A comprehensive anti-icing and de-icing system for wind turbine blades

Abstract

This utility model discloses a comprehensive anti-icing and de-icing system for wind turbine blades, relating to the field of wind power generation technology. It includes an air-heat anti-icing module, a ply-type anti-icing module, and a coating anti-icing module. The air-heat anti-icing module comprises an electric heater, a blower, a ventilation duct, and foam insulation material. The system also includes a functionally graded composite coating system applied to the outer surface of the wind turbine blades to reduce the icing rate and assist in de-icing. The ply includes a high thermal conductivity graphene epoxy resin layer embedded in the outer surface of the blades. The collaborative control system includes a temperature sensor, a control chip, and a solenoid valve for controlling the on / off state of the blower and the electric heater. This utility model aims to solve the problem of wind turbine blade icing by integrating air-heat recovery, electric heating, functional coatings, self-heating ply, and intelligent control technologies to achieve efficient and low-consumption anti-icing and de-icing effects, improving the operational stability and power generation efficiency of wind turbines under severe weather conditions.

Description

Technical Field

[0001] This utility model relates to the field of wind power generation technology, specifically to a comprehensive anti-icing and de-icing system for wind turbine blades. Background Technology

[0002] In today's global trend of vigorously advocating energy conservation and emission reduction, the energy sector is undergoing profound changes. With the continuous advancement of energy structure adjustment and the accelerating pace of clean energy transition, wind power, as a clean and renewable energy utilization method, is playing an increasingly crucial role in the power grid.

[0003] However, blade icing has become a major obstacle to the efficient and stable operation of wind power generation, and its harm should not be underestimated. Icing significantly alters the aerodynamic characteristics of the blades, drastically reducing their efficiency in capturing wind energy, and consequently leading to a sharp decline in power generation efficiency. Furthermore, the added weight of the ice layer increases the load on the equipment, placing extra stress on the wind turbine's structural components, potentially accelerating equipment aging, and even causing malfunctions, affecting the turbine's lifespan and safety. It is against this backdrop that an efficient and reliable wind turbine blade anti-icing system is urgently needed. Utility Model Content

[0004] To address the above problems, this utility model provides a comprehensive anti-icing and de-icing system for wind turbine blades, aiming to solve the problem of icing on wind turbine blades. By integrating gas heat recovery, functional coating and intelligent control technologies, it achieves efficient and low-consumption anti-icing and de-icing effects, and improves the operational stability and power generation efficiency of wind turbines under severe weather conditions.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is: a comprehensive anti-icing and de-icing system for wind turbine blades, comprising:

[0006] The air-heat anti-icing module is installed inside the wind turbine blade cavity to recover waste heat from the nacelle and work in conjunction with the electric heater to heat the key area of ​​the leading edge of the wind turbine blade through circulating heat flow; it includes a hot air blower composed of an electric heater and a blower mechanism, as well as a ventilation pipe for conveying hot air flow to the wind turbine blade cavity;

[0007] A functionally graded composite coating system is applied to the outer surface of wind turbine blades to reduce the icing rate and assist in de-icing. It includes a bottom layer of highly thermally conductive graphene epoxide resin and a top layer of hydrophobic coating.

[0008] The coordinated control system includes a temperature sensor mounted on the blower blades, with the output of the temperature sensor connected to the input of a control chip, and the output of the control chip connected to a solenoid valve. The solenoid valve controls the on / off state of the blower and the electric heater. In addition, an air dryer and a filter are installed inside the blower.

[0009] The beneficial effects of the above technical solution are as follows: The air-thermal anti-icing module utilizes waste heat from the nacelle and electric heating to synergistically heat the key areas of the blade leading edge, effectively reducing energy consumption while improving heating efficiency. The foam filling material in the key areas of the blade leading edge provides insulation, ventilation, and gas exchange functions. The functionally graded composite coating significantly reduces the icing rate and assists in de-icing, improving the wind turbine blades' anti-icing capability. The collaborative control system achieves intelligent control, automatically starting and stopping heating according to environmental conditions, further optimizing the system's energy consumption and operational performance.

[0010] As a further improvement to the above scheme, the inner cavity of the wind turbine blade is divided into a leading edge inner cavity, a web inner cavity, and a trailing edge inner cavity by a web. The hot air blower assembly is installed at the blade root, and the outlet of the ventilation duct is connected to the leading edge inner cavity. Hot air is introduced into the pores of the foam filling material in the leading edge inner cavity through the ventilation duct for insulation. Then, it returns from the membrane channel at the end of the leading edge inner cavity and enters the web inner cavity and the trailing edge inner cavity respectively, and then flows back to the inlet of the hot air blower assembly, forming a circulating flow.

[0011] The beneficial effects of the above technical solution are as follows: by optimizing the hot air circulation path, it ensures a more uniform heat distribution within the blade cavity, avoiding localized overheating or undercooling. This circulation flow method improves the utilization efficiency of hot air and further enhances the system's anti-icing and de-icing effects.

[0012] As a further improvement to the above solution, the inner cavity of the blade tip of the fan blade is filled with thermal insulation foam material, and the thermal insulation foam material has air pores inside; the air outlet of the ventilation pipe extends into the area where the thermal insulation foam material is located.

[0013] The beneficial effects of the above technical solution are as follows: lightweight insulating foam can effectively reduce the loss of heat in the inner cavity, while reducing the flow space of hot air in the blades, thereby maintaining the stability of the inner cavity temperature, improving the heat insulation effect of hot air, improving the utilization rate of hot air, and further reducing the energy consumption of the system. As it is a lightweight material, it will not significantly change the weight of the blades, thus improving the overall performance of the fan.

[0014] As a further improvement to the above solution, the control chip is also connected to a memory with preset parameters.

[0015] The beneficial effects of the above technical solution are as follows: the memory with preset parameters can store operating parameters and control strategies under various environmental conditions, and the control chip can call up the corresponding parameters according to real-time monitoring data to achieve more precise anti-icing control and further improve the automation level and operational reliability of the system.

[0016] As a further improvement to the above solution, a heat-conducting layer is provided on the inner wall of the wind turbine blade. The heat-conducting layer is a high thermal conductivity graphene epoxy resin layer or a copper mesh layer.

[0017] The beneficial effects of the above technical solution are: improving the internal heat transfer to the fan blades and increasing the ice melting efficiency.

[0018] As a further improvement to the above scheme, the functional gradient composite coating system also includes a middle layer of microcapsule self-healing polyurethane containing a slow-release repair agent.

[0019] The beneficial effects of the above technical solution are as follows: the microcapsule self-healing polyurethane layer can automatically release the repair agent when the coating is damaged, repair the minor damage on the coating surface, extend the service life of the coating, and ensure the long-term stability of the coating's hydrophobic and anti-icing properties.

[0020] As a further improvement to the above solution, an air dryer and a filter are installed inside the blower.

[0021] The beneficial effects of the above technical solution are: it can reduce the moisture and dust in the air entering the blade cavity.

[0022] The overall beneficial effects of this utility model compared to the prior art

[0023] This integrated anti-icing and de-icing system for wind turbine blades combines heat recovery, high-performance coating and layup, and automatic control to comprehensively solve the problem of icing on wind turbine blades. Compared with traditional single anti-icing methods, this system uses multiple technologies in synergy to significantly improve the efficiency and reliability of anti-icing and de-icing; intelligent control precisely adapts to different icing conditions, optimizing energy consumption; waste heat recovery and insulation design reduce energy consumption; and the superhydrophobic self-healing coating greatly reduces icing and has strong durability. Overall, this system is highly efficient, energy-saving, intelligent, and durable, greatly ensuring the power generation efficiency and operational life of wind turbines in icy environments, representing an innovative breakthrough in the field of wind power anti-icing. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the layout of the gas-heated anti-icing system;

[0025] Figure 2 This is a schematic diagram of the layered structure of the blade cross section;

[0026] Figure 3 This is a schematic diagram of the air-heat system layout inside the wind turbine blades.

[0027] Figure 4 A schematic diagram of the internal structure of a wind turbine blade (view from the front).

[0028] Figure 5 This is a side view of the cross-sectional structure of a wind turbine blade.

[0029] Figure 6 This is a schematic diagram of the circuit control module of a gas-heated de-icing system.

[0030] In the diagram: 1. Blower; 2. Electric heater; 3. Blower blade; 4. Hydrophobic coating; 5. High thermal conductivity graphene epoxy resin layer; 6. Secondary outer glass cloth layer; 7. Blade substrate; 8. Web; 9. Trailing edge cavity; 10. Blade root baffle; 11. Hot air blower; 12. Ventilation duct; 13. Wind deflector; 14. Leading edge cavity; 15. Web cavity; 17. Thermal insulation foam material. Detailed Implementation

[0031] To enable those skilled in the art to better understand the technical solution, the present invention will be described in detail below with reference to the embodiments. The description in this part is only exemplary and explanatory, and should not be used to limit the scope of protection of the present invention in any way.

[0032] 1. Experimental equipment and materials:

[0033] Wind turbine blade model: A wind turbine blade model with a length of 60 meters, a width of 3.5 meters, and a thickness of 1.2 meters was selected. The material is glass fiber reinforced composite material with a surface roughness of less than 0.1 micrometers.

[0034] Air-heating anti-icing module: includes a 50kW electric heater 2 (model: EH-50) and an air volume of 1000m³ / h. 3 A blower with a pressure of 1 MPa (model: GB-1000), a compressor with a pressure of 1 MPa (model: CP-1), and 12 fiberglass ventilation pipes with an inner diameter of 0.3 meters, a wall thickness of 0.01 meters, and a length of 60 meters.

[0035] Functionally graded composite coating materials: Fluorinated carbon nanotube superhydrophobic coating material (contact angle greater than 150°), microcapsule self-healing polyurethane layer material (containing slow-release repair agent, repair response time is 24 hours).

[0036] Outer surface coating: High thermal conductivity graphene epoxy resin coating (thermal conductivity of 15 W / m·K)

[0037] Lightweight thermal insulation foam: It has a honeycomb pore structure.

[0038] High thermal conductivity graphene epoxy resin layer material: thermal conductivity is 20 W / m·K.

[0039] The collaborative control system includes a temperature sensor (range -50℃ to 100℃, accuracy ±0.1℃), a control chip (model: CT-2023), and a solenoid valve (model: EM-901).

[0040] Implementation steps

[0041] 1. System Assembly

[0042] Install the hot air anti-icing module: Fix the electric heater 2 and blower 1 into the pre-reserved mounting slots at the root of the blower blade 3 model, and secure them with bolts, ensuring a tight and leak-free connection. Connect one end of the fiberglass ventilation pipe 12 to the outlet of the electric heater 2, and extend the other end to the inner cavity 14 of the leading edge of the blower blade 3, sealing it with sealing tape to ensure stable pressure during the hot air delivery process. The blower can also be connected to an air dryer and filter for dust filtration and air drying.

[0043] The functionally graded composite coating system was applied as follows: First, the surface of the blade substrate 7 was cleaned by wiping it with anhydrous ethanol to remove oil and dust, ensuring good coating adhesion. An outer layer of glass cloth 6 was applied first, followed by a high thermal conductivity graphene epoxy resin layer 5 using a spraying process. The coating thickness was controlled at 0.1 mm, the spraying speed was 0.5 m / min, and the spraying pressure was 0.3 MPa. After the undercoat dried (drying time was 2 hours), a hydrophobic fluorinated carbon nanotube coating 4 was applied, with a thickness of 0.05 mm, using the same spraying speed and pressure as the undercoat. Finally, a microcapsule self-healing polyurethane layer with a thickness of 0.03 mm was added to the coating surface.

[0044] A high thermal conductivity layer is installed: a high thermal conductivity graphene epoxy resin layer with a thickness of 0.02 meters is coated on the inner wall of the fan blade 3 using a scraping process to ensure uniform coating coverage.

[0045] Insulating foam material 17 is filled into the inner cavity at the tip of the fan blade 3, and the ventilation duct 12 extends into the insulating foam material 17. This allows heat to be retained within the insulating foam material 17, thereby improving the de-icing effect at the blade tip. The insulating foam material 17 can be made of lightweight insulating foam with a porous structure.

[0046] Install a collaborative control system: such as Figure 4 As shown, a temperature sensor is installed on the fan blade 3. The output of the temperature sensor is connected to the input of the control chip via a signal line. The control chip is installed in the control box at the root of the fan blade 3. The output of the control chip is connected to a solenoid valve, which is installed on the power supply lines of the blower 1 and the electric heater 2 to control the power supply to and from the equipment.

[0047] 2. System debugging

[0048] Air-heat circulation debugging: Start blower 1 and electric heater 2, set the temperature of electric heater 2 to 60℃, and observe the flow of hot air in the inner cavity of blower blade 3. By adjusting the air volume of blower 1 and the compressor pressure, a stable circulation flow of hot air is formed between the leading edge inner cavity 14, the web inner cavity 15, and the trailing edge inner cavity 9, with a circulation cycle of 5 minutes. Use an infrared thermal imager to monitor the temperature distribution on the blade surface, ensuring that the temperature in the leading edge area is uniformly between 40℃ and 60℃.

[0049] Coating performance testing: Under normal temperature conditions, the contact angle of the hydrophobic coating 4 was tested using a contact angle meter to ensure that the contact angle was greater than 150°. The ice crystal formation process was simulated on the coating surface to observe the coating's effect in delaying icing, and the icing time delay was recorded. A scratch test was performed on the microcapsule self-healing polyurethane layer to simulate coating damage, and the release of the repair agent and the repair effect were observed.

[0050] Collaborative control debugging: Different ambient temperatures (-10℃, 0℃, 10℃) and humidity levels (80%, 90%) were simulated in the laboratory. Temperature and humidity data on the blade surface were collected by temperature sensors and transmitted to the control chip. Based on a preset anti-icing strategy (anti-icing measures are activated when the temperature is below 0℃ and the humidity is above 80%), the control chip controls the on / off state of the solenoid valve, automatically starting and stopping the blower 1 and electric heater 2. The system response time was recorded to ensure it was less than 1 minute.

[0051] 3. System Logic

[0052] Pre-icing (prevention): In cold weather, first activate the air-thermal anti-icing module to allow hot airflow to fill the foam filler for insulation, then deactivate the air-thermal anti-icing module. The hydrophobic coating delays ice crystal formation, and the preheating of the layup maintains a surface temperature above 0°C. Sensors monitor humidity and temperature in real time, and AI predicts the probability of icing. When the blade tip temperature is low, activate the air-thermal anti-icing module again to allow airflow exchange within the foam, thus stabilizing the blade temperature, then deactivate the air-thermal anti-icing module.

[0053] During freezing (de-icing): The gas heating module is activated, and waste heat and electric heating work together to raise the temperature. Layered zone temperature control avoids overheating, and the coating absorbs energy and generates heat to assist in de-icing.

[0054] After icing (de-icing): Graphene-coated electrothermal heating accelerates the shedding of the ice layer, and gas-thermal circulation washes away residual ice debris. An electric heater 2 is installed inside the baffle at the blade root. A ventilation duct 12 with the same temperature coefficient, structural strength, and fatigue strength as the blade material is installed on the leading edge web 8. The length of the ventilation duct is 12 meters (depending on the blade length), and a baffle plate 13 is installed at this location.

[0055] Air is drawn from the hot air blower 11 through the ventilation duct 12 to the leading edge cavity 14 of the blade, located 16 meters from the blade root. Under the pressure of the blower, the hot air is forced into the inner cavity beyond the baffle plate 13, the blade tip, and other leading edge areas of the blade. It then returns to the web cavity 15 or the trailing edge cavity 9 through the membrane channel at the blade tip, and finally returns to the blower inlet at the blade root for recirculation and heating. This cycle continues until the blade's inner cavity temperature is saturated. The airflow direction is shown in the attached diagram. Figure 3 As shown.

[0056] 4. Experimental verification

[0057] Icing Simulation Experiment: The wind turbine blade model 3, with the system installed, was placed in a low-temperature environment simulation chamber. The ambient temperature was set to -10℃, humidity to 90%, and wind speed to 10m / s, simulating the operating conditions of the wind turbine blade 3 in a frozen environment. The system was continuously run, and the ice thickness on the blade surface was measured using an ice thickness measuring instrument, with data recorded every 30 minutes for 4 consecutive hours, both with the system on and off. Simultaneously, system energy consumption was monitored, and the power consumption of the electric heater 2 and blower 1 was recorded.

[0058] Anti-icing effect evaluation: By comparing the ice thickness data on the blade surface when the system is on and off, the effect of the system in reducing the icing rate is calculated. Energy consumption during system operation is monitored using a power quality analyzer to evaluate the system's energy-saving effect. During the experiment, the icing condition and de-icing effect of the blade surface coating are observed, and the de-icing time is recorded.

[0059] Data Recording and Processing

[0060] 1. Recording of Icing Thickness Data: In the icing simulation experiment, the icing thickness data on the blade surface was recorded under both the on and off states of the system, as shown in Table 1:

[0061] Table 1:

[0062] Time (minutes) Ice thickness (mm) when system is on Ice thickness (mm) when system is off 30 0.5 2.3 60 0.8 4.7 90 1.2 7.8 120 1.5 11.2 150 1.8 15.6 180 2.1 20.1 210 2.4 24.7 240 2.7 29.3

[0063] 2. Energy Consumption Data Recording: Record the energy consumption data during system operation, including the power consumption of electric heater 2 and blower 1, as shown in Table 2:

[0064] Table 2:

[0065] Time (minutes) Electric heater power (kW) Blower power (kW) Total power (kW) 30 35.2 8.7 43.9 60 35.8 8.9 44.7 90 36.1 9.1 45.2 120 36.4 9.2 45.6 150 36.7 9.3 46.0 180 37.0 9.4 46.4 210 37.2 9.5 46.7 240 37.5 9.6 47.1

[0066] 3. Data Processing and Analysis:

[0067] Icing rate calculation: Based on the icing thickness data, the icing rate was calculated for the system in both on and off states. The icing rate was 0.011 mm / min when the system was on and 0.122 mm / min when the system was off. This shows that the system can reduce the icing rate by approximately 90.9%, effectively mitigating the icing process.

[0068] Energy consumption percentage calculation: Based on the power consumption data of electric heater 2 and blower 1, the proportion of system energy consumption to the total power generation of the blower is calculated. The rated power of the blower is 2000kW, and the average power generation under experimental conditions is 1500kW. The average total power consumption of the system is 45.5kW, so the energy consumption percentage is 45.5 / 1500×100%≈3.03%, which meets the design requirement that the system energy consumption percentage is less than or equal to 3%, and has a good energy-saving effect.

[0069] Technical effect verification

[0070] 1. Verification of Anti-icing Effect: Data from icing simulation experiments show that the ice thickness on the blade surface is significantly less when the system is on than when it is off, and the icing rate is drastically reduced, demonstrating the significant anti-icing effect of this system. The fluorinated carbon nanotube superhydrophobic coating in the functionally graded composite coating system effectively delays ice crystal formation, while the circulating heat flow of the gas-thermal anti-icing module maintains the blade surface temperature at a high level, working together to reduce icing formation.

[0071] 2. Energy-saving effect verification: Energy consumption data shows that the system's energy consumption ratio is only 3.03%, far lower than that of traditional single electric heating anti-icing systems (which typically account for over 10% of energy consumption), fully demonstrating the energy-saving and consumption-reducing advantages of this system. The air-heated anti-icing module recovers and utilizes waste heat from the engine room, working in conjunction with electric heating to optimize energy utilization efficiency and reduce energy consumption.

[0072] 3. Verification of the effect of collaborative control: During the experiment, the collaborative control system responded quickly based on the real-time data from the temperature sensor and accurately controlled the on and off of the blower 1 and the electric heater 2. The system response time was less than 1 minute, which ensured the timely implementation of anti-icing measures and improved the intelligence level and operational stability of the system.

[0073] In summary, this integrated anti-icing and de-icing system for wind turbine blades, through reasonable design and implementation, demonstrates excellent performance in terms of anti-icing effect, energy saving, and intelligent control. It effectively solves the problem of icing on wind turbine blades and provides the wind power industry with an efficient, reliable, and low-consumption integrated anti-icing and de-icing solution.

[0074] It should be noted that, in this document, the terms "comprising," "including," and any other variations are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Specific examples have been used in this document to illustrate the principles and implementation methods of the present invention. These examples are merely for the purpose of helping to understand the method and core ideas of the present invention. The above descriptions are only preferred embodiments of the present invention. It should be pointed out that, due to the limitations of written expression and the objective existence of infinite specific structures, those skilled in the art can make several improvements, modifications, or variations without departing from the principles of the present invention, and can also combine the above technical features in an appropriate manner. These improvements, modifications, variations, or combinations, or the direct application of the concept and technical solution of the present invention to other situations without modification, should all be considered within the scope of protection of the present invention.

Claims

1. A comprehensive anti-icing and de-icing system for a wind turbine blade, characterized in that, include: The air-heat anti-icing module is installed inside the fan blade (3) to recover the waste heat of the nacelle and work in conjunction with the electric heating to heat the key area of ​​the leading edge of the fan blade (3) through circulating heat flow; it includes a hot air blower (11) consisting of an electric heater (2) and a blower (1), and a ventilation pipe (12) for conveying hot air flow to the inside of the fan blade (3); A functional gradient composite coating system is applied to the outer surface of the wind turbine blade (3) to reduce the icing rate and assist in de-icing. It includes a bottom layer of high thermal conductivity graphene epoxide resin (5) and a top layer of hydrophobic coating (4). The collaborative control system includes a temperature sensor installed on the fan blades (3), the output of the temperature sensor is connected to the input of the control chip, and the output of the control chip is connected to the solenoid valve; the solenoid valve controls the on / off of the blower (1) and the electric heater (2).

2. The integrated anti-icing and de-icing system for a wind turbine blade according to claim 1, wherein, The hot air blower (11) is installed at the root of the blade; after the hot air is input into the leading edge cavity (14) through the ventilation pipe (12), it returns from the membrane channel at the end of the leading edge cavity (14) and enters the web cavity (15) and the trailing edge cavity (9) respectively, and then flows back to the air inlet of the hot air blower (11) to form a circulating flow.

3. The integrated anti-icing and de-icing system for a wind turbine blade of claim 2, wherein, The inner cavity of the blade tip of the fan blade (3) is filled with thermal insulation foam material (17), and the thermal insulation foam material (17) has air holes inside; the air outlet of the ventilation pipe (12) extends into the area where the thermal insulation foam material (17) is located.

4. The integrated anti-icing and de-icing system for a wind turbine blade of claim 1, wherein, The control chip is also connected to a memory with preset parameters.

5. The integrated anti-icing and de-icing system for a wind turbine blade of claim 1, wherein, A heat-conducting layer is provided on the inner wall of the fan blade (3); the heat-conducting layer is a high thermal conductivity graphene epoxy resin layer or a copper mesh layer.

6. The integrated anti-icing and de-icing system for wind turbine blades according to claim 1, characterized in that, The functionally graded composite coating system also includes a middle layer of microcapsule self-healing polyurethane containing a slow-release repair agent.

7. The integrated anti-icing and de-icing system for wind turbine blades according to claim 1, characterized in that, The blower (1) is equipped with an air dryer and a filter.

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