Leading-Edge Coating Applicator for Uniform Wind Blade Repair
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Solution Overview
Problem
Current maintenance and repair methods for wind turbine blades, especially for damage along the leading edge, are time-consuming, costly, and often result in uneven or misshapen coatings when automated, affecting aerodynamic performance and requiring further maintenance.
Innovation Solution
An applicator tool with a flexible extrusion plate and spacers that shape and dispense coating material along the blade's leading edge, allowing for precise and uniform coating application, either manually or with robotic assistance, to restore the blade's aerodynamic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual coating application is used to repair blade damage, then the coating can be applied to restore the blade, but the coating becomes uneven or misshapen affecting aerodynamic performance
Solution Approach 1:
A flexible coating applicator tool with a shaped extrusion plate is introduced as an intermediary between the coating material and the blade surface. The extrusion plate defines a controlled gap that shapes the coating material as it exits, ensuring uniform application without manual shaping while maintaining ease of application.
Solution Approach 2:
The gap height between the extrusion plate and blade surface is controlled as a critical parameter. By adjusting and maintaining a consistent gap distance, the coating thickness and uniformity are precisely controlled, transforming the unpredictable manual application into a parameter-controlled process.
2Ease of manufacture
If blade disassembly and ground-based repair is performed, then comprehensive repair can be conducted, but significant time and cost are required for disassembly and reassembly
Solution Approach 1:
The repair function is extracted from the ground-based workshop environment and transferred to an in-situ applicator tool that can be applied directly to the blade while mounted on the turbine. This eliminates the need to disassemble and transport the blade, removing the time-consuming logistics while maintaining repair capability.
Solution Approach 2:
The applicator tool is designed to be self-contained with the coating material, allowing the blade to be repaired in place without requiring external workshop facilities or complex disassembly procedures. The tool serves the repair function directly at the location of need.
3Productivity
If automated coating application is implemented, then repair speed increases, but the coating becomes uneven or misshapen requiring further maintenance
Solution Approach 1:
The extrusion plate is made of flexible material that can conform to the curved blade surface while maintaining a consistent gap height. This flexibility allows automated application on complex geometries while the rigid gap structure ensures uniform coating thickness, combining speed with precision.
Solution Approach 2:
The extrusion plate is pre-shaped with the desired coating profile and gap dimensions before application. This preliminary preparation of the coating geometry ensures that when material is extruded, it automatically takes the correct shape without requiring post-application shaping or correction.
4Ease of operation
If rope access methods are used for blade repair, then the blade can be accessed while mounted, but significant skill and time are required for proper coating application
Solution Approach 1:
The shaped extrusion plate acts as an intermediary that encapsulates the complexity of coating application. Instead of requiring the operator to manually shape and control the coating, the pre-formed extrusion plate does this automatically, reducing skill requirements while maintaining accessibility.
Solution Approach 2:
The applicator tool is self-shaping and self-controlling during application. The flexible extrusion plate automatically conforms to the blade surface and maintains consistent coating parameters, making the repair process less dependent on operator skill while preserving the ability to work on mounted blades.
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 tool enables efficient and precise repair of wind turbine blades by applying a uniform coating that minimizes aerodynamic disruptions, reducing downtime and maintenance needs while maintaining blade efficiency.
Implementation Method 1
The one or more spacers are configured to define a gap between an outer surface of the wind turbine blade and the inner surface of the extrusion plate for dispensing of a coating material
Implementation Method 2
The spatula is configured to shape the coating material into a coating over a damaged area of the wind turbine blade
Data Source
AI summary
An applicator tool (40) for repairing damage (26) to a wind turbine blade (20) includes a spatula (42) including a flexible extrusion plate (44) and one or more spacers (60, 106) positioned proximate an inner surface (58) of the extrusion plate (44). The one or more spacers (60, 106) are configured to define a gap between an outer surface (34) of the wind turbine blade (20) and the inner surface (58) of the extrusion plate (44). A feed tube (86) is provided for supplying a coating material to the spatula (42), wherein the spatula (42) is configured to shape the coating material into a coating (30) over a damaged area (26) of the wind turbine blade (20).