Wind Turbine Blade Mould Masking for Smooth Coating Boundaries
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Solution Overview
Problem
Existing methods for masking moulds in wind turbine blade manufacturing result in sharp coating thickness steps and jagged boundaries, requiring burdensome post-processing or reapplication of coatings, especially when masking tape is not removed before the coating dries.
Innovation Solution
A method using a masking device with a lip portion that creates a gap between the masking device and the coating upon termination of spraying, allowing the coating to dry without peeling, and a transition zone for gradual coating coverage, enabling uniform coating application and reducing post-processing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masking tape is used to define the coating zone boundary, then the coating can be applied to the correct zone, but a sharp step in coating thickness is created at the boundary
Solution Approach 1:
The masking device geometry is changed from a sharp-edged tape to a lip portion with a rounded leading edge. This geometric parameter change allows the coating to transition gradually from full thickness to zero thickness across the lip curvature, eliminating the sharp step while maintaining precise zone boundary definition.
Solution Approach 2:
The leading edge of the masking device lip portion is formed with a curved radius instead of a sharp edge. This curvature creates a gradual transition zone where the coating thickness decreases smoothly from the coating zone into the non-coating zone, producing a gentle slope rather than a sharp step in the coating profile.
2Productivity
If masking tape is removed after the coating dries, then the masking function is complete, but the coating peels off leaving a jagged boundary
Solution Approach 1:
The masking device material properties are changed from adhesive tape to a non-adhesive rigid or semi-rigid lip structure. This parameter change eliminates the peeling mechanism entirely, as the coating cannot adhere to the masking device to begin with, ensuring coating integrity remains intact throughout the drying process and removal.
Solution Approach 2:
The lip portion of the masking device acts as an intermediary barrier that physically prevents coating material from reaching the non-coating zone without relying on adhesion. The geometric barrier rather than chemical adhesion ensures the coating remains intact and can be cleanly removed without peeling or damaging the cured coating.
3Extent of automation
If coating is applied in a single pass autonomously, then the coating process is efficient, but the masking tape cannot be removed in time before drying
Solution Approach 1:
The rigid lip portion of the masking device serves as a permanent geometric barrier during the entire coating and drying process. Unlike temporary adhesive tape, this intermediary structure remains in place throughout automated single-pass coating and subsequent drying without requiring timely removal, allowing full automation without timing constraints.
Solution Approach 2:
The masking device is pre-positioned with a geometry that anticipates the full coating process including drying time. The lip portion is designed to maintain its masking function throughout the entire process, allowing the coating to be applied autonomously in a single pass and dry completely before the masking device needs to be removed, eliminating rush timing requirements.
4Manufacturing precision
If a sharp boundary is created at the coating zone, then the masking is precise, but post-processing such as grinding or sanding is required to achieve a uniform coating
Solution Approach 1:
The curved leading edge of the masking device lip portion creates a gradual transition in coating thickness rather than a sharp boundary. This curvature produces a gentle slope that eliminates the need for post-processing operations like grinding or sanding, as the coating surface is already smooth and uniform across the boundary zone.
Solution Approach 2:
The masking device geometry is changed from a sharp-edged configuration to a rounded lip portion. This parameter change in the masking device shape directly translates to a changed coating profile parameter, creating a gradual thickness transition that eliminates discontinuities and removes the need for subsequent post-processing to achieve a uniform coating surface.
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
The method ensures a smooth transition in coating thickness, facilitating automated spray coating and reducing post-moulding processing, resulting in a uniform coating without sharp edges or steps.
Implementation Method 1
the masking device is configured so that, upon terminating spraying of the coating at the first longitudinal boundary of the coating zone, the lip portion of the masking device is separated from the coating applied on the first longitudinal boundary of the coating zone by a gap
Data Source
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AI summary
A method of masking a mould (40) for moulding a wind turbine blade shell part (24, 26), the method comprising the steps of: arranging a masking device (50) in a mould (40) so that the masking device (50) covers the non-coating zone (46) of the mould surface (41), spraying a coating (70) onto a mould surface of the mould so that the coating is applied to a coating zone (44) of the mould surface (41) and prevented from being applied to a non-coating zone (46) of the mould surface (41) by the arrangement of the masking device (50), and removing the masking device (50) from the mould so that the non-coating zone (46) is exposed. The masking device (50) is configured so that, upon terminating spraying of the coating (70) at the first longitudinal boundary (45) of the coating zone (44), a lip portion (52) of the masking device (50) is separated from the coating (70) applied on the coating zone (44) by a gap (G).