Wind Turbine Blade Protector Application With Robotic Curing
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Solution Overview
Problem
Existing methods for applying a leading-edge protector to wind turbine blades are time-consuming, prone to voids, and require manual application of adhesives, making it difficult to use fast-curing adhesives and maintain the protector's position during curing.
Innovation Solution
A robotic applicator device with multiple stations, including a dispensing, adhesive, applicator, curing, and optional cleaning and sensing stations, to automate the application of a leading-edge protector, ensuring precise placement and curing of the protector on the blade.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual application method is used, then flexibility and simplicity are maintained, but application time increases and voids are introduced
Solution Approach 1:
The patent replaces manual mechanical application with an automated robotic system that uses dispensing mechanisms, adhesive application robots, and automated positioning systems to apply the leading-edge protector, thereby increasing application speed while maintaining quality
Solution Approach 2:
The system incorporates self-positioning capabilities where the protector material automatically aligns with the blade leading edge through guidance mechanisms, and the adhesive cures in place without continuous manual adjustment, reducing void formation while maintaining simplicity
2Productivity
If fast-curing adhesive is used, then productivity increases, but manual application cannot keep up with curing speed
Solution Approach 1:
The patent employs automated robotic dispensing systems that can apply adhesive and position the protector material at speeds matching fast-curing adhesives, eliminating the limitation of manual application speed and enabling the use of high-performance fast-curing adhesive formulations
Solution Approach 2:
The system maintains continuous application and positioning action throughout the adhesive curing process, with automated systems operating without interruption to ensure complete coverage and bonding before the adhesive sets, maximizing productivity with fast-curing materials
3Device complexity
If manual positioning is used, then equipment complexity is minimized, but maintaining protector position during curing becomes difficult
Solution Approach 1:
The patent replaces manual positioning with automated robotic positioning systems that use sensors, feedback control, and precise motion control to maintain the protector's position during curing, significantly improving reliability without excessive complexity
Solution Approach 2:
The system incorporates feedback mechanisms where sensors monitor the position of the leading-edge protector during application and curing, and automated systems adjust positioning in real-time to maintain proper alignment and prevent displacement, ensuring reliable bonding
4Device complexity
If manual adhesive application is used, then device complexity is reduced, but voids and air bubbles are introduced
Solution Approach 1:
The patent replaces manual adhesive application with automated dispensing systems that use controlled delivery mechanisms, such as pumps and nozzles, to apply adhesive uniformly without trapping air bubbles, improving manufacturing precision while managing device complexity through standardized components
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 robotic applicator device enables quick, efficient, and void-free application of the leading-edge protector, enhancing aerodynamic performance and reducing maintenance time and equipment requirements.
Implementation Method 1
a curing station configured to cure the adhesive so as to bond the leading-edge protector to the leading edge of the wind turbine blade
Data Source
AI summary
A robotic applicator device (40) for applying a protector (48) to a leading edge (30) of a wind turbine blade (20) includes a main frame (42), a drive (44) coupled to the main frame (42), and a plurality of stations (46) carried by the main frame (42) configured to apply the protector (48) to the leading edge (30) of the wind turbine blade (20). The stations (46) include a dispensing station (50) configured to hold and dispense a material (64) that forms the protector (48), an adhesive station (52) configured to apply adhesive (66) to an adherend surface (68) of the dispensed protector material (64) and/or the leading edge (30), an applicator station (54) configured to place the adherend surface (68) of the protector (48) onto the leading edge (30) of the wind turbine blade (20), and a curing station (56) configured to cure the adhesive (66) so as to bond the protector (48) to the leading edge (30). A method for applying the protector (48) to the leading edge (30) of the wind turbine blade (20) is also disclosed.