A service robot for offshore wind turbine units

Abstract

The application discloses a ship-boat coupling type inspection robot for offshore wind turbine generator units, which comprises a drone and an unmanned ship, and a ship body monitoring module for assisting the drone in monitoring tasks is arranged on the unmanned ship; the body of the drone is in a cylindrical frame structure, can conveniently pass through inside a wind turbine tower drum, and the body is provided with a drone monitoring module; the drone monitoring module comprises an image acquisition device, a sound and image acquisition device and a vibration acquisition device, and can effectively acquire various data inside the tower drum of the wind turbine generator unit. The ship-boat coupling type inspection robot can realize all-around state monitoring and fault diagnosis of offshore wind turbine generator units by adopting the combined operation mode of the unmanned ship and the drone, can timely master the operation state of the wind turbine generator unit, early discover potential fault signs, reduce the fault rate, ensure safe and efficient power generation operation of the wind turbine generator unit, simultaneously changes the previous manual inspection mode, greatly saves the operation and maintenance cost, and ensures personnel safety.

Description

Technical Field

[0001] This invention belongs to the field of offshore wind power operation and maintenance technology, specifically relating to a ship-machine coupled inspection robot for offshore wind turbines. Background Technology

[0002] In today's society, productivity is developing rapidly, and energy issues are becoming increasingly serious. In recent years, wind energy has become increasingly prominent in the world's energy structure, and wind power will gradually become the third largest conventional energy source after thermal power and hydropower. With the successive launch of large-scale offshore wind power construction plans in my country and the warranty period of most of the currently operating wind turbines gradually exceeding or nearing its end, the current situation of high failure rate and high operation and maintenance costs is increasingly attracting the attention of wind power operators, manufacturers, and third-party operation and maintenance companies.

[0003] Offshore wind turbines, especially floating turbines far from the coast, operate under harsh conditions and have a high failure rate. This often leads to unplanned shutdowns or reduced-load operation, affecting normal production. Therefore, strengthening the maintenance and upkeep of wind turbines, particularly quickly identifying the causes of operational failures and taking appropriate measures, is crucial. However, current inspection methods mainly rely on dispatching technicians on maintenance vessels for manual inspections. When inspecting the upper part of the turbine, technicians must climb to designated locations to conduct a wide range of checks. Given the unpredictable weather at sea, each inspection of offshore wind turbines is not only extremely costly but also poses certain safety hazards.

[0004] Unmanned surface vessels (USVs) are surface robots that automatically cruise on water according to preset tasks, utilizing precise satellite positioning and their own sensors. They have advantages such as high payload capacity and long continuous operation endurance, but their field of vision is limited due to their proximity to the sea surface. Unmanned aerial vehicles (UAVs), on the other hand, have advantages such as good maneuverability, rapid response, and a wide field of vision, but their payload capacity is smaller and their continuous operation endurance is shorter. Therefore, combining USVs and UAVs can achieve complementary functions, ensuring good maritime cruising capabilities while also providing good visibility and maneuverability. In the field of offshore wind power operation and maintenance technology, there is a multi-functional offshore wind power inspection vessel with publication number CN211844830U that uses a combination of USVs and UAVs to conduct joint inspections of offshore wind turbines. However, the UAV used is a conventional UAV, which can only perform visual inspections of the wind turbine's outer surface through image acquisition devices. It cannot perform more detailed inspections of other conditions inside the wind turbine tower, and manual fault diagnosis of the offshore wind turbine is still required afterward. Therefore, developing a monitoring device that can perform real-time remote monitoring and comprehensive fault diagnosis, tailored to the environmental and operational characteristics of offshore wind turbines, is of great significance for promoting the development of offshore wind power. Summary of the Invention

[0005] The main objective of this invention is to address the problem of limited inspection functions in existing inspection robots for offshore wind turbines by providing a ship-machine coupled inspection robot for offshore wind turbines. This robot can enter the interior of the wind turbine tower and closely adhere to the inner wall of the tower, enabling comprehensive condition monitoring and fault diagnosis of the offshore wind turbine.

[0006] This invention is implemented as follows:

[0007] This invention provides a ship-machine coupled inspection robot for offshore wind turbines, including a drone for undertaking the main monitoring task and an unmanned vessel for carrying the drone, wherein the unmanned vessel is equipped with a hull monitoring module to assist the drone in monitoring tasks.

[0008] The drone includes a fuselage and a power module, a control box, and a drone detection module mounted on the fuselage. The fuselage is a cylindrical frame structure, which facilitates the drone's movement inside the wind turbine tower. The power module provides power for the drone's flight. The control box contains a control module, a communication module, a GPS positioning module, and a power supply. The control box can control the drone's flight attitude. The drone detection module includes an image acquisition device, which can monitor the operating status of the offshore wind turbine.

[0009] Preferably, the power module includes four power units, each power unit including a motor and a propeller mounted on the motor output shaft. The motors of the four power units are evenly arranged around the top of the cylindrical frame structure and fixed by motor covers.

[0010] Preferably, the unmanned vessel has a three-hull structure, including a main hull and auxiliary hulls symmetrically arranged on both sides of the main hull. The unmanned vessel also has a cabin for accommodating the unmanned aircraft, and the top of the cabin has an openable cover.

[0011] Preferably, the UAV detection module further includes an acoustic imaging acquisition device for collecting abnormal acoustic wave information emitted by offshore wind turbines during operation.

[0012] Preferably, the UAV detection module further includes a vibration acquisition device for collecting abnormal vibration signals during the operation of the offshore wind turbine. The vibration acquisition device is located on the side of the fuselage, and an electromagnet is provided next to the vibration acquisition device. The electromagnet enables the vibration acquisition device to be in close contact with the inner wall of the wind turbine tower for data acquisition.

[0013] Preferably, the side of the fuselage is also provided with a horizontal propulsion device for providing horizontal thrust to the UAV. The horizontal propulsion device includes a motor located opposite the vibration acquisition device and a propeller located on the output shaft of the motor.

[0014] Preferably, the image acquisition device includes a camera for acquiring image information and an infrared thermal imager for acquiring temperature information.

[0015] Preferably, the hull monitoring module includes a wind monitoring device installed on the unmanned vessel for judging the takeoff environment of the unmanned aerial vehicle.

[0016] Preferably, the hull monitoring module also includes a waterproof camera device installed on the unmanned vessel.

[0017] Preferably, the hull monitoring module also includes an ultrasonic obstacle avoidance device installed on the unmanned vessel.

[0018] The beneficial effects of this invention are:

[0019] This invention provides a ship-machine coupled inspection robot for offshore wind turbines. By using unmanned ships and drones in a joint operation, it can monitor and diagnose various aspects of the status of offshore wind turbines. It can promptly grasp the operating status of wind turbines, detect potential fault signs early, reduce the failure rate, and ensure the safe and efficient power generation of wind turbines. At the same time, it changes the previous manual inspection method, greatly saves operation and maintenance costs, and ensures personnel safety. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the ship-vessel coupled inspection robot when its top cover is open, as provided in an embodiment of the present invention.

[0021] Figure 2 This is a schematic diagram of the structure of the ship-vessel coupled inspection robot when its top cover is closed, as provided in an embodiment of the present invention.

[0022] Figure 3 This is a schematic diagram of the structure of the UAV in the ship-vessel coupled inspection robot provided in an embodiment of the present invention;

[0023] Figure 4 This is a top view of the drone in the ship-vessel coupled inspection robot provided in an embodiment of the present invention.

[0024] In the diagram: 10-hull, 101-control box, 102-mounting bracket, 103-motor cover, 104-propeller frame, 105-high-definition camera, 106-infrared thermal imager, 107-microphone array, 108-vibration sensor, 109-ring electromagnet, 110-propulsion motor, 111-propulsion propeller, 112-power unit 1, 113-power unit 2, 114-power unit 3, 115-power unit 4, 20-main hull, 21-auxiliary hull, 22-connecting rod, 201-cabin, 202-top cover, 203-main control module, 204-signal transceiver, 205-wind speed sensor, 206-main camera, 207-waterproof searchlight, 208-wide-angle camera, 209-ultrasonic sensor, 210-energy storage device. Detailed Implementation

[0025] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0026] This invention provides a coupled inspection robot for offshore wind turbines, comprising a drone for performing the main monitoring tasks and an unmanned surface vessel (USV) for carrying the drone. Specifically:

[0027] like Figures 1 to 4 As shown, the drone is a frame-type drone, including a body 10 and a power module, a control box 101, and a drone detection module mounted on the body 10. The body 10 is a cylindrical frame structure made of hollow tubing, which provides protection for the various modules mounted on the body 10, ensuring that the drone can successfully complete relevant data collection tasks when it enters the wind turbine tower. It also facilitates the drone's close contact with the inner wall of the wind turbine tower after entering. The power module includes four power units, each of which includes a motor and a propeller mounted on the motor output shaft. The motors of the four power units are evenly arranged in the propeller outer frame 104 on the upper edge of the body 10 and are fixed by a motor cover 103. The motor cover 103 reduces the impact of marine salt spray environment on the motor and its internal circuitry. The propeller outer frame 104 can, to a certain extent, resist external wind fields and protect the propeller.

[0028] The four power units mentioned above are, in order, power unit 112, power unit 113, power unit 114, and power unit 115, wherein power unit 114 is located opposite power unit 112, and power unit 113 is located opposite power unit 115. When the propellers in power unit 112 and power unit 114 rotate clockwise, while the propellers in power unit 213 and power unit 115 rotate counterclockwise, and all propellers rotate at the same speed, the drone can hover horizontally in the air. If the motor speeds in power unit 213 and power unit 115 remain constant, while the motor speeds in power unit 112 and power unit 114 decrease, the drone will turn clockwise. If the motor speeds in power unit 112 and power unit 114 remain constant, while the motor speeds in power unit 213 and power unit 115 decrease, the drone will turn counterclockwise. If the motor speeds in power unit 112, power unit 113, power unit 114, and power unit 115 all decrease simultaneously, the drone will descend vertically. If the rotational speeds of the motors in power units 112, 113, 114, and 115 increase simultaneously, the drone will ascend vertically. If the rotational speeds of the motors in power units 112 and 115 remain constant, while the rotational speeds of the motors in power units 113 and 114 decrease, the drone's fuselage will tilt towards the angle between power units 113 and 114, and the resulting force will allow the drone to fly horizontally in that direction. If the rotational speeds of the motors in power units 113 and 114 remain constant, while the rotational speeds of the motors in power units 112 and 115 decrease, the drone's fuselage will tilt towards the angle between power units 112 and 115, and the resulting force will allow the drone to fly horizontally in that direction.

[0029] The control box 101 is fixed to the middle of the body 10 of the UAV by the mounting bracket 102. The control box 101 contains a control module, a communication module, a GPS positioning module and a power supply. The control box 101 is connected to the power module and the UAV detection module by wires. The control box 101 can control the flight attitude of the UAV and realize the collection of relevant data at fixed points. At the same time, the UAV can also be manually controlled by technicians to perform targeted fault diagnosis in designated areas.

[0030] like Figure 3 and Figure 4As shown, based on the main fault conditions faced by offshore wind turbines, the UAV detection module includes an image acquisition device, an audio-visual acquisition device, and a vibration acquisition device. Each detection device in the UAV detection module is respectively installed on the four sides of the fuselage 10. The image acquisition device includes a high-definition camera 105 and an infrared thermal imager 106. The high-definition camera 105 is located on one side of the fuselage 10. The high-definition camera 105 can be used to acquire image information of the offshore wind turbine and also provides visual navigation for the UAV during flight. The infrared thermal imager 106 is located next to the high-definition camera 105 and can collect temperature information of the gearbox, generator, bearings, and power converter of the offshore wind turbine. The acoustic image acquisition device is a microphone array 107, which is positioned opposite the image acquisition device. The microphone array 107 can simultaneously capture sound signals from multiple different points and perform spatial audio filtering to generate the direction of sound waves. This allows for the collection of sound wave information emitted when the blades, gearboxes, and bearing materials of offshore wind turbines are subjected to pressure or stress. The vibration acquisition device includes a vibration sensor 108 and a ring electromagnet 109. The vibration sensor 108 is positioned in the middle of the ring electromagnet 109, which tightly attaches it to the wind turbine. When the wind turbine malfunctions, it triggers abnormal vibrations in the corresponding system. The vibration sensor 108 can then collect vibration signals from the wind turbine gearbox, generator, main shaft, blades, tower, etc. It is worth noting that the UAV detection module includes, but is not limited to, the aforementioned sensors. Depending on actual needs, other sensors can also be mounted on the fuselage 10 to adapt to other types of detection tasks.

[0031] Furthermore, in order to improve the maneuverability of the UAV within the wind turbine tower, a horizontal propulsion device is provided on the side of the body 10 to provide horizontal thrust to the UAV. The horizontal propulsion device includes a propulsion motor 110 located opposite the vibration acquisition device and a propulsion propeller 111 located on the output shaft of the propulsion motor 110. The horizontal propulsion device enables the UAV to more flexibly complete various monitoring tasks of the wind turbine within the wind turbine tower.

[0032] When collecting vibration and sound signals of the wind turbine inside the tower, the propeller first generates thrust to make the hovering drone adhere to the inner wall of the tower. Then, the annular electromagnet 109 is energized to firmly attach the drone to the inner wall of the wind turbine tower. At this time, turning off the propeller in the power module can reduce the interference of the drone's own vibration and noise on the detection results. Then, the vibration sensor 108 and the microphone array 107 can effectively collect the vibration and sound signals of the wind turbine.

[0033] like Figure 1 and Figure 2 As shown, the unmanned surface vessel (USV) includes a hull and a main control module 203, a hull monitoring module, an energy storage device 210, and a signal transceiver device 204 mounted on the hull. The hull employs a trimaran structure, comprising a main hull 20 and two auxiliary hulls 21 located on either side of the main hull 20. The auxiliary hulls 21 are connected to the cabin 201 via arc-shaped connecting rods 22 and are parallel to the main hull 20. This trimaran design significantly increases the width of the USV, making it less prone to capsizing and improving its stability and safety during navigation in rough seas. The stern of the main hull 20 is provided with a cylindrical cabin 201 corresponding to the shape of the aforementioned drone frame. The cabin 201 is used to accommodate the drone. The top of the cabin 201 is also provided with two semi-circular, openable covers 202. When the covers 202 are closed, they can protect and waterproof the drone. When it is necessary to release the drone from the cabin 201, the covers 202 will open outwards, allowing the frame-type drone in the cabin 201 to take off and operate.

[0034] The hull monitoring module is used to assist the ship-vessel coupled inspection robot in successfully completing the offshore wind turbine inspection task. The hull monitoring module includes a wind power monitoring device, a waterproof camera device, and an ultrasonic obstacle avoidance device. The wind monitoring device is a wind speed sensor 205, which is installed on the deck of the main hull 20. This device detects the wind speed to determine if the conditions for takeoff of the UAV are met. The waterproof camera device includes two main cameras 206 symmetrically positioned at the front of the main hull 20 and wide-angle cameras 208 symmetrically positioned on the two auxiliary hulls 21. This device monitors the mechanical damage and corrosion of the water-based foundations or floating bases of offshore wind turbines. Waterproof searchlights 207 are also installed around the main cameras 206 to further improve the image acquisition effect. The ultrasonic obstacle avoidance device is an ultrasonic sensor 209, located at the highest point of the UAV (i.e., the top of the upper cover 202 of the cabin 201). This allows the ultrasonic obstacle avoidance device to emit ultrasonic waves as far as possible to detect surrounding obstacles, thus avoiding floating foundations of offshore wind turbines or large floating debris in the ocean, ensuring the safe navigation of the UAV.

[0035] The main control module 203 of the unmanned vessel is located on the deck of the main hull 20. The main control module 203 can plan, navigate and control the cruise path of the unmanned vessel. The energy storage device 210 of the unmanned vessel is located on the side of the main hull 20 and is used to power the entire unmanned vessel. The signal transceiver device 204 of the unmanned vessel is located at the stern of the auxiliary hull 21. The signal transceiver device 204 can guide the unmanned vessel to land and communicate with the command center to send the data information collected by the unmanned vessel to the technicians in real time for analysis and processing.

[0036] The specific method of using this invention is as follows:

[0037] Before inspecting offshore wind turbines, especially floating offshore wind turbines far from the coast, the inspection trajectory of the unmanned vessel coupled with the ship needs to be set in advance according to the actual inspection task or fault diagnosis requirements. The unmanned vessel will then autonomously cruise along the preset trajectory. After reaching the designated location, the unmanned vessel will collect data on the corrosion of the floating foundation of the floating offshore wind turbine. After completing the image acquisition task, the unmanned vessel will dock at the preset position and replenish its energy through the preset charging interface or energy interface. When drone inspection is required, the cover 202 of the cabin 201 is opened, and the drone is released to collect video data on the outside of the offshore wind turbine. Then, it enters the tower column and closely follows the inner wall of the wind turbine to collect data such as vibration, temperature, acoustic emission, and lubricating oil volume, and sends the data to the technicians in real time, thereby completing the monitoring task of the offshore wind turbine. After the inspection task is completed, the drone returns to the cabin 201. The specific return technology can adopt the existing drone-controlled trajectory return technology. Of course, an additional camera can be equipped for manual remote operation to complete the final return and positioning.

[0038] The above embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Although the invention has been described in detail with reference to the embodiments, those skilled in the art should understand that various combinations, modifications, or equivalent substitutions of the technical solutions of the invention do not depart from the spirit and scope of the invention and should be covered within the scope of the claims of the invention.

Claims

1. A ship-machine coupled inspection robot for offshore wind turbines, characterized in that: It includes a drone for undertaking the main monitoring task and an unmanned vessel for carrying the drone, wherein the unmanned vessel is equipped with a hull monitoring module to assist the drone in monitoring tasks; The drone includes a fuselage and a power module, a control box, and a drone detection module mounted on the fuselage. The fuselage has a cylindrical frame structure to facilitate the drone's movement inside the wind turbine tower. The power module provides power for the drone's flight. The control box contains a control module, a communication module, a GPS positioning module, and a power supply. The control box can control the drone's flight attitude. The drone detection module includes an image acquisition device, which can monitor the operating status of the offshore wind turbine. The power module includes four power units, each of which includes a motor and a propeller mounted on the motor output shaft. The motors of the four power units are evenly arranged in the outer frame of the propeller on the upper edge of the fuselage. The four power units are designated as Power Unit 1, Power Unit 2, Power Unit 3, and Power Unit 4, respectively. Power Unit 3 is located opposite Power Unit 1, and Power Unit 2 is located opposite Power Unit 4. The UAV detection module also includes a vibration acquisition device for collecting abnormal vibration signals when the offshore wind turbine is working. The vibration acquisition device is located on the side of the aircraft body, and an electromagnet is provided next to the vibration acquisition device. The UAV detection module also includes an acoustic imaging acquisition device for collecting abnormal acoustic wave information emitted by offshore wind turbines during operation. The side of the fuselage is also provided with a horizontal propulsion device for providing horizontal thrust to the UAV. The horizontal propulsion device includes a motor located opposite the vibration acquisition device and a propeller located on the output shaft of the motor. When collecting vibration and sound signals from the wind turbine inside the tower, the propeller first generates thrust to make the hovering drone adhere to the inner wall of the tower. Then, the electromagnet is energized to firmly attach the drone to the inner wall of the wind turbine tower. At this time, the propeller in the power module is turned off to reduce the interference of the drone's own vibration and noise on the detection results. The vibration and sound signals of the wind turbine can then be effectively collected through the vibration acquisition device and the sound and image acquisition device.

2. The ship-machine coupled inspection robot for offshore wind turbines as described in claim 1, characterized in that: The unmanned vessel adopts a three-hull structure, including a main hull and auxiliary hulls symmetrically arranged on both sides of the main hull. The unmanned vessel also has a cabin on its hull for accommodating the unmanned aircraft.

3. The ship-machine coupled inspection robot for offshore wind turbines as described in claim 2, characterized in that: The cabin is equipped with an opening and closing cover.

4. The ship-machine coupled inspection robot for offshore wind turbines as described in claim 1, characterized in that: The image acquisition device includes a camera for acquiring image information and an infrared thermal imager for acquiring temperature information.

5. A ship-machine coupled inspection robot for offshore wind turbines as described in claim 1 or 2, characterized in that: The hull monitoring module includes a wind monitoring device installed on the unmanned vessel to determine the takeoff environment of the unmanned aerial vehicle.

6. The ship-machine coupled inspection robot for offshore wind turbines as described in claim 5, characterized in that: The hull monitoring module also includes a waterproof camera device installed on the unmanned vessel.

7. The ship-machine coupled inspection robot for offshore wind turbines as described in claim 6, characterized in that: The hull monitoring module also includes an ultrasonic obstacle avoidance device installed on the unmanned vessel.

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