Ice Sensor: Design of an Enclosure

Abstract: With increased awareness about the human impact on the environment, the number of wind turbines has increased worldwide, including countries that experience a cold climate. With the cold climate, the risk of icing on the wings increases which in turn increases the risk of both production losses and damage on both products and humans. Sensors are designed to detect icing early so that the ice can be removed as quickly and safely as possible. Therefore, many companies have chosen to invest in the development of de-icing systems and ice sensors.
This report describes the thesis in Industrial design engineering at Luleå University of Technology that concern the design of an enclosure to a new variant of an ice sensor for ice detection. Studies about wind turbines, cold climate and icing hazards are made early and are ongoing throughout the project. Focus groups are conducted for greater insight in the creative process at the same time as many creative methods is carried out. Simple FE-calculations are made during the project in order to get an indication of the strength of parts and components. During the detailed design phase, the concept and dimensions are specified while CAD models are developed. Then a prototype is 3D-printed for tests of icing on the top part and for testing how well the entire concept works. Throughout the projects progress, material and manufacturing possibilities to the final product are also investigated.
A final result is presented and described where there is four main parts; the top-part, the middle-part, the rubber cylinder and the component box. The icing test gives an indication of how the final result should be further developed and that some icing is attracted to the enclosure. The conclusion from the test of the mounting onto the blade of the wind turbine is that the concept ought to work. The project results in a prototype, drawings, material descriptions, product visualizations and animations which are delivered to the clients.