Automated preparation and spraying system for surface coating materials of wind turbine blades

Abstract

To achieve the above objectives, this utility model provides an automated preparation and spraying system for surface coating auxiliary materials for wind turbine blades, comprising: a coating preparation module including a high-speed separator and a planetary mixer, wherein the outlet of the high-speed separator is connected to the inlet of the planetary mixer; an automatic spraying module including a coating nozzle; and a coating delivery module including a pipeline, one end of which is connected to the outlet of the planetary mixer, and the other end of which is connected to the automatic spraying module. By structurally integrating the coating preparation module, the coating delivery module, and the automatic spraying module, and utilizing the pipeline to achieve direct and sealed connections between the modules, this utility model constructs a fully automated, closed-loop operation system from coating auxiliary material input to finished coating spraying.

Description

Technical Field

[0001] This utility model relates to the field of wind turbine blade manufacturing equipment technology, and in particular to an automated preparation and spraying system for surface coating auxiliary materials of wind turbine blades. Background Technology

[0002] Wind power, as a clean and renewable energy source, plays an increasingly important role in the global energy structure transformation. Wind turbine blades are key components of wind turbines for capturing wind energy; they are enormous, complex in shape, and exposed to harsh natural environments for extended periods. Therefore, preparing a high-performance protective coating on the blade substrate surface is crucial for resisting ultraviolet radiation, moisture, salt spray, rainwater erosion, and dust abrasion, ensuring the aerodynamic performance and structural integrity of the blades, and extending their service life. With the rapid development of the wind power industry, increasingly higher demands are being placed on the quality, efficiency, and automation level of wind turbine blade surface coating preparation.

[0003] In existing technological practices for wind turbine blade coating, the industry has seen some attempts to improve automation levels. For example, Chinese patent application CN 113171919 A ​​discloses a surface coating processing device for wind turbine blades. This device mainly focuses on the automated transfer of blades between the spraying and drying stations. The core of its technical solution lies in setting up a ground conveying system that integrates conveying, limiting, and flipping functions, in conjunction with a spraying device and a drying device installed on an upper support device, to achieve continuous operation of blade transportation, positioning, flipping, spraying, and drying.

[0004] However, after in-depth analysis, we found that while the existing technical solution achieves a certain degree of automated handling of the blade body, its structural design itself has inherent and insurmountable defects in the core process of coating preparation and spraying. Specifically, the solution only provides a macroscopic, functionally independent "spraying device," without disclosing or teaching how the coating is supplied to this device. In actual production scenarios, this means that the coating preparation process—including the precise proportioning, mixing, and homogenization of various auxiliary materials such as the main agent, curing agent, and diluent—is completely separated from this automated spraying station. Typically, the coating is prepared manually or semi-automatically in a mixing tank in a separate mixing zone far from the spraying site. Subsequently, the prepared finished coating needs to be manually transferred before being connected to the so-called "spraying device."

[0005] This structural layout, which completely separates the coating preparation and spraying processes in terms of physical space and process flow, directly leads to the following serious technical problems: First, during the long-distance, open transport of the coating from the preparation area to the spraying area, it is highly susceptible to contamination by dust and impurities in the environment. Simultaneously, the solvents in the coating also evaporate, causing uncontrollable changes in key performance parameters such as viscosity and solid content, directly affecting the final coating quality. Second, this reliance on manual transport and loading not only increases auxiliary labor and time costs, reducing the overall production cycle time, but also fragments the entire production process into discontinuous segments, preventing true full-process automation and leaving production efficiency bottlenecks. More importantly, this structural layout itself cannot solve the fundamental problem of poor quality consistency caused by manual proportioning and uneven mixing in the coating preparation stage. Therefore, the market urgently needs a new system architecture that can fundamentally change this separated production model, structurally integrating automated and precise coating preparation with automated and precise spraying to address the aforementioned technical deficiencies. Utility Model Content

[0006] The purpose of this invention is to provide an automated preparation and spraying system for coating auxiliary materials on wind turbine blades, in order to solve the technical problems of low production efficiency, poor coating quality consistency, and easy contamination of materials caused by the structural separation of coating preparation and spraying processes in the prior art.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] An automated preparation and spraying system for surface coating materials of wind turbine blades includes: a coating preparation module, including a high-speed separator and a planetary mixer, wherein the outlet of the high-speed separator is connected to the inlet of the planetary mixer; an automatic spraying module, including a coating nozzle; and a coating delivery module, including a pipeline, wherein one end of the pipeline is connected to the outlet of the planetary mixer and the other end is connected to the automatic spraying module.

[0009] By structurally integrating the paint preparation module, paint delivery module, and automatic spraying module, and utilizing pipelines to achieve direct, closed-loop connections between the modules, this invention constructs a fully automated, closed-loop operating system from paint auxiliary material input to finished paint spraying. This system architecture fundamentally eliminates the dispersed and independent process layout of traditional processes, avoiding secondary pollution, material property changes, and efficiency bottlenecks caused by manual handling, thereby significantly improving production efficiency and coating quality stability.

[0010] Preferably, the high-speed separator is a vertical, floor-mounted device with its base fixedly connected to the ground; the planetary mixer includes a mixing tank and a liftable mixing head supported by an independent bracket.

[0011] This structure provides a stable, floor-mounted foundation for the high-speed separator and an easily operable independent support structure for the planetary mixer, ensuring operational stability and convenience at the source of coating preparation. Floor-mounted installation effectively suppresses vibrations during high-speed operation, guaranteeing the reliability of the mixing process; while the independently supported mixing head provides the structural basis for subsequent refined operations, together laying the foundation for the reliable operation of the entire automated process.

[0012] Preferably, the mixing head of the planetary mixer is separable from the mixing tank, and the mixing head can be raised and lowered vertically under the drive of the independent support to move between a position above the mixing tank and a position inside the mixing tank.

[0013] This design further clarifies the intricate internal structure of the planetary mixer. The detachable and liftable design of the mixing head and mixing tank makes auxiliary operations such as cleaning, material changing, and maintenance of key mixing components extremely simple and quick. This ingenious structural design significantly reduces auxiliary time for production changeovers while ensuring the quality of the finished product, thereby improving the production flexibility and overall operational efficiency of the entire automated system.

[0014] Preferably, the pipeline is a high-pressure pipeline, and its pipe wall structure can withstand an internal pressure of 0.3MPa to 0.5MPa.

[0015] By employing a high-pressure resistant structure for the pipelines connecting the preparation module and the spraying module, the safety and reliability of the material transport chain are ensured. In the automated process, the coating may need to be pressurized to meet spraying requirements. The high-pressure resistant pipeline structure can safely carry and transport these pressurized fluids, effectively preventing the risk of leakage due to excessive pressure. This is a key element in ensuring the continuous and safe operation of the entire system.

[0016] Preferably, the automatic spraying module further includes an electrostatic spraying device, which is connected in series in the pipeline and located between the planetary mixer and the paint nozzle.

[0017] This solution introduces a key technology to improve spraying efficiency by adding electrostatic spraying equipment in series along the paint delivery path. The uniform paint flow through this equipment is effectively electrostatically applied, creating the necessary physical conditions for subsequently utilizing electric field forces to significantly improve paint adhesion. This is one of the core structures for achieving high-efficiency, low-waste, and environmentally friendly spraying operations.

[0018] Preferably, the automatic spraying module further includes a multi-axis motion mechanism, and the paint nozzle is installed at the end of the multi-axis motion mechanism.

[0019] By adding a multi-axis motion mechanism to support and drive the paint nozzle, a high-performance motion execution platform is provided for achieving automated and precise spraying. Wind turbine blades have huge and complex curved surfaces. Only through this mechanism with multi-degree-of-freedom motion capabilities can the precise control of the nozzle's motion trajectory and attitude be achieved. This is the physical basis for automated and high-quality spraying of complex workpieces.

[0020] Preferably, the multi-axis motion mechanism can control the spraying axis of the paint nozzle to be perpendicular to the surface of the wind turbine blade, and the distance between the nozzle orifice and the surface of the wind turbine blade is maintained at 200mm to 300mm.

[0021] This scheme further defines the precise spatial relationships achievable by the multi-axis motion mechanism. Through programmed control, the nozzle and blade surface are kept at the optimal spraying angle and distance at all times, ensuring that the electrostatic field remains in a uniform and efficient working state. This constant maintenance of the spraying geometry maximizes the "encircling effect" of the coating, providing the final structural guarantee for obtaining a high-performance coating with uniform thickness and stable quality.

[0022] In summary, this invention integrates coating preparation and spraying into a single structure, and optimizes the internal structure and connections of each functional module, thus constructing a closed, continuous, and highly efficient automated workflow. This system not only solves the problems of low efficiency and unstable quality caused by the separation of processes in existing technologies, but also significantly improves coating utilization and coating quality through precise automated control, achieving efficient, high-quality, and environmentally friendly production of coatings for wind turbine blade surfaces. Attached Figure Description

[0023] Figure 1 This invention relates to an automated preparation and spraying system for surface coating materials of wind turbine blades, as described in one embodiment of the present invention. Detailed Implementation

[0024] To make the objectives, technical solutions and advantages of this utility model clearer, the present utility model will be described in further detail below with reference to the accompanying drawings.

[0025] Please see Figure 1This embodiment provides an automated preparation and spraying system for surface coating materials of wind turbine blades. The technical solution is as follows: An automated preparation and spraying system for surface coating materials of wind turbine blades includes: a coating preparation module, including a high-speed separator 1 and a planetary mixer 2, wherein the outlet of the high-speed separator 1 is connected to the inlet of the planetary mixer 2; an automatic spraying module, including a coating nozzle 5; and a coating conveying module, including a pipe 4, wherein one end of the pipe 4 is connected to the outlet of the planetary mixer 2, and the other end is connected to the automatic spraying module.

[0026] By structurally integrating the paint preparation module, paint delivery module, and automatic spraying module, and utilizing pipeline 4 to achieve direct and sealed connections between the modules, this invention constructs a fully automated, closed-loop operating system from paint auxiliary material input to finished paint spraying. This system architecture fundamentally eliminates the dispersed and independent process layout of traditional processes, avoids secondary pollution, material property changes, and efficiency bottlenecks caused by manual handling, thereby significantly improving production efficiency and coating quality stability.

[0027] In this embodiment, as a preferred structure, the high-speed separator 1 is a vertical, floor-mounted device with its base fixedly connected to the ground; the planetary mixer 2 includes a mixing tank and a liftable mixing head supported by an independent bracket. This structure ensures operational stability and ease of use in the initial stage of coating preparation by providing a stable floor-mounted foundation for the high-speed separator 1 and designing an easy-to-operate independent support structure for the planetary mixer 2. Floor-mounted installation effectively suppresses vibration during high-speed operation, ensuring the reliability of the mixing process; while the independently supported mixing head provides the structural prerequisite for subsequent refined operations, together laying the foundation for the reliable operation of the entire automated process.

[0028] Furthermore, the mixing head and mixing tank of planetary mixer 2 are separable. The mixing head can be raised and lowered vertically under the drive of an independent support, moving between a position above and inside the mixing tank. This design further clarifies the intricate internal structure of planetary mixer 2. The separable and height-adjustable design of the mixing head and mixing tank makes auxiliary operations such as cleaning, material changing, and maintenance of key mixing components extremely simple and quick. This ingenious structural design significantly reduces auxiliary time for production changeovers while ensuring the quality of the finished product, thereby improving the production flexibility and overall operating efficiency of the entire automated system.

[0029] As an optimization of the conveying process, pipe 4 is a high-pressure pipe, with its wall structure capable of withstanding internal pressures of 0.3 MPa to 0.5 MPa. By adopting a high-pressure resistant structure for pipe 4, which connects the preparation module and the spraying module, the safety and reliability of the material conveying link are ensured. In the automated process, the coating may need to be pressurized to meet spraying requirements. The high-pressure resistant pipe structure can safely carry and transport these pressurized fluids, effectively preventing the risk of leakage due to excessive pressure. It is a key element in ensuring the continuous and safe operation of the entire system.

[0030] In this embodiment, the automatic spraying module also includes an electrostatic spraying device 3, which is connected in series in the pipe 4 and located between the planetary mixer 2 and the paint nozzle 5. This solution, by adding the electrostatic spraying device 3 in series in the paint delivery path, fundamentally introduces a key technological means to improve spraying efficiency. When the uniform paint flows through this device, it is effectively electrostatically charged, creating the necessary physical conditions for subsequently utilizing electric field force to significantly improve paint adhesion efficiency. This is one of the core structures for achieving high-efficiency, low-waste, and environmentally friendly spraying operations.

[0031] To achieve automated spraying, the automatic spraying module also includes a multi-axis motion mechanism, with the paint nozzle 5 mounted at its end. By adding this multi-axis motion mechanism to support and drive the paint nozzle 5, a high-performance motion execution platform is provided for achieving automated and precise spraying. The wind turbine blade 6 has a large and complex curved surface; only through this mechanism with multi-degree-of-freedom motion capabilities can precise control of the nozzle's trajectory and attitude be achieved. This is the physical basis for automated, high-quality spraying of complex workpieces.

[0032] The "multi-axis motion mechanism" mentioned here is a device well-known to those skilled in the art, capable of enabling an end effector to perform multi-degree-of-freedom motion and attitude adjustment in three-dimensional space. Specifically, in this embodiment, the multi-axis motion mechanism can be an industrial robot with six or more degrees of freedom, such as an articulated robot. This type of industrial robot has flexible motion capabilities, enabling its end effector (i.e., the location where the paint nozzle 5 is installed) to accurately track the complex spatial curvature of the wind turbine blade 6.

[0033] Alternatively, as another feasible implementation, the multi-axis motion mechanism can also employ a gantry-type Cartesian robot. This type of robot typically includes a beam and a slide that move along three linear axes (X, Y, and Z), with one or more rotary axes (such as axes A, B, and C) mounted at their ends, collectively forming a large, highly rigid multi-axis motion system. This structure is particularly suitable for large-scale, high-precision reciprocating spraying of large, elongated workpieces such as wind turbine blades.

[0034] Whether using articulated industrial robots or gantry robots, the goal is to provide a high-performance motion execution platform for the paint nozzle 5 through multi-axis linkage, so as to achieve precise and automated spraying of the complex curved surface of the wind turbine blade 6.

[0035] As a means of precise control over the spraying process, the multi-axis motion mechanism can control the spraying axis of the paint nozzle 5 to be perpendicular to the surface of the wind turbine blade 6, and maintain the distance between the nozzle 5 and the surface of the wind turbine blade 6 at 200mm to 300mm. This scheme further defines the precise spatial positional relationship that the multi-axis motion mechanism can achieve. Through programmed control, the nozzle and the blade surface are kept at the optimal spraying angle and distance at all times, ensuring that the electrostatic field is always in a uniform and efficient working state. This constant maintenance of the spraying geometry maximizes the "encircling effect" of the paint, which is the final structural guarantee for obtaining a high-performance coating with uniform thickness and stable quality.

[0036] Specifically, in this embodiment, the workflow of the entire system is as follows:

[0037] First, in the coating preparation stage, two or more coating additives, such as coating material A (e.g., the main agent) and coating material B (e.g., the curing agent), are pumped from the raw material tank to the high-speed separator 1 via their respective feed pumps. The high-speed separator 1, with its internal high-speed rotating components, performs forced initial dispersion and mixing of the two materials at a speed of, for example, 1000 r / min to 3000 r / min. This process lasts approximately 15 to 30 minutes and aims to quickly break up any agglomerates that may be present in the materials. In some cases, the high-speed separator may also be referred to as a high-speed disperser.

[0038] Subsequently, the initially dispersed mixture automatically flows from the outlet of the high-speed separator 1 into the mixing tank of the planetary mixer 2 connected thereto. At this point, the mixing head of the planetary mixer 2 descends into the mixing tank, where it performs thorough homogenization at a relatively low speed, for example, 50 to 80 rpm. Its unique planetary motion trajectory ensures thorough mixing without dead zones, resulting in highly uniform materials at both the macroscopic and microscopic levels. This deep mixing process lasts approximately 30 to 60 minutes, ultimately forming a stable finished coating.

[0039] Next, in the conveying and spraying stage, the mixed finished paint, driven by a pump, enters the high-pressure pipeline 4 from the outlet of the planetary mixer 2. The paint is steadily conveyed in pipeline 4 at a pressure of 0.3 MPa to 0.5 MPa and flows through the electrostatic spraying equipment 3 connected in series in the pipeline. In the electrostatic spraying equipment 3, the paint is subjected to high-voltage electrostatic charge, ensuring its pressure is maintained between 0.3 MPa and 0.5 MPa. The charged, pressurized paint finally reaches the paint nozzle 5 installed at the end of a multi-axis motion mechanism (such as an industrial robot or gantry).

[0040] Finally, in the automated execution phase, the central control system drives the multi-axis motion mechanism according to a pre-programmed three-dimensional path program for a specific wind turbine blade 6. This mechanism drives the paint nozzle 5, ensuring that its nozzle maintains a constant distance of 200mm to 300mm from the complex curved surface of the blade 6, and maintains a 90° vertical spraying angle. The paint nozzle 5 sprays charged atomized paint evenly onto the blade surface at a set pressure and flow rate. The multi-axis motion mechanism moves precisely and smoothly along the blade contour, thereby achieving automated, uniform, and high-quality coating application to the entire blade surface. The entire spraying process is continuous, with spray intervals set from 15 to 30 minutes to accommodate different paint surface drying requirements.

[0041] The above description is only a preferred embodiment of the present utility model and does not limit the scope of implementation of the present utility model. All equivalent changes and modifications made in accordance with the scope defined by the claims of the present utility model shall still fall within the protection scope of the present utility model.

Claims

1. An automated system for the production and spraying of a wind turbine blade surface coating aid, characterized in that include: A coating preparation module includes a high-speed separator (1) and a planetary mixer (2), wherein the outlet of the high-speed separator (1) is connected to the inlet of the planetary mixer (2); An automatic spraying module includes a paint nozzle (5); And a paint delivery module, including a pipe (4), one end of which is connected to the outlet of the planetary mixer (2), and the other end is connected to the automatic spraying module.

2. An automated wind turbine blade surface coating preparation and spraying system as claimed in claim 1, wherein, The high-speed separator (1) is a vertical, floor-mounted device with its base fixedly connected to the ground; the planetary mixer (2) includes a mixing tank and a lifting mixing head supported by an independent bracket.

3. An automated wind turbine blade surface coating preparation and spraying system as claimed in claim 2, wherein, The stirring head of the planetary mixer (2) can be separated from the mixing tank. The stirring head can be raised and lowered vertically under the drive of the independent support, so as to move between the position above the mixing tank and the position inside the mixing tank.

4. An automated wind turbine blade surface coating preparation and spraying system as claimed in claim 3, wherein, The pipeline (4) is a high-pressure pipeline, and its pipe wall structure can withstand an internal pressure of 0.3MPa to 0.5MPa.

5. An automated wind turbine blade surface coating preparation and spraying system as claimed in claim 4, wherein, The automatic spraying module also includes an electrostatic spraying device (3), which is connected in series in the pipe (4) and located between the planetary mixer (2) and the paint nozzle (5).

6. An automated wind turbine blade surface coating preparation and spraying system as claimed in claim 5, wherein, The automatic spraying module also includes a multi-axis motion mechanism, and the paint nozzle (5) is installed at the end of the multi-axis motion mechanism.

7. An automated wind turbine blade surface coating preparation and spraying system as claimed in claim 6, wherein, The multi-axis motion mechanism can control the spraying axis of the paint nozzle (5) to be perpendicular to the surface of the wind turbine blade (6), and the distance between the nozzle (5) and the surface of the wind turbine blade (6) is maintained at 200mm to 300mm.

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