Automatic manufacturing system of polyurea film for protecting wind power generator blade

Abstract

The present invention relates to an automatic polyurea film manufacturing system for protecting wind turbine blades, comprising a conveying unit that moves a base film in one direction, a spray injection unit that applies a polyurea resin composition onto the base film moved by the conveying unit, a curing unit that cures the polyurea film on which the polyurea resin composition is applied through the spray injection unit, and a winding unit that winds the polyurea film cured by the curing unit into a roll type, wherein the spray injection unit, the curing unit, and the winding unit are sequentially installed along the conveying unit so that the application and curing of the polyurea resin composition and the winding of the polyurea film can be performed continuously, thereby providing an automatic polyurea film manufacturing system for protecting wind turbine blades that enables mass production of high-quality polyurea films.

Description

Technology Field

[0001] The present invention relates to an automatic manufacturing system for polyurea films for protecting wind turbine blades, and more specifically, to an automatic manufacturing system for polyurea films for protecting wind turbine blades that enables high-quality mass production of polyurea films used to protect the surface of wind turbine blades. Background Technology

[0002] Wind turbine blades are critical structural components of wind power generation and must withstand high rotational speeds and mechanical stress over long periods in extreme environments, including rain, snow, strong winds, ultraviolet rays, seawater, and temperature fluctuations. Consequently, the blade surfaces can easily be damaged or worn down, which can lead to reduced power generation efficiency and costly repairs or replacements.

[0003] To solve the aforementioned problem, a technology has been developed and is being used to protect the surface of wind turbine blades from external environmental factors by attaching a film to the surface of the blades.

[0004] Protective films for wind turbine blades generally require excellent properties such as high strength, wear resistance, chemical resistance, and durability, and to achieve this, various polymer materials and advanced manufacturing technologies are applied. For example, blade protective films can be manufactured by spray-coating polyurethane or polyurea onto an adhesive film, and the manufactured film is applied to the surface of the blade using coating technology.

[0005] However, conventionally, the production of protective films for wind turbine blades was carried out through discontinuous manual labor, which resulted in quality degradation such as bubble formation and uneven coating thickness, as well as difficulties in mass production due to the long time required for each process. The problem to be solved

[0006] The present invention was devised to solve the problems of the aforementioned prior art, and aims to provide an automatic manufacturing system for a polyurea film for protecting wind turbine blades that can improve the quality of the polyurea film for protecting wind turbine blades while ensuring mass production capability. means of solving the problem

[0007] As a means to solve the aforementioned technical problem,

[0008] The present invention provides an automatic production system for a polyurea film for protecting wind turbine blades, comprising: a conveying unit for moving a base film in one direction; a spray injection unit for applying a polyurea resin composition onto a base film moved by the conveying unit; a curing unit for curing a polyurea film on which the polyurea resin composition is applied through the spray injection unit; and a winding unit for winding the polyurea film cured by the curing unit into a roll type; wherein the spray injection unit, the curing unit, and the winding unit are sequentially installed along the conveying unit so that the application of the polyurea resin composition, curing, and subsequent winding of the polyurea film can be performed continuously.

[0009] In this case, the above-mentioned film may be a release film that can be attached to the surface of a wind turbine blade.

[0010] In this case, the polyurea resin composition may include a polyol and an isocyanate.

[0011] In this case, the spray nozzle mixes the polyurea resin composition with compressed air and applies it to the substrate film through a spray nozzle, wherein the spray nozzle can control one or more of the spray angle, flow rate, and particle size of the polyurea resin composition.

[0012] In this case, the curing unit may include a tunnel-type body installed in the conveying unit to allow the polyurea film to pass through the interior, a heating unit installed in the tunnel-type body to heat the interior of the tunnel-type body, and a control unit that controls the operation of the heating unit to adjust the curing temperature of the polyurea film.

[0013] In this case, the winding part can wind the polyurea film while adjusting its tension.

[0014] In addition, the present invention provides a method for producing a polyurea film using the above-described automatic polyurea film production system for protecting wind turbine blades, comprising: (a) a step of placing and moving a base film on a conveyor belt; (b) a step of applying a polyurea resin composition to the base film moving along the conveyor belt; (c) a step of introducing the polyurea film into a tunnel-type body; (d) a step of curing the polyurea film by heating the interior of the tunnel-type body with a heating means; (e) a step of slowly cooling the polyurea film to a temperature lower than that of step (d); and (f) a step of winding the polyurea film discharged from the tunnel-type body after slow cooling into a roll type. Effects of the invention

[0015] According to the present invention, since a polyurea resin composition is atomized and sprayed while conveying a substrate film at an optimal speed using a conveyor belt, no bubbles are generated and uniformity of coating thickness is ensured, thereby improving the quality of the polyurea film.

[0016] In addition, since continuous curing and winding are possible after applying a polyurea resin composition to a substrate film, polyurea films can be mass-produced at a low cost.

[0017] Furthermore, the application of an automated system ensures precise and consistent quality during the film production process, which can increase the durability of wind turbine blades and reduce maintenance costs.

[0018] In addition, improved blade durability reduces the time required for high-altitude repairs, thereby ensuring worker safety and reducing labor costs. Furthermore, since the maintenance cycle is extended, downtime can be minimized, allowing the operating time of the wind turbine to be maximized. Brief explanation of the drawing

[0019] FIG. 1 is a front structural diagram of an automatic polyurea film manufacturing system for protecting wind turbine blades according to a preferred embodiment of the present invention. FIG. 2 is a planar structural diagram of the system shown in FIG. 1, FIG. 3 is a photograph showing the spray injection unit of the system illustrated in FIG. 1. FIG. 4 is a photograph showing a polyurea resin composition raw material mixing device of the spray injection unit illustrated in FIG. 3. FIG. 5 is a photograph showing the cured part of the system illustrated in FIG. 1. FIG. 6 is a side view of the system illustrated in FIG. 1, showing the open and closed state of the tunnel-type body. FIG. 7 is a photograph showing the control unit display of the system illustrated in FIG. 1. Figure 8 is a photograph showing the winding section of the system illustrated in Figure 1. Specific details for implementing the invention

[0020] Hereinafter, embodiments of the present invention are described in detail with reference to the attached drawings so that those skilled in the art can easily implement the invention. However, the present invention may be embodied in various different forms and is not limited to the embodiments described herein. Furthermore, in order to clearly explain the present invention in the drawings, parts unrelated to the explanation have been omitted, and similar parts throughout the specification are described using similar reference numerals.

[0022] FIG. 1 is a front structural diagram of an automatic polyurea film manufacturing system for protecting wind turbine blades according to a preferred embodiment of the present invention, FIG. 2 is a plan structural diagram of the system shown in FIG. 1, FIG. 3 is a photograph showing the spray injection unit of the system shown in FIG. 1, FIG. 4 is a photograph showing the polyurea resin composition raw material mixing device of the spray injection unit shown in FIG. 3, FIG. 5 is a photograph showing the curing unit of the system shown in FIG. 1, FIG. 6 is a side view of the system shown in FIG. 1 showing the open / closed state of the tunnel-type main body, FIG. 7 is a photograph showing the control unit display of the system shown in FIG. 1, FIG. 8 is a photograph showing the winding unit of the system shown in FIG. 1.

[0024] Referring to FIGS. 1 to 8, an automatic polyurea film manufacturing system (100) for protecting wind turbine blades according to a preferred embodiment of the present invention includes a transfer unit (110), a spray injection unit (120), a curing unit (130), and a winding unit (140).

[0026] The transfer unit (110) is for moving the substrate film (10) in one direction and can be implemented in the form of a conveyor belt (111).

[0027] Specifically, the transfer section (110) is installed continuously without interruption from the spray injection section (120) to the curing section (130) and to the winding section (140), and moves the substrate film (10), which is unwound from the roller (20) and loaded on top, from the spray injection section (120) toward the winding section (140).

[0028] In the case of the transfer unit (110), the transfer speed is adjusted so that the polyurea resin composition is uniformly applied and cured as the base film (10) passes through the spray unit (120) and the curing unit (130), and then wound with a constant tension in the winding unit (140). That is, the operating speed of the transfer unit (110) is controlled by taking into account the time required for the coating and curing processes.

[0029] Meanwhile, for the base film (10), it is preferable to use a release film so that a cured polyurea film is wound in a roll type and unwound as needed to be attached to the blade surface quickly and easily.

[0031] The spray injection unit (120) is for applying a polyurea resin composition onto a substrate film (10) that is loaded and moved on the conveying unit (110), and is installed at the front end of the conveying unit (110) with respect to the conveying direction of the substrate film (10).

[0032] In the case of the spray injection unit (120), an automatic air atomizing spray injection device comprising a pump, hose, tube, compressed air generating device, and spray nozzle may be applied so as to mix a polyurea resin composition having a predetermined viscosity with compressed air and spray it into fine particles. Figure 3 shows a photograph of such an automatic air atomizing spray injection device.

[0033] Specifically, the pump pumps the polyurea resin composition through a hose and tube to a spray nozzle, and the compressed air generating device supplies compressed air to the spray nozzle, thereby mixing the polyurea resin composition and compressed air at the spray nozzle and spraying it at high pressure.

[0034] In this case, the polyurea resin composition may be used by mixing a polyol and an isocyanate in a predetermined ratio. The mixing ratio of the polyol and the isocyanate is not particularly limited and can be adjusted according to the required quality. The mixing and supply of the polyol and the isocyanate can be carried out by the resin mixing device shown in FIG. 4.

[0035] The spray nozzle is configured to control the spray angle, flow rate, and particle size of the polyurea resin composition. The spray angle is controlled by tilting the spray nozzle, or the block on which the spray nozzle is installed, to a certain angle using a driving device such as a motor, the flow rate is controlled by controlling the spray time, and the particle size can be controlled by increasing or decreasing the size of the nozzle opening or the pressure of the compressed air.

[0037] The curing section (130) is for curing a polyurea film coated with a polyurea resin composition through a spray section (120), and is installed continuously along the conveying section (110) at the rear end of the spray section (120).

[0038] Specifically, the curing unit (130) includes a tunnel-type main body (131), a heating unit (134), and a control unit (137).

[0039] The tunnel-type body (131) forms a space for curing a polyurea film and has a box shape with openings (132) provided at the lower ends. As a result, the polyurea film can enter the tunnel-type body (110) through the openings (132) continuously after the polyurea resin composition is applied while passing through the spray injection unit (120). For reference, FIG. 5 shows a photograph of a curing unit (130) including such a tunnel-type body (131).

[0040] It is preferable that the opening (132) of the tunnel-type main body (131) be formed small enough to allow the polyurea film to pass through. This is because if the opening (132) is too large, heat generated from the heating unit (134) leaks out through the opening (132), thereby degrading the curing quality of the polyurea film, and conversely, if the opening (132) is too small, the polyurea film may be damaged during the entry and exit process.

[0041] In order to minimize internal heat loss to the outside along with the size adjustment of the opening (132), the tunnel-shaped body (131) is composed of an outer wall (131a), an inner wall (131b), and an insulating material (131c) filled between the outer wall (131a) and the inner wall (131b).

[0042] The inner surface of the inner wall (131b) can be coated with glaze or treated to prevent dust, thereby preventing the polyurea film passing through the interior of the tunnel-type body (131) from being contaminated.

[0043] In addition, it is preferable to use ceramic fibers such as alumina and mullite as the insulating material (131c), but it is not particularly limited.

[0044] Meanwhile, the length of the tunnel-type main body (131) is set by considering the temperature and time required for curing the polyurea film, and the size and installation range of the heating part (134) accordingly.

[0045] Additionally, the tunnel-type main body (131) is configured to be openable and closable by hinge-connecting one side to the installation frame of the transfer unit (110) as shown in FIG. 6 for setting, maintenance, and repair of the heating system provided inside. For convenience in opening and closing the tunnel-type main body (131), at least one handle (133) that can be grasped by a worker may be installed on the other side of the tunnel-type main body (131).

[0046] The heating unit (134) is installed in the tunnel-type body (131) to supply heat used to cure the polyurea film.

[0047] For reference, the heating unit (134) is described here as being installed on the upper part of the tunnel-type main body (131), but it should be understood that the installation location of the heating unit (134) is not limited to the upper part of the tunnel-type main body (131), and it is also possible to install it on the side of the tunnel-type main body (131) as needed.

[0048] The heating unit (134) may include two or more heating means so that the temperature can be set differently for each predetermined area along the longitudinal direction of the tunnel-type body (131). For example, the heating unit (134) may be composed of a first heating means (135) installed at the front end of the tunnel-type body (131) and a second heating means (136) installed at the rear end of the tunnel-type body (134).

[0049] In this case, the first heating means (135) heats and maintains the front section of the tunnel-type body (131) at 85 to 95°C, preferably 90°C, thereby curing the polyurea film that enters and is transported into the tunnel-type body (131), and the second heating means (136) heats and maintains the rear section of the tunnel-type body (131) at 55 to 70°C, preferably 60 to 65°C, which is lower than the front section, thereby slowly cooling the polyurea film that is transported after curing.

[0050] The heating means (135) (136) are provided in an appropriate number to maintain a set temperature in each zone of the tunnel-type body (131). Here, a form in which the heating means (135) (136) each consist of two is presented.

[0051] The heating means (135)(136) can use various known heat sources, such as a hot air blower consisting of a heating coil and a fan, an electric heater, or a heating lamp, and is not particularly limited.

[0052] The control unit (137) controls the operation of the heating unit (134) to maintain the internal temperature of the tunnel-type body (131) at a set value.

[0053] Specifically, the temperature is measured by a temperature sensor (138) installed in each area of ​​the tunnel-type main body (131), namely the curing area and the slow cooling area of ​​the polyurea film, and this temperature information is transmitted to the control unit (137). The control unit (137) operates the heating unit (134) if the temperature received from the temperature sensor (138) is lower than the set value, and stops the operation of the heating unit (134) if it is higher.

[0054] The temperature control of the control unit (137) as described above is automatically performed between the upper and lower limits of the preset internal temperature.

[0055] For reference, FIG. 7 shows the display screen of the control unit (137). As shown in FIG. 7, the control unit (137) may include not only the operation control of the curing unit (130) described above, but also the control functions of the transfer unit (110), the spray injection unit (120), and the winding unit (140) described later.

[0057] The winding section (140) is for winding a polyurea film cured by the curing section (130) into a roll type and may be configured to include a main roller (141) that rotates by a motor (142) and winds the polyurea film, and at least one guide roller that guides the polyurea film to be stably supplied to the main roller (141).

[0058] In the case of the winding unit (140), the polyurea film can be stably wound by controlling the tension of the polyurea film through motor speed control, and the wound polyurea film can be stored or transported as is. A photograph of the winding unit (140) is disclosed in FIG. 8.

[0060] The automatic polyurea film manufacturing system (100) for protecting wind turbine blades according to a preferred embodiment of the present invention has been described above. Below, a method for manufacturing a polyurea film using the automatic polyurea film manufacturing system (100) for protecting wind turbine blades will be described.

[0062] First, the base film unwound from the roller is placed on the conveyor belt and moved.

[0063] Subsequently, a polyurea resin composition in which polyol and isocyanate are mixed in an appropriate ratio by a resin mixing device is mixed with compressed air and sprayed onto a substrate film at high pressure through a nozzle.

[0064] Afterward, the polyurea film is introduced into the interior of the tunnel-type body, and the polyurea film is cured for a certain period of time by supplying heat to the interior of the tunnel-type body using a heating means. The curing temperature of the polyurea film can be set to 85 to 95°C, preferably 90°C.

[0065] Next, when curing is complete, the polyurea film is slowly cooled to a temperature lower than the curing temperature. The cooling temperature of the polyurea film can be set to 55 to 70°C, preferably 60 to 65°C.

[0066] Finally, the polyurea film discharged from the tunnel-type body after slow cooling is wound into a roll type, completing the manufacturing of the polyurea film.

[0068] Preferred embodiments of the present invention have been described in detail above with reference to the drawings. The description of the present invention is for illustrative purposes only, and those skilled in the art will understand that other specific forms can be easily modified without altering the technical spirit or essential features of the present invention. Accordingly, the scope of the present invention is defined by the claims set forth below rather than by the detailed description above, and all modifications or variations derived from the meaning, scope, and equivalent concepts of the claims should be interpreted as being included within the scope of the present invention. Explanation of the symbols

[0069] 10 : Base film 20 : Roller 100: Polyurea film manufacturing system 110: Transfer unit 111: Conveyor belt 120: Spray nozzle 130 : Hardening section 131 : Tunnel-type main body 131a : Exterior wall 131b : Interior wall 131c : Insulation 132 : Opening 133 : Handle 134 : Heating part 135: First heating means 136: Second heating means 137 : Control unit 138 : Temperature sensor 140: Winding section 141: Main roller 142 : Motor

Claims

Claim 1 A conveying unit for moving a substrate film in one direction; a spray injection unit for applying a polyurea resin composition onto a substrate film moved by the conveying unit; and a curing unit for curing a polyurea film coated with a polyurea resin composition through the spray injection unit. and a winding unit for winding a polyurea film cured by the curing unit into a roll type; wherein the spray injection unit, the curing unit, and the winding unit are sequentially installed along the conveying unit so that the winding of the polyurea film after the application and curing of the polyurea resin composition can be performed continuously; wherein the curing unit includes a tunnel-type body installed in the conveying unit so that the polyurea film can pass through the interior, a heating unit installed in the tunnel-type body so as to heat the interior of the tunnel-type body, and a control unit that controls the operation of the heating unit to adjust the curing temperature of the polyurea film; wherein the tunnel-type body is composed of an outer wall, an inner wall, and an insulating material filled between the outer wall and the inner wall to minimize heat loss, and the inner surface of the inner wall is coated with glaze or treated to prevent dust, thereby preventing contamination of the polyurea film, and the insulating material is composed of ceramic fibers of alumina or mullite to enhance thermal insulation performance, while one side of the tunnel-type body is hinged to the installation frame of the conveying unit An automatic polyurea film manufacturing system for protecting wind turbine blades, characterized by being configured to be openable and closable in combination, thereby facilitating the setting, maintenance, and repair of the heating system provided inside. Claim 2 An automatic production system for a polyurea film for protecting a wind turbine blade, characterized in that, in claim 1, the above-mentioned film is a release film that can be attached to the surface of a wind turbine blade. Claim 3 An automatic polyurea film manufacturing system for protecting wind turbine blades, characterized in that, in claim 1, the polyurea resin composition comprises a polyol and an isocyanate. Claim 4 An automatic polyurea film manufacturing system for protecting wind turbine blades, characterized in that, in claim 1, the spray injection unit mixes the polyurea resin composition with compressed air and applies it to the substrate film through a spray nozzle, wherein the spray nozzle is capable of adjusting one or more of the spray angle, flow rate, and particle size of the polyurea resin composition. Claim 5 delete Claim 6 An automatic polyurea film manufacturing system for protecting wind turbine blades, characterized in that, in claim 1, the winding unit controls the tension of the polyurea film and winds it. Claim 7 A method for producing a polyurea film using an automatic polyurea film production system for protecting wind turbine blades according to any one of claims 1 to 4 and 6, comprising: (a) a step of placing and moving a base film on a conveyor belt; (b) a step of applying a polyurea resin composition to the base film moving along the conveyor belt; (c) a step of introducing the polyurea film into a tunnel-type body; (d) a step of curing the polyurea film by heating the interior of the tunnel-type body with a heating means; (e) a step of slowly cooling the polyurea film to a temperature lower than that of step (d); and (f) a step of winding the polyurea film discharged from the tunnel-type body after slow cooling into a roll type.

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