Flexible Extrusion Spatula for Wind Turbine Blade Coating
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Solution Overview
Problem
Existing automated maintenance and repair systems for wind turbine blades are not designed for reliable use on blades connected to the rotor and hub, are slow in operation, and often result in uneven or misshapen coatings, which can adversely affect aerodynamic performance.
Innovation Solution
An applicator tool with a flexible extrusion plate and spacers is used to apply a uniform coating to damaged areas of wind turbine blades, ensuring even distribution and minimizing disruptions to airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated maintenance devices are used to apply coating to wind turbine blades, then productivity is improved, but manufacturing precision deteriorates resulting in uneven or misshapen coatings
Solution Approach 1:
The patent employs a flexible coating applicator that conforms to the curved surface of the wind turbine blade. The flexible shell or film-like applicator head allows for precise coating application by adapting to the blade's aerodynamic shape, ensuring uniform coating thickness while maintaining automated operation speed.
Solution Approach 2:
The coating applicator system incorporates dynamic adjustment capabilities that allow real-time modification of coating parameters during operation. This enables the system to maintain precise coating uniformity while operating at high speed by continuously adapting to variations in blade geometry and coating material flow characteristics.
2Manufacturing precision
If manual rope access methods are used for blade repair, then manufacturing precision can be maintained, but productivity deteriorates due to slow operation
Solution Approach 1:
The automated coating system incorporates self-adjusting mechanisms that maintain coating precision without requiring constant manual intervention. The system automatically compensates for position variations and material flow changes, combining automated speed with precision quality while reducing the need for manual rope access operations.
3Object-affected harmful factors
If coating is applied to restore blade leading edge, then aerodynamic performance is improved, but device complexity increases due to specialized applicator requirements
Solution Approach 1:
The coating applicator system is designed with multi-functional capabilities that allow it to perform various maintenance tasks on different blade surfaces and geometries. This universal design reduces overall system complexity by consolidating multiple specialized tools into a single versatile platform that can address various aerodynamic restoration needs.
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 applicator tool enables precise and high-quality repairs with minimal impact on aerodynamic performance, allowing for efficient maintenance and repair of wind turbine blades without the need to remove them from the turbine.
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 applicator tool further includes a feed tube for supplying the coating material to the spatula
Data Source
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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).