Wind Turbine Blade Leading Edge Thermal Spraying Method
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Solution Overview
Problem
It is difficult to achieve accurate thermal spraying on the leading edge of a wind turbine blade due to its large curvature, leading to inconsistencies in protective layer thickness and quality.
Innovation Solution
A method involving thermal spraying in the blade spanwise direction, followed by changing the position to the blade chord direction, and adjusting the thickness of the protective layer to gradually decrease towards the edge, ensuring precise application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal spraying is performed on the leading edge portion of the wind turbine blade, then a protective layer is formed to protect against erosion, but the large curvature of the leading edge makes it difficult to determine the thermal spraying direction, resulting in insufficient position accuracy and desired thickness
Solution Approach 1:
The thermal spraying process is divided into multiple steps: first spraying in the blade spanwise direction, then changing position to the blade chord direction, and spraying again in the spanwise direction. This segmentation allows the spraying direction to be adjusted to match the curvature changes, improving position accuracy and achieving the desired protective layer thickness despite the large curvature of the leading edge.
2Reliability
If thermal spraying is performed to form a protective layer, then erosion resistance is improved, but the thickness consistency and quality of the protective layer cannot be ensured due to the large curvature
Solution Approach 1:
The protective layer thickness is designed to gradually decrease from the root toward the tip in the blade chord direction, with the end portion thickness specifically controlled to decrease toward its edge. This local quality variation optimizes the protective layer for different regions of the leading edge, ensuring adequate protection where needed while minimizing excess material, thereby improving overall quality and thickness consistency despite the large curvature.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the formation of a protective layer with the desired thickness and quality, even on large wind turbine blades, minimizing fluid loss and improving position accuracy.
Implementation Method 1
a first thermal spraying step of performing thermal spraying in the blade spanwise direction, a blade chord position changing step of performing a position change such that the thermal spraying is performed at an adjacent position adjacent to a blade chord direction of the protective layer formed in the first thermal spraying step, and a second thermal spraying step of performing the thermal spraying in the blade spanwise direction at the adjacent position
Data Source
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AI summary
Provided is a method for manufacturing a wind turbine blade with which it is possible to obtain a protective layer having a desired thickness and quality, by improving the positional accuracy of thermal spraying. Provided is a method for manufacturing a wind turbine blade (5) in which a protective layer is provided on a front edge (16) side of a tip end portion (12) in a blade length direction (L1) of a wind turbine blade body (5a) formed from FRP, the method comprising: a first thermal spraying step for performing thermal spraying in the blade length direction (L1); a blade chord position changing step for changing a position such that thermal spraying is performed at an adjacent position that is adjacent, in a blade chord direction (C1), to the protective layer (30) formed in the first thermal spraying step; and a second thermal spraying step for performing thermal spraying in the blade length direction (L1) at the adjacent position.