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<p>The automated spraying of the inner walls of wind turbine towers, particularly on conical surfaces, faces significant challenges with conventional methods due to their inability to adapt to geometric variations, resulting in poor coating uniformity and low qualification rates. To address this issue, a predictive model for paint film thickness distribution was developed based on the <i>β</i>-distribution and tower geometry, leading to the design of a spiral spraying method. The relationship between spray gun operating parameters and film overlap spacing was analyzed, and spraying parameters were optimized with film thickness and uniformity as objective functions. The results indicate that, under a constant film distribution model, the coating uniformity index (<i>UI</i>) between adjacent spray trajectories increases, then decreases, and finally increases again with the rise of the spray gun speed ratio. When the speed ratio is maintained within the range of 91–96, the <i>UI</i> remains below 5%, meeting industrial standards. At a speed ratio of 94.0, the UI reaches its minimum value of 1.49%, achieving the optimal overlap effect. Experiments conducted on industrial-scale conical tower sections further validated the effectiveness of the model, with a final coating <i>UI</i> of 2.8%. This study provides both theoretical and practical foundations for high-quality and efficient automated spraying operations. Future work will focus on extending the model to more complex geometries and environmental conditions to promote its optimization in industrial applications.</p>

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A film superposition method for uniform spiral spraying in wind turbine towers

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Yu Wu,
  • Sen Jiang,
  • Hao Fang,
  • Zhineng Wang,
  • Xiaochuan Wang

摘要

The automated spraying of the inner walls of wind turbine towers, particularly on conical surfaces, faces significant challenges with conventional methods due to their inability to adapt to geometric variations, resulting in poor coating uniformity and low qualification rates. To address this issue, a predictive model for paint film thickness distribution was developed based on the β-distribution and tower geometry, leading to the design of a spiral spraying method. The relationship between spray gun operating parameters and film overlap spacing was analyzed, and spraying parameters were optimized with film thickness and uniformity as objective functions. The results indicate that, under a constant film distribution model, the coating uniformity index (UI) between adjacent spray trajectories increases, then decreases, and finally increases again with the rise of the spray gun speed ratio. When the speed ratio is maintained within the range of 91–96, the UI remains below 5%, meeting industrial standards. At a speed ratio of 94.0, the UI reaches its minimum value of 1.49%, achieving the optimal overlap effect. Experiments conducted on industrial-scale conical tower sections further validated the effectiveness of the model, with a final coating UI of 2.8%. This study provides both theoretical and practical foundations for high-quality and efficient automated spraying operations. Future work will focus on extending the model to more complex geometries and environmental conditions to promote its optimization in industrial applications.