NOZZLE ASSEMBLY FOR REPAIRING OR UPGRADING WIND BLADES, METHOD THEREOF AND KIT FOR THE SAME

Abstract

This invention relates generally to a nozzle, method thereof and a kit set for the same for spreading material on curved surface, in the field of repairing services for wind turbine blades and other similar composite components. More particularly, the present invention relates to a nozzle for spreading material on a leading edge of a wind turbine blade for guiding the material along the surface, generally, for repairing or upgrading. In addition it relates to a method and a kit for performing the application.

Claims

1. A nozzle assembly (10) for repairing wind blades comprising a main rigid body (11) having at least a rear concave surface (13) and a frontal convex surface (14), wherein the concave shape is curved inwards in relation to a position in front and along a wind blade (22) leading edge surface to be repaired; at least an intake adapter (12) in the bottom portion of the main rigid body (11) for receiving a sticky repair or upgrade material, injected by a pistol-like caulking gun; at least an entry reservoir (15) inside the main rigid body (11) positioned in its bottom portion for accumulating injected material; at least a discharge reservoir (16) inside the main rigid body positioned in the top portion of the main rigid body for accumulating injected material; at least one discharge opening (18) in a range at least from 100 μm thickness along at least a portion of the top of the main rigid body (11) located at distance of up to one quarter lateral length from the border of the rear concave surface (13) and after of discharge reservoir (16), for spreading the sticky repair or upgrade material (24) uniformly and directly on the wind blade leading edge to be repaired, a plurality of channels (17) passing through the main rigid body (11) for connecting the entry reservoir (15) and the discharge reservoir (16), assisting in the uniform distribution of the injected material between the entry reservoir (15) and the discharge reservoir (16).

2. A nozzle assembly (10) according to the claim 1 wherein the at least one discharge opening (18) is preferably in a range from 300 μm to 950 μm.

3. A nozzle assembly (10) according to the claim 1, wherein the rear concave surface shape (13) is configured to fit different wind blade aerodynamic shapes or profiles.

4. A nozzle assembly (10) according to the claim 1, wherein the intake adapter (12) is located over the frontal convex surface (14), before the entrance of the at least an entry reservoir (15) and its central axis is perpendicular to the frontal convex surface (14).

5. A nozzle assembly (10) according to the claim 1 wherein the nozzle assembly (10) is made either of metal, plastic or a flexible material.

6. A method of repairing wind blades comprising the steps of surface preparation by: cleaning the area where the repair or upgrade material (24) will be applied with a solvent covering at least twice the distance of the work area surface, in this case the leading edge bonding line, on each side using a tac rag to avoid any contamination, and rinsing with distilled water to check if surface is fully cleaned, and checking if the water does not stay evenly on the cleaned surface and/or if breaks/beads appear, if so, the cleaning process needs to be repeated as necessary until area is fully cleaned, and sanding down the surface carefully removing all damaged material in case of a repair or roughen top coat in case of an upgrade, and removing dust carefully with clean rag then do a second pass with a tack rag, and further comprising product application steps by locating the nozzle centered over the Leading Edge of the blade wherein the center of the intake hole should be aligned, by hand, with the bonding line of the blade or exact midpoint between the suction side shell and the pressure side shell, and commencing the pumping of the material to be applied into the intake hole and continue until both reservoirs and channels have been filled, at which point the material will begin to be displaced from the discharge opening wherein the pumping of the material may be done either with a manual, electrical or pneumatic system, the latter being preferable to ensure a constant material flow, and once the material is showing from the discharge opening, beginning to displace the nozzle away from the first material applied wherein the nozzle should at no point in time come in contact with the discharged material, and ensuring the correct constant speed of displacement and material flow requirements are met so the displaced material has the thickness as specified by the supplier of the repair or upgrade material, and sliding the nozzle and pumping equipment over the entire application area effectively coating the LE with the upgrade or repair material, and when finished, creating a negative pressure on the pumping equipment to reverse the flow of material and effectively stop the application visually ensuring that no residue material contaminates the adjacent areas, and checking the material thickness by using a wet thickness gauge in an area where this verification will not compromise the application.

7. A method of repairing wind blades according to the claim 6 wherein the steps of surface preparation and product application are performed by a robot arm.

8. A repairing wind blade kit set comprising an elastomeric sticky repair or upgrade material (24) including at least a nozzle assembly 10 according to the claim 1, and at least one of an orbital sander, and a 120 grit sanding paper, and a solvent cleaner, and clean rags, and distilled water, and alcohol based clean, and a manual, pneumatic or electric cartridge gun, and adhesion promoter, and drying rags, and wet film thickness gauge, and air compressor with hoses, and Leading Edge Protection or repair material, and a manual or robotic displacement system.

Description

DESCRIPTION OF DRAWINGS

[0028] The above and other exemplary aspects and/or advantages will become more apparent by describing in detail exemplary embodiments with reference to the accompanying drawings, which are not necessarily drawn on scale. In the drawings, some identical or nearly identical components that are illustrated in various figures can be represented by a corresponding numeral. For purposes of clarity, not every component can be labeled in every drawing.

[0029] FIG. 1 is an isometric view of the nozzle.

[0030] FIG. 2 is a top view of the nozzle showing the opening as well as the distribution of the channels along the nozzle.

[0031] FIG. 3 is a detailed view of the nozzle zooming the opening along the nozzle profile.

[0032] FIG. 4 is a cross section view taken along the lines A-A and C-C in FIG. 5. Section C-C shows the entry reservoir and the section A-A shows the discharge reservoir.

[0033] FIG. 5 is rear view of the nozzle, which refers to the concave surface.

[0034] FIG. 6 is a lateral view of the nozzle, which refers to the convex surface.

[0035] FIG. 7 is a cross section view taken along the line F-F in FIG. 6 showing the top reservoir.

[0036] FIG. 8 and FIG. 9 are an isometric view of the nozzle indicating a coordinate system XYZ and the intake adapter (12) variations of positioning along the nozzle body.

[0037] FIG. 10 is an embodiment showing, schematically, the method of using the nozzle manually to apply material over a leading edge surface.

[0038] FIG. 11 is an embodiment showing, schematically, the method of using the nozzle by using a robot arm, or similar robotic equipment, to apply material over a leading edge surface.

DETAILED DESCRIPTION OF THE INVENTION

[0039] This invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including”, “comprising”, “having”, “containing” or “involving”, and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

[0040] FIG. 1 shows an isometric view of the nozzle 10 having an intake adapter 12 to be attached to any suitable cartridges and applicators commercially available in the market, like a caulking gun, but not limited to it. The nozzle assembly 10 comprises a main rigid body 11, which is configured by at least a rear concave surface and a frontal convex surface shape curving inwards in relation to a position in front and along a wind blade 22 leading edge surface. The rigid body 11 of the nozzle assembly 10 can be manufactured of plastic, metal or any other suitable material, like a flexible material. The entry reservoir 15 and discharge reservoir 16 are also shown.

[0041] The intake adapter 12 is configured to receive the sticky repair or upgrade material 24 into the nozzle assembly 10 injecting such material inside the nozzle assembly 10 by in the bottom portion of the main rigid body and reaching the entry reservoir 15, wherein the sticky repair or upgrade material 24 is fed by such intake adapter 12, by using a pistol-like caulking gun, in the entry reservoir 15 where the sticky repair or upgrade material 24 is accumulated before being spread through the specific channels 17 and then, accumulated on the discharge reservoir 16 before being spread to the entire discharge opening 18 reaching the wind blade 22 leading edge area to be repaired.

[0042] FIG. 2 shows the top view of the nozzle showing the discharge opening 18 as well as the distribution of the specific channels 17 along and inside the nozzle assembly 10. The discharge opening 18 is placed after at least one discharge reservoir 16 and it may have up to 650μ thick “t” opening all along the top of the main rigid body 11. At least one discharge reservoir 16 is placed inside the main rigid body and positioned in the top portion of the main rigid body 11.

[0043] As depicted in FIG. 2, there is a plurality of specific channels 17 passing through the main rigid body 11 and connecting the entry reservoir 15 to the discharge reservoir 16. FIG. 3 shows a detailed view of the nozzle zooming the discharge opening 18 along the nozzle profile of up to 650μ thick along the top of the main rigid body 11 substantially near the concave surface 13 and afterwards the discharge reservoir 16 for spreading sticky repair or upgrade material 24 uniformly and directly on wind blade 22 leading edge to be repaired.

[0044] The discharge opening 18 up to 650 microns thick is to allow for thickness control of the material, which ultimately also depends on the flow of the material.

[0045] It must be noted that different size nozzles are covered by the present invention as long as the shape and functionality are the same as long as the discharge opening is the same since it is specified.

[0046] FIG. 4 shows a cross section view taken along the lines A-A and C-C in FIG. 5. Section C-C shows the entry reservoir 15 and the section A-A shows the discharge reservoir 16. In FIG. 5 is rear view of the nozzle, which refers to the concave surface showing at least eight specific channels 17 substantially spaced inside the main body 11. It is noted that the reservoirs 15 and 16 follow the shape of the main body 11 and are closed by a wall from the outside whereas, by the inside wall, they are interconnect to each other by the specific channels 17.

[0047] Illustrated in FIG. 6 is a lateral view of the nozzle wherein the direction arrow representing the material inflow direction 19 as well as the material outflow direction 20, after the material passes through the main rigid body 11 to reach the discharge reservoir 16 after the material being accumulated in the entry reservoir 15, whereas the FIG. 7 is a cross section view taken along the line F-F in FIG. 6 showing the discharger reservoir 16. In other words, the interior of the nozzle assembly 10 has specific channels 17 where the leading edge protection (LEP) is spread to reach the entire discharge opening 18 by passing at least two intermediary reservoirs, spaced and interconnected to each other by specific channels 17 which are placed inside the main body 11, because of this, the material is previously accumulated before being spread to the area to be repaired.

[0048] The prior accumulation on such reservoirs (15, 16) allows a smooth flow of material inside the nozzle assembly 10 providing a constant flow.

[0049] FIG. 8 depicted an isometric view of the nozzle wherein the coordinate X, of a coordinate system XYZ, pass along the longitudinal axis of the nozzle and centered to the intake adapter (12).

[0050] FIG. 9 shows the same isometric view and coordinate system XYZ depicted in the FIG. 8 wherein the intake adapter (12) is placed perpendicular over the Frontal convex surface (14) in a 90° in relation the longitudinal axis-X, alternatively.

[0051] Further, it is an object of this invention to provide a method to efficiently repair the area damaged over a wind blade surface, especially in the leading edge.

[0052] Thus, as depicted in FIG. 10, schematically, one embodiment of the invention relates to a method of repairing wind blades 22 by using the nozzle assembly 10 comprising the steps of positioning the nozzle assembly 10 by the rear concave surface shape 13 above and in contact to the surface to be repaired, feeding sticky repair or upgrade material 24 by the intake adapter 12 to the entry reservoir 15 in the bottom portion of the main rigid body 11 up to the sticky repair or upgrade material 24 reaches the discharge opening 18, moving the nozzle assembly 10 by hand or by a robot lengthwise along the leading edge of the wind blade while pumping stick repair material with a pistol-like caulking gun.

[0053] In one embodiment, the direction of the material during inflow 19 and outflow 20 is at the same plane, more precisely, in-between 90° to 180°, as depicted in FIGS. 9 and 6, respectively, in a way that deviation of the material flow may occurs or not, helping to control the resistance of flow during the application. On the other hand, the direction of nozzle moving direction 21 is in the contrary of material inflow 19 and outflow 20, as depicted in FIG. 7. Such method of repairing allows achieving an accuracy of ±2 mm of the deviations of the position where the LEP is to be applied 24 consistent of the lateral movement of the entire piece and consequently the application that may occur while using the nozzle.

[0054] In general, the method of repairing wind blades comprising the steps of surface preparation by cleaning the area where the repair or upgrade material 24 will be applied with a solvent covering at least twice the distance of the work area surface, in this case the leading edge bonding line, on each side using a tac rag to avoid any contamination, rinsing with distilled water to check if surface is fully cleaned, checking if the water does not stay evenly on the cleaned surface and/or if breaks/beads appear, if so, the cleaning process needs to be repeated as necessary until area is fully cleaned, sanding down the surface carefully removing all damaged material in case of a repair or roughen top coat in case of an upgrade, removing dust carefully with clean rag then do a second pass with a tack rag.

[0055] Cleaning the area comprises removing chlorides or salts, dust, grease or any other contaminates from the area where the repair or upgrade material 24 will be applied, with plenty of distilled water or appropriate substitute. New rags may be use constantly to avoid any contamination.

[0056] The area to be clean must be at least twice the distance of the work are from the leading edge bonding line on each side.

[0057] Rinsing may also involves removing particles and residual contamination eventually introduced during cleaning. It is understood that rising is not always required to check if the surface is fully cleaned once the cleaning process may be optimized.

[0058] In general rinse steps may involve water or solvent-based, force, temperature and time, being understood that the rinsing with distilled water is to avoid product damage or undesirable surface modification in order to not itself interfere with subsequent steps like sanding, product application and coating. For this reason, the rising step it is not limited to distilled water, but can be also a solvent base that match with process and windblade requirements.

[0059] Solvent cleaner may be an acetone or similar. Salt test equipment may also be used and are those commercially available and suitable for the specific surface.

[0060] Checking if the water does not stay evenly on the cleaned surface may be performed by visual inspection.

[0061] The sanding step may require marking the area, e.g. with a tape, to be sanded before sanding, to prevent over spread to areas other than the leading edge. Sanding step is performed by suing an orbital sander with a 120-grit sanding disc, carefully removing all damaged material.

[0062] The exact rugosity of the surface on to which the repair or upgrade material 24 will be applied is specified by the material manufacturer.

[0063] The method of repairing wind blades comprises further the steps of product application by locating the nozzle centered over the Leading Edge of the blade wherein the center of the intake hole should be aligned, by, with the bonding line of the blade or exact midpoint between the suction side shell and the pressure side shell (Y-axis lengthways, shown in FIGS. 10 and 11).

[0064] The locating the nozzle centered over the Leading Edge of the blade wherein the center of the intake hole should be aligned can be also performed by a robot arm, alternatively, as depicted in FIG. 11, schematically.

[0065] Yet, the method includes the steps of commencing the pumping of the material, by at least one operator (25, 26) or a robot arm (27) to be applied into the intake hole and continue until both reservoirs and channels have been filled, at which point the material will begin to be displaced from the discharge opening wherein the pumping of the material may be done either with a manual, electrical or pneumatic system, with, as example, a pistol-like caulking gun (23), the latter being preferable to ensure a constant material flow. Once the material is showing from the discharge opening, beginning to displace the nozzle away from the first material applied wherein the nozzle should at no point in time come in contact with the discharged material.

[0066] Further, the steps include ensuring the correct constant speed of displacement and material flow requirements are met so the displaced material has the thickness as specified by the supplier of the repair or upgrade material, sliding the nozzle and pumping equipment over the entire application area effectively coating the LE with the upgrade or repair material.

[0067] When finished, creating a negative pressure on the pumping equipment, or alternative action having the same result, to reverse the flow of material and effectively stop the application ensuring that no residue material contaminates the adjacent areas.

[0068] Yet, checking the material thickness by using a wet thickness gauge in an area where this verification will not compromise the application. The wet thickness gauge must be placed at 90° to the coated substance and ensured the gauge is firmly in contact with the substrate. After the gauge is removed from the substrate, it must be observed the MIL value of the largest tooth or notch that is wet and the smallest tooth that is not wet. The wet film thickness lies between these two values.

[0069] The wet thickness gauge may be any commercial one which are designed to quickly and easily measure the thickness of coatings immediately after they have been applied to a substrate. These gauges are also commonly known as: Combs, MIL Gauges, Step Gauges and Notched Gauges.

[0070] The clean rags may be made of textile, such as microfiber ragas. Drying rags can be any cheap rag.

[0071] Another embodiment of the invention relates to a kit directed to other articles not essentially and physically connected to the nozzle, but in a way grouped together for performing the method.

[0072] The kit comprising an elastomeric sticky repair or upgrade material 24 and a nozzle assembly (10) as described in claim 1 and including at least an application nozzle, an orbital sander, a 120 grit sanding paper, a solvent cleaner, a clean rags, a distilled water, an alcohol based cleaner, a manual, pneumatic or electric cartridge gun, an adhesion promoter, if specified, a drying rags, a wet film thickness gauge, an air compressor with hoses, a LEP or repair material and a manual or robotic displacement system.

[0073] The relation between the method and kit set may be specified as the use of at least an orbital sander with a 120 grit sanding paper, a solvent cleaner, clean rags, and distilled water, alcohol based cleaner for the step of surface preparation, and, at least a manual, pneumatic or electric cartridge gun, adhesion promoter (if specified), a wet film thickness gauge, air compressor with hoses, LEP or repair material, and a manual or robotic displacement system for the step to product application.

[0074] As needed, the kit set may further include alternatives of elements that are part of it that provide the same result e.g., commercial alternatives for orbital sander with a 120 grit sanding paper, a solvent cleaner, clean rags, and distilled water, alcohol based cleaner for the step of surface preparation, and, at least a manual, pneumatic or electric cartridge gun, adhesion promoter (if specified), a wet film thickness gauge, air compressor with hoses, LEP or repair material, and a manual or robotic displacement system for the step to product application, as well as instruction manual of the kit set.

[0075] Orbital sanders is preferred because it uses a round disc to sand in both an orbital as well as rotary motion. By combining these two sanding motions at the same time, it reduces swirl marks that can ruin a fine finish in the area to be repaired or updated. Palm sander or details sander may also be used alternatively or in a complementary way, if necessary to get the result.

[0076] It is to be noted that the instruction manual of the kit for applying the method by using the nozzle assembly here disclosed includes the description about the method according to the present invention explained in above. Further, includes dust mask, hearing protection, protective eyewear, gloves and other safety equipment that are required by health and safety legislation and hazards, and consequently does not need to be claimed by not involving invention matter.

[0077] It is understood that adhesion promoter is not always required otherwise specified.

NUMERALS EXPLANATION OF NUMERALS

[0078] 10 Nozzle assembly [0079] 11 Rigid body [0080] 12 Intake adapter [0081] 13 Rear concave surface [0082] 14 Frontal convex surface [0083] 15 Entry reservoir [0084] 16 Discharge reservoir [0085] 17 Specific channels [0086] 18 Discharge opening [0087] 19 Material inflow direction [0088] 20 Material outflow direction [0089] 21 Nozzle moving direction [0090] 22 Windblade concept [0091] 23 Cartridge, pistol-like caulking gun [0092] 24 Repair or upgrade material applied [0093] 25 Operator A [0094] 26 Operator B [0095] 27 Robot arm

Terminology Definitions

[0096] The term “robot” as used herein generally is understood to have a broader meaning than an automatically controlled, reprogrammable, multipurpose, manipulator programmable in three or more axes, which may be either fixed in place or mobile for use in industrial automation applications. It is may be a simple mechanical agent that is guided by a person, a computer program or electronic circuit.

[0097] The term “Leading Edge” is understood as a surface of the wind blade that first contacts the air, or fluid in general, but also as the foremost edge of generally an airfoil section, encompassing aerodynamic definition as well as structural point of view, covering a narrow and a broader leading edge, from the tip-end to the root-end of a general conceptual blade. “Leading Edge Protection” stands for any suitable material for protecting the leading edge.

[0098] The term “contamination” and “contaminates” means anything that will interfere with performance, long-term reliability, final finishing, or surface appearance if it remains on the wind blade.

[0099] The term “visual inspection” it to be understood in a broader sense as is a common method of quality control used in maintenance of a product, meaning inspection of equipment and structures using either or all of raw human senses such as vision, hearing, touch and smell and/or any non-specialized inspection equipment, but herein comprise inspections requiring Ultrasonic, X-Ray equipment, Infra-red, etc. yet requiring specialized equipment, training and certification.

Modes for Invention

[0100] The preferred embodiment of the invention relates to the nozzle assembly 10 wherein the rear concave surface shape 13 is configured to fit different wind blade aerodynamic shapes or profile and locations lengthwise of the wind blade leading edge in relation to its longitudinal axis, in the case the blade radius it is not a standard one.

[0101] Another embodiment of the invention relates to a nozzle assembly 10 wherein the rear concave surface shape 13 is profiled fit to a wind blade leading edge in order to avoid material waste and reduce resistance to flow during sticky material application.

[0102] Yet, alternative embodiment relates to a nozzle assembly 10 wherein the intake adapter 12 is located over the frontal convex surface 14, before the entrance of the at least an entry reservoir 15 and its central axis is perpendicular to the frontal convex surface 14.

[0103] As above described in detail, the method can be performed by operator or a robot.

INDUSTRIAL APPLICABILITY

[0104] Composites are being used more and more extensively in Wind Energy Industry because they provide an excellent combination of features like strength versus weight, durability, corrosion resistance, among others.

[0105] One of the challenges of such industry is to pace the demand by mass production. This scenario influences the repairing services as well, so consequently, improving the efficiency also in repairing is desired and needed.

[0106] While the invention has been disclosed by this specification, including its accompanying drawings and examples, various equivalents, modifications and improvements will be apparent to the person skilled in the art. Such equivalents, modifications and improvements are also intended to be encompassed by the following claims.