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FORMAL DESIGN PRESENTATION�Team 953�SLS Coating Solutions�Design and Manufacture Surface Coating to Remove Ice on Wind Turbines

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Outline

  1. Background – Wind Energy
  2. Coating and Small-Scale Testing
  3. Overall Design 
  4. Horizontal Mechanism
  5. Vertical Mechanism
  6. Cold Plate
  7. Q & A

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Background

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U.S. Wind Turbine Database

Heatmap of Wind Turbines in the U.S. [1]

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Background

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Wind turbine with ice forming on blades [4]

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  • ≈ 4 million dollars to replace turbines
  • 20 % losses

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Ice patrol workers next to iced turbine [2]

Percentage of total wind energy generated in Texas [3]

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SLS Coating Features

  • Developed by sponsor
  • Ultra-low ice shear force
  • Low Contact-Angle Hysteresis
  • High durability
    • Up to 1000 abrasion cycles

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Superhydrophobic coating in action [5]

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Small Scale Testing

  • Cuvette: 3 cm x 4.5 cm
  • Shear and normal force testing
  • Abrasion testing
  • Cooling stage

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Testing set-up for testing

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Final Design

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Testing Machine

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  • Functions:
    • Cold Plate reaches –10 degrees Celsius
    • Can measure Shear and Adhesion forces
    • Automated abrasion�

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Adhesion Testing

  • Measures ice adhesion force
  • Lifts ice off surface
  • Not commonly tested

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Shear Testing

  • Standard coating testing method
  • Applies force until the sample detaches
  • Measures shear force needed to remove ice

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Abrasion Testing

  • Durability test
  • Abrades surface 100 times per cycle
  • Slotted weights can be added to abrasion attachment
  • Configurable abrasive surface

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Cold Plate

  • Delays Melting of Ice
  • Water cooled system
  • Temperature Controlled

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Cold Plate

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  • Adjustable substrate sizes
  • Adapted for shear, adhesion and abrasion testing

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Cooling System Animation

  • TeTech high performance Peltiers
  • Small Heat Exchanger

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  • PID Temperature Controller

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Cooling System

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  • High Performance Peltier elements

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Cooling System

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  • PID Temperature Controller

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  • High Performance Peltier elements

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Cooling System

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Software

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  • Raspberry PI Touchscreen Interface
  • Data processed through LabVIEW

Initial touchscreen prototype

Snipping of software flowchart

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Future Use

  • No standard machine for ice removal testing in market
  • Integration of multiple tests
  • Can be used for other applications

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Q & A

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References

[1] https://eerscmap.usgs.gov/uswtdb/viewer/#3.45/35.45/-93.65

[2] https://www.bladefence.com/blog/author/sanna-heinonen

[3] https://windexchange.energy.gov/states/tx

[4] https://www.windpowerengineering.com/the-cold-hard-truth-about-ice-on-turbine-blades/

[5] Super Hydrophobic Surface and Magnetic Liquid - The Slow Mo Guys https://www.youtube.com/watch?v=i3jA40arq9Y

[6] https://wwindea.org/blog/2019/02/25/wind-power-capacity-worldwide-reaches-600-gw-539-gw-added-in-2018/

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Electrical schematic:

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  • Controller, micro stepper driver, and touchpad interface connections

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