Damp and cold conditions have long plagued the efficiency of wind power. When ice forms on rotor blades, it induces rotational imbalance, leading to increased wear and tear. A team of experts from the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM and the Fraunhofer Institute for Manufacturing Engineering and Automation IPA has pioneered a solution to safeguard wind turbines against the menace of ice.
The project, named “TURBO — Temporary coating by means of ,” introduces a cost-effective alternative that could revolutionize the way wind energy is harnessed and maintained. Traditionally, combating this issue has been an expensive endeavor. From integrating heating mats into blades to using helicopters for de-icing agent application, operators faced substantial costs and production interruptions as the turbines would have to be shut down, often for days.
“Drones that are only used when needed offer a cost-effective alternative,” said Andreas Stake, project manager at Fraunhofer IFAM, in a . Although this isn’t the to clear ice off turbine blades, it still isn’t an off-the-shelf solution that fits all scenarios and comes with its share of challenges. Environmental Friendliness Takes Flight.
The key challenge was to develop an environmentally friendly coating material that adheres well to the rotor blades and remains durable for an extended period to ward off ice. The team at Fraunhofer IFAM created a prototype coating made from urea and wax that meets these criteria. This coating material can be efficiently applied using a , ensuring quick drying.
The efficacy of the coating was rigorously tested in an ice chamber, confirming its ability to reliably protect against frost formation. To apply the coating precisely, the team at Fraunhofer IPA designed specialized equipment. An airless pump system with a lance and nozzle featuring a diameter of just 0.
3 millimeters, enables the spraying of droplets as small as 100 micrometers. This precision ensures that even at wind speeds of 35 kilometers per hour, the coating can be accurately applied to the crucial edges of the rotor blades where ice first begins to form when wet, cold air hits the . The science behind the solution The success of the project hinged on sophisticated fluid dynamic simulations.
Dr. Oliver Tiedje, project manager at Fraunhofer IPA, and his team utilized their extensive experience in modeling coating processes to determine crucial technical parameters. “Our decades of experience in modeling coating processes really helped us out.
We were able to draw on this expertise,” Dr. Tiedje explained. “However, we did have to adapt the process parameters to the complex geometry of the .
” Buoyed by their achievements, the researchers are now collaborating with industry partners to refine the technique further and prepare it for mass production. They see applications extending beyond wind turbines, with potential uses in protecting overhead lines in rail transport and refurbishing challenging-to-reach parts of buildings. The project, supported by 19 companies across various sectors— including coating and raw material manufacturers, manufacturers of drones, and operators of wind turbines— was submitted as an Industrial Collective Research project (IGF) and received funding from the Federal Ministry for Economic Affairs and Climate Action (BMWK).
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From: interestingengineering
URL: https://interestingengineering.com/innovation/this-new-drone-tech-will-spin-wind-turbines-through-the-winter
