其他产品新能源/风电

风力发电叶片模具脱模剂涂刷系统

Wind Turbine Blade Mold Release Agent Application System

客户挑战 / Challenge

某风电叶片制造商60m级叶片模具脱模剂涂刷依赖人工，每次涂刷需3名工人耗时4小时。人工涂刷厚薄不均导致脱模困难，叶片表面缺陷率高达8%，每片修补成本约2万元。生产节拍严重受限。

A wind turbine blade manufacturer relied on manual application of mold release agent for 60m-class blade molds — 3 workers × 4 hours per application. Uneven coating caused demolding difficulties with 8% surface defect rate, costing ~$2,800/blade in repairs. Production cadence was severely constrained.

解决方案 / Solution

开发大型龙门式自动涂刷系统，装配12组扇形专用涂刷头（超软PP刷丝，Φ0.05mm），配合精密计量泵控制脱模剂喷涂量。刷头沿模具曲面自动仿形，覆盖率通过机器视觉实时检测。整套系统PLC控制，一键切换模具程序。

Developed a large gantry-style automatic application system with 12 specialized fan-shaped brush heads (ultra-soft PP bristles, Φ0.05mm), paired with precision metering pumps for release agent flow control. Brush heads auto-contour to mold surfaces with real-time coverage detection via machine vision. PLC-controlled with one-touch mold program switching.

实施效果 / Results

涂刷时间从12工时降至1小时（自动），脱模剂用量减少35%。叶片表面缺陷率从8%降至0.5%，年减少修补费用约320万元。模具周转率提升40%，支持年增产叶片60片。

Application time reduced from 12 man-hours to 1 hour (automated). Release agent consumption down 35%. Surface defect rate dropped from 8% to 0.5%, annual repair savings of ~$450,000. Mold turnover rate up 40%, enabling 60 additional blades/year.