• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Wind turbine blade, with retrofitted coating in and around areas where the blade is particularly susceptible to erosion damage, which is established by the coating comprising an adhesive layer, a fiber reinforced polymer layer and one or more non-reinforced polymer layers over the fiber-reinforced layer as the polymer layers extend beyond the fiber-reinforced layer and includes areas of the wind turbine blade surface which are less susceptible to erosion damage. A method for forming such a wind turbine blade, and forming such a coating as well as the coating itself, is also established with the invention.
    公开号:DK201570881A1
    申请号:DKP201570881
    申请日:2015-12-28
    公开日:2017-01-30
    发明作者:Kim Tangager
    申请人:Blade Repair Solutions Ivs；
    IPC主号:
    专利说明:

    Method for establishing erosion-resistant surface portion of a wind turbine blade, method of forming an erosion-resistant coating, wind turbine blade with retrofitted coating in and around areas where the blade is particularly exposed to erosion damage, coating for mounting on the front of a wind turbine blade.
    It has been found that some of the many wind turbines that have been erected over time do not always have blades whose surfaces can withstand the erosion they are exposed to during operation. In particular, the newer long wind turbine blades have been found to cause problems, because here the relative velocity between the air and the blade surface is quite high, and the accelerated test methods used so far do not always produce true results for this type of blade. Therefore, there is an increasing need for a coating that can be retrofitted to older wind turbine blades, especially those with incipient or advanced surface damage caused by particles in the atmosphere.
    It is known that one can establish a new coating on a wind turbine blade, by hoisting a basket of manpower up to the wing, and then directly apply or spray various hardening polymer coatings, possibly. extensive fiber reinforcement. This process is both dangerous and cumbersome, and it also demands the weather, which for many wind turbines is only met for a few days a year.
    It is also known to dismantle wind turbine blades and then establish in a suitable factory hall a new and more erosion resistant surface using conventional techniques known from fiberglass technology. However, it is labor intensive, and the craftsmanship processes can easily lead to the introduction of faults, which only become apparent after the blade has been put into operation after finishing work. In any case, a tormai mea optinaeisen is to provide a three-step measure for establishing an erosion-resistant surface part of a wind turbine blade which does not have the disadvantages mentioned.
    This is achieved by a method as claimed in claim 1. The specificity of the method is that the coating is made by casting on a model of the wind turbine blade surface (a so-called plug) that the plug is positioned so that it corresponds to the leading edge of the blade, that the coating is deformed from the plug and reworked and that the coating is glued to the actual wind turbine blade, aligning the leading edge of the coating with the leading edge of the wind turbine blade. In this way, you can ensure that all casting parameters are fully controlled during the manufacturing process. Quality control of the pre-cast coating can also be established, and should any errors occur during the process, it is easy to cast a new coating. This is by no means possible when, as is known, work is directly done with casting on a wind turbine blade, because here it is partly difficult to quality test the newly established surface, and should faults be found, it is a very cumbersome process to remove the faulty coating. When preparing a plug initially, it must either be manufactured, and if it is already manufactured, it must be cleaned of any residue from any previous casting and set up properly.
    It is known that the old wind turbine blade must be thoroughly cleaned before new surface parts are glued to it, but it has now surprisingly been found that sand blasting with CO2 in solid particle form as claimed in claim 2 ensures that all foreign bodies and loose elements are removed from the surface. .
    In this type of new coatings, it is especially important that the transition between areas with and areas without coating occurs gradually, so that no edges or bumps can break, which can break the air flow around the wing profile. Here it is especially advantageous to work with casting on a plug,
    Torai aet τχ gives mungnea rudder anDerjeaning that a boost is increased inside. This is used to rework the edge area by grinding on the inner side, ie the side facing the wind turbine blade surface. This means that the side facing away from the wind turbine blade surface remains unworked, and the advantage here is that the freely cast surface, which is quite smooth due to the flow properties of the polymer, is not affected or altered during machining.
    In the method according to the invention, as stated in claims 4 and 5, either the entire coating can be applied to the surface of a wind turbine blade in a workflow, or one can work with predetermined lengths of the coating, which are mounted individually one after the other on the blade surface. If a turbine blade is removed and you harden in a controlled environment, for example in a factory hall, you can fairly easily work on gluing all the newly formed coating in one and the same workflow, but you work in a basket which is, for example, raised to the wing of a nacelle, it is considerably easier to work with predetermined lengths of the coating, for example lengths of 1 to 5 meters in length, but preferably 2 to 4 meters in length. These sub-coatings are then glued in place one by one in the same order as they were in the casting, so that the joints can be made absolutely precise without cracks or double coating. Particular overlap may be established in that the ends of the predetermined lengths have a step at each end, the step at one end being from the surface facing away from the wind turbine blade, while at the opposite end from the surface facing the wind turbine blade. Such two steps can be laid over each other without a bump in place, and this will also result in improved durability, especially since there will be no gaps between successive lengths which could be particularly sensitive to erosion.
    In the casting process, a counterstain strengthening of the coating can be conveniently established, especially in the face of the mill blade, which is most susceptible to erosion. It is done in practice, as claimed in claim 6, by laying on the plug along the leading edge a continuous fiber mat extending from the leading edge and a suitable piece down each side. The mixed polymer (in the case of two-component polymer) is then poured into the fiber mat along the leading edge, dosing so abundantly that the fiber mat is soaked and the polymer also runs out of the fiber mat at each side and down the side of the plug. In this process, a coherent layer of polymer must be formed adjacent to the fiber mat at each side, and this coherent layer must extend a suitable distance down the side of the plug. When the liquid polymer is dosed, the area along the end edge area of the fiber mat must be glossed at each side with a tool such as a trowel so that a smooth transition can occur without droplets that can otherwise be formed here. The appropriate width of the fiber mat relative to the leading edge may depend on how wide the leading edge is and where erosion is loaded at a location on the wind turbine blade being worked, but a distance from the edge of the mat to the front line of between 5 and 10 cm will be appropriate in most cases. The continuous fiber-free polymer film formed beyond the width of the fiber reinforcement shall have a maximum length from the leading edge measured along the side of the profile of 10 to 25 cm. The process of pouring self-curing polymer onto the top of the plug is repeated until an appropriate layer thickness is achieved, and typically a layer thickness of about 1300 µm is reached after about 4 layers.
    Claim 7 discloses the process steps by which a step-down of the ends of predetermined lengths of the coating can be established. This is done by merging the fiber mat on the plug to put transverse plastic film across the plug. The plastic foil must be shaped like uniform strips that do not adhere to the polymer used in the casting and the foil must also be of very low thickness. In the subsequent casting, the AiMiTiMnies are established an aasKinoar joint with the thioag layer and a layer of fibers without fibers. This is then utilized in cutting to the predetermined pieces by cutting through both sides of the plastic strip, so that along one edge only the fiber-reinforced portion of the coating and the polymer layers over there are left undamaged while cutting along the opposite edge from the opposite side and only through the molded polymer layers without damaging the fiber-reinforced layer. The process provides a step-up at each end, and by gluing the coating to the final space on the wind turbine blade, the step-up can be used to overlap from one predetermined length to the next. Then, the overlap zone has the same thickness as the rest of the coating, and no cracks will exist between the coating parts which could be sensitive to erosion effects.
    As instructed in claim 8, the sizing on the wind turbine blade must be done from the tip end up to the root end with a predetermined coating piece being applied so that it has a step-up only with fiber-reinforced part facing the root end. This fiber-reinforced coating then receives a polymer coating upon application of the next coating piece to the blade, as it is mounted such that its polymer edge step overlaps the fiber-reinforced step of the previous piece.
    As explained in claim 9, the bonding is effected by application of adhesive on both the surface facing the wind turbine blade and on the wind turbine blade itself, and then the two parts are assembled, although it must be ensured that no air pockets are formed at the joint. It may also be necessary to re-adjust the position of parts of the coating immediately after gluing to get the correct placement, but by choosing a glue type without too much chopping, this can easily be done.
    The tip itself is a chapter in its own right, because here it is desired that the fiber reinforcement is needed in the new way around the tip, which requires that other sarnies be sewn a fiber bag that fits the tip and which can subsequently be mounted on the tip of the wind turbine blade corresponding tip. After casting, this bag can then be mounted with glue on the tip of the wind turbine blade. This creates a strong and very secure protection of the tip.
    Baskets 11 to 15 relate to the processes that must be carried out to create the product that is the coating. In the execution of these processes, a coating is obtained with superior properties in the form of resistance to erosion and in the form of adhesion to a wind turbine blade. In particular, the polymer layers which extend beyond the fiber-reinforced layers help to ensure the resistance to the tearing of the coating, which can come from the forces that arise from, for example, icing of a wind turbine blade in operation. At the same time, these coating layers help to provide a gradual transition between the parts of the wind turbine blade that have received coating and those parts where there is no coating.
    Claims 16 to 18 relate to the wind turbine blade itself and the particular properties it achieves when a coating comprising a fiber-reinforced polymer layer along the front line and polymer layers extending from here and down each side of the blade profile are mounted thereon.
    Claims 19 to 21 relate to the coating itself as such and the particular properties associated therewith.
    The invention will now be explained in more detail with reference to the drawings, in which:
    FIG. 1 shows a section in schematic form, through a coating,
    FIG. 2 schematically shows how a plug has a leading edge having a horizontal tangent and how distances can be measured from the leading edge and down the sides of the peg,
    FIG. 3 is a cross-sectional view of a plug with cast out layers,
    FIG. 4 shows the same section as FIG. 3, but with more details,
    FIG. 5 is a representation of the coating after shaping,
    FIG. 6 is a side view of a plug with a plastic strip mounted across the pie,
    FIG. 7 shows sections through coating segments cut apart by the plastic strip,
    FIG. 8 shows a section similar to that of FIG. 7, but before separating the two consecutive coating segments,
    FIG. 9 shows a sketch of a conventional wind turbine with 3 wind turbines, front and side,
    FIG. 10 is a sketch of a mill blade in 3D view indicating an coating 10 according to the invention,
    FIG. 11 is a sectional view of a wind turbine blade 25 and corresponding plug 6 of the type shown in FIG. 10 and with indication of the coating 10 and FIG. 12 is a side view of the mill blade shown in FIG. 10. In FIG. 1 is a schematic section through a layered coating 10. The coating 10 comprises a plurality of polymer layers 1,2, 3, 4 which are interconnected, one layer being molded on top of the next within the time frame prescribed by the manufacturer. to ensure an appropriate polymerization effect between the individual layers. For example, the polymer used may be a LEP 4601 produced and sold by 3M under the trade name 3M LEP 4601. This polymer is moisture curing and the polymerization time will then depend on local conditions such as temperature and humidity in the room where the layers are cast. The lower layer 1 differs from the other layers in that it comprises a fiber reinforcement. The fibers may be glass, metal, aramid or carbon fibers or mixtures thereof. Usually, the fiber reinforcement will be a commonly known woven and or felted product with one-, two- or three-axis weaving. The fiber reinforcement may thus comprise a woven layer as well as a nugget mat type layer. Moldy matte ormats relatively long paraneiDunates of fibers that are randomly interposed in a common plane. Such fiber reinforcements are commercially available under the designations as: UD650, BIAX600 and TRIAX900.
    The fiber-reinforced layer 1 is thus formed by applying the fiber reinforcement to a mold surface 5, and then pouring the polymer into the fiber reinforcement until it is saturated and the polymer runs out of the fiber layer and onto a surrounding mold surface. The fiber reinforced layer 1 is a classic fiber coating in which a polymer filler fills the spaces between elongated, ordered or unordered glass or other high modulus material and high breaking strength. The subsequent layers, 2, 3 and 4 are formed by the same method on top of layer 1, however, without adding additional fiber material, the same or a similar polymer being poured over the previous layer and here being allowed to cure partially before the next layer is applied. In order to obtain a uniform layer thickness, the surface on which the layers are formed must be sloped and must not include hollows or local valleys in which the polymer can collect and form puddles. Such a surface is formed, for example, of an elongated u-profile, corresponding to a wing profile with a leading line 21. On the leading line 21, the u-profile will have a horizontal tangent 20, but at all other points the tangent of the surface across the u-profile will be angled. relative to the horizontal, and approaching vertically the farther away from the vertex or leading line you set the tangent. FIG. 1 can thus be a section through a layered surface portion formed on an elongated u-profile, the section being laid in the longitudinal direction of the u-profile and through the apex.
    A U-profile is shown in FIG. 2 is seen from the end, and here the apex is marked with a "0", and with each arrow 11,12 the distance from the vertex and down to a predetermined location 13 on the outside of the profile measured along the profile surface is indicated. Several are shown the same distance on both sides, and this can vary between 100 mm and any distance given by xxx mm.
    According to the invention, an erosion-resistant surface portion is established on a wind turbine blade 25, initially forming a copy of the outer geometry of the wind turbine blade surface, a so-called plug 6. This can be formed from drawings of the wind turbine blade 25 or from the measurement made on the blade itself. receive the surface portion or by measuring a corresponding wing. The plug 6 can be 3D printed or manufactured from foamed plastic or similar light material from well known techniques for forming molds for large fiber reinforced blanks. In cases where it is a leading edge of the wind turbine blade that is to receive the coating, the plug 6 is set up so that the leading edge faces upwards, whereby the outer geometry of the plug will appear somewhat like the un-profile shown in FIG. 2. A section through a wind turbine blade and a section through a corresponding plug at the same location are shown in FIG. 11. The leading edge of the wind turbine blade 25 / plug 6, as it faces upwards, will have a horizontal tangent 20 at its apex, and from there, the outside of a corresponding plug will incline more and more, corresponding to a tangent approaching more and more a vertical position. . It is assumed that the apex will lie on the leading edge of the wing 21, although this is not an absolute truth. The front line may thus vary well, for example in relation to how the blade is angled during operation. However, if the blade / plug is set on an upright position, it can be set so that the most common leading edge line during operation will lie close to the geometric vertex, which is the position on the upwardly facing surface where a transverse tangent 20 is horizontal. If you continue downwards along the sides of the wind turbine blade, you will reach a point where the slope of the tangent relative to the horizontal becomes over 90 degrees, and here the profile begins to narrow towards a common trailing edge 29, where the two sides meet again. Thus, the surface of the plug 6 creates a mold for the casting of the surface coating which is geometrically and size-equal to a suitable part of the front edge and associated sides of a mill blade.
    It is desired that the coating 10 which is molded with the plug 6 as a mold can again be deformed therefrom and therefore the plug is initially coated with a deforming agent (not shown in the figures). It may be a conventional abrasive or a surface treatment such as a form of nanno coating or it may be a so-called "booth coat" known from lacquer boxes. This coat forms a cohesive film which, however, has little adhesion to a substrate, so that paint or varnish which lands on it can be easily peeled off together with the booth coat when, for example, such a thick layer is formed that it is dangerous or bothersome . In this case, the booth coating is useful as an abrasive as it does not adhere to the surface of the plug, but forms a coherently mechanically stable film which can be cast on top. When the molded blank is deformed, there may be residues of booth-coat film on it, but since in this case the blank must still be subjected to sandpaper machining to ensure adherence to the later bonding to the wind turbine blade surface, it has no significant significance. On the booth coated plug 6, an erosion resistant coating 10 is now cast across the leading edge 21 thereof and down the sides to a predetermined distance from the leading line 21, and the coating 10 is deformed from the plug 6 upon curing.
    Thereafter, the coating 10 can be glued to the surface part of a wind turbine blade, ensuring that it gets the same position on the actual wind turbine blade 25 as it had on the plug 6. In particular, it is important that the molded coating 10, when mounted, receives the same leading line 21 on The wind turbine blade 25, which it had when it was cast on the plug 6. By following this method in establishing an erosion-resistant coating 10 on a wind turbine blade 25, it can be ensured that the coating is voltage-free when mounted and will then have maximum strength. By casting the coating on a plug b, heavy, special properties are obtained, allowing other parameters such as temperature, humidity, and curing times to be kept within narrow limits, which is especially important in casting, which includes several successive curing polymer layers which must bond properly to each other. Before mounting on a wind turbine blade 25, the surface 8 facing the wind turbine blade 10 must be treated in the form of sandpaper machining so that this surface appears rough and thus has better adhesion to the sizing. When replacing an older wind turbine blade with a new erosion-resistant coating 10, it is necessary first to clean the surface of foreign bodies or loose elements in the most commonly eroded surface of the wind turbine blade, especially in areas where the surface is substantially perpendicular to the airflow. When the relative velocity between the wind turbine blade and the air exceeds 150 km / h, the surface of the wind turbine blade is subjected to significant erosion from items such as soil dust, insects, salt crystals, rainwater, snow and hail particles. The cleaning can be done mechanically by blowing with solid particles of plastic, sand or CO 2, as is known in the surface treatment. As a rule, blowing with dry ice, or solid CO 2 particles, is preferred, as this technique ensures that deposits on the wind turbine blade surface not only slide further into the surface, but burst away from the surface. When a coating 10 is cast on a surface of a plug 6, as described herein, the molding mass will run down the sides and eventually form droplets 7 on the surface 5. However, the pre-cast coating is cut at a suitable distance 13 from these drops by cutting the coating at a predetermined distance from the leading edge 21 as indicated in FIG. 4. At the intersection, a thickness of material is formed which, if not machined, may cause errors in the air flow around the wind turbine blade 25 after mounting of the coating 10 thereon. Therefore, grind
    The edge on the inside, face the side o facing the wind turbine blade with, for example, sandpaper 23, or machined with suitable hand tools as indicated in Figs. 5. A sliding transition is obtained from the new coating 10 on the wind turbine blade 25 and the original surface, where no coating is present. At the same time it should be emphasized that grinding from the inside causes the surface of the new coating to have the same structure on its entire surface facing away from the wind turbine blade 9, which is formed by the free-flowing casting mass on the outside of the plug. Further, sanding with sandpaper 23 on the inside will improve adhesion between the surface of the wind turbine blade and the coating so that improved adhesion is achieved by gluing.
    There are several ways in which a bonding of the new coating 10 to the wind turbine blade surface can be performed. It can happen while the wing 25 is stuck in the nacelle 24 and faces down along the mill tower 26, or it can happen on a detached wing while lying down with the leading edge facing up. If work is done on the wind turbine blade 25 while it is in the nacelle 24, it can be foreseen that very long pieces of new coating will be difficult to handle properly and get the glue in place. Therefore, in this case there will be cut pieces that are mounted individually in succession. These pieces we typically have a length along the front line of between 2 m and 4 m. Work is done from the wing tip, ie the tip end 18 and up along the wing towards the root end 19, since the individual pieces can be formed so that a smaller overlap can be established, without that this causes uneven surfaces on the wing surface. If work is done on a dismantled mill blade, the coating can be applied in a total workflow. Whether working on a downed blade or on a wing sitting in the nacelle 24 of the mill, both the surface of the wind turbine blade and the coating against the facing surface of the wind turbine blade must initially be applied to glue after which the two glue-coated surfaces are assembled. This must be done in a manner that generates the fewest possible air confinements, and at most no airflow problems. It is undetectable that the drying edge of the blade and the corresponding leading edge of the coating are initially assembled, and that pressure contact between the wind turbine blade and the surface facing the wind turbine blade is then established contact-wise.
    While casting the coating 10 on a plug 6, there are various important instructions that must be followed if the result is to be approved: the fiber reinforcement must be coherent over the leading line 21, - the polymer must be dosed along the leading line 21, with the first casting being done soaking the fiber reinforcement and the polymer must flow out of the fiber reinforcement and down the sides of the plug in an even layer, - by the following casting, cast on top of the fiber coating, but following the same procedure, pouring the polymer on top, and then allowing it to flow freely from here and down the sides, - the transition between the part of the plug where the fiber reinforcement lies and the part where there is only polymer must be glossed before the polymer is cured, - await a suitable degree of polymerization and the next layer is cast in the same way.
    It should be noted that gliding is a necessary operation, as the surface tension of the polymer will otherwise cause droplets or a bead to form at this transition. By molding the lower polymer layer with the fiber reinforcement individually and awaiting partial curing of this layer before casting the next layer without reinforcement, it is also ensured that the fiber reinforcement remains located in the layer closest to the wind turbine blade surface. This cannot easily be achieved if, for example, a molding mold is molded into an arousal passage with injection, the polymer in a fiber reinforced mold cavity. Here, the reinforcement would be able to swim up and settle in a more or less random place in the injected polymer, and subsequently, upon curing, be trapped here. However, it is important for the erosion resistance of the coating that the fiber reinforcement is located at a predetermined location in the coating, which is easy to achieve by the prescribed method.
    The surface tension and flow properties and viscosity of the polymer may vary slightly depending on batch, temperature and other parameters, so the final thickness of a cast layer is not necessarily the same from time to time. Usually, 3 casts need to be made on top of the fibrous layer before a suitable thickness is established, but more or less casts may occur. Furthermore, there may be little difference in the thickness which is desired to be established, which can then be regulated by casting more or fewer layers on top of each other. If smaller lengths of coating 10 are to be cast, as will be the case when measuring lengths to be set up to be installed on a wind turbine blade 25 while in the nacelle 24, this may conveniently be accomplished in a total operation of a plug 6 comprising the portion of the wing 25 to be coated. Here, the fiber reinforcement is initially applied to the plug 6, as previously described, and then the fiber coating is covered with transverse strips of plastic foil 15 at a suitable width for each metered length. The plastic foil 15 should have a width in the longitudinal direction of the plug of 2 to 10 cm, preferably 4 cm. It must extend across the leading edge 21 and down both sides and must not bind to the polymer. After coating with the plastic foil 15 for each measured length, the casting is continued as previously described. At the first cast, the polymer runs under the foil and soaks the fiber reinforcement, where the following casts will be deposited on top of the round coating. When the individual measured lengths are to be separated, this is done by cutting the coating 10 along the edges of the plastic foil, thereby cutting from above the polymeric layers of the film two edges 16 facing the tip end 18 of the plug without damaging the fiber reinforcement, while at the of the two edges 17 of the film facing the root end 19 are cut from below or from the surface 8 facing the wing, cutting only the fiber-reinforced polymer layer 1 and leaving the polymer layers 2,3,4 without fiber reinforcement undamaged. This is illustrated in Figs. 8th
    Thereafter, two consecutive lengths of coating can be separated as shown in the sectional drawing of FIG. 7, the transverse plastic film 15 itself is not strongly bonded to the polymer and therefore can be easily removed.
    FIG. 8 shows the section lines along the edges 16,17 of the foil 15 before the two cuts have been made and the two coating sections have been separated as shown in FIG. 7th
    From the tip end 18 and up to the root end 19, a metered length of the coating 10 will then be terminated with a clean fiber-reinforced polymer layer 1, the overlying fiber-free polymer layers sitting on a subsequent metered length of the coating 10. The two lengths can then be set up. one after the other with polymeric layer 2,3,4 overlapping a fiber-reinforced layer 1. This makes it possible to obtain an overlap between two consecutive lengths of coatings, without causing unevennesses which must subsequently be processed. This is a great advantage, but of course requires keeping track of the individual measured lengths so that they are mounted on the wing in the same order as they were cast on the plug, so that the joints between them can be optimal, although the cutting can vary slightly from length to length.
    When the glue is pulled through the pieces of the vinyl wrap, both the wind turbine blade 25 and the coating 10 against the wind turbine blade surface 8 are applied, and then the two surfaces are brought together. Here, it is important to choose a glue that does not have too strong a chop, as it becomes impossible to adjust the position of the coating after first contact between the glue-applied surfaces.
    At tip end 18, the conditions are a little special, because here the coating has to extend all the way around the blade, so it is especially important that some sliding between the coating and the wing surface is possible during assembly. When an erosion-resistant coating, as described above, is to be made, the fiber reinforcement to be used must be considered and the final thickness must also be determined. Here it has been found that bi-ax or tri-ax weavings possibly. in combination with mats of the '' chopped mats '' thief works best. It is believed that the cellular structure of the weaves with the fibers concentrated along the edges of box-shaped structures helps to ensure, for example, the kinetic energy of raindrops in the impact towards the surface is evenly distributed over a larger area, so that the original fiber structure of the wind turbine blade is not exposed to the same degree. for point-shaped loads. At the same time, when the total layer thickness reaches between 1200 µm and 1400 µm, the polymer layer will protect against surface erosion because the polymer has high toughness and impact strength. Typically, the individual layers must then have a thickness between 100pm and 400pm, preferably 200pm
    It should be noted that the two-component self-curing properties of the selected polymer produce an exothermic process by which the excess heat must be able to be dissipated. It puts a damper on how thick a layer can be cast in each casting process. If the layer thickness becomes too large, the heat cannot escape quickly enough, and zones where the curing has gone too fast may occur, with the weakening of the final eyewall.
    In addition to the thickness of the coating, the width of the fiber reinforcement must be determined and it must be determined how far beyond the fiber reinforcement the non-reinforced layers should extend. These dimensions may vary over the length of the blade as the blade profile also changes in character. It will usually be appropriate with a total length from the leading edge to the outer edge 13 of the fiber-free layers, which is between 10 and 15 cm. However, if the wing is wider, a longer distance to the outer rim may come into play.
    As seen in FIG. 12, when viewed from either the leading edge or the trailing edge, the wing profile will curb a portion and not follow a straight line 30 which, for the sake of illustration, is shown in FIG. 12 and in FIG. 10. This is another reason why the casting must be done on a plug 6 which follows this curvature. This review is based on a preparation based on manual execution of the various steps in the preparation of the coating, but the coating can also be manufactured by machine. Here, a plug with the face facing the leading edge of the blade profile is brought upwards to be moved relative to one or more workstations, where at each workstation part of the manufacturing process is carried out. For example, the following workstations are provided: a cleaning station, a booth coat spraying station, a fiber mats station, a number of polymer application stations. For each operation, the plug and one workstation are moved relative to each other so that the workstation can process the entire plug length, however timed so that cure or drying times are taken into account for the substances involved in the process. Glittering operations are not included here, as they can possibly be completely avoided by, for example, very precise dosing of polymer in the transverse direction of the profile. Some workstations can be equipped with robotic equipment, one or two, two or three rotary arms, and other very low-noise systems, so that such a workstation can be easily reconfigured to perform many different work processes, optionally only one workstation which is then reconfigured between each work assignment. For example, the workstation may be arranged as a bridge passing over the plug, and on each side thereof is supported by its own rail vehicle, which can propel the bridge on rails lying on each side of the peg throughout its length. Alternatively, the plug is mounted on rails so that it is longitudinally movable past one or more stationary work stations set up along the rails. One of the advantages of mechanical formation of the coating can be that the working area can be completely free of humans, so that no person is exposed to possible toxic effects of the substances involved in the work processes. When a pre-cast coating first sits on a wind turbine blade 25 in a wind turbine 27, there will first be an adhesive layer, then a fiber reinforced polymer layer 1, then one or more non-reinforced polymer layers 2,3,4, however, the polymer layers 2,3,4 stretch pass past the fiber reinforced layer 1 and sit glued to areas of the wind turbine blade 25 which are less susceptible to erosion. It is especially important that the fiber-reinforced polymer layer 1 sits precisely where the erosion load is greatest, so that the optimum protective effect of the coating is achieved 10. On the leading edge of the blade 25, the fiber reinforcement will then lie where the wind strikes perpendicular to the surface when the wind turbine blade 25 is in operation, and this line thus forms the center axis 28 of the coating 10. From the center axis 28, the coating extends out and down the sides of the blade profile. A little down the profile, to each side, the coating then transitions to a reinforcement-free polymer coating 2,3,4.
    The last part of the reinforcement-free polymer layers on the blade will then further have a gradually decreasing thickness, due to the post-machining by twisting, at least one end to increase the weight. uneven detail ensures that no significant unevenness occurs on the surface when the coating 10 is mounted, thus avoiding possible disruptions of the flow of air around the wing. It also becomes possible to set up the coating without any finishing work, which is especially important when installing on a blade which has not been taken down, because it ensures that the set-up can be done with the least possible disruption to the operation of the wind turbine, as the set-up takes place at the least possible time consumption per meters of wing profile.
    Reference number: 1 Fiber-reinforced polymer layer 2 Second polymer layer 3 Third polymer layer 4 Fourth polymer layer 5 Molding surface 6 Plug 7 Drops 8 Facing the wing 9 Away from the wing facing surface 10 Coating 11 Arrow 12 Arrow 13 Predefined position on the outside / polymer layer edge 14 Finishing edge area 15 Transverse plastic foil 16 Facing tip edge Foil edge 17 Toward root end Foil edge 18 Tip end 19 Root end 20 Tangent 21 Front line 22 Excess piece 23 Sandpaper 24 Nacelle 25 Wind turbine blade 26 Mill tower 27 Wind turbine 28 Center axis 29 Rear edge 30 Straight line
    权利要求:
    Claims (21)
    [1]
    A method of establishing erosion-resistant surface part on a wind turbine blade (25) characterized by a. A copy, hereinafter referred to as plug (6), of the outer geometry of the wind turbine surface portion, is prepared, b. The plug (6) is thus oriented in the space at the leading edge. facing upward whereby a tangent (20) to the leading edge forms a horizontal line and touch points between horizontal tangents (20) and the plug (6) are called the leading edge (21), c. the plug (6) is coated with abrasive and / or other surface treatment which allows casting on and subsequently deforming from the surface of the plug, d. On the plug (6), an erosion resistant coating (10) is cast across the leading edge (21) and a predetermined length from the leading edge (21) and down the two sides of the plug (6), e. the coating (10) is deformed from the plug (6), and f. the coating (10) is subsequently glued to the surface portion of a wind turbine blade, the front line (21) of the erosion-resistant coating being aligned with The wind turbine blade's corresponding leading line.
    [2]
    Process according to claim 1, characterized in that the surface part of the wind turbine blade is cleaned by blowing with particles of CO2 in solid form also known as dry ice prior to mounting the coating (10).
    [3]
    A method according to claim 2, characterized in that the covering (iu) mounted from the peg (b) is energized by cutting off an excess piece (22) on both sides at a predetermined distance (11, 12) from the leading edge (21) and the rim (13) formed at the cut is thinned down from its inside by grinding.
    [4]
    Method according to one or more of the preceding claims, characterized in that predetermined lengths of coating (10) are manufactured and mounted individually in extension from the wing tip (18) and upwards on a wind turbine blade (25) while being vertically suspended from one another. a nacelle (24).
    [5]
    Method according to one or more of claims 1-3, characterized in that a total coating for a wind turbine blade (25) is manufactured and mounted coherently on the wind turbine blade (25) while it is removed and lowered.
    [6]
    Method according to claim 1, characterized in that a continuous fiberglass mat extending from the leading edge (21) and a predetermined length down the side of the lug (6) is mounted after the abrasive treatment, and then at least one layer ( 1,2,3,4) comprising a curing polymer directly on the peg (6) as follows: a) along the leading edge of the plug (21), a polymer is dosed down into / onto the fiberglass mat so abundantly that the polymer runs out of the fiberglass and down the side of the b) the transition between fiberglass-coated and non-fiber-coated plug is smoothed; c) the polymerization time is awaited, steps a, b and c are performed an appropriate number of times to obtain a predetermined overall layer thickness.
    [7]
    Method according to claims 4 and 6, characterized in that, for each predetermined piece along the peg (6), the glass fiber mat is applied to a transverse piastrone (ii) with a thirsty rana (ii) the venaenae moa root end (19) and another edge (16). ) facing the tip end (18) and a fixed predetermined extension in the longitudinal direction of the plug as the foil (15) extends from the leading edge (21) down along each side of the plug (6), after which the polymer is dosed and a predetermined portion of the coating is cut off from a previous section along the transverse plastic film (15) after curing all layers, however, so that along the one edge (17) of the film only the fiber-reinforced layer (1) is cut through and along the other edge (16) of the film only the polymer layers ( 2,3,4) above the fiberglass reinforced layer (1) so that the two pieces of the coating can be separated by slip between the transverse plastic film (15) and polymer, thereby terminating one end of the piece with a fiber edge. the polymer overflow (2,3,4) and the other end is terminated with polymer edge without a fiber reinforced layer (1).
    [8]
    Method according to claim 7, characterized in that the finished casting parts are applied to the surface of the mill blade from the tip of the blade (18) with a non-polymeric fiber edge facing the root end (19) of the blade, so that the next piece is applied with its polymer edge without a fiber support. overlapping the fiber edge of the previous piece.
    [9]
    Method according to one or more of the preceding claims, characterized in that the coating (10) is glued on the surface of the wind turbine blade, with both the surface of the turbine blade and the surface facing the wind turbine blade being applied glue prior to joining the coating to the surface of the wind turbine blade.
    [10]
    Method according to one or more of the preceding claims, characterized in that a special coating unit is made for the tip (ib), wherein the tip mat extends roundly around the tip.
    [11]
    A method of forming an erosion resistant coating (10) characterized in that the following steps are performed to form the coating (10): a) preparing a size (1) model (6) of a surface called a plug (6) and b) is coated with an abrasive or similar surface treatment which permits molding of molded articles and c) thereon is applied a fiber mat comprising woven fiber in either bi-axle or tri-ax weave and / or layers of chopped so that the end edges of the fiber mat lying on downward sloping surfaces of the plug (6) on either side of the front line (21) of the plug (6), d) repeating the molding of self-curing liquid plume layers in and on the fiber mat, the polymer layers (2,3,4) extending beyond the edges of the mat to achieve a total layer thickness with the fiber mat of between 1200 µm and 1400 µm at the leading edge (21).
    [12]
    Method according to claim 11, characterized in that the surface part is deformed and the polymer layer (s) (2,3,4) is cut at a predetermined distance (11, 12) from the leading edge (21) and thus from the edge of the fiber reinforcement.
    [13]
    Process according to claim 11, characterized in that a multi-component liquid polymer, of type 4601 as made of 3M, is used for the casting.
    [14]
    Process according to claim 11, characterized in that the individual polymer layers (2,3,4) are cast over the fiber reinforcement (1) with the polymer step Tiyaenae on the peg (b), in that the flowability of the unearthly polymer is chosen so that the layers (2,3) (4) individually having a thickness of not less than 100 microns and not above 400 microns and preferably maintained at 200 microns.
    [15]
    Method according to claim 11, characterized in that between the castings a gliding of the polymer is made in the region of the downward edge of the fiber reinforcement against the peg (6).
    [16]
    Wind turbine blade (25) with retrofitted coating (10) in and around areas where the wind turbine blade (25) is particularly susceptible to erosion damage, characterized in that the coating (10) comprises an adhesive layer, a fiber reinforced polymer layer (1) and one or more non-reinforced polymer layers (2,3,4), the polymer layers (2,3,4) extending beyond the fiber-reinforced layer (1) and comprising areas of the wind turbine blade surface which are less susceptible to erosion damage.
    [17]
    Wind turbine blade according to claim 16, characterized in that at the tip of the wind turbine blade, the fiber-reinforced layer extends all the way around the blade.
    [18]
    Wind turbine blade according to claim 16, characterized in that the edge (13) of the polymer layer comprises a region which gradually becomes thinner, so that the transition between the coating-bearing and non-coating-bearing surfaces of the wind turbine is free from unevenness.
    [19]
    Coating (10) for mounting on the front edge of a wind turbine blade, wherein the coating (10) has a surface (8) facing the wind turbine blade (25) and a surface (9) facing away from the wind turbine blade (9). center axis (28) as well as a fiber reinforcement extending from the center axis (28), and with a Toru-tuned attenuate the center axis (28) to an atsiutenae edge of the fiber reinforcement, where the polymer filler polymer extends continuously from the edge of the fiber reinforcement and further away from the center axis (28). ), whereby the coating is mountable on a wind turbine blade (25) so that its center axis (28) aligns with the leading edge line (21) of the wind turbine blade and extends away from the leading edge line (21) and down both sides of the blade profile.
    [20]
    Coating according to Claim 19, characterized in that the plumber filler of the coating has a final edge region (14), the thickness of which is gradually decreasing.
    [21]
    Coating according to claim 19, characterized in that the coating is a U-shaped elongated profile, with the center axis (28) located at the top of the U-box and wherein the two legs of the U-box comprise fiber-free polymer flaps.
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    同族专利:
    公开号 | 公开日
    AU2016383416A1|2018-07-19|
    EP3397853A1|2018-11-07|
    US11065789B2|2021-07-20|
    CN108495998A|2018-09-04|
    EP3397853A4|2019-09-11|
    US20190001534A1|2019-01-03|
    WO2017114528A1|2017-07-06|
    CA3009379A1|2017-06-07|
    JP2019504964A|2019-02-21|
    CN108495998B|2020-02-14|
    DK179826B1|2019-07-16|
    DK201700687A1|2017-12-18|
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    法律状态:
    2018-09-21| PHB| Application deemed withdrawn due to non-payment or other reasons|Effective date: 20180729 |
    优先权:
    申请号 | 申请日 | 专利标题
    DKPA201570307|2015-05-26|PCT/DK2016/050428| WO2017114528A1|2015-05-26|2016-12-13|Method for establishing of erosion resistant surface part on a wind turbine blade, method for creation of an erosion resistant coating, wind turbine blade with retrofitted coating in and around areas where the blade is especially exposed to erosion damages, coating for mounting on a wind turbine blade's front edge|
    CN201680079501.0A| CN108495998B|2015-05-26|2016-12-13|Corrosion-resistant method, corrosion-resistant surface member, and method for manufacturing corrosion-resistant surface member|
    JP2018552114A| JP2019504964A|2015-05-26|2016-12-13|A method for forming an erosion resistant surface on a wind turbine blade, a method for forming an erosion resistant coating, a wind turbine blade having a modified coating in and around an area where the blade is particularly exposed to erosion damage, a wind turbine Coating for mounting on the leading edge of the blade|
    EP16881305.3A| EP3397853A4|2015-05-26|2016-12-13|Method for establishing of erosion resistant surface part on a wind turbine blade, method for creation of an erosion resistant coating, wind turbine blade with retrofitted coating in and around areas where the blade is especially exposed to erosion damages, coating for mounting on a wind turbine blade's front edge|
    AU2016383416A| AU2016383416A1|2015-05-26|2016-12-13|Method for establishing of erosion resistant surface part on a wind turbine blade, method for creation of an erosion resistant coating, wind turbine blade with retrofitted coating in and around areas where the blade is especially exposed to erosion damages, coating for mounting on a wind turbine blade's front edge|
    CA3009379A| CA3009379A1|2015-05-26|2016-12-13|Erosion resistant coatings for wind turbine blades and methods of manufacture|
    US16/066,384| US11065789B2|2015-05-26|2016-12-13|Method for establishing of erosion resistant surface part on a wind turbine blade, method for creation of an erosion resistant coating, wind turbine blade with retrofitted coating in and around areas where the blade is especially exposed to erosion damages, coating for mounting on a wind turbine blade's front edge|
    DKPA201700687A| DK179826B1|2015-05-26|2017-12-05|Method for establishing erosion-resistant surface part on a wind turbine blade, method for forming an erosion-resistant coating, wind turbine blade with retrofitted coating in ...|
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