Coating applicator tool tip for repairing leading edge damage on wind turbine blades together with an automated device

Abstract

A paint applicator tool head configured for use with a robotic maintenance device comprises a tool head body having a frame, a supply container, a drive device for actuating delivery of a flow of paint from the supply container, a feed tube, a nozzle to receive a flow from the feed tube, and a spreading tool, such as a roller brush or spatula, to receive a flow from the nozzle. The paint applicator tool head is moved by an articulated arm of the maintenance device over a surface of a wind turbine blade containing damage, so that the roller brush or spatula can apply multiple layers of paint to cover and fill the damage. The nozzle supplies paint continuously directly onto the roller brush or spatula, and the drive device can be configured to independently adjust the supply of two or more different components in the supply container, which can be mixed to form the paint.

Description

Technical Field

[0001] This application generally relates to wind turbines, and more particularly to automated robotic devices and methods for repairing damage along the leading edge of wind turbine blades without the need to remove the blades from the wind turbine tower or for manual repair by a rope access technician. Background Technology

[0002] Wind turbines are used to generate electricity using renewable resources and without burning fossil fuels. Typically, a wind turbine converts the kinetic energy from the wind into electricity. A conventional wind turbine power generation unit includes a base, a tower supported by the base, and an energy generation unit located atop the tower. The energy generation unit typically includes one or more nacelles to house multiple mechanical and electrical components (such as generators, gearboxes, and main bearings), and the wind turbine also includes a rotor that is operationally connected to the components within the nacelle via a main shaft extending from the nacelle. Single-rotor and multi-rotor wind turbines (which may have multiple nacelles) are known, but for efficiency, the following description primarily concerns a single-rotor design. The rotor includes a central hub and multiple blades that extend radially from the central hub and are configured to interact with the wind to rotate the rotor. The rotor is supported on a main shaft, which is operationally connected, directly or indirectly, to a generator housed within the nacelle. Thus, when the wind causes the blades to rotate, electrical energy is generated by the generator. Wind power has grown significantly over the past few decades, and many wind turbine power generation facilities are located on land and at sea.

[0003] As mentioned above, the blades interact with the wind to generate the mechanical rotation of the rotor, which can then be converted into electrical energy. Wind turbine blades are complex structures that must be built to withstand long-term operation in harsh environments while maximizing lift and minimizing drag. The blades move through the environment surrounding the wind turbine at varying speeds, but this movement is typically high-speed. Consequently, the blades typically undergo erosion and damage over time during operation due to friction from the air and potential impacts from airborne particles, debris, or other objects, especially along the leading edge facing the direction of the windward movement. Erosion or damage along the leading edge of the blade adversely affects its aerodynamic quality over time, resulting in lower power output for a given inlet wind speed. This erosion and damage to the blades can be corrected through routine maintenance and repair procedures.

[0004] Blades are typically formed from a shell of layered fiber composites, aluminum, or similar materials, having an outer skin defined by a series of coating (polymer elastomers, paints, etc.) layers surrounding and covering the outer surface of the shell. The shell encloses the internal components of the blade (e.g., including shear webs and spars) and isolates them from the environment. The outer skin can be defined by multiple different material layers, including at least an outermost topcoat, a second layer beneath the outermost topcoat, and a third layer beneath the second layer. Other layers are often also present beneath the third layer, including a substrate typically made of fiber composites, etc. The topcoat, second layer, and third layer can be formed of materials of different colors to more easily reveal the depth to which erosion or damage has penetrated the blade's outer skin. Based on which layer the damage extends into, damage to the blade's outer skin can be classified into several different severity levels; for example, erosion of the third layer would be a "Category 2" severity level, which would be higher than a cut in the second layer, while a cut in the second layer would be a "Category 1" severity level. For low-level damage or erosion, such damage can be repaired by depositing a coating on the area to fill the damage and restoring the blade to its original state along its leading edge.

[0005] These types of repairs to wind turbine blades are typically performed in three ways. First, the blade can be removed from the rest of the wind turbine and lowered to the ground for repair. This process is time-consuming and expensive because it requires removal, relocation, and reassembly of the blade relative to the top of the tower. Second, operators with rope skills can descend along the wind turbine blades while still attached to the rotor hub to assess the blades and perform repairs as needed. Again, this process is time-consuming and expensive because it requires experienced rope technicians and time to perform the repairs manually. Third, operators can perform repairs on a platform that is raised to a position adjacent to the blades on the wind turbine, or extends from the nacelle or hub of the wind turbine, or from a vehicle-mounted lift or boom-style lift. In all conventional methods, the wind turbine must be stopped and locked during the repair period, resulting in significant power generation losses for wind turbine operators for these necessary maintenance and repair operations. This could cause some operators to delay or postpone such repairs, which could lead to more significant structural damage and even longer delays when more thorough repairs are required at the wind turbine blades.

[0006] In recent years, there has been a desire to allow for some automated maintenance of wind turbine blades, thereby improving the speed and / or accuracy of the process. However, such automated maintenance devices are not always designed for reliable use on wind turbine blades that are still attached to the rotor and hub of the wind turbine, and such systems are very slow to operate. As a result, conventional automation options have not been adopted because manual repairs by rope technicians continue to be faster and more efficient in many cases. Further improvements to automated maintenance and repair systems are expected.

[0007] Therefore, wind turbine manufacturers and operators continue to seek improved options for automated maintenance and repair of wind turbine blades in modern wind turbine designs. Summary of the Invention

[0008] For these and other purposes, embodiments of the present invention focus on a coating applicator tool head configured for use with a robotic maintenance apparatus to repair damage around the leading edge of a wind turbine blade. The tool head includes a tool head body, a feed tube, a roller brush, and a nozzle. The tool head body has a frame and an interface component configured to mechanically and electrically connect with a corresponding interface mounted on an articulated arm of the robotic maintenance apparatus. The feed tube is configured to receive a flow of coating from a supply container and deliver the flow to a nozzle positioned adjacent to the roller brush. The nozzle distributes the coating flow along the width of the roller brush, applying the coating directly onto the roller brush. The roller brush is configured to roll along the surface of the wind turbine blade, thereby transferring coating onto the surface of the wind turbine blade and applying a coating layer to cover and repair damage on the wind turbine blade. The direct application of coating to the roller brush via the nozzle as the roller brush moves above the blade surface ensures thorough and uniform coverage, thus improving repair.

[0009] In one embodiment, the nozzle includes a nozzle body, an inlet, and an outlet. The nozzle body extends laterally along the width of the roller brush between opposite ends supported by a frame of a tool end body. The inlet is centrally located between the opposite ends of the nozzle body, and the outlet is defined by an elongated slit cut into the nozzle body to extend between the opposite ends and facing the roller brush, the elongated slit being configured to dispense paint along the width of the roller brush. In such an embodiment, the nozzle body is also defined by at least partially flexible material such that the pressure of the paint flow from the inlet expands the elongated slit at the central portion compared to portions closer to the opposite ends. This results in a higher paint distribution rate at the center of the roller brush compared to the opposite ends.

[0010] In another embodiment, the paint applicator tool tip includes a supply container that can be supported on the tool tip body. The supply container defines a storage volume for holding paint to be applied to the wind turbine blades. The paint applicator tool tip also includes a drive mechanism that is operatively engaged with and actuated to deliver a flow of paint from the supply container to a feed pipe connected to the supply container.

[0011] In another embodiment, the supply container defines at least two chambers configured to hold different components that can be mixed together to form a paint. The drive unit includes an independent actuator associated with each of the at least two chambers. The tool end then includes a mixing component connected to the supply container and feed pipe, configured to receive the different components from the at least two chambers and mix them into a paint. In such an embodiment, the tool end may also include a control system operatively connected to the drive unit. The control system causes the independent actuators to operate at independently adjustable speeds to supply the individual components at a mix ratio suitable for generating a paint when mixed at the mixing component. To this end, the control system varies the speed of the independent actuators to change the flow rate of paint being dispensed onto the roller brush at the nozzle. The flow rate is adjusted according to the movement speed of the roller brush to ensure continuous application of paint to the roller brush during operation of the tool end.

[0012] In another embodiment, the individual actuators of the drive unit are defined by pistons, each configured to move relative to one of the chambers to cause the associated components to flow out of that chamber and into the mixing component. Thus, the drive unit includes individual actuation motors that engage with the respective pistons. The mixing components in these and other embodiments are defined by a static mixer that mixes the different components as they flow through its elongated length.

[0013] In another embodiment, the paint applicator tool tip also includes a discharge container connected to the mixing component, and a valve operatively connected to the mixing component, the discharge container, and the feed pipe. The valve controls the flow of paint leaving the mixing component to be delivered into the discharge container or the feed pipe. For example, the valve initially directs paint into the discharge container until the mixing rate of the different components has reached a desired threshold, and then the valve directs paint into the feed pipe for delivery to the nozzle and roller brush.

[0014] In another embodiment, the roller brush is mounted on the frame at opposite ends in such a way that it can rotate freely relative to the frame. The rotation of the roller brush is then actuated by moving the tool end back and forth along the surface of the wind turbine blade by an articulated arm. In some embodiments, the tool end also includes a curing device mounted on the frame at a location spaced apart from the roller brush. The curing device is configured to apply heat and / or light toward the coating after it has been applied to the surface of the wind turbine blade to aid in the curing and solidification of the repaired area covered by the coating. For example, the curing device may be a heater configured to generate and radiate infrared heat, or a light source configured to cure the coating using ultraviolet light. IR heat or UV light aids in the curing and solidification of the repaired area covered by the coating. It should be understood that the various features described in these embodiments of the coating applicator tool end can be combined in any combination and sub-combination to achieve the desired technical advantages and effects described herein.

[0015] A further embodiment of the paint applicator tool tip may be defined as follows. In one such embodiment, the paint applicator includes: a tool tip body, a dispensing tool, a supply container, a drive unit, a mixing component, and a control system. The tool tip body includes a frame and an interface component configured to be mechanically and electrically coupled to a corresponding interface disposed on an articulated arm of a maintenance device. The dispensing tool is mounted on the frame and configured to move along the surface of a wind turbine blade to dispense paint onto the blade. The supply container defines at least two chambers configured to hold different components that can be mixed together to form a paint to be dispensed onto the dispensing tool for application to the blade. The drive unit is operatively engaged with the supply container such that actuation of the drive unit results in the delivery of a paint flow from the supply container. The drive unit includes an independent actuator associated with each of the at least two chambers. The mixing component is connected to the supply container and configured to receive the different components from the chambers and mix the different components into a paint. The control system enables the independent actuators of the drive unit to operate at independently adjustable speeds, thereby supplying the individual components of different components at a mixing ratio suitable for generating a coating when mixing occurs at the mixing component. Therefore, the tool tip of this embodiment is configured to combine and mix different components into a coating using independent, variable mixing ratios, enabling the tool tip to dispense many different types of coatings that can be used to construct and / or repair wind turbine blades.

[0016] In one implementation, the control system alters the speed of the individual actuators to change the flow rate of paint being dispensed onto the dispensing tool. The flow rate is adjusted based on the moving speed of the dispensing tool to ensure continuous application of paint to the dispensing tool during operation of the paint applicator tool tip.

[0017] In another embodiment, the individual actuators of the drive unit are pistons, each configured to move relative to one of the chambers to cause the associated component to flow out of that chamber and into the mixing component. The drive unit will include individual actuation motors that engage with the respective pistons. The mixing component is defined by a static mixer configured to mix the different components as they flow through an elongated length of the static mixer.

[0018] In another embodiment, the dispensing tool includes a spatula comprising a flexible extrusion plate and one or more spacers positioned near the inner surface of the extrusion plate. The extrusion plate includes a leading edge, a trailing edge, opposing side edges, an outer surface, and an inner surface. The extrusion plate also includes a central region defined by a central axis. The one or more spacers are configured to define a gap between the outer surface of the wind turbine blade and the inner surface of the extrusion plate for dispensing the coating. The applicator tool also includes a feed tube for supplying coating to the spatula. The spatula is configured to shape the coating into a layer over a damaged area of ​​the wind turbine blade.

[0019] The one or more spacers define a height profile that typically corresponds to the shape of the coating from the applicator tool. For example, the height profile may have a maximum value in a central region adjacent to the extrusion plate and gradually decrease to approximately zero at a side edge adjacent to the extrusion plate. In one embodiment, the extrusion plate may be selectively movable relative to the one or more spacers. For example, the extrusion plate may be selectively slid relative to the one or more spacers. The relative movement between the extrusion plate and the one or more spacers is configured to change the height profile.

[0020] In one embodiment of the dispensing tool equipped with a scraper, the one or more spacers include a plurality of ribs coupled to an inner surface of an extrusion plate and extending from a front edge toward a rear edge, wherein the plurality of ribs define grooves between adjacent ribs. In this embodiment, the plurality of ribs may be integrally formed with the extrusion plate. The plurality of ribs may be positioned around a central region on the inner surface of the extrusion plate, and regions of the inner surface adjacent to the side edges may be without ribs. In one aspect, the height of the plurality of ribs may vary across the extrusion plate, and the plurality of ribs may be symmetrical about a central axis. In an exemplary embodiment, the height of the plurality of ribs may be maximum in a region adjacent to the central region of the extrusion plate and gradually decrease in height away from the central region toward the side edges.

[0021] In another embodiment of the distributing tool equipped with a scraper, the one or more spacers include one or more ridges having a front edge, a rear edge, an upper edge, and a lower edge. The lower edge may form an acute angle with respect to the upper edge and may be configured to engage the outer surface of a wind turbine blade during use. In this embodiment, the extrusion plate is separate from the one or more ridges and may also be movable relative to the one or more ridges. The one or more ridges may be positioned approximately on the inner surface of the extrusion plate around a central region and may extend in a direction generally parallel to the central axis. In one embodiment, the extrusion plate may be coupled to a rigid support, the one or more ridges may be coupled to a feed tube, and the rigid support may slide relative to the feed tube.

[0022] In another embodiment, the dispensing tool is a roller brush rotatably connected to the frame, and the roller brush is mounted on the frame at opposite ends in such a way that it can rotate freely relative to the frame. The rotation of the roller brush is actuated by moving the end of the paint applicator tool back and forth along the surface of the wind turbine blade by a joint arm.

[0023] Embodiments of the present invention also address a method for automatically repairing damage around the leading edge of a wind turbine blade. The method includes the steps of: coupling a paint applicator tool tip to an articulated arm of a robotic maintenance device already positioned along the leading edge of the wind turbine blade, such that the articulated arm can move the paint applicator tool tip to position around the included damage on the blade. The method further includes the step of: actuating a drive mechanism associated with a supply container operatively connected to the tool tip, such that an independent actuator of the drive mechanism moves relative to corresponding chambers of different components of the supply container that can be mixed together to form a paint for the wind turbine blade. Actuation of the drive mechanism delivers a stream of different components to a mixing component, which then mixes the streams of different components to generate a paint stream delivered to a dispensing tool. The method further includes the step of: using the articulated arm to move the paint applicator tool tip, causing the dispensing tool to move along the surface of the blade to apply multiple layers of paint to the surface of the blade, thereby covering and repairing the damage on the blade. The independent actuators of the drive unit are controlled to move at independently adjustable speeds, thereby supplying different components at a desired mixing ratio suitable for generating coatings when mixing occurs at the mixing component.

[0024] In one embodiment, the method includes the step of changing the speed of an independent actuator of the drive unit to alter the flow rate of paint being delivered to the dispensing tool. The flow rate is adjusted based on the moving speed of the dispensing tool to continuously apply paint to the dispensing tool during operation of the tool tip.

[0025] In one embodiment, the dispensing tool includes a scraper comprising a flexible extrusion plate and one or more spacers positioned proximate to the inner surface of the extrusion plate. The extrusion plate includes a leading edge, a trailing edge, opposing side edges, an outer surface, and an inner surface. The extrusion plate also includes a central region defined by a central axis. The one or more spacers are configured to define a gap between the outer surface of the wind turbine blade and the inner surface of the extrusion plate for dispensing paint. The applicator tool also includes a feed tube for supplying paint to the scraper. The scraper is configured to form the paint as a coating over a damaged area of ​​the wind turbine blade. The method includes the steps of: engaging the applicator tool to the outer surface of the wind turbine blade; supplying paint to the applicator tool; moving the applicator tool along the outer surface of the wind turbine blade; and dispensing paint from the applicator tool to form a coating over a damaged area of ​​the wind turbine blade.

[0026] In another embodiment, the dispensing tool is a roller brush rotatably coupled to a frame, and the tool end also includes a nozzle positioned adjacent to the roller brush and connected to a mixing component to receive the paint flow. In such an embodiment, the method further includes the steps of: dispensing the paint flow along the width of the roller brush using the nozzle; and distributing the paint flow directly from the nozzle onto the roller brush while the roller brush rolls along the surface of a wind turbine blade. For example, the distribution step may include distributing a higher distribution rate of paint to the center of the roller brush compared to the opposite ends along the width of the roller brush.

[0027] In another embodiment, the method includes the step of applying heat and / or light toward the coating after the coating is applied to the surface of the blade to help cure and solidify the repaired area covered by the coating.

[0028] In another embodiment, the tool end includes a discharge container connected to the mixing component and a valve operationally connected to the mixing component, the discharge container, and the dispensing tool. The method then further includes the steps of: controlling the paint flow initially from the mixing component to the discharge container using the valve until the mixing rate of the different components has reached a desired threshold; and, after the mixing rate has reached the desired threshold, actuating the valve to switch the paint flow from the mixing component to the dispensing tool.

[0029] The steps and elements described herein can be reconfigured and combined in many different combinations to achieve the desired technical effects of different types of wind turbines that may be required in the art. Attached Figure Description

[0030] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description of the invention given above and the detailed description given below, serve to illustrate the invention.

[0031] Figure 1 This is a perspective view of a wind turbine according to one embodiment of the present invention.

[0032] Figure 2 yes Figure 1 A front view of a wind turbine blade, showing various levels of erosion damage along the leading edge of an upward-pitched pitch.

[0033] Figure 3 This is a top perspective view of a robot maintenance device including a paint applicator tool tip according to an embodiment of the present invention, the maintenance device being installed... Figure 2 The appropriate position on the leading edge of the wind turbine blade, wherein the articulated arm moves above the surface containing the damage.

[0034] Figure 4 It is similar to Figure 3 The top 3D view shows most of the robot's maintenance equipment, but in a phantom view to highlight the paint applicator tool tip that can be attached to the articulated arm.

[0035] Figure 5 Is with Figure 4 Similarly, the top perspective view after the articulated arm is attached to the paint applicator tool tip shows the paint applicator tool tip in use applying multiple layers of paint to the leading edge of a wind turbine blade to repair damage.

[0036] Figure 6 yes Figure 5 A side view of the end of a paint applicator tool, showing the damage caused by applying paint to a wind turbine blade during operation.

[0037] Figure 7 yes Figure 6 A side cross-sectional view of the tool tip of a paint applicator shows several internal features of the tool tip.

[0038] Figure 8 yes Figure 5 A detailed front view of the nozzle and roller brush at the end of the paint applicator tool, wherein a portion of the roller brush is shown in phantom form to reveal further details of the nozzle in operation.

[0039] Figure 9 yes Figure 5 The front view of the paint applicator tool tip again shows the paint applicator tool tip in use at the wind turbine blade.

[0040] Figure 10 yes Figure 2 The cross-sectional view of the wind turbine blade shown shows that paint has been applied to the damaged area on the leading edge of the blade.

[0041] Figure 11 It is a three-dimensional view of the scraper of the applicator tool;

[0042] Figure 12 yes Figure 11 The front view of the scraper shown;

[0043] Figure 13 This is a side view of the applicator tool, where... Figure 11 The scrapers are being used to repair damage to the leading edge of wind turbine blades;

[0044] Figure 14 It runs through Figure 13 The arrangement shown is generally a cross-sectional view taken along line 7-7;

[0045] Figure 15 yes Figure 13 Another cross-sectional view of the arrangement shown;

[0046] Figure 16 It runs through Figure 15 The arrangement shown is a cross-sectional view taken along line 9-9;

[0047] Figure 17 This is a top-view perspective of the scraper of the applicator tool;

[0048] Figure 18 yes Figure 17 A 3D view of the bottom of the scraper shown;

[0049] Figure 19 This is a side view of the applicator tool, where... Figure 17 The scrapers are being used to repair damage to the leading edge of wind turbine blades;

[0050] Figure 20 yes Figure 19 The arrangement shown is a cross-sectional view taken along line 13-13;

[0051] Figure 21 It runs through Figure 19 Another cross-sectional view of the arrangement shown;

[0052] Figure 22 It runs through Figure 21 The arrangement shown is generally a cross-sectional view taken along line 15-15; and

[0053] Figure 23 It is a partial three-dimensional view of the scraper of the applicator tool. Detailed Implementation

[0054] Reference Figures 1 to 23 This paper details an embodiment of a paint applicator tool tip configured for use with a robotic maintenance device, and a method for automatically repairing damage around the leading edge of a wind turbine blade. The maintenance device also employs a novel and advantageous method for repairing so-called Category 1 and Category 2 damage to the outer coating of wind turbine blades, which may include: scanning the blade to image the damaged area, polishing and cleaning the surface of the blade surrounding the damaged area, and then applying one or more layers of paint to repair the damage by spraying or the like. This method produces high-quality and precise repairs, again helping to minimize operational downtime while avoiding the need for rope technicians and the associated safety and timing issues of manual repairs. The paint applicator tool tip allows for the mixing of multi-component paints at varying ratios, and then the paint is applied as needed to repair a given wind turbine blade.

[0055] In some embodiments, the applicator tool includes a scraper for shaping coating on the leading edge of the wind turbine blade as the applicator tool moves along the blade. The scraper is configured to apply a uniform and flat coating of material, which is typically thickest in cross-section near the leading edge of the blade and gradually decreases in thickness in a generally continuous and smooth manner along the upper and lower surfaces of the blade and in the direction toward the trailing edge. This allows the coating to blend smoothly with the existing blade surface at locations away from the leading edge. The shape of the coating applied by the applicator tool is configured to adequately repair the damaged area of ​​the blade while minimizing aerodynamic disturbances to the airflow above the blade. Therefore, repair is achieved with minimal impact on the aerodynamic performance of the blade. The scraper and associated method produce high-quality and precise repair of damaged areas of wind turbine blades, overcoming many drawbacks of existing repair devices and processes.

[0056] Furthermore, in some embodiments, the coating applicator tool tip dispenses coating directly onto a roller brush, which moves together with the tool tip to apply the coating to the blade surface, thereby reliably applying coating to repair blade damage according to the general maintenance method described above. Other advantages and effects of the embodiments of the invention will become apparent from the following description.

[0057] Throughout this application, the correction of erosion damage on wind turbine blades is generally referred to as “repair” to such damage. In some contexts, “damage” refers to more significant damage to the blade (potentially beyond what is described herein as “Category-1” and “Category-2” damage), and therefore the operation of maintenance devices can be considered as routine maintenance actions that occur before the blade is “damaged” in such contexts. In this respect, maintenance devices are able to provide preventative maintenance to remove wear and erosion effects before they cause the necessary repairs to the “damage” on the wind turbine blade, and also to provide more thorough repairs after damage has occurred on the blade.

[0058] Convert to reference Figure 1 The wind turbine 10 is shown as comprising: a tower 12, a nacelle 14 disposed at the apex of the tower 12, and a rotor 16 operatively coupled to a generator (not shown) housed within the nacelle 14. The rotor 16 of the wind turbine 10 includes a central hub 18 and a plurality of wind turbine blades 20 projecting outward from the central hub 18 at circumferentially distributed locations about the hub 18. As shown, the rotor 16 includes three wind turbine blades 20, but the number of blades 20 can vary from one wind turbine to another. The wind turbine blades 20 are configured to interact with the airflow to generate lift, which causes the rotor 16 to generally spin within a plane defined by the wind turbine blades 20. As the rotor 16 spins, the wind turbine blades 20 pass through the air, wherein the leading edge 22 guides the respective wind turbine blades 20 during rotation. The wind turbine blades 20 in use are separated from the ground surface by a considerable distance, which typically makes maintenance and repair difficult. However, the paint applicator tool tip and associated robotic maintenance device of the present invention improve the repair process, making it easier and less time-consuming, as will be described in detail below.

[0059] As the wind turbine 10 ages, one or more of the wind turbine blades 20 may undergo erosion due to prolonged and continuous exposure to the environment. An example of this erosion damage 26 is... Figure 1 As shown in, and in Figure 2 A more detailed view is provided. While not specifically limited to any particular source, erosion damage 26 can occur due to airborne particles that abrade the leading edge 22 of the wind turbine blade 20 during operation. Therefore, erosion can occur in the erosion zone including the leading edge 22, but it can also occur in other areas of the surface 30 of the blade 20. Thus, when the robotic maintenance device is configured to repair damage and move along the leading edge 22, it is also capable of performing maintenance and repair actions anywhere along the outer surface of the blade 20.

[0060] Erosion damage 26 is specifically characterized as material loss of the wind turbine blade 20. Material loss may be uniformly distributed, but is typically non-uniform across the leading edge 22 or any other surface of the wind turbine blade 20. Erosion can include localized surface defects, such as random pitting and shallow groove or crack-like features, rather than uniform material loss from the surface skin; these localized surface defects may be the result of localized, interconnected pitting (due to impacts with debris or other materials in the environment). In any case, if erosion damage 26 is not repaired in a timely manner, the wind turbine blade 20 becomes less efficient in rotating the rotor 16, and ultimately, the structural integrity of the wind turbine blade 20 may be significantly compromised. (Refer to...) Figure 2 From the detailed view, it should be understood that the erosion damage 26 can be defined with different severity levels based on how deep the damage extends inward into the material layers of the outer shell defining the blade 20. In the example shown, the erosion damage 26 includes areas where material erosion or cutting penetrates the outer layer into a second layer of material beneath the surface layer, which is classified as "Category 1" severity level; and includes additional areas where material erosion or cutting penetrates the outer and second layers of material into a third layer of material beneath the second layer, which is classified as "Category 2" severity level. For reference, deeper cuts and erosions defining more severe damage are generally classified at higher levels, such as Category 3, Category 4, or Category 5. Figure 2 In the diagram, the first layer is shown as 28a, the exposed area of ​​the second layer is shown as 28b, and the exposed area of ​​the third layer is shown as 28c. The materials of these different layers 28a, 28b, and 28c can differ in color, which can help identify the severity of the damage and confirm repairs after they have been completed using maintenance equipment. By quickly identifying and correcting this lower level of erosion damage 26, more significant damage to the blade 20 and the resulting increased operational downtime can be avoided.

[0061] Figure 3An overview of a robotic maintenance device 40 including a paint applicator tool tip 80 according to an embodiment of the invention is provided. The maintenance device 40 includes a body 42 having a first body portion 44 and a second body portion 46 extending toward opposite sides of the leading edge 22 of the blade 20 when the maintenance device 40 is mounted on top of the leading edge 22 of the blade 20, as shown in the figure. It should be appreciated that the wind turbine 10 is stopped together with the blade 20 to operate in a generally horizontal orientation with variable pitch of the blade 20, such that the leading edge 22 faces upward when the maintenance device 40 is placed on the blade 20. The maintenance device 40 can be moved onto the blade 20 in various ways, including by crane and / or by aircraft, without departing from the scope of the invention. The body 42 generally defines a frame on which other components of the maintenance device 40 will be mounted, as set forth in the following description.

[0062] The articulated arm 48 is attached to one end of the body 42 so as to protrude outward beyond the front portion of the maintenance device 40. In this embodiment, the articulated arm 48 is defined by a series of arm portions 50 joined together at a rotary joint 52. Movement of the arm portions 50 at the joint 52 allows the free end 54 of the articulated arm 48 to move around the periphery and surface of the wind turbine blade 20. For this purpose, in this embodiment, the free end 54 can access any portion of the surface of the blade 20 for inspection or maintenance and repair operations (or any portion within the physical area defined by the articulated arm 48). The free end 54 of the articulated arm 48 also carries components that define a portion of the vision system 56 of the maintenance device 40. For example, the vision system 56 may include a laser (not shown) and / or a scanning camera 58 configured to image damaged areas on the surface 30 and / or blade 20 near the leading edge 22.

[0063] For example Figure 3 As shown, in this embodiment, the maintenance device 40 also includes a mast 60 that projects upward from the body 42 to a position completely above the rest of the maintenance device 40. The vision system 56 also includes a panoramic camera 62 mounted on the mast 60. This panoramic camera images the rest of the maintenance device 40 to provide a complete overview of its operational status and actions. This overview may be desirable when the maintenance device 40 is being monitored or controlled at least partially from an off-site location (including on the ground surface rather than on the blade 20). In other embodiments, more or fewer camera devices may be provided to allow visual feedback to be provided to the maintenance device 40 and / or the operator.

[0064] The body 42 serves as a support for one or more tool ends, which can be selectively engaged by the articulated arm 48 to perform necessary repair and maintenance actions. In the illustrated embodiment, two exemplary tool ends are mounted on the maintenance device 40. The first is a cleaning / grinding tool end 70, configured to grind and then clean the damaged surface of the wind turbine blade 20 in preparation for repair. The second is a paint applicator tool end 80, configured to apply multiple layers of paint to the surface of the blade 20 to fill damaged areas, thereby repairing the blade 20. The paint applicator tool end 80 is one of the main aspects of this application and will be referred to... Figures 4 to 9 Further detailed description. It should be understood that the total number of tool ends located on the maintenance device 40 may vary in other embodiments without departing from the scope of the invention, because each tool end is designed to provide a certain function, and this function needs to be adaptable to different contexts and applications. The free end 54 of the articulated arm 48 includes an interface component 64 that can be mechanically and electrically connected to a corresponding interface component 66 located on each of the tool ends 70, 80.

[0065] Maintenance device 40 also includes Figure 3 The control system 90 is schematically illustrated and implemented on a known hardware and software platform. The control system 90 is operationally connected to other parts of the maintenance device 40 (including the articulated arm 48, vision system 56, and motion drive 100) to operate these components. The control system 90 is capable of responding to input from the vision system 56 and / or from an off-site operator to modify the actions taken by the maintenance device 40 based on the required repair or maintenance on the blade 20.

[0066] Figure 3 The motion drive device 100 is further illustrated. As mentioned above, the body 42 includes a first body portion 44 and a second body portion 46, which extend toward opposite sides of the leading edge 22 of the blade 20 when the maintenance device 40 is mounted on top of the leading edge 22. The motion drive device 100 is defined by a plurality of components positioned along a longitudinal guide rail 102, which extends along the length of the maintenance device 40 at its free end defined by the first body portion 44 and the second body portion 46. Moreover, in the illustrated position, a plurality of idler wheels 104 connected to the lower surface of the body 42 between the first body portion 44 and the second body portion 46 are located directly on the leading edge 22 of the blade 20. Figure 3Two of these idler wheels 104 can be seen. The idler wheels 104 can rotate freely along the surface of the blade 20 in response to movement of the maintenance device 40 generated by the mobile drive 100, as will be described. The idler wheels 104 help support the weight of the maintenance device 40 on the blade 20, so that the entire weight is not applied to the mobile drive 100 and its components. These idler wheels 104 can be formed of plastic material or any other suitable material (typically a low-friction material) to help avoid any damage during engagement with the blade 20. The mobile drive 100 includes a plurality of clamping actuators 106a, 106b, 106c extending from the longitudinal guide rail 102 to selectively clamp into opposite sides of the wind turbine blade 20. The idler wheels 104 and the clamping actuators 106a, 106b, 106c define the direct contact point between the maintenance device 40 and the blade 20 in this embodiment. It should be understood that in other embodiments, only one idler wheel 104 or any number of idler wheels 104 may be provided.

[0067] exist Figure 3 In the illustrated embodiment, the movement drive 100 includes three pairs of actuators among the plurality of clamping actuators 106a, 106b, and 106c. For this purpose, the plurality of clamping actuators includes a front pair of clamping actuators 106a located at one longitudinal end of the body 42, a middle pair of clamping actuators 106b, and a rear pair of clamping actuators 106c located at the other longitudinal end of the body 42. The middle pair of clamping actuators 106b is located between the front pair and the rear pair of clamping actuators. The movement drive 100 is configured to move one pair of clamping actuators at a time relative to the other pairs of clamping actuators to produce movement in any direction along the leading edge 22 of the blade 20. For this purpose, the plurality of clamping actuators 106a, 106b, and 106c are configured to produce a stable crawling movement along the blade 20 when the maintenance device 40 is positioned for repair and maintenance operations. It should be understood that other embodiments of the motion drive 100 may include more than three pairs of clamping actuators without departing from the scope of the invention. This design of the motion drive 100 allows both the movement of the maintenance device 40 and its rigid engagement in place during repair method steps, so that repair actions are more precise and accurate (e.g., without generating unnecessary additional vibration), thus helping to minimize downtime during repair operations.

[0068] Now, let's switch to reference. Figure 4 and Figure 5 Various positions of the paint applicator tool tip 80 according to this embodiment are shown. Figure 4In these views, the tool end 80 is shown in a retracted position on the body 42 of the robotic maintenance device 40, which is shown as a phantom to allow for focused attention on the tool end 80. Once the maintenance device 40 has been moved close to the location of the damage 26 and the surface 30 has been prepared for repair (e.g., by polishing and cleaning the surface around the damage 26 as identified above), the articulated arm 48 moves to a position where its interface component 64 engages with the interface component 66 on the tool end 80. Although many other components of the paint applicator tool end 80 are in... Figure 4 Not visible in the view, but the interface component 66 is advantageously oriented towards the top front of the maintenance device 40 to facilitate access to the articulated arm 48 and its interface component 64. After the articulated arm 48 engages with the tool end 80, the articulated arm 48 moves the tool end 80 to a position above the surface 30 (e.g., Figure 5 As shown), the step of applying paint to repair damage 26 is performed (for example, as along movement arrow 174). The articulated arm 48 is usually the only part of the maintenance device 40 that is moving during this repair step because the clamping actuators 106a, 106b, 106c of the movement drive 100 are clamped into engagement to hold the maintenance device 40 firmly in place without vibration or movement that would otherwise adversely affect the operation of the tool tip 80.

[0069] along with Figure 5 The orientation of the paint applicator tool tip 80 is varied, and more parts of the tool tip 80 are visible. See also... Figure 6 It shows, as Figure 5A detailed side view of the tool tip 80 in operation is shown. The paint applicator tool tip 80 of this embodiment includes a tool tip body 110, which includes a frame 112 and the aforementioned interface component 66. In this embodiment, the frame 112 provides a structure on which all the following components are supported. The tool tip 80 also includes a supply container 114 mounted on the frame 112, which defines a storage volume for holding paint to be applied to the surface 30 of the wind turbine blade 20. The supply container 114 is operatively engaged with a drive unit 116, which can be actuated to deliver a flow of paint from the supply container 114. The tool tip 80 also includes: a feed pipe 118 connected to the supply container 114 for receiving the paint flow, a nozzle 120 connected to the feed pipe 118, and an applicator device 122 positioned to receive the paint flow from the nozzle 120. In this embodiment, the applicator device 122 is advantageously defined by a roller brush 122, but it should be understood that other embodiments of the tool tip 80 may include other types of applicators configured to apply paint to the surface 30, including but not limited to contoured dispensing tools (such as scrapers). In a further alternative embodiment, paint may be applied directly to the surface 30 of the blade 20 via a nozzle 120 or a similar dispenser. Thus, the paint applicator tool tip 80 is actuated to generate a paint flow, and the paint flow is applied by rolling the tool tip across the surface 30 to fill the damage 26, thereby repairing the blade 20. When the articulated arm 48 is as Figure 6 As the tool tip 80 is moved back and forth along surface 30, as indicated by arrow 124, paint is applied by roller brush 122 in a manner similar to painting. It should be understood that, in other embodiments, the supply container 114 and its drive mechanism 116 may alternatively be fixedly mounted on the body 42 of the maintenance device 40, wherein appropriate pipes or conduits supply the dispensed paint to the remainder of the paint applicator tool tip 80.

[0070] from Figure 6 and Figure 7 The internal layout and construction of these and other components of the paint applicator tool tip 80 can be seen in further detail. (See also:) Figure 7As can be readily understood from the cross-section, the supply container 114 of the tool tip 80 includes a first chamber 130 and a second chamber 132 separated from each other by an internal partition wall 134. The first chamber 130 and the second chamber 132 are configured to hold different components that can be mixed together to form a coating to be applied to the wind turbine blade 20. For this purpose, when the drive unit 116 is actuated to cause the different components to flow out of the first chamber 130 and the second chamber 132, these different components converge at a common outlet 136 communicating with the respective chambers in the first chamber 130 and the second chamber 132. The different components can then be thoroughly mixed together using a mixing component 138, as described in further detail below. Although two chambers 130, 132 are shown in the supply container 114 of these figures, it should be understood that in other embodiments within the scope of the invention, other embodiments of the tool tip 80 may use more than two chambers to combine more components to form the coating; for example, the supply container 114 may include at least two chambers.

[0071] Further components of the drive unit 116 are also made from Figure 7 The cross-section is disclosed. In this respect, the drive unit 116 includes independent actuators associated with each of the chambers in the first chamber 130 and the second chamber 132. One of these independent actuators is defined by a first piston 140 located within the first chamber 130 and a first motor 142 (schematically shown) engaged with the first piston 140. The first piston 140 may include a face part 144 and a drive rod 146, the face part moving within the first chamber 130 to urge one of the different components into the outlet 136, the drive rod extending rearward from the face part 144 to engage directly with the first motor 142. The drive rod 146 generally also extends to the outside of the housing defined by the frame 112, such that this portion of the first piston 140 is visible from the outside of the tool end 80. In a similar manner, another actuator of the independent actuators is defined by a second piston 150 located within the second chamber 132 and a second motor 152 engaged with the second piston 150. The second piston 150 also includes a face component 154 that moves within the second chamber 132, and a drive rod 156 that extends rearward from the face component 154 and directly engages with the second motor 152. The first motor 142 and the second motor 152 are independently actuated by the control system 90 to advance the first piston 140 and the second piston 150 into the first chamber 130 and the second chamber 132 as indicated by arrow 160, so as to cause the different components to flow into the outlet 136 and the downstream mixing component 138.

[0072] More specifically, the control system 90 is operationally connected to the first motor 142 and the second motor 152 of the drive unit 116. Figure 7(Shown schematically), thus defining a control / control system for the tool tip 80 of the paint applicator. The control system 90 can communicate with the first motor 142 and the second motor 152 via the aforementioned interface components 64, 66. The control system 90 causes the first motor 142 and the second motor 152 to operate at independently adjustable speeds; for example, the first motor 142 is controlled and operated to move the first piston 140 at an adjustable speed, and this speed may differ from the speed at which the second motor 152 is controlled and operated to move the second piston 150. This arrangement provides the technical benefit of allowing different components with varying or adjustable mixing ratios to be delivered to the mixing component 138 to form a paint. Different paints may require different component mixing ratios, therefore, by providing the drive unit 116 in the manner shown in these figures, the tool tip 80 is configured to handle many different types of paint that may need to be applied to different wind turbine blade designs. Moreover, the flow of distributing different components and the relative speed of the resulting paint can be adjusted by the first motor 142 and the second motor 152 to correspond to the movement speed of the roller brush 122, thereby ensuring continuous application of paint to the surface 30.

[0073] Although the independent actuators of the drive unit 116 are shown in this embodiment as a first independent piston 140 and a second independent piston 150, it should be understood that, without departing from the scope of the invention, other types of actuators for causing flow out of the chambers 130, 132 of the supply container 114 may be used in other embodiments. Similarly, it should be understood that, in further embodiments, the electric or mechanical motors 142, 152 in this embodiment may be replaced by pneumatic and / or hydraulic actuators for propelling the corresponding pistons 140, 150 (such embodiments will typically include hydraulic or pneumatic supply lines extending from the maintenance device 40 to the tool tip 80, such components are not shown in the illustrated embodiment for simplicity). Regardless of the specific structural arrangement used, the drive unit 116 advantageously enables the independent and adjustable supply of different components in the supply container 114 to form the coating.

[0074] Hybrid component 138 in Figure 6 and Figure 7The following diagram illustrates this in further detail. The mixing component 138 in this embodiment is a static mixer 138, which includes a mixer inlet 162, an elongated mixer body 164 defining a conduit, and a mixer outlet 168 having a series of mixing baffles 166 (or similar components) located within the conduit. The mixer inlet 162 is directly coupled to a common outlet 136 in a supply container 114. As different components from the supply container 114 flow through the static mixer 138, the mixing baffles 166 divide and recombine the flow in such a way that the different components are thoroughly mixed together to form a coating. The mixer outlet 168 is directly coupled to one end of a feed pipe 118, thereby delivering the now-mixed coating flow into the feed pipe 118. It should be understood that in other embodiments, other types of known mixing components and other types of mixing baffles may be used.

[0075] In this embodiment, the feed tube 118 is an elongated, flexible tube extending from one end connected to the mixer outlet 168 to the other end connected to the nozzle 120. When the nozzle 120 and roller brush 122 are attached to a support arm 170 of the frame 112 extending downwards from the longitudinal center point of the supply container 114, the feed tube 118 in this embodiment bends rearward to deliver the paint flow from the mixing component 138 to the nozzle 120. A support bracket 172 can be attached to the front end of the frame 112 to help guide the feed tube 118 and hold it in place relative to the remainder of the tool end 80. The support bracket 172 is typically defined by a simple, elongated L-shaped or Z-shaped bracket, such as... Figure 7 As shown. In an alternative embodiment of the tool end 80 where the nozzle 120 and roller brush 122 are repositioned, the feed tube 118 may be modified or omitted entirely according to the design shown, as long as the nozzle 120 continues to receive paint flow from the supply container 114 and mixing component 138.

[0076] exist Figure 6Further components that may optionally be included in some embodiments of the paint applicator tool tip 80 are schematically shown. For this purpose, the tool tip 80 also includes a discharge container 202 connected to the mixing component 138 via a valve 200. The valve 200 is a selection valve (such as a three-way valve) for controlling whether the paint flows from the mixing component 138 to the discharge container 202 or to the feed pipe 118. At this point, the control system 90 typically operates the valve 200 to initially direct paint into the discharge container 202 until the mixing rate of the different components has reached a desired threshold (e.g., this threshold may be related to the desired mixing ratio of the different components to form paint as needed in that particular maintenance / repair operation). The control system 90 then switches the valve 200 to direct (in this embodiment via the feed pipe 118) paint flow to the nozzle 120 and the roller brush 122. Valve 200 and discharge container 202 allow the initial dispensing of different components to be discarded into discharge container 202 until mixing component 138 correctly generates the desired coating, at which point dispensing can begin onto roller brush 122 or another similar applicator tool.

[0077] Now, referring to Figure 7 and Figure 8 The nozzle 120 and roller brush 122 are shown in further detail. In this embodiment, the nozzle 120 includes a nozzle body 176 extending laterally between opposite ends 178a, 178b, which are connected to two support arms 170 projecting downwards from opposite lateral sides of the frame 112. Figure 7 Most clearly illustrated, the nozzle body 176 takes the form of a hollow tubular or cylindrical component that defines a flow path between a nozzle inlet 180 and a nozzle outlet 184 located at the central portion 182 of the nozzle body 176 (generally midway between opposite ends 178a, 178b). In this embodiment, the nozzle inlet 180 and nozzle outlet 184 are defined by a radial opening through the nozzle body 176, and the nozzle inlet 180 is generally a circular orifice shaped to receive flow from a similarly shaped feed tube 118, while the nozzle outlet 184 is defined by an elongated slit extending laterally along a large portion of the width of the nozzle between opposite ends 178a, 178b of the nozzle 120. The nozzle inlet 180 is separated from the nozzle outlet 184 by an amount along the outer periphery of the nozzle body 176, shown in this embodiment as approximately 90 degrees circumferentially separated along the outer periphery of the nozzle body 176. It should be understood that the specific positioning of these components of nozzle 120 can be reconfigured in other embodiments.

[0078] As paint flows into nozzle 120 via nozzle inlet 180, pressure from the flow in feed pipe 118 causes the flow to expand through hollow tubular nozzle body 176 to spread across the width of nozzle 120. Thus, the inflow of paint at the central portion 182 expands to become an outflow of paint at nozzle outlet 184, spanning a large portion of the width of nozzle 120 and the width of the roller brush 122 positioned adjacent to nozzle 120. For this purpose, nozzle outlet 184 is positioned to point towards and adjacent to roller brush 122, such that paint flow is applied directly from nozzle 120 to roller brush 122. This arrangement advantageously ensures that all paint flow is reliably delivered to roller brush 122 for immediate application to the surface 30 of wind turbine blade 20. In other embodiments of tool tip 80, nozzle 120 and its components can be adjusted (e.g., by providing different types of outlets).

[0079] As from Figure 8 As can also be seen, the nozzle body 176 of this embodiment is defined by at least a portion of a flexible material. It should be understood that the pressure in the paint flow (which is substantially constant within the nozzle 120) will have a greater effect on the portion of flexible material at the central portion 182, which is further away from the support provided by the support arm 170 compared to the opposite ends 178a, 178b. Thus, when under the pressure of the paint flow through the nozzle 120, the elongated slit defining the nozzle outlet 184 can expand more coarsely in the opening region along the central portion 182 compared to the portions adjacent to the opposite ends 178a, 178b of the nozzle outlet 184. Figure 8 This arrangement, as seen in the diagram, allows the nozzle 120 to distribute more paint along the center of the roller brush 122 compared to its opposite ends. Typically, when repairing damage 26 on a wind turbine blade 20, the deepest part of the damage 26 is centered as the roller brush 122 moves across the surface 30 to apply paint, and by applying more paint to the center of the roller brush 122, the paint application more easily fills the damage 26, thus allowing for repair with an effective number of passes of the roller brush 122 across the surface 30.

[0080] Figure 7 and Figure 8 Further details of a roller brush 122 used with this embodiment of the paint applicator tool tip 80 are also shown. The roller brush 122 is a cylindrical brush rotatably mounted on a support wheel shaft 188 that extends between the bottom ends of the support arms 170 and the connection between the support wheel shaft 188 and the support arms 170. The roller brush 122 is freely rotatable relative to the support wheel shaft 188 and the rest of the tool tip 80. As a result, when the articulated arm 48 moves the tool tip 80 above the surface 30 of the blade 20 and the roller brush 122 contacts the surface 30 (e.g., ... Figure 6 and Figure 7 As indicated by arrow 124 in the diagram, the roller brush 122 is actuated to rotate by these movements. Therefore, in this embodiment, no drive or motor is required for individually moving the roller brush 122, thus simplifying the construction and assembly of the tool end 80.

[0081] Therefore, as Figures 6 to 9 As shown, repairs can be performed using a robotic maintenance device 40 and a paint applicator tool tip 80. For this purpose, after the articulated arm 48 is coupled to the tool tip 80 and moves the tool tip 80 to a position above the damage 26 on the wind turbine blade 20, and after the roller brush 122 contacts the surface 30 containing the damage 26, the articulated arm 48 is controlled to move the tool tip 80 longitudinally back and forth above the surface 30. As a result of the clamping actuators 106a, 106b, 106c, the maintenance device 40 remains stationary during these movements. This back-and-forth movement causes the roller brush 122 to rotate along the surface 30, as... Figure 6 and Figure 8 As shown, the drive unit 116 is actuated simultaneously with this movement, causing the paint flow to be directly distributed onto the roller brush 122 at the nozzle 120. At this point, as the roller brush 122 moves along the surface 30, paint is continuously applied to the roller brush 122, thereby applying paint over the damaged area 26. Figure 9 As indicated by multiple positions and movement arrows 192, the roller brush 122 can make multiple longitudinal passes around the leading edge 22 at different angles to apply paint over and fill the entire damaged area 26 to cover and repair it. The specific number of passes and various angles taken by the tool tip 80 can be set based on previous repair experience stored in the control system 90 and / or based on a scan of the damaged area using the vision system 56 at the start of the repair process. In cases where multiple different components are mixed at the tool tip 80 to form the paint, the drive unit 116 also independently controls the speed of the actuator to provide the desired mixing ratio as the different components flow through the mixing component 138 to generate the paint. This method reliably produces high-quality and precise repairs of so-called Category 1 and Category 2 damage on wind turbine blades 20 due to the continuous direct dispensing of paint from the nozzle 120 onto the roller brush 122 and allows for setting varying mixing ratios based on the paint being applied by the tool tip 80. It should be appreciated that if different colors or types of paint are to be applied to the blade 20, according to this embodiment of the invention, additional tool ends will be provided for each different type of paint, and the articulated arm 48 will engage with any tool end containing the paint required for the current part being repaired.

[0082] By operating the above method, routine maintenance to remove erosion damage 26 from the blade 20 can be performed while the blade 20 remains attached to the wind turbine 10. Furthermore, since the maintenance device 40 and tool tip 80 are completely autonomous, no manual intervention, such as that of rope technicians, is required. Therefore, the tool tip 80 and its associated method of repairing the blade 20 improve the maintenance capabilities of the wind turbine blade 20, and thereby help minimize operational downtime by ensuring that necessary maintenance and repairs are performed at regular intervals in a precise and accurate automated manner.

[0083] In some implementations, such as Figure 6 As shown, an additional component may be included on the tool end 80 of the paint applicator. This additional component is a curing device 190, which is mounted on the frame 112 at a position spaced apart from the roller brush 122. The curing device 190 is schematically shown in this set of figures. The curing device 190 is operated by a control system 90 to apply heat, etc., to the paint after it has been applied to the surface 30 by the roller brush 122. For example, the curing device 190 may be a heater configured to generate and radiate infrared heat, or a light source configured to cure the paint using ultraviolet light. IR heat or UV light helps to cure and solidify the repaired area covered by the paint. It should be understood that the specific mounting location and equipment used for the curing device 190 can be modified according to any known design. In embodiments including the curing device 190, the repair method includes moving the infrared curing device 190 on the same surface on which the paint was applied by the roller brush 122 after the paint has been applied by the roller brush, using an articulated arm 48. Further implementations may include additional steps, such as using a vision system 56 to verify the accuracy and adequacy of repairs performed by applying paint after operating the paint applicator tool tip 80.

[0084] The paint applicator tool tip 80 according to an embodiment of the invention facilitates the routine repair of damage 26 (such as erosion damage) on wind turbine blades 20 by a robotic maintenance device 40, typically located along and around the leading edge 22 of the wind turbine blade. The tool tip 90 is configured to combine and mix different components into a paint using independent, variable mixing ratios, thereby enabling the tool tip 80 to dispense many different types of paint that can be used to build and / or repair wind turbine blades 20. Therefore, the tool tip 80 facilitates the use of the maintenance device 40 by most (if not all) wind turbine operators. Furthermore, the continuous and direct dispensing of paint from the nozzle 120 to the roller brush 122 ensures thorough and even coverage as the roller brush 122 is moved over the surface 30 via the tool tip 80 and the articulated arm 48. Thus, the paint applicator tool tip 80 improves the field of automated repair and maintenance of wind turbine blades 20, which will help improve compatibility with routine maintenance programs and increase uptime for wind turbine operators.

[0085] Figure 10 An example is shown of a repaired section of a wind turbine blade 20 having damage 26 on its leading edge 22. This repaired section includes a material coating 30 above the damage 26 on the leading edge 22 of the blade 20. The coating 30 is configured to define a new outer surface 232 that interacts with the air flowing over the blade 20. Therefore, the coating 30 protects the damage 26 on the wind turbine blade 20 and prevents or reduces the possibility of further propagation of the damage 26, such as reaching a higher category of damage. Additionally, the coating 30 is preferably shaped to minimize any negative impact of this repair on the aerodynamic performance of the wind turbine blade 20 during service. Thus, the new outer surface 232 is configured to minimize disturbance of the airflow above the blade 20. In this respect and as... Figure 10 As illustrated, coating 30 is configured to have its maximum thickness at or around the leading edge 22 of blade 20, and then gradually decrease in thickness along both outer surfaces 234 of blade 20 (i.e., the leeward and windward sides) in a direction away from the leading edge 22 and toward the trailing edge (not shown) of blade 20. Ideally, the thickness of coating 30 should gradually decrease to approximately zero at the outer edge 236 of coating 30. This allows coating 30 to be smoothly incorporated into the existing surface 234 of blade 20, thereby minimizing airflow disturbance during the transition from the outer surface 232 of coating 230 to the original outer surface 234 of blade 20. In the example, coating 230 may be formed of epoxy or polyurethane, but other materials are also possible. Applicator tools help to provide a precise and high-quality coating 230 on the leading edge 22 of wind turbine blade 20 having the shape and characteristics described above.

[0086] Figures 11 to 16 An applicator tool 240 according to one example is illustrated. According to this example, the applicator tool 240 includes a scraper 242 for shaping a coating 230 applied to the leading edge 22 of a wind turbine blade 20. Figure 11 and Figure 12 Details of the scraper 242 are illustrated. In this example, the scraper 242 may include a generally flexible or bendable extruded plate 244 made of, for example, rubber or other generally flexible engineering plastics. The extruded plate 244 may be generally rectangular in shape and includes a leading edge 246, a trailing edge 248, and opposing side edges 250, 252 extending between the leading edge 246 and the trailing edge 248. The extruded plate 244 may also include an outer surface 256 and an inner surface 258 of the scraper 242. The outer surface 256 is configured to face away from the leading edge 22 of the wind turbine blade 20 during use, and the inner surface 258 is configured to face the leading edge 22 of the blade 20 during use (see Figure 258). Figure 14 and Figure 16 In the example, the thickness of the extruded plate 244 between the outer surface 256 and the inner surface 258 can be from about 1 mm to about 2 mm. More preferably, the thickness of the extruded plate 244 can be about 1.5 mm. However, other thickness values ​​are also possible depending on the specific application. The extruded plate 244 can be formed of a low-friction material or include a coating, such as a polytetrafluoroethylene coating, which provides low-friction properties at least for the inner surface 258.

[0087] In this example, the scraper 242 may include spacers to provide a gap between the outer surface 234 of the blade 20 and the inner surface 258 of the extrusion plate 244. In this example, the spacers may include a plurality of ribs 260 disposed below the inner surface 258 of the extrusion plate 244. In one example, the plurality of ribs 260 may extend from the inner surface 258 of the extrusion plate 244 of the scraper 242 in a spaced-apart manner. The ribs 260 may be generally parallel to each other and extend from the front edge 246 of the extrusion plate 244 toward the rear edge 248. In one example, the plurality of ribs 260 extend all the way to the rear edge 248 of the extrusion plate 244. Figure 11 However, in an alternative example, the plurality of ribs 260 stop (not shown) without reaching the rear edge 248 of the extrusion plate 244. The plurality of ribs 260 may extend away from the front edge 246 and substantially perpendicular to the front edge 246 of the extrusion plate 244 along the inner surface 258. The substantially right angle between the front edge 246 and the plurality of ribs 260 is merely exemplary, and other angles are also possible in alternative examples.

[0088] The plurality of ribs 260 are spaced apart to define a groove 262 between adjacent ribs 260. The groove 262 is formed by a portion of the side surfaces of the adjacent ribs 260 and the inner surface 258 of the extrusion plate 244 between the adjacent ribs 260. In the example, the plurality of ribs 260 are uniformly spaced apart from each other at a fixed distance. By way of example and not limitation, the ribs 260 may be spaced apart from each other between about 3 mm and about 8 mm. More preferably, the ribs 260 may be spaced apart from each other about 5 mm. However, other values ​​are still possible and still within the scope of the invention. In another example, the spacing between the ribs 260 across the width of the scraper 242 (not shown) may be non-uniform. For example, the spacing between adjacent ribs 260 may be minimum at the central region 264 adjacent to the scraper 242 (as generally defined by the region around the central axis 266) and increase in the direction toward the side edges 250, 252 of the extrusion plate 244. In one example, the plurality of ribs 260 may be integrally formed with the extrusion plate 244, such that, for example, the scraper 242 may be formed from a single body. However, in another example, the plurality of ribs 260 may be formed individually and fixedly attached to the inner surface 258 of the extrusion plate 244 of the scraper 242. The plurality of ribs 260 may also be made of or coated with a low-friction material.

[0089] As will be described in detail below, the applicator tool 240 is movable along the leading edge 22 of the wind turbine blade 20 to apply a coating 230 to the blade 20. At this point, a scraper 242 is configured to engage with the wind turbine blade 20 and extrude the coating applied to the blade 20 immediately following the scraper 242, such that after the scraper 242 passes over the deposited coating, the coating 230 has a desired smoothness and shape, such as those described above. As mentioned above, the plurality of ribs 260 are configured to operate as spacers to provide a gap 268 between the outer surface 234 of the wind turbine blade 20 and the inner surface 258 of the extrusion plate 244. The gap 268 generally corresponds to the desired shape of the coating 230, and as the applicator tool 240 moves along the leading edge 22 of the blade 20, the coating is substantially extruded from the gap 268 to define the coating 230, as will be described in more detail below. Therefore, the plurality of ribs 260, in conjunction with the extrusion plate 244, define the shape of the coating 230 on the blade 20. More specifically, the height profile 270 of the plurality of ribs 260 ( Figure 12 The shape of the coating 230 applied to the leading edge 22 of the blade 20 is roughly defined.

[0090] In the example, the height profile 2270, which may be defined by the plurality of ribs 260, is configured to have a maximum height in the central region 264 of the extrusion plate 244, and the height gradually decreases away from the central region 264 toward the side edges 250, 252 of the extrusion plate 244. In a preferred example, the height of the ribs 260 gradually decreases to approximately zero in the direction away from the central region 264 toward the side edges 250, 252 of the extrusion plate 244. The height profile 2270 can have a wide range of configurations such that the height is maximum near the central region 264 and then gradually decreases to approximately zero near the side edges 250, 252. For example, the region of maximum height in the height profile 2270 may extend above the plurality of ribs 260 in the central region 264 (e.g., 3, 5, or 7 ribs), and then the height begins to gradually decrease outside this region. Moreover, the gradual decrease in rib height can be configured differently. For example, the rib height may gradually decrease from the maximum height in the central region 264 to approximately zero in a linear, parabolic, or exponential manner. Other gradual decrease configurations are also possible. In any case, the height profile 2270 of the plurality of ribs 260 functions to generally define the cross-sectional shape of the coating 230 applied to the wind turbine blade 20. In one example, a plurality of scrapers 242 may be provided, each of which will have a different height profile 2270. Thus, a particular height profile 2270 can be selected based on the needs or expectations of the coating 230 for a particular application. In one example, the height profile 2270 of the plurality of ribs 260 is preferably generally symmetrical about the central axis 266 of the extrusion plate 244, such that the resulting coating 230 is generally symmetrical about the leading edge 22 of the blade 20.

[0091] Figures 13 to 16The use of an applicator tool 240 for repairing the leading edge 22 of a wind turbine blade 20 is illustrated in more detail. The applicator tool 240 typically includes a frame 274 having a front support 276 and a rear support 278. The front support 276 includes a pair of arms 280 terminating at corresponding compression pads 282. One or more springs 284 or other biasing mechanisms may be coupled to the arms 280 and / or the pads 282 to press the scraper 242 against the outer surface 234 of the wind turbine blade 20, as indicated by arrow F. The rear support 278 may include a feed pipe 118 operationally coupled (e.g., via a pump, etc.) to a paint source (not shown) and configured to supply paint to the outer surface 234 of the wind turbine blade 20. The scraper 242 may be positioned on the frame 274 for support by the front support 276 and the rear support 278. For example, the compression pad 282 can be adhered to or otherwise selectively and detachably attached to the outer surface 256 of the front edge 246 and side edges 250, 252 adjacent to the extrusion plate 244 of the scraper 242. Furthermore, the central region 264 of the scraper 242 adjacent to the rear edge 248 can be supported by a rear support 278, such as by a small tab, hook, or possibly by the feed tube 118. The feed tube 118 is generally located below the scraper 242. Figure 13 and Figure 15 As illustrated, the frame 274 or scraper 242 may be angled relative to the leading edge 22 of the blade 20, such that the trailing edge 248 of the scraper 242 is higher than the leading edge 246 of the scraper 242 by a greater distance than the blade 20. This defines a funnel-shaped space 288 between the blade 20 and the scraper 242, wherein the area between the blade 20 and the scraper 242 gradually decreases in the direction toward the leading edge 246 of the scraper 242. The feed pipe 118 is configured to extend into the funnel-shaped space 288 and deliver paint within this space to form a coating 230.

[0092] like Figures 13 to 16 As illustrated, to maintain and repair damage 26 on the leading edge 22 of a wind turbine blade 20, an applicator tool 240 can be positioned on the blade 20 such that the plurality of ribs 260 face the surface 234 of the blade 20, and the ends of the ribs 260 engage the outer surface 234 of the blade 20. A compression pad 282 can press a scraper 242 against the outer surface 234 of the blade 20 at a distance from the leading edge 22. Furthermore, the central axis 266 of the compression plate 244 can be configured to align with the leading edge 22 of the blade 20. This arrangement is, for example, in… Figure 14 and Figure 16 As shown in the diagram. The paint can then be guided to the feed pipe 118 for deposition in the funnel-shaped space 288 between the surface 234 of the blade 20 and the scraper 242. This is, for example, in... Figure 15An example was provided in the text.

[0093] When the paint fills the funnel-shaped space 288, the applicator tool 240 can move along the leading edge 22 of the blade 20, such as Figure 13 and Figure 15 As illustrated by arrow A, as the applicator tool 240 moves, it causes paint to enter the funnel towards the leading edge 246 of the scraper 242 and is extruded essentially from the groove 262 at the leading edge 246 of the extrusion plate 244. In this example, due to the presence of ribs 260 at the leading edge 246 of the extrusion plate 244, the paint is applied to the outer surface 234 of the blade 20 in the form of strips 290 separated from each other. The height of the strips 290 is determined by the height profile 270 of the scraper 242. After the paint is applied to the outer surface 234 of the wind turbine blade 20 in strips 290, the paint flows under the influence of gravity, surface tension, or other effects to form a smooth and continuous coating 230 with a shape determined by the height profile 270 of the scraper 242 (see, for example, [link to relevant documentation]). Figure 10 In this example, the paint must generally be substantially flowable (i.e., have a suitable viscosity), which allows the paint to coalesce to form a continuous coating 230, but does not allow the material to simply flow uncontrollably across the outer surface 234 of the blade 20, which could occur with paints that are too low in viscosity. It should be understood that after the coating 230 has dried or cured, the applicator tool 240 can be used to make additional passage over the damage 26 on the leading edge 22 of the blade 20. Thus, the final coating 230 can consist of multiple layers, each applied using the applicator tool 240 as described above.

[0094] Figures 17 to 21 An applicator tool according to another example is illustrated. Similar to the applicator tool described above, this tool is configured to apply a coating to damage on the leading edge of a wind turbine blade in an improved manner. However, there are several differences between the applicator tool of this example and the applicator tool described above, which will be highlighted below. For example, one difference is the manner in which the coating is applied to the wind turbine blade. More specifically, the applicator tool described above applies strips of paint to the surface of the wind turbine blade due to the rib / groove construction of the scraper. The rib / groove construction of the scraper, in turn, results in defining the height profile of the scraper, which ultimately defines the shape of the coating on the blade. In any case, after the strip is applied to the blade, the paint must have a suitable viscosity that allows the material to flow under the influence of gravity and surface tension effects to form a smooth and continuous coating.

[0095] However, in the alternative example described below, the applicator tool is configured to operate in a different manner. As described in more detail below, the applicator tool is configured to more directly shape the paint being extruded from the applicator tool. In other words, the shape of the paint extruded from the applicator tool roughly and more directly corresponds to the final shape of the coating on the leading edge of the wind turbine blade. Therefore, using this alternative applicator tool avoids applying the paint in strips and merging these strips to form the final coating. This distinction can be particularly relevant when working with paints of high viscosity, such that the paint strips using the aforementioned applicator tool do not flow together under gravity and other effects, thus preventing the formation of a smooth and continuous coating on the blade. Therefore, the alternative applicator tool described below is ideally suited for high-viscosity paints.

[0096] Another difference between the above-described applicator tool and the alternative applicator tool described below is the ability to more dynamically change the profile of the coating applied to the blade. As discussed above, the profile of the coating is primarily determined by the height profile of the plurality of ribs on the extrusion plate. Recall that if a different profile is required, a different scraper is typically needed to provide that new profile. In the alternative example, the applicator tool is configured to have the ability to selectively adjust a certain aspect of the profile of the coating provided by the applicator tool as it passes along the blade. This adjustable feature, as well as other features of the alternative applicator tool, will now be described in detail.

[0097] The applicator tool 240 includes a scraper 242 for shaping a coating 230 applied to the leading edge 22 of the wind turbine blade 20. In an example, the scraper 242 may include a generally flexible or bendable extrusion plate 244 made of, for example, rubber or other generally flexible engineering plastic. The extrusion plate 244 may be generally rectangular in shape and includes a leading edge 246, a trailing edge 248, and opposing side edges 250, 252 extending between the leading edge 246 and the trailing edge 248. The extrusion plate 244 may also include an outer surface 256 and an inner surface 258 of the scraper 242. The outer surface 256 is configured to face away from the leading edge 22 of the wind turbine blade 20 during use, and the inner surface 258 is configured to face the leading edge 22 of the blade 20 during use (see Figure 258). Figure 19 and Figure 21 In the example, the thickness of the extrusion plate 244 between the outer surface 256 and the inner surface 258 can be from about 1 mm to about 2 mm. More preferably, the thickness of the extrusion plate 244 can be about 1.5 mm. However, other thickness values ​​are also possible depending on the specific application.

[0098] Similar to the above, the scraper 242 may include one or more spacers to provide a gap between the surface 234 of the blade 20 and the inner surface 258 of the extrusion plate 244. In this example, the one or more spacers may include rigid blades or ridges 306 disposed below the inner surface 258 of the extrusion plate 244. Unlike the applicator tool described above, the ridge 306 is not integrally formed with the extrusion plate 244, but is a separate component that works in conjunction with the extrusion plate 244 during the operation of the applicator tool 240. The ridge 306 includes a leading edge 308, a trailing edge 310, an upper edge 312, and a lower edge 314. In this example, the leading edge 308 forms a generally right angle with respect to the upper edge 312, and the lower edge 314 forms an acute angle with respect to the upper edge 312 (see [link to example]). Figure 18 and Figure 21 For example, the lower edge 314 may be at an angle between about 15 degrees and about 45 degrees relative to the upper edge 312. As described in more detail below, the lower edge 314 is configured to engage with the leading edge 22 of the wind turbine blade 20 during use, and the ridge 306 is constructed to provide a gap between the outer surface 234 of the blade 20 and the inner surface 258 of the extrusion plate 244. The scraper 242 also includes a feed tube 118, which is coupled at one end to the trailing edge 310 of the ridge 306 and at the other end operationally coupled (e.g., via a pump) to a paint source (not shown) for supplying paint to the outer surface 234 of the wind turbine blade 20. In one example, the ridge 306 may be integrally formed with the end of the feed tube 118. In another example, these components may be separate and subsequently coupled together.

[0099] The extrusion plate 244 is supported by a rigid support 320 having a tubular portion 320 and fingers 322 connected to and extending forward from the tubular portion 320. For example, the rigid support 320 may include small protrusions received in holes within the extrusion plate 244. However, other attachment devices are also possible. The tubular portion 320 is typically arranged around the end of the feed tube 118 in a coaxial and telescopic manner, for example. The fingers 322 extend from the upper region of the tubular portion 320 and include a generally arched central portion 324 and a pair of wings 326 extending on either side of the central portion 322. The extrusion plate 244 is coupled to the rigid support 320 and is typically positioned between the fingers 322 and the ridge 306 of the support 320. In this example, the extrusion plate 244 is selectively movable relative to the ridge 306. More specifically, the rigid support 320 can slide above the feed tube 118, which causes the extrusion plate 244 to slide relative to the ridge 306 generally along arrow B ( Figure 17The direction of movement is illustrated in the diagram. The relative movement between the extrusion plate 244 and the ridge 306 (which can only allow a limited distance of movement) allows for changes in the height profile of the paint extruded from the applicator tool 240. For example, in a forward position of the extrusion plate 244 relative to the ridge 306, the height of the paint (e.g., at the central axis 266 of the extrusion plate 244) can be minimal, while in a rearward position of the extrusion plate 244 relative to the ridge 306, the height of the paint at the central axis of the extrusion plate 244 can be maximum. In other words, although the applicator tool 240 is configured to provide a similar... Figure 10 The coating 230 is shown, but the thickness of the coating (such as at the leading edge 22 of the blade 20) can be varied depending on the position of the extrusion plate 244 relative to the ridge 306. In any case, when the desired thickness of the coating 230 is determined, fixing screws can be used to fix the relative position of the extrusion plate 244 and the ridge 306, thereby fixing the thickness of the coating 230, for example, at the leading edge 22. Additionally, the feed tube 118 and the rigid support 320 may have keying features 328 (e.g., keys and corresponding keyways) to prevent relative rotation between the feed tube 118 and the rigid support 320.

[0100] As will be detailed below, the applicator tool 240 can move along the leading edge 22 of the wind turbine blade 20 to apply coating 230 to the blade 20. At this point, the scraper 242 is configured to engage with the wind turbine blade 20 and extrude the coating applied to the blade 20 immediately behind the extrusion plate 244 of the scraper 242, such that the coating 230 has the desired smoothness and shape after the scraper 242 passes over the deposited coating. As mentioned above, the ridge 306 is configured to operate as a spacer to provide a gap 268 between the outer surface 234 of the wind turbine blade 20 and the inner surface 258 of the extrusion plate 244. In this example, the gap 268 corresponds more directly to the desired shape of the coating 230, and as the applicator tool 240 moves along the leading edge 22 of the blade 20, the coating is substantially extruded from the gap 268 to ultimately define the coating 230, as will be explained in more detail below. Therefore, the ridge 306, in conjunction with the extrusion plate 244, defines the shape of the coating 230 on the blade 20. More specifically, the position of the extrusion plate 244 relative to the ridge 306 defines a height profile, which in turn defines the shape of the coating 230 applied to the leading edge 22 of the blade 20.

[0101] In the example, the height profile 270 defined by ridge 306 can be configured to have a maximum height in the central region 264 of the extrusion plate 244, and gradually decrease in height away from the central region 264 and toward the side edges 250, 252 of the extrusion plate 244. In a preferred example, there is only a single ridge 306 in the central region 264 of the scraper 242. Due to the lack of other ridges away from the central region 264, the height profile 270 defined by ridge 306 gradually decreases to approximately zero in the direction away from the central region 264 and toward the side edges 250, 252 of the extrusion plate 244. The height profile 270 can have a wide range of configurations such that the height is maximum near the central region 264 and then gradually decreases to approximately zero near the side edges 250, 252. The height profile 270 provided by ridge 306 operates to define the cross-sectional shape of the coating 230 applied to the wind turbine blade 20. As explained above, the relative positions of the extrusion plate 244 and the ridge 306 can be adjusted to change the height profile 270 provided by the scraper 242. A specific height profile 270 can be selected based on the needs or expectations of the coating 230 for a particular application. In the example, the height profile 270 provided by the ridge 306 is approximately symmetrical about the central axis 266 of the extrusion plate 244, such that the resulting coating 230 is approximately symmetrical about the leading edge 22 of the blade 20.

[0102] like Figures 19 to 22 As illustrated, to maintain and repair damage 26 on the leading edge of a wind turbine blade 20, an applicator tool 240 can be positioned on the blade 20 such that the ridge 306, and more specifically the lower edge 314 of the ridge, engages the surface 234 of the blade 20 approximately along the leading edge 22. The applicator tool 240 may also include a compression pad 282 or other biasing mechanism that presses a pressure plate 244 against the outer surface 234 of the blade 20 at a distance from the leading edge 22. Furthermore, the central axis 266 of the scraper 242 can be configured to align with the ridge 306 (and the leading edge 22 of the blade 20). This arrangement is, for example, in… Figure 20 and Figure 22 As shown in the diagram. The coating can then be guided to the feed pipe 118 for deposition in the funnel-shaped space 288 between the outer surface 234 of the blade 20 and the inner surface 258 of the extrusion plate 244. This is, for example, in... Figure 21 It is shown in the middle.

[0103] When the paint fills the funnel-shaped space 288, the applicator tool 240 can move along the leading edge 22 of the blade 20, such as Figure 19 and Figure 21As illustrated by arrow A, as the applicator tool 240 moves, paint is forced into the funnel towards the leading edge 246 of the scraper 242 and is essentially extruded from the leading edge 246 of the extrusion plate 244. In this example, the paint is applied as a whole (e.g., instead of in strips) to the outer surface 234 of the blade 20 to form a smooth and continuous coating 230 with a profile corresponding to the height profile 270 of the scraper 242 (e.g., see [link to other examples]). Figure 10 It should be understood that after the coating 230 has dried or cured, the applicator tool 240 may pass additionally through the damage 26 on the leading edge 22 of the blade 20. Thus, the final coating 230 may consist of multiple layers, each of which is applied using the applicator tool 240 as described above.

[0104] Figure 23 An applicator tool 240 very similar to the one described above is illustrated. The main difference is that the scraper 242 includes multiple ridges 306 instead of a single ridge, as described above. The additional ridges 306 not only help define the height profile 270, but are also configured to provide stability to the applicator tool 240 as the tool moves along the leading edge 22 of the wind turbine blade 20. For example, with a single ridge 306, the applicator tool 240 might easily move away from the leading edge 22 of the blade 20 (e.g., slip). The multiple ridges 306 now engage the surface 234 of the blade 20 at multiple locations around the leading edge 22, thereby reducing the likelihood that the applicator tool 240 will slip off the leading edge 22 as it moves.

[0105] The aforementioned applicator tool 240 improves the maintenance and repair of erosion damage at the leading edge of wind turbine blades. More specifically, applicator tool 240 provides means and methods for applying a coating over damage at the leading edge to prevent further damage to the wind turbine blade. Furthermore, applicator tool 240 provides a coating with an ideal profile, i.e., maximum thickness at the leading edge of the blade, then gradually decreasing in thickness away from the leading edge to approximately zero thickness, so as to smoothly integrate into the outer surface of the wind turbine blade. The profile provided by applicator tool 240 minimizes disturbances to the airflow above the blade and any reduction in aerodynamic performance caused by these disturbances. Applicator tool 240 is particularly advantageous when repairing wind turbine blades under field conditions, such as when the blade is still attached to the rotor hub at the top of the wind turbine tower. Therefore, even under less than ideal field conditions, applicator tool 240 is able to provide high-quality and precise repair of damaged areas of wind turbine blades.

[0106] While the invention has been illustrated by way of description of various preferred embodiments, and while these embodiments have been described in considerable detail, the applicant does not intend to limit the scope of the appended claims or restrict them in any way to such details. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, various features of the invention can be used alone or in any combination, depending on the user's needs and preferences.

Claims

1. A paint applicator tool tip (80) configured in conjunction with a robotic maintenance device (40) for repairing damage around the leading edge (22) of a wind turbine blade (20), the paint applicator tool tip being characterized in that: The tool end body (110) includes a frame (112) and an interface component (66), which is configured to be mechanically and electrically connected to a corresponding interface (64) provided on the articulated arm (48) of the robot maintenance device; A spreading tool (122) is mounted on the frame and configured to move along the surface of the wind turbine blade to spread coating on the surface; A supply container (114) defining at least two chambers (130, 132) configured to hold different components that can be mixed together to form a coating to be dispensed onto the dispensing tool for application to the wind turbine blades; A drive unit (116) is operationally engaged with the supply container and actuated to deliver a flow of paint from the supply container, the drive unit comprising an independent actuator (140, 150) associated with each of the at least two chambers. A mixing component (138) is connected to the supply container and is configured to receive the different components from the at least two chambers and mix the different components into the coating. as well as A control system (90), operatively connected to the drive unit, causes the independent actuators to operate at independently adjustable speeds, thereby supplying the individual components of the different components at a mixing ratio suitable for generating the coating when mixed at the mixing component. The control system is characterized in that it changes the speed of the independent actuator to change the flow rate of paint being distributed onto the dispensing tool, the flow rate being adjusted according to the moving speed of the dispensing tool, so as to continuously apply the paint onto the dispensing tool during operation of the paint applicator tool tip.

2. The coating applicator tool tip according to claim 1, characterized in that, The individual actuators of the drive device are defined by pistons, each configured to move relative to one of the at least two chambers to cause associated components to flow out of the chamber and into the mixing component, and the drive device also includes an individual actuation motor that engages with each of the pistons.

3. The coating applicator tool tip according to claim 1 or 2, characterized in that, The mixing component is defined by a static mixer configured to mix the different components as they flow through an elongated length of the static mixer.

4. The coating applicator tool tip according to claim 1 or 2, further characterized in that: An emission container, the emission container being connected to the mixing component; and A valve, operatively connected to the mixing component, the discharge container, and the dispensing tool, controls the delivery of the paint stream exiting the mixing component into the discharge container or the dispensing tool. The characteristic feature is that the valve initially guides the coating into the discharge container until the mixing rate of the different components has reached a desired threshold, and then the valve guides the coating into the dispensing tool.

5. The coating applicator tool tip according to claim 1, characterized in that, The distributing tool is a scraper (242), which includes: A flexible extrusion plate (244) having a front edge (246), a rear edge (248), opposite side edges (250, 252), an outer surface (256), and an inner surface (258), the extrusion plate (244) also having a central region (264) defined by a central axis (266); and One or more spacers (260, 306) positioned close to the inner surface (258) of the extrusion plate (244), wherein the spacers (260, 306) are configured to define a gap between the outer surface (234) of the wind turbine blade (20) and the inner surface (258) of the extrusion plate (244); and Feed pipe (118), the feed pipe being used to supply paint to the scraper (242), The scraper (242) is configured to form the coating as a coating (230) over the damaged area (26) of the wind turbine blade (20).

6. The coating applicator tool tip according to claim 5, wherein, The one or more spacers (260, 306) define a height profile (270) that corresponds to the shape of the coating (230) from the applicator tool (240).

7. The coating applicator tool tip according to claim 6, wherein, The height profile (270) has a maximum value in the central region (264) adjacent to the extrusion plate (244), and the side edges (250, 252) adjacent to the extrusion plate (244) gradually decrease to approximately zero.

8. The coating applicator tool tip according to any one of claims 5 to 7, wherein, The extrusion plate (244) moves selectively relative to the one or more spacers (306).

9. The coating applicator tool tip according to claim 6 or 7, wherein, The relative movement between the extrusion plate (244) and the one or more spacers (306) alters the height profile (270).

10. The coating applicator tool tip according to any one of claims 5 to 7, wherein, The one or more spacers include a plurality of ribs (260) connected to the inner surface (258) of the extrusion plate (244) and extending from the front edge (246) toward the rear edge (248), wherein the plurality of ribs (260) define a groove (262) between adjacent ribs (260).

11. The coating applicator tool tip according to claim 10, wherein, The height of the plurality of ribs (260) varies, wherein the height of the plurality of ribs (260) has a maximum value in the central region (264) adjacent to the extrusion plate (244), and the height decreases away from the central region (264) and toward the side edges (250, 252).

12. The coating applicator tool tip according to claim 5, wherein, The one or more spacers include one or more ridges (306) having a front edge (308), a rear edge (310), an upper edge (312), and a lower edge (314).

13. The coating applicator tool tip according to claim 12, wherein, The lower edge (314) forms an acute angle with respect to the upper edge (312), and wherein the lower edge (314) is configured to engage the outer surface (234) of the wind turbine blade (20).

14. The coating applicator tool tip according to claim 12 or 13, wherein, The one or more ridges (306) are separated from the extrusion plate (244).

15. The coating applicator tool tip according to claim 12 or 13, wherein, The one or more ridges (306) are positioned around the central region (264) near the inner surface (258) of the extrusion plate (244), and wherein the one or more ridges (306) extend in a direction generally parallel to the central axis (266).

16. The coating applicator tool tip according to claim 12 or 13, wherein, The extrusion plate (244) is connected to a rigid support (320), wherein one or more ridges (306) are connected to the feed tube (118), and wherein the rigid support (320) is slidable relative to the feed tube (118).

17. The coating applicator tool tip according to claim 1 or 2, characterized in that, The dispensing tool is a roller brush rotatably connected to the frame, the roller brush being mounted on the frame at opposite ends in such a way that the roller brush can rotate freely relative to the frame, and the rotation of the roller brush is actuated by moving the end of the paint applicator tool back and forth along the surface of the wind turbine blade by the articulated arm.

18. The coating applicator tool tip according to claim 1 or 2, further characterized in that: A curing device is mounted on the frame at a location spaced apart from the dispensing tool. The curing device is configured to apply heat and / or light toward the coating after the coating is applied to the surface of the wind turbine blade to help cure and solidify the repaired area covered by the coating.

19. A method for automatically repairing damage around the leading edge (22) of a wind turbine blade (20) connected to a wind turbine (10), the method being characterized in that: The paint applicator tool tip (80) is connected to the articulated arm (48) of the robotic maintenance device (40) which has been positioned along the leading edge of the wind turbine blade, such that the articulated arm can move the paint applicator tool tip to position it around the damaged location on the wind turbine blade. A drive unit (116) associated with the supply container (114) which is operationally connected to the tool end of the paint applicator is actuated to move the individual actuators (140, 150) of the drive unit relative to the corresponding chambers (130, 132) of the supply container containing different components that can be mixed together to form a paint for the wind turbine blade, thereby delivering the flow of the different components to the mixing component (138). The mixing component is used to mix the streams of the different components to generate a paint stream that is delivered to the dispensing tool (122); The coating applicator tool tip is moved by the articulated arm to move the dispensing tool along the surface (30) of the wind turbine blade to apply multiple layers of the coating to the surface of the wind turbine blade, thereby covering and repairing the damage on the wind turbine blade; as well as The independent actuators of the drive unit are controlled to move at independently adjustable speeds, thereby supplying the different components at a desired mixing ratio suitable for generating the coating when mixing occurs at the mixing component. in: The speed of the independent actuator of the drive device is changed to alter the flow rate of the paint being delivered to the dispensing tool, the flow rate being adjusted according to the moving speed of the dispensing tool, so that the paint is continuously applied to the dispensing tool during operation of the paint applicator tool tip.

20. The method according to claim 19, characterized in that, The distributing tool is a scraper (242), which includes: A flexible extrusion plate (244) having a front edge (246), a rear edge (248), opposite side edges (250, 252), an outer surface (256), and an inner surface (258), the extrusion plate (244) also having a central region (264) defined by a central axis (266); and One or more spacers (260, 306) positioned close to the inner surface (258) of the extrusion plate (244), wherein the spacers (260, 306) are configured to define a gap between the outer surface (234) of the wind turbine blade (20) and the inner surface (258) of the extrusion plate (244); and Feed pipe (118), the feed pipe being used to supply paint to the scraper (242), The scraper (242) is configured to form the coating into a coating (230) over the damaged area (26) of the wind turbine blade (20), and the method is further characterized in that: The applicator tool (240) is engaged to the outer surface (234) of the wind turbine blade (20). The coating is supplied to the applicator tool (240); The applicator tool (240) is moved along the outer surface (234) of the wind turbine blade (20); and The coating is dispensed from the applicator tool (240) to form the coating (230) over the damaged area (26) of the wind turbine blade (20).

21. The method according to claim 19 or 20, characterized in that, The distributing tool is a roller brush rotatably coupled to a frame of the paint applicator tool end, the paint applicator tool end also including a nozzle positioned adjacent to the roller brush and connected to the mixing component to receive the paint flow, and the method is further characterized in that: The paint flow is distributed through the nozzle along the width of the roller brush; as well as As the roller brush rolls along the surface of the wind turbine blade, the paint flow is directly distributed from the nozzle onto the roller brush.

22. The method according to claim 21, characterized in that, The step of distributing the paint stream directly from the nozzle to the roller brush further includes: The paint is distributed to the center of the roller brush at a higher distribution rate compared to the opposite ends along the width of the roller brush.

23. The method according to claim 19 or 20, further characterized in that: After the coating is applied to the surface of the wind turbine blade, heat and / or light are applied toward the coating to help cure and solidify the repaired area covered by the coating.

24. The method according to claim 19 or 20, characterized in that, The coating applicator tool tip further includes a discharge container connected to the mixing component, and a valve operationally connected to the mixing component, the discharge container, and the dispensing tool, and the method is further characterized in that: The valve controls the initial flow of the coating from the mixing component to the discharge container until the mixing rate of the different components has reached a desired threshold. as well as After the mixing rate has reached the desired threshold, the valve is actuated to switch the paint flow from the mixing component to the dispensing tool.

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