liquid storage tank is fixedly installed inside the fan blades and is used to store the anti-salt spray protective liquid. The main delivery pipeline connects the liquid storage tank to the internal flow channel of the base; An electromagnetic control valve is installed on the main delivery pipeline to control the flow of fluid.

[0011] Preferably, the system also includes a control unit, which is used to control the operating state of the fluid distribution system according to environmental parameters.

[0012] Preferably, the control unit includes: Environmental sensors are used to monitor the surrounding salt spray concentration, temperature, and humidity; The central processing unit receives and processes the signals from the environmental sensors, and controls the fluid distribution system to perform corresponding actions based on the processing results; The wireless communication module is used for data interaction with the remote monitoring center.

[0013] Preferably, the porous permeable layer has a thermal expansion and contraction layer and a microporous layer respectively disposed on opposite sides, the micropores are disposed on the microporous layer, and the thermal expansion and contraction layer expands when heated, compressing the porous permeable layer; it also includes a temperature control component for controlling the heating temperature of the thermal expansion and contraction layer.

[0014] Preferably, the temperature control component includes a control housing and a movable block that slides within the control housing along the centrifugal direction of the fan blade rotation. An elastic element is provided between the control housing and the movable block to push it to reset in a normal state. The control housing is provided with two or more sets of fixed contacts with different resistance values. The movement of the movable block causes the movable contact on it to connect with one of the fixed contacts.

[0015] The present invention has the following beneficial technical effects: This invention combines passive physical protection with high-hardness, corrosion-resistant materials and active chemical protection with dynamic liquid film isolation through a base, protective module, and fluid distribution system. The protective effect far surpasses that of a single coating or edge-wrapping solution, achieving on-demand, precise active protection, avoiding waste of protective fluid, and automatically responding to environmental changes. It effectively slows down the corrosion and wear rate of the blade leading edge, significantly extending the overall service life of the wind turbine blades. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention installed on the wind turbine blade; Figure 2 This is a cross-sectional structural diagram of the base and protection module of the present invention; Figure 3 This is a schematic diagram of the fluid distribution system of the present invention; Figure 4 This is a schematic diagram of the structure of the base of the present invention; Figure 5 This is a schematic diagram of the module structure of the control unit of the present invention; Figure 6 This is a schematic diagram showing the combination of the porous permeable layer, the thermal expansion and contraction layer, and the temperature control component of the present invention; Figure 7 This is a schematic diagram of the temperature control component structure of the present invention.

[0017] The attached figures are labeled as follows: 1. Base; 11. Base body; 12. Adhesive layer; 13. Mounting rail; 14. Internal flow channel; 2. Protective module; 21. Modular shell; 22. Windward side; 23. Porous permeable layer; 24. Connecting block; 25. Thermal expansion and contraction layer; 26. Microporous layer; 27. Temperature control component; 271. Control shell; 272. Fixed contact; 273. Movable block; 274. Elastic element; 3. Fluid distribution system; 31. Storage tank; 32. Main delivery pipeline; 33. Electromagnetic control valve; 4. Control unit; 41. Environmental sensor; 42. Central processing unit; 43. Wireless communication module; 5. Fan blades; 6. Flexible sealing gasket; 7. Superhydrophobic self-cleaning coating; 8. Liquid level observation window; 9. Liquid replenishment port. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Example 1: A salt spray erosion protection component for offshore wind turbine blades is installed on the leading edge of wind turbine blade 5, as shown in the reference. Figures 1-5 ,include: Base 1, protection module 2, fluid distribution system 3, and control unit 4; The base 1 is the mounting base of the entire component. The outline of the base 1 matches the airfoil surface of the wind turbine blade 5 and is used to fit and fix it to the wind turbine blade 5. The base 1 is fixed to the leading edge area of ​​the wind turbine blade 5 by high-strength adhesive or mechanical fasteners. The base 1 has an S-shaped internal flow channel 14 for fluid flow. The internal flow channel 14 is connected to the fluid distribution system 3. The inner wall of the internal flow channel 14 is fixed with a flexible sealing gasket 6 to prevent moisture and salt spray from penetrating into the interface between the base 1 and the modular shell 21. The base 1 includes a base body 11 and a mounting track 13. The base body 11 is made of lightweight, high-strength composite material, and its inner surface is provided with an adhesive layer 12 that conforms to the surface of the wind turbine blade 5. The mounting track 13 is opened along the length of the base body 11. The protective module 2 is embedded in the mounting track 13 of the base 1 through a connecting block 24 to achieve sliding installation.

[0020] The protective module 2 is the core component that directly withstands erosion. It is detachably mounted on the base 1 for easy replacement and maintenance. The protective module 2 covers and protects the leading edge area of ​​the wind turbine blades 5. The protective module 2 includes a modular shell 21, a porous permeable layer 23, and a connecting block 24. The modular shell 21 is made of corrosion-resistant and erosion-resistant titanium alloy or ceramic matrix composite material, exhibiting excellent corrosion resistance and erosion resistance. The front end of the modular shell 21 forms a sharp windward edge 22 to minimize aerodynamic drag. Furthermore, the outer surface of the modular shell 21 is coated with a superhydrophobic self-cleaning coating 7, utilizing the lotus leaf effect to prevent water droplets and salt spray particles from adhering.

[0021] A porous permeable layer 23 is disposed within the inner cavity of the modular housing 21. Micropores are uniformly formed on the outer wall of the modular housing 21, and these micropores are connected to the porous permeable layer 23. The porous permeable layer 23 is used for uniform permeation of a protective fluid. The protective fluid can be an anti-salt spray protective liquid or other corrosion-resistant protective liquid. The anti-salt spray protective liquid can be a solution containing corrosion inhibitors and hydrophobic components, or an aqueous solution of propylene glycol containing corrosion inhibitors. The porous permeable layer 23 is used to uniformly "permeate" the protective fluid onto the surface of the modular housing 21, forming a dynamic liquid film that isolates salt spray particles. The connecting block 24 is fixedly connected to the inner side of the modular housing 21 and slides in engagement with the mounting track 13 of the base 1.

[0022] The fluid distribution system 3 is used to distribute protective fluid. The fluid distribution system 3 includes a storage tank 31, a main delivery pipeline 32, and an electromagnetic control valve 33. The storage tank 31 is fixedly installed inside the fan blades 5, and the storage tank 31 is provided with a liquid level observation window 8 and a replenishment port 9. The main delivery pipeline 32 connects the storage tank 31 to the internal flow channel 14 of the base 1, and the electromagnetic control valve 33 is fixedly installed in series on the main delivery pipeline 32 to control the flow of fluid.

[0023] A micro-pump is installed inside the storage tank 31. This micro-pump provides power to pump protective fluid into the internal flow channel 14 of the base 1 via the main delivery pipeline 32. The micro-pump can be a diaphragm pump. Its inlet is connected to the bottom of the storage tank 31 via a pipeline, and its outlet is connected to the main delivery pipeline 32. The pipeline passes through the hub and blades, ultimately connecting to the inlet of the internal flow channel 14 of the base 1. The electromagnetic control valve 33, under the command of the control unit 4, precisely controls the timing and flow rate of the protective fluid supply.

[0024] The control unit 4 is used to control the operating status of the fluid distribution system 3 according to environmental parameters. The control unit 4 includes an environmental sensor 41, a central processing unit 42, and a wireless communication module 43. The environmental sensor 41 includes a salt spray concentration sensor and a humidity sensor, etc., to monitor the environment around the fan blades 5 in real time. The central processing unit 42 and the wireless communication module 43 are encapsulated in a waterproof box and installed inside the fan blades 5 near the root. All electrical components are connected via shielded cables and powered by an independent power supply inside the fan blades 5.

[0025] The central processing unit 42 receives and processes signals from the environmental sensor 41, analyzes the sensor data according to a preset algorithm, and automatically starts the micro pump and opens the electromagnetic control valve 33 when the salt spray concentration or humidity exceeds the threshold for active protection. The wireless communication module 43 is used to interact with the remote monitoring center, uploading the component's operating status and environmental data to the remote monitoring center to achieve intelligent operation and maintenance.

[0026] Working Principle: During fan operation, the environmental sensor 41 of the control unit 4 continuously monitors the environment. When the air humidity exceeds 85% and the salt spray concentration exceeds the set value, the central processing unit 42 determines it to be a high-risk condition and immediately issues a command. The micro pump starts, the electromagnetic control valve 33 opens, and the protective fluid is pumped out from the storage tank 31, enters the internal flow channel 14 of the base 1 through the main delivery pipeline 32, and then evenly permeates the entire porous permeable layer 23. Finally, the protective fluid slowly seeps out from the micropores of the porous permeable layer 23 and passes through the micropores, forming an extremely thin and uniform liquid film on the windward side 22 and leading edge surface of the modular shell 21. This liquid film can effectively block and dissolve the attached salt spray particles and is carried away by the shearing action of the high-speed airflow. At the same time, the corrosion inhibitor also provides chemical protection to the metal surface. When the environment improves, the system automatically shuts down to conserve the protective fluid.

[0027] Example 2 includes all the contents of Example 1, except that, referring to... Figure 6 As shown: The porous permeable layer 23 adopts a flexible and extrudable structure, such as a sponge. A thermal expansion and contraction layer 25 is provided inside the modular shell 21. The thermal expansion and contraction layer 25 is relatively attached to the side of the porous permeable layer 23 away from the micropores. When the porous permeable layer 23 contains protective fluid, the thermal expansion and contraction layer 25 expands due to heat and squeezes the porous permeable layer 23. The squeezing of the porous permeable layer 23 can accelerate the overflow of the protective fluid inside through the micropores of the microporous layer 26.

[0028] Example 3 includes all the contents of Example 2, except that, referring to... Figure 6 , Figure 7 As shown: Since offshore wind turbines generate electricity by rotating when there is wind and stop when there is no wind, there are two states: rotating and not rotating. The rotation of the turbine blades 5 can accelerate the formation and dissipation of the liquid film on their outer surface.

[0029] Therefore, a temperature control component 27 for controlling the temperature of the thermal expansion and contraction layer 25 is provided inside the modular housing 21. The temperature control component 27 includes a control housing 271 and a movable block 273 that slides in the control housing 271 along the centrifugal direction of the fan blade 5. The movable block 273 is connected to the opposite side walls of the inner cavity of the control housing 271 through corresponding elastic elements 274 on both sides. The elastic elements 274 can be elastic ropes or springs. The movable block 273 is provided with movable contacts for conducting electricity. The control housing 271 is provided with multiple sets of independent fixed contacts 272 along the centrifugal rotation direction of the fan blade 5. The resistance values ​​of each set of fixed contacts 272 are different. All fixed contacts 272 correspond to a set of heating wires, which are used to heat the thermal expansion and contraction layer 25. The heating wires are connected to different fixed contacts 272s, and their heating temperatures are different.

[0030] When the fan blades 5 are not rotating, the movable block 273 is in its initial position due to the restriction of the elastic element 274. At this time, the movable contact on the movable block 273 is connected to one of the fixed contacts 272. When it is necessary to form an extremely thin and uniform liquid film on the windward side 22 and the leading edge surface of the modular housing 21, the control unit 4 controls the movable contact to be energized, thereby energizing the heating wire to heat the thermal expansion and contraction layer 25. The thermal expansion and contraction layer 25 exerts the greatest pressure on the porous permeable layer 23 when heated, and the protective fluid discharged from the porous permeable layer 23 is the fastest. When the fan blade 5 rotates, the different rotation speeds of the fan blade 5 cause the movable block 273 to overcome the different sliding distances of the elastic element 274 along the centrifugal direction of the fan blade 5 rotation, thereby realizing the connection between the movable contact on the movable block 273 and the fixed contact 272 at the corresponding position under the rotation speed. The faster the fan blades 5 rotate, the lower the temperature at which the heating wire heats the thermal expansion and contraction layer 25, thereby controlling the speed of the protective fluid discharged from the porous permeable layer 23. The thermal expansion and contraction layer 25 only affects the speed of the protective fluid discharged from the porous permeable layer 23.

[0031] Example 4 includes all the content of Example 3, except that: The microporous layer 26 can be made of a material that deforms under heat, so that when the heating wire is not energized to heat the thermal expansion and contraction layer 25 under normal conditions, the micropores of the microporous layer 26 are in a closed state. When the heating wire is energized to heat the thermal expansion and contraction layer 25, the microporous layer 26 is indirectly heated through the porous permeable layer 23. The microporous layer 26 is heated so that its micropores open, and the opening temperature varies depending on the heating temperature.

[0032] The embodiments described above are merely illustrative of specific implementations of the present invention, and while the descriptions are detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A protective assembly for preventing salt spray erosion on the surface of offshore wind turbine blades, characterized in that, include: The base (1) has an outline that matches the airfoil surface of the fan blade (5) and is used to attach and fix it to the fan blade (5). The protective module (2) is detachably installed on the outer side of the base (1) to cover and protect the leading edge area of ​​the fan blades (5); The protective module (2) includes a modular shell (21) and a porous permeable layer (23) disposed inside the modular shell (21). The outer side of the modular shell (21) is provided with micropores that are connected to the porous permeable layer (23). A fluid distribution system (3) is used to deliver anti-salt spray protective fluid to the porous permeable layer (23); The porous permeable layer (23) has a thermal expansion and contraction layer (25) and a microporous layer (26) on opposite sides, respectively. The micropores are disposed on the microporous layer (26). The thermal expansion and contraction layer (25) expands when heated and compresses the porous permeable layer (23). The porous permeable layer (23) also includes a temperature control component (27) for controlling the temperature of the thermal expansion and contraction layer (25) when heated. The temperature control component (27) includes a control housing (271) and a movable block (273) that slides in the control housing (271) along the centrifugal direction of the fan blade (5). An elastic element (274) is provided between the control housing (271) and the movable block (273) to push it to reset in the normal state. The control housing (271) is provided with two or more fixed contacts (272) with different resistance values. The movable block (273) moves so that the movable contact on it is connected to one of the fixed contacts (272).

2. The anti-salt spray erosion protection component for offshore wind turbine blades according to claim 1, characterized in that, The base (1) includes a base body (11), an installation track (13) opened along the length of the base body (11), and an internal flow channel (14) embedded inside the base body (11). The fluid distribution system (3) is connected to the porous permeable layer (23) through the internal flow channel (14). The inner wall of the internal flow channel (14) is provided with a flexible sealing gasket (6) to prevent moisture and salt spray from penetrating into the bonding interface.

3. The anti-salt spray erosion protection component for offshore wind turbine blades according to claim 2, characterized in that, The inner side of the modular shell (21) is provided with a connecting block (24), which slides in cooperation with the mounting track (13) of the base (1).

4. The anti-salt spray erosion protection component for offshore wind turbine blades according to claim 1, characterized in that, The outer surface of the modular housing (21) is coated with a superhydrophobic self-cleaning coating (7).

5. The anti-salt spray erosion protection component for offshore wind turbine blades according to claim 1, characterized in that, The front end of the modular shell (21) forms a sharp windward edge (22).

6. The anti-salt spray erosion protection component for offshore wind turbine blades according to claim 1, characterized in that, The fluid distribution system (3) includes: The liquid storage tank (31) is fixedly installed inside the fan blade (5) and is used to store the anti-salt spray protective liquid; The main delivery pipeline (32) connects the liquid storage tank (31) to the internal flow channel (14) of the base (1). An electromagnetic control valve (33) is installed on the main delivery pipeline (32) to control the flow of fluid.

7. The anti-salt spray erosion protection component for offshore wind turbine blades according to claim 6, characterized in that, It also includes a control unit (4) for controlling the working state of the fluid distribution system (3) according to environmental parameters.

8. The anti-salt spray erosion protection component for offshore wind turbine blades according to claim 7, characterized in that, The control unit (4) includes: An environmental sensor (41) is used to monitor the surrounding salt spray concentration, temperature, and humidity; The central processing unit (42) receives and processes the signals from the environmental sensor (41), and controls the fluid distribution system (3) to perform corresponding actions based on the processing results; The wireless communication module (43) is used for data interaction with the remote monitoring center.

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