Robot deployment system

Abstract

A robotic deployment system (1) for maintenance of a wind turbine (2), comprising: a mobile deployment unit (10) on which one or more propulsion units are mounted to generate a thrust force having at least a horizontal component force for driving the mobile deployment unit (10) to move towards wind turbine blades (4) of the wind turbine (2); and a support unit (50) connected to the mobile deployment unit (10) by means of an auxiliary cable (23), the support unit (50) comprising auxiliary equipment and / or maintenance material for supporting the operation of the mobile deployment unit (10) by means of the auxiliary cable (23); the support unit (50) can be suspended in the air by a first cable (22a) connected to the nacelle (8) of the wind turbine (2); during operation, the mobile deployment unit (10) can be suspended in the air at least partially by means of the second cable (20); a second cable (20) is connected between the mobile deployment unit (10) and a second cable anchor point located above the support unit (50).

Description

TECHNICAL FIELD

[0001] The present application relates to a robot deployment system, in particular to a robot deployment system for wind turbine maintenance. BACKGROUND

[0002] The service life of a wind turbine is usually 20 to 25 years, during which time operation and maintenance (O&M) is critical to maximizing the economic and environmental benefits of a wind power asset. Current maintenance work is usually carried out by personnel with professional training through a rope access method, i.e. personnel suspended in the air from the nacelle moving along the length of the wind turbine blade (WTB). Such operations are not only dangerous, but also inefficient and ineffective, especially in offshore wind farms. Therefore, to avoid human intervention in high-altitude work, a robot system is preferred.

[0003] This field has attracted widespread attention from industry and academia, and there are a large number of related research projects underway or completed. The process of deploying a robot system to the WTB needs to have efficient, reliable and fail-safe characteristics, which is one of the key issues of such technology. Since the robot needs to work in the air, the initial deployment of the robot system on the surface of the WTB is a particularly critical step.

[0004] For example, WO2021019274A1 discloses a four-anchor scheme for lifting a maintenance device from the ground to a target position on the WTB. Specifically, the entire system is lifted from the ground by a cable descending from the nacelle, and when the system is hoisted to a predetermined height on the WTB, additional cables below the system are used to adjust the position, distance and direction from the WTB until a vacuum chuck on the system is adsorbed on the inclined surface of the WTB. However, this four-anchor mechanism is complex to deploy, especially in offshore wind turbines.

[0005] As an alternative, WO2021121524A1 and US20210095642A1 respectively disclose a robot device with a plurality of movable gripping devices and a plurality of feet with suction cups, enabling the robot device to crawl or descend from the root of the WTB near the nacelle to the target position. However, this mechanism requires the robot device to move along the length of the WTB, so it cannot quickly reach the target position, is inefficient, and can cause additional downtime of the wind turbine. In addition, when the movable gripping device or vacuum chuck fails (e.g. instantaneous power failure or WTB surface anomaly) and falls off the WTB, such a robot device cannot guarantee fail-safe. Once detachment occurs, it is difficult and time-consuming to re-establish the attachment process, because the above-mentioned solutions all need to hoist the robot device back to the root of the WTB to restart the attachment process. More importantly, due to the small size of such a robot device and the limited attachment capability to the WTB, it is usually not possible to carry larger or heavier devices during maintenance.

[0006] Therefore, there is an urgent need for a robotic deployment system that is efficient, reliable, fail-safe, and capable of transporting large or heavy equipment to the vicinity of the maintenance location. Summary of the Invention

[0007] This invention provides a robotic deployment system comprising a mobile deployment unit and a support unit, both suspended by a first cable and a second cable, respectively, and raised to a height close to the target work location. The mobile deployment unit, similar to a drone, is capable of directional movement toward and attachment to a wind turbine blade (WTB) to perform maintenance and / or repair tasks. Because the mobile deployment unit is at least partially suspended in the air by cables, the energy consumption required to maintain the unit in the air is significantly reduced compared to existing drones, thereby enabling efficient and reliable deployment of the service equipment. Furthermore, the cable attachment structure provides a superior fail-safe mechanism, allowing the mobile deployment unit to quickly reattach to the WTB in the event of accidental detachment.

[0008] Furthermore, the mobile deployment unit can be connected to a support unit via an auxiliary cable. The support unit can provide the mobile deployment unit with power, pneumatic system support, and optical and data communication connections via this auxiliary cable, thereby enabling communication with auxiliary equipment located within the support unit. This structure helps minimize the size and weight of the mobile deployment unit, thereby improving its mobility, reducing energy consumption, and lowering the likelihood of detachment after attachment to the WTB.

[0009] According to a first aspect of the present invention, a robotic deployment system for wind turbine maintenance is provided, comprising: A mobile deployment unit, on which one or more propulsion units are mounted, the propulsion units being configured to generate thrust having at least a horizontal component for driving the mobile deployment unit toward the wind turbine blades of a wind turbine; and A support unit is connected to the mobile deployment unit via an auxiliary cable. The support unit includes auxiliary equipment for supporting the operation of the mobile deployment unit via the auxiliary cable. The support unit can be suspended in the air by a first cable connected to the wind turbine nacelle, and during operation, the mobile deployment unit can be at least partially suspended in the air by a second cable; the second cable connects the mobile deployment unit to a second cable anchor point located above the support unit.

[0010] The support unit and the mobile deployment unit can be connected to: i) the cabin, respectively connected by a first cable and a second cable; or ii) the connecting arm, respectively connected by a third cable and a second cable, wherein the connecting arm can be suspended by the first cable, which is connected between the connecting arm and the cabin.

[0011] The robotic deployment system is primarily used to transport and attach service equipment to wind turbine blades, enabling the equipment to perform service operations (e.g., inspection, repair, and / or maintenance) while in close proximity to or in contact with the WTB surface. Specifically, during the service process, the wind turbine is locked to prevent rotation, and the WTB surface is at an angle to the vertical axis. The inspection / service equipment can inspect the WTB using one or more non-destructive testing techniques, such as ultrasound, X-ray, shear interference, acoustic emission, thermal imaging, and impact testing. It also includes repair tools, such as robotic arms, for repairing and / or maintaining the WTB.

[0012] The robot deployment system comprises two main components: a support unit and a mobile deployment unit, connected by auxiliary cables. The support unit and the mobile deployment unit are suspended by a first cable and a second cable, respectively, for example, directly connected or indirectly connected via a connecting arm. During use, the support unit can remain substantially stationary, while the mobile deployment unit can move toward and attach to the WTB to perform maintenance tasks.

[0013] The support unit provides the mobile deployment unit with power, pneumatic systems, vacuum supply, and other functions, such as optical and data communication support, via auxiliary cables. More specifically, most of the equipment required to maintain the operation of the mobile deployment unit, such as batteries, air compressors, vacuum pumps, diagnostic and data processing equipment, can be carried by the support unit. Therefore, by transferring the equipment load to the support unit, this structure can significantly reduce the weight of the mobile deployment unit, improve its mobility, and reduce energy consumption.

[0014] The support unit may include a cable connector for connecting a first cable or a third cable, wherein the first cable can be directly connected to the nacelle via an anchor or a first cable winch mounted on the nacelle. More specifically, the cable connector may be directly or indirectly connected to a first end of the first or third cable, and the second end of the first cable may be connected to an anchor or a first cable winch mounted on the nacelle or elsewhere on the wind turbine above the support unit. In some embodiments, the first cable may be wrapped around or hooked onto the hub of the wind turbine. The cable connector may be a ring anchor, a quick-release connector, or other connector suitable for supporting the weight of the robot deployment system.

[0015] During operation, the support unit can be raised to a height close to the target work position by winding up the first cable. In a preferred embodiment, the first cable can be wound up and down by a first cable winch located in the engine room to control the height of the support unit. Preferably, the first cable winch can be remotely controlled by service personnel away from the engine room via radio communication, or controlled via a control panel electrically connected to the first cable winch. In some embodiments, the first cable winch can be retrofitted into the engine room as part of the assembly process and can be retained in the engine room for future service use after service is completed.

[0016] In some embodiments, the first cable may be directly connected to the support unit, for example, to a cable connector on the support unit. In a preferred embodiment, the first cable may be connected to the cable connector of the support unit in sequence via a connecting arm and a third cable, wherein the connecting arm may also be connected to a second cable for suspending the mobile deployment unit. That is, in these embodiments, the connecting arm may include an anchor point for the second cable located above the support unit and the mobile deployment unit. Here, "above" means that the second cable anchor point is located at a height higher than the support unit and the mobile deployment unit. The third cable may be connected between the connecting arm and the support unit and may be considered an extension of the first cable. Therefore, in these embodiments, the heights of the support unit and the mobile deployment unit can be controlled simultaneously by retracting and extending the first cable winch located in the cabin.

[0017] The mobile deployment unit may resemble a drone. For example, it may include one or more propulsion units for maneuvering the mobile deployment unit. However, unlike commercially available drones, in a suspended state, the weight of the mobile deployment unit may be at least partially supported by a second cable, for example, before being attached to the surface of a wind turbine blade.

[0018] In a preferred embodiment, the robot deployment system may include one or more of a first, second, and / or third cable. In some embodiments, particularly where the mobile deployment unit and / or support unit are connected to a first and / or second cable delivered by an existing cable winch, the robot deployment system may be supplied without one or two cables.

[0019] The first, second, and third cables can be any flexible cable with sufficient tensile strength to support at least the full weight of the support unit and / or mobile deployment unit. The cables can be made of metal wire, natural fibers, or synthetic fibers.

[0020] The mobile deployment unit may be at least partially suspended in the air by a second cable. For example, the entire weight of the mobile deployment unit, including its service equipment, may be supported by the second cable. More specifically, the mobile deployment unit may include a cable connector for direct connection to a first end of the second cable. The second end of the second cable may: i) be directly connected to a second cable anchor or second cable winch (both can be collectively referred to as the second cable anchor point) located in the nacelle or other wind turbine section above the support unit and the mobile deployment unit; and preferably ii) be directly connected to a connecting arm, thereby connecting to the first cable via the connecting arm. In either of these cases, the second cable is suspended by the second cable anchor point (e.g., the nacelle or connecting arm) located above the support unit, thus the support of the mobile deployment unit may be independent of the support unit. More specifically, since both the support unit and the mobile deployment unit are suspended by the connecting arm, the anchor point of the second cable must be located above the support unit. This structure can result in a relatively long second cable, thus producing only a small angular displacement when the mobile deployment unit moves around the second cable anchor point. This design helps reduce vertical displacement during the horizontal displacement of the mobile deployment unit, making control easier; it also minimizes the decrease in the vertical component force provided by the second cable when the mobile deployment unit moves toward the WTB.

[0021] In embodiments where the second cable is directly connected to the cabin, the second cable can be connected to a second cable winch, which operates similarly to the first cable winch. That is, the second cable winch can be used to control the height of the mobile deployment unit. The first and second cable winches can operate independently or preferably simultaneously. By synchronously raising and lowering the first and second cables, this structure helps to keep the support unit and the mobile deployment unit close to each other, thereby minimizing the length of the auxiliary cable between them.

[0022] In a preferred embodiment, when the second cable is connected to the first cable via the connecting arm, the third cable and the second cable can be connected to opposite ends of the connecting arm, spaced apart from each other, to prevent the two cables from tangling. The first cable can be connected to the middle of the connecting arm. The connecting arm can be equipped with a counterweight to balance the weight difference between the mobile deployment unit and the support unit. During use, the height of the support unit and the mobile deployment unit can be controlled simultaneously by the first cable winch to achieve synchronous lifting and lowering.

[0023] Optionally, the robotic system further includes a stabilizing cable connecting the support unit to an anchor located below it for stabilizing the support unit. For example, the anchor can be positioned on the ground or below the platform structure on an offshore wind turbine platform. The anchor can be a conventional ground anchor or a heavy object temporarily placed on the ground or in the sea. This structure minimizes the swaying of the support unit under strong wind conditions, thereby improving the overall stability of the support unit and the mobile deployment unit. In other embodiments, the anchor can be directly connected to the wind turbine tower or indirectly connected via a horizontal extension arm.

[0024] Optionally, the first cable may extend generally parallel to the wind turbine tower. Optionally, the third cable may also extend generally parallel to the wind turbine tower. More specifically, at least a portion of the first cable may extend substantially along the vertical axis. This type of structure helps to eliminate the horizontal component of the force acting on the support unit, thereby minimizing or eliminating the tilting of the support unit.

[0025] Because the mobile deployment unit is at least partially suspended in the air, the lift required to maintain its hovering is significantly reduced, or even eliminated, compared to existing drones. This structure not only allows it to carry heavier loads, such as more powerful robotic arms or equipment, but also significantly reduces the energy consumption required to maintain its levitation, improves maneuverability, and reduces the likelihood of it detaching from the WTB surface.

[0026] Once the mobile deployment unit is securely connected to the cables, it can be lifted directly from the ground or at sea to a height approximately level with the target operating position on the wind turbine blades, for example, by winding the second or first cable toward the nacelle, depending on the configuration. "Approximately level" as used herein refers to a slight height increase that may occur after the mobile deployment unit is attached to the wind turbine blades. Specifically, because the mobile deployment unit is attached to and moves around the nacelle or support unit, it is typically not lifted to the precise height of the operating position, but rather to a slightly lower height that is approximately level with it. Alternatively, the mobile deployment unit can also be lowered directly to a height approximately level with the target operating position on the wind turbine blades, for example, by releasing the second or first cable from the direction of the nacelle or support unit. Subsequently, one or more propulsion units can generate thrust, including at least a horizontal component, to propel the mobile deployment unit toward the wind turbine blades. That is, the key function of the one or more propulsion units is to propel the mobile deployment unit toward the wind turbine blades, at least in the horizontal direction. Furthermore, the propulsion units can control the height of the mobile deployment unit by adjusting the vertical force applied to it.

[0027] The one or more propulsion units may include propellers and / or turbine engines, or other suitable propulsion devices. Preferably, the propulsion unit comprises only propellers similar to those used in existing unmanned aerial vehicles.

[0028] Optionally, the mobile deployment unit may further include one or more of the following components: a sensor component for sensing the position and / or attitude of the mobile deployment unit and generating a sensing signal based on the sensing, the sensor component may include one or more of an accelerometer, a gyroscope, a rangefinder, a GPS sensor and a displacement sensor; A controller is configured to control one or more propulsion units based on the sensor signals, wherein the controller is optionally configured to control the propulsion units based on a closed-loop control method. One or more attachment devices for detachably attaching the mobile deployment unit to the surface of a wind turbine blade, the attachment devices including a vacuum adsorption device and / or an electromagnetic device.

[0029] In some embodiments, the one or more propulsion units are configured to generate thrust along multiple horizontal axes to enable translational movement of the mobile deployment unit in the horizontal direction and / or rotational movement about any axis. That is, the mobile deployment unit may not include a propulsion unit for lifting itself, and its vertical position may be entirely controlled by retracting and extending a second cable and / or a first cable. For example, one or more propulsion units may generate torque or moment to rotate or tilt the mobile deployment unit, thereby enabling the attachment device to align with the inclined surface of a wind turbine blade. The advantage of this structure is that it reduces the number of required propulsion units, thereby reducing the manufacturing cost of the robotic deployment system.

[0030] Preferably, the one or more propulsion units include a set of main propulsion units, each configured to generate thrust along a first horizontal axis; and a set of secondary propulsion units, each configured to generate thrust along a second horizontal axis perpendicular to the first horizontal axis. For example, the main propulsion units may be uniformly distributed in a vertical plane relative to the center of the mobile deployment unit. Therefore, by applying unequal thrust between the different main propulsion units, torque or moment can be generated in the mobile deployment unit, causing it to rotate or tilt. In one embodiment, four main propulsion units may be arranged in the same vertical plane, which is horizontally offset from the center of the mobile deployment unit. In another embodiment, the secondary propulsion units may be aligned along a horizontal plane at the center of the mobile deployment unit, and the horizontal thrust generated by these propulsion units may cause the mobile deployment unit to move along a second horizontal axis. In some embodiments, the main propulsion units need not be in the same vertical plane, and / or the secondary propulsion units need not be in the same horizontal plane.

[0031] Alternatively, the one or more propulsion units can be configured to generate thrust along multiple axes to enable translational movement of the mobile deployment unit in any direction and / or rotational movement about any axis. That is, the propulsion unit can generate thrust with both horizontal and vertical components. Therefore, the propulsion unit can be configured to enable translational movement of the mobile deployment unit in any direction and / or rotational movement about any axis. Specifically, the propulsion unit can also provide upward / downward thrust to the mobile deployment unit to adjust its vertical position, thereby aligning it with the target working position.

[0032] The one or more propulsion units, or more specifically the thrust generated therefrom, can be controlled by a controller based on position, distance, and / or attitude data received from the sensor components. More specifically, the sensor components may include a gyroscope for sensing the attitude and / or angular velocity of the mobile deployment unit, and / or a global positioning system (GPS) for sensing the position of the mobile deployment unit, and / or a rangefinder (such as a laser / ultrasonic rangefinder) for sensing the relative position of the mobile deployment unit to the wind turbine blades (e.g., distance to the WTB surface) and / or its relative position to the ground (e.g., its height). Furthermore, the sensor components may also include one or more of a GPS, an accelerometer, and a distance sensor for sensing the velocity and / or acceleration of the mobile deployment unit.

[0033] The control unit can control the propulsion units in a closed-loop manner based on signals received in real time from the sensor components, thereby fine-tuning the thrust generated by the one or more propulsion units in real time. This structure helps to counteract the effects of wind, thus maintaining the stability of the mobile deployment unit before it attaches to the wind turbine blades, while improving its reliability and maneuverability.

[0034] Once the mobile deployment unit is maneuvered to a position close to or in contact with the wind turbine blades, the controller can activate one or more attachment devices to attach them to the surface of the wind turbine blades. The attachment devices may include vacuum suction devices or electromagnetic devices to achieve releasable attachment. Therefore, once the mobile deployment unit is attached to the WTB, it will no longer require the support of a second cable; for example, its weight can be entirely supported by the WTB through the attachment devices.

[0035] The mobile deployment unit may include a storage structure for storing service equipment or modules, such as detection, repair, and / or maintenance devices. The storage structure may include one or more storage compartments disposed within the mobile deployment unit, and / or a platform formed on the outer surface of the mobile deployment unit. In the latter, the platform may be positioned on the same side as the mobile deployment unit and the attachment device, such that when the mobile deployment unit is attached to a wind turbine blade, the service equipment can be close to or in contact with the surface of the wind turbine blade.

[0036] Overall, this structure not only facilitates the efficient and reliable deployment of service equipment but also constitutes a superior fail-safe mechanism. Specifically, in the event of accidental detachment, the mobile deployment unit of the tether can still be suspended by the second cable and maintained at approximately the height of the target operating position, thereby enabling rapid redeployment via one or more propulsion units.

[0037] Optionally, the one or more propulsion units may include multiple propulsion units, which may be identical or different from each other. The multiple propulsion units may be arranged to generate thrust in the same or different directions.

[0038] Optionally, the one or more propulsion units can be rotatably mounted on the mobile deployment unit to change the direction of the generated thrust. For example, some or all of the propulsion units can be mounted on the mobile deployment unit via a swing arm controlled by a controller. This structure allows for adjustment of the thrust direction, thereby facilitating the steering or tilting of the mobile deployment unit. Furthermore, this structure can reduce the number of propulsion units required.

[0039] Optionally, the second cable can be configured to reduce tension after the mobile deployment unit is attached to the surface of the wind turbine blade. In some cases, especially in strong winds, the blades may still vibrate to some extent even when the wind turbine is locked. Therefore, appropriately loosening the second cable after the mobile deployment unit is attached to the wind turbine blade can reduce the possibility of accidental detachment of the mobile deployment unit.

[0040] Optionally, the one or more propulsion units are configured to generate total thrust, the horizontal component of which is at least 10 N.

[0041] Optionally, the robot deployment system includes multiple mobile deployment units, each connected to a support unit via auxiliary cables and capable of independent operation. That is, the support unit can simultaneously support the operation of multiple mobile deployment units, each configured to serve different or the same work location. This structure offers the advantage that multiple mobile deployment units can share resources provided by the support unit, such as power, pneumatic systems, and vacuum supply, thereby reducing the need for repetitive auxiliary equipment and improving overall maintenance efficiency.

[0042] The multiple mobile deployment units can be suspended individually by their respective second cables. Each second cable can be connected to any part of the naval cabin, connecting arm, or support unit. Alternatively, the multiple mobile deployment units can be connected to the same second cable via their respective auxiliary second cables. For example, when multiple mobile deployment units are operating in adjacent locations, they can be connected to a common second cable via their respective auxiliary second cables, the length of which can be the same or different depending on the corresponding target operating location. This structure has the advantage of reducing the possibility of cable tangling and shortening the system deployment time.

[0043] Preferably, the multiple mobile deployment units can simultaneously serve the same wind turbine blade, or serve different blades of the same wind turbine respectively.

[0044] In some embodiments, multiple mobile deployment units can work collaboratively while servicing the same work location. For example, each mobile deployment unit can deploy a corresponding robotic arm to perform the same or different tasks at the same work location. Such a structure is advantageous for completing more complex tasks or improving the efficiency of service operations.

[0045] Optionally, the robot deployment system further includes a docking station to which the mobile deployment unit can dock when not in operation. More specifically, when idle, the mobile deployment unit can move to the docking station and releasably lock onto it; when a service task needs to be performed, it can be released from the docking station. The advantage of this structure is that it stabilizes the position of the mobile deployment unit when not in use, thereby preventing collisions with support units and / or other mobile deployment units. Furthermore, this arrangement reduces the tension applied to the second cable and / or auxiliary cable when the mobile deployment unit is idle.

[0046] The docking station may be located on the support unit and / or on one or more cables connected to the support unit. Preferably, the docking station is located on the support unit. In embodiments with multiple mobile deployment units, the docking station can accommodate all mobile deployment units.

[0047] Optionally, the robot deployment system further includes an auxiliary winch and / or a rewind spring winch for adjusting the length of the auxiliary cable. The auxiliary winch or rewind spring winch is preferably mounted on the support unit, but may also be mounted on the mobile deployment unit. In embodiments where a second cable connects the mobile deployment unit and the support unit and includes the auxiliary cable, the auxiliary winch and / or rewind spring winch may also be configured to adjust the length of the second cable.

[0048] Optionally, the mobile deployment unit can be configured to retrieve a payload from the support unit for servicing the wind turbine blades and return the payload to the support unit after the service is completed. That is, the support unit may include storage space for storing auxiliary equipment and repair materials needed to complete a specific maintenance task. For example, the mobile deployment unit may carry an ultrasonic scanner as a payload to detect the work location; when a repair task is required, the scanner can be quickly replaced by a welder. This structure facilitates the rapid replacement of different equipment in areas close to the work location, thereby improving maintenance efficiency and flexibility.

[0049] Optionally, the support unit can be configured to carry service personnel and elevate them to the work location. In certain situations, such as when the work location requires manual inspection or in an emergency where the mobile deployment unit malfunctions, the support unit can act as a lifting device to transport service personnel to the target work location. In some embodiments, the support unit may further include an onboard control panel, allowing service personnel to control the support unit and / or the mobile deployment unit from their location. Therefore, this structure can provide an alternative or supplementary means of controlling the mobile deployment unit and / or the support unit.

[0050] Optionally, the first cable includes a cable for supplying power to the support unit and / or the mobile deployment unit. For example, the first cable may be made of an electrical conductor, capable of both supplying power and supporting the weight of the entire robot deployment system. Alternatively, the first cable may include a cable and separate suspension cables for suspending the support unit and / or the mobile deployment unit. More specifically, the suspension cables and the cable may extend coaxially and be encapsulated in a cable sheath to form an integral first cable, or they may exist as two separate components of the first cable.

[0051] Optionally, the first cable includes a cable for establishing data communication between the support unit and the remote terminal. Alternatively, the data communication between the support unit and the remote terminal can also be achieved wirelessly, for example, via radio waves.

[0052] According to a second aspect of the present invention, a method for deploying the robot deployment system described in the first aspect is provided, the method comprising the following steps: The support unit is moved to a height close to the working position of the wind turbine blades by the first cable, thereby suspending the support unit in the air; The mobile deployment unit is moved to a height close to the service location of the wind turbine blades via a second cable, thereby suspending the mobile deployment unit in the air; and Control one or more propulsion units of the mobile deployment unit to drive the mobile deployment unit toward the wind turbine blades.

[0053] The movement step may include retracting or extending a first cable at a first cable winch located on the nacelle, thereby raising or lowering the support unit vertically. The support unit may be moved to a height above, below, or substantially level with the target working position. Preferably, the support unit is moved to a height below the target working position to reduce the possibility of the auxiliary cable contacting the wind turbine blades. The movement step may also include retracting or extending a second cable, for example via a second cable winch, or via a first cable winch when the second cable is connected to the connecting arm, thereby raising or lowering the mobile deployment unit vertically. The mobile deployment unit may be moved to a height above, below, or substantially level with the target working position, and then driven toward the wind turbine blades by one or more propulsion units. Preferably, the mobile deployment unit is moved to a height below the target working position and above the support unit.

[0054] Optionally, the method further includes the following steps: releasing the mobile deployment unit from the docking station before operation; and / or docking the mobile deployment unit back to the docking station after operation. That is, the mobile deployment unit can be unlocked from the docking station with the second cable fully tightened, and then its controlled descent to the work position is achieved by releasing the second cable. Once the operation is complete, the second cable can be wound up, allowing the mobile deployment unit to gradually rise to and dock with the docking station. During docking and / or release, one or more propulsion units can drive the mobile deployment unit toward or away from the docking station, thereby improving the efficiency and safety of the process.

[0055] The features of the first or second aspect of this invention can be applied to any other features in other applications. Attached Figure Description

[0056] Some embodiments of the present invention will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1A The deployment of the robot deployment system according to the first embodiment of the present invention is illustrated schematically; Figure 1B for Figure 1A Enlarged schematic diagram of the mobile deployment unit in the idle position and the attached position shown; Figure 2A and Figure 2B This is a perspective view of the mobile deployment unit according to the first embodiment of the present invention; Figure 2C and Figure 2D for Figure 2A and Figure 2B Side view of the mobile deployment unit shown; Figures 3A-3C A side view showing different stages of the attachment process; Figure 4The deployment of a robot deployment system according to a second embodiment of the present invention is illustrated schematically. Detailed Implementation Example

[0057] Figure 1A The deployment of the robot deployment system 1 according to the first embodiment of the present invention is shown; Figure 1B for Figure 1A The diagram shows enlarged views of the mobile deployment unit in its idle and attached positions, respectively.

[0058] The robot deployment system 1 is used to transport service equipment (such as a robotic arm) to the wind turbine blades 4 of the wind turbine 2 via a mobile deployment unit 10. The robot deployment system 1 also includes a support unit 50, which is connected to the mobile deployment unit 10 via an auxiliary cable 23 to support its operation.

[0059] The wind turbine 2 is a common type of wind turbine, with a nacelle 8 at its upper end. Inside the nacelle 8 is a generator, whose rotor is axially connected to a hub 6, on which multiple wind turbine blades 4 are mounted. During normal operation, the wind turbine blades 4 drive the rotor to rotate, thereby converting the acquired kinetic energy into electrical energy.

[0060] During maintenance, such as when the machine is shut down, the rotor is locked to prevent rotation, and the wind turbine blade 4 is also stationary. Typically, the target wind turbine blade 4 extends vertically downwards, allowing personnel to safely descend from the nacelle 8 for maintenance. However, due to the design and curvature of the wind turbine blade 4, its surface usually has an angle of inclination of approximately 3°–5° relative to the vertical axis. Therefore, during service, neither personnel nor existing robotic devices can be directly descended to the work position; instead, they must crawl from the root of the wind turbine blade, maintaining continuous contact with its surface, to the target work position.

[0061] In addition to service equipment, auxiliary equipment is required to support the operation of the mobile deployment unit 10, such as power control units, air compressors, and vacuum pumps. This auxiliary equipment typically weighs over 10 kg, and may even exceed 100 kg. Ideally, the auxiliary equipment should be located close to the mobile deployment unit 10, especially when servicing large wind turbine blades exceeding 100 meters in length, to reduce the complexity of cable management and pressure loss in the air ducts. However, directly mounting such auxiliary equipment onto the mobile deployment unit would significantly increase its weight, necessitating a more powerful but heavier thruster to compensate for the load, resulting in both performance and structural penalties.

[0062] This invention provides a mobile deployment unit 10 employing drone technology for reliably and efficiently transporting service equipment to the target operating location on a wind turbine blade 4, without having to crawl along the surface of the wind turbine blade as in existing technologies. Figure 1A As shown, the mobile deployment unit 10 and the support unit 50 are connected to opposite ends of the connecting arm 54 via a second cable 20 and a third cable 22b, respectively (i.e., the end connected by the second cable 20 constitutes the second cable anchor point). The connecting arm 54 is connected to the first cable 22a via its middle section and is suspended in the cabin 8. Thus, the mobile deployment unit 10 and the support unit 50 are suspended in the air via their respective second cables 20 and third cables 22b, thereby eliminating the need for the upward thrust required to maintain the levitation of the mobile deployment unit 10. In the illustrated embodiment, the first cable 22a is supplied by a first cable winch (not shown) via a support arm (not shown) extending from the cabin 8. During use, the first cable winch can control the winding and unwinding of the first cable 22a, thereby simultaneously raising or lowering the mobile deployment unit 10 and the support unit 50 to the target operating position. For example, the first cable winch is used to wind up the first cable 22a to simultaneously raise both units, and to lower them when the cable is unwound. In other embodiments, the first cable may extend from the bottom of the nacelle and be anchored inside the nacelle. In still other embodiments, the first cable may be wrapped around or hooked to the hub of the wind turbine.

[0063] In the illustrated embodiment, the first cable 22a and the third cable 22b also include cables for supplying power to the various components of the robot deployment system 1, such as cable winches, sensors, controllers, propellers, and vacuum suction devices located in the support unit 50 and the mobile deployment unit 10. Furthermore, the cables are also used to enable communication between the controller on the support unit 50 and other auxiliary equipment and remote terminals.

[0064] The robot deployment system 1 also includes a stabilizing cable 22c, which connects the support unit 50 to the ground anchor 56. The ground anchor can be fixedly or detachably connected to the ground. The stabilizing cable 22c and the third cable 22b are respectively connected to opposite sides (upper and lower) of the support unit 50, thereby restricting the lateral movement of the support unit 50. In the illustrated embodiment, the ground anchor is positioned directly below the support unit 50, allowing the stabilizing cable 22c and the third cable 22b to extend approximately parallel to the longitudinal axis of the wind turbine. The advantage of this structure is that it significantly improves the stability of the support unit 50, making it particularly suitable for locations in environments with persistently strong winds.

[0065] The support unit 50, suspended by the third cable 22b and stabilized by the stabilizing cable 22c, is connected to the mobile deployment unit 10 via the auxiliary cable 23. In the illustrated embodiment, the support unit 50 includes a power supply device, such as a power socket, which is connected to a power supply line via a cable in the third cable 22b and electrically connected to the various electrical components within the mobile deployment unit 10 via the auxiliary cable 23. In other embodiments, the support unit 50 may include any device or hardware suitable for supporting the operation of the mobile deployment unit 10.

[0066] In the illustrated embodiment, the auxiliary cable 23 includes a power cord, a vacuum tube, and a data communication cable, all encapsulated within a cable sheath to form an integrated single-cable structure. The auxiliary cable 23 is used to supply power to the mobile deployment unit 10, provide a vacuum source, and simultaneously enable data communication with auxiliary equipment on the support unit 50. In other embodiments, the auxiliary cable 23 may also include one or more of the power cord, vacuum tube, and data communication cable, and these components may be encapsulated together or disposed separately.

[0067] The advantage of this structure is that it eliminates the need to directly mount heavy equipment (such as batteries, vacuum pumps, processors and other auxiliary equipment) and maintenance materials onto the mobile deployment unit 10, thereby significantly improving its mobility and energy efficiency, while reducing the risk of accidental detachment from the wind turbine blades 4.

[0068] The support unit 50 is also equipped with an auxiliary cable winch (not shown) for controlling the length of the auxiliary cable 23. For example, the auxiliary cable winch can release or reel in the auxiliary cable 23 accordingly as the mobile deployment unit 10 moves away from or nears the support unit 50. This structure not only prevents excessive tension in the auxiliary cable during the use of the mobile deployment unit 10, but also avoids excessive swaying of the mobile deployment unit 10 when it is idle.

[0069] During operation, service personnel can first connect one end of the first cable 22a to the connecting arm 54, and then use a winch to raise the entire robot deployment system 1 from the ground or ship to a specific height. At this specific height, the mobile deployment unit 10 will be approximately level with the work position. At position P, the mobile deployment unit 10 is completely suspended in the air by the second cable 20, with a certain horizontal distance between it and the work position. Due to this distance, the mobile deployment unit 10 cannot be directly attached to the wind turbine blade 4, nor can it be effectively maintained using service equipment.

[0070] Once the robot deployment system 1 is raised to the target location, service personnel can attach the stabilizing cable 22c to the ground anchor (not shown) located directly below the support unit. Thus, the third cable 22b and the stabilizing cable 22c extend substantially parallel to the direction of the wind turbine tower.

[0071] The mobile deployment unit 10 is equipped with multiple propellers, each configured to generate substantially horizontal thrust. Therefore, the propellers drive the mobile deployment unit 10 horizontally toward the wind turbine blade 4 until it reaches position P', during which the mobile deployment unit 10 remains suspended by cables. Specifically, the propellers propel the mobile deployment unit 10 to a position where its vacuum adsorption device contacts or at least approaches the surface of the wind turbine blade 4, thereby allowing the mobile deployment unit 10 to be releasably attached to the blade surface.

[0072] Once the vacuum adsorption device successfully adsorbs the wind turbine blades 4, the weight of the mobile deployment unit 10 and its load can be entirely supported by the wind turbine blades 4. In some situations, especially in strong winds, even when the wind turbine is locked, its blades 4 may still experience some vibration. To prevent accidental detachment, after the mobile deployment unit 10 is attached to the wind turbine blades 4, the first cable winch can appropriately loosen the cable to create some slack. The reduced cable tension provides cushioning, thereby decreasing the likelihood of the mobile deployment unit 10 accidentally detaching from the wind turbine blades 4.

[0073] In the event of accidental detachment, such as due to poor surface conditions or a temporary power outage, the present invention allows the mobile deployment unit 10 to quickly reattach to the wind turbine blade 4. That is, since the mobile deployment unit 10 is already suspended at the target height, simply restarting the propeller moves it toward the wind turbine blade 4 and reattaches it. Therefore, the present invention provides an effective fail-safe mechanism that significantly reduces downtime delays caused by accidental detachment.

[0074] Furthermore, the mobile deployment unit 10 is configured to collect a payload (not shown) from the support unit 50 for maintaining and / or repairing the wind turbine blades 4, and return the payload to the support unit 50 after the task is completed. For example, the payload may include various tools suitable for different stages of the maintenance work, such as welders, grinders, rotary drills, sanders, and spray guns, and may also include testing equipment, such as ultrasonic testing, X-ray testing, shear interference, acoustic emission, thermal imaging, and impact testing equipment. The payload may be directly mounted on the mobile deployment unit 10 or operated via its robotic arm. Therefore, when performing a specific task, the mobile deployment unit 10 can retrieve the corresponding payload from the support unit 50 to perform the task, and then return it to the support unit 50 after the task is completed. The advantage of this structure is that it eliminates the need to carry all tools and equipment on the mobile deployment unit 10 for extended periods, thereby significantly reducing its weight and improving its mobility and energy efficiency.

[0075] The support unit 50 also includes a platform (not shown) for carrying one or more service personnel and capable of elevating them to a height equal to, higher than, or lower than the work position. In other words, the support unit 50 also functions as a lifting platform, allowing service personnel to closely inspect the work position and intervene in the mobile deployment unit 10 in emergencies. The support unit 50 also includes a control panel, allowing service personnel to control the operation of the mobile deployment unit 10 locally, in addition to remote control.

[0076] The support unit 50 is further provided with a docking station (not shown) for optional docking when the mobile deployment unit 10 is in an idle state. This docking station includes a releasable latch that engages with a corresponding connection mechanism on the mobile deployment unit 10. More specifically, when the mobile deployment unit 10 is in an idle state, the auxiliary cable 23 winds it up to a position close to the support unit 50. Upon approaching the support unit 50, the mobile deployment unit 10 can be advanced to the docking station and engaged therewith. Conversely, when the mobile deployment unit 10 receives an instruction to perform a task, the latch at the docking station is released, thereby releasing the mobile deployment unit 10 for operation.

[0077] Mobile deployment unit Figure 2A and Figure 2B These are perspective views of the mobile deployment unit 10 according to a first embodiment of the present invention, taken from different angles. Figure 2C and Figure 2D for Figure 2A and Figure 2B Side view of China Mobile deployment unit 10 from different angles.

[0078] like Figures 2A-2D As shown, the mobile deployment unit 10 includes a main body 12. The main body 12 has a cuboid structure and an internal storage compartment for storing service equipment (such as testing, repair, and / or maintenance devices). The main body 12 also has a controller, which is communicatively connected to the sensor assembly, for controlling a plurality of propellers 30, 32 mounted on the main body 12 via external brackets.

[0079] The sensor assembly is configured to sense the position, distance, and / or attitude of the mobile deployment unit 10. In the illustrated embodiment, the sensor assembly includes: a gyroscope for sensing the attitude and / or angular velocity of the main body 12; a Global Positioning System (GPS) for sensing the position of the main body 12; a laser / ultrasonic rangefinder for sensing the relative position of the main body with respect to wind turbine blades and / or the ground or a vessel; and an accelerometer for sensing the velocity and / or acceleration of the main body 12. Since all electrical components on the mobile deployment unit 10 are powered by the support unit 50 via auxiliary cable 23, no onboard battery is required.

[0080] See Figure 2C and Figure 2D The mobile deployment unit 10 has a cable connector 24 on top of its main body 12. This cable connector 24 is configured to be releasably connected to a second cable 20. Therefore, during use, the main body 12 is suspended in the air by the second cable 20 via the cable connector 24. The mobile deployment unit 10 also includes an auxiliary cable connector (not shown) for connecting an auxiliary cable 23.

[0081] The mobile deployment unit 10 includes a set of main propellers 30 and a set of secondary propellers 32, respectively disposed on one side of the main body 12; multiple vacuum adsorption devices 40 are installed on the opposite side. The vacuum adsorption devices 40 are driven by a vacuum pump mounted on the support unit 50 and supplied with negative pressure through a vacuum hose in the auxiliary cable 23. The main propeller assembly 30 includes four main propellers 30 arranged vertically, respectively mounted at the four corners of one side of the cuboid main body 12. More specifically, these four main propellers 30 are coplanarly arranged in the same vertical plane offset from the side wall of the main body and oriented in the same direction, configured to provide horizontal thrust when the mobile deployment unit 10 is suspended by the second cable 20.

[0082] This structure can not only generate the same thrust through all propellers to achieve translational motion of the main body 12, but also achieve rotational motion on any axis by adjusting the thrust generated by different propellers, thereby causing the main body 12 to tilt.

[0083] For example, the total horizontal force required to push the mobile deployment unit 10 from position P to position P' (e.g., at position P', the cable 20 is tilted at an angle α of 5° relative to the vertical axis) is 0.087W, where W is the weight of the mobile deployment unit 10. Therefore, if the mobile deployment unit 10 weighs 100 kg, the theoretical horizontal thrust required to achieve the movement is approximately 87 N (ignoring gusts). Clearly, the total thrust provided by the propeller should have a larger horizontal component to counteract wind interference. According to the invention, the propeller is configured to generate a total thrust ranging from 10 N to 300 N to accommodate different service equipment transportation needs and varying weather conditions. For transporting heavier equipment, a higher-power propeller can be used to generate thrust exceeding 300 N.

[0084] Figures 3A-3C Side views of different stages of the attachment process. Figure 3A The mobile deployment unit 10 has been raised to the target height and is roughly level with the working position of the wind turbine blade 4, and is ready to go before the propeller is started. Figure 3B The mobile deployment unit 10 is shown to be driven by all the main propellers and moving horizontally toward the wind turbine blades 4, with each propeller generating essentially the same thrust. Figure 3C The vacuum adsorption device 40 of the mobile deployment unit 10 is shown to have come into contact with and adhered to the inclined surface of the wind turbine blade 4.

[0085] Specifically, to ensure firm adhesion, all adsorption devices must be stably in contact with the inclined surface of the blades before activating the vacuum adsorption device 40. To this end, the main propellers rotate the main body 12 about a horizontal axis, aligning all vacuum adsorption devices 40 with the inclined surface of the wind turbine blades 4. For example, the lower pair of main propellers 30b can generate greater thrust than the upper pair 30a, causing the main body 12 to pitch and tilt, achieving precise alignment of the adsorption surfaces.

[0086] See Figure 2C and Figure 2D The secondary propeller assembly 32 includes two axially aligned secondary propellers 32, positioned on the same horizontal plane and at the same height as the center of the main body 12. These two secondary propellers 32 are oriented in the same direction and configured to generate thrust in the horizontal direction. That is, when the mobile deployment unit 10 is suspended by cables, these two secondary propellers 32 generate thrust in a horizontal direction perpendicular to the thrust generated by the main propeller 30, thereby driving the mobile deployment unit 10 to translate in that direction. In other words, the secondary propellers enable the main body 12 to move laterally relative to the wind turbine blades 4, rather than towards the blades 4.

[0087] The plurality of vacuum adsorption devices 40 consists of four units, which are installed on one side of the main body 12, opposite to the propellers 30 and 32. Each vacuum adsorption device 40 can be independently controlled by a controller to open as needed to attach to the surface of the wind turbine blade 4, or to close to detach from the blade surface. Example

[0088] Figure 4 The deployment of the robot deployment system 101 according to a second embodiment of the present invention is shown.

[0089] The robot deployment system 101 is structurally and functionally basically the same as the robot deployment system 1 in the first embodiment. It includes a support unit 150, which supports the operation of the mobile deployment unit 110 via an auxiliary cable 123. The mobile deployment unit 110 is the same as the mobile deployment unit 10 in the first embodiment. For the sake of simplicity, the same structure will not be described again here.

[0090] Unlike the first embodiment, the support unit 150 and the mobile deployment unit 110 are suspended by a first cable 122a and a second cable 120, respectively. The first cable 122a and the second cable 120 are supplied by first and second cable winches (not shown), respectively, and pass through a connecting arm 154 (i.e., the second cable anchor point) fixedly mounted on the nacelle 8. This connecting arm separates the two cables to prevent entanglement. Therefore, in this second embodiment, the connecting arm 154 is a fixed structure, and the lifting height of the mobile deployment unit 110 and the support unit 150 is controlled by their respective independent cable winches. In other embodiments, the first cable and the second cable may also be connected to the nacelle by their respective cable winches, without the need for a connecting arm.

[0091] In the illustrated embodiment, the first cable winch and the second cable winch are controlled synchronously, so the support unit 150 and the mobile deployment unit 110 can be raised and lowered simultaneously, and their relative displacement remains constant during operation. Alternatively or as a supplement, the first cable winch and the second cable winch can also be controlled independently according to operational requirements. For example, the second cable can be wound and unwound separately so that the mobile deployment unit 110 covers different working positions on the wind turbine blade 4, while the support unit 150 remains stationary; or the tension of the second cable 120 can be adjusted after the mobile deployment unit is attached to the wind turbine blade 4 or docked to the docking station.

[0092] Because the second cable 120 is connected to the nacelle 8, its length is longer than in the first embodiment. This results in a smaller angle α between the second cable 120 and the vertical axis when the mobile deployment unit 110 moves toward the wind turbine blade 4. The advantage of this structure is that it increases the vertical component of force provided by the second cable 120, thereby enhancing the suspension support capacity of the mobile deployment unit 110 and reducing the energy consumption of its onboard propulsion unit.

Claims

1. A robotic deployment system for wind turbine maintenance, comprising: A mobile deployment unit, on which one or more propulsion units are mounted, the propulsion units being configured to generate thrust having at least a horizontal component for driving the mobile deployment unit toward the blades of a wind turbine; as well as A support unit is connected to the mobile deployment unit via an auxiliary cable. The support unit includes auxiliary equipment and / or maintenance materials for supporting the operation of the mobile deployment unit via the auxiliary cable. The support unit can be suspended in the air by a first cable connected to the nacelle of the wind turbine; and during operation, the mobile deployment unit can be at least partially suspended in the air by a second cable; the second cable connects the mobile deployment unit to a second cable anchor point located above the support unit.

2. The robot deployment system according to claim 1, wherein the support unit is connected to the mobile deployment unit at: i) The cabin is connected to the second cable via a first cable; or ii) A connecting arm, which is connected to the second cable via a third cable, and the connecting arm is connected to and suspended from the cabin via the first cable.

3. The robot deployment system according to claim 1 or 2, further comprising the first cable.

4. The robot deployment system according to claim 3 further includes a first cable winch disposed in the cabin, the first cable being configured to be retracted and extended by the winch to control the lifting height of the support unit.

5. The robot deployment system according to claim 3 or 4, wherein the system further includes a stabilizing cable connected between the support unit and an anchor below it for stabilizing the support unit.

6. The robot deployment system according to any one of claims 3 to 5, wherein the first cable extends substantially parallel to the wind turbine tower.

7. The robot deployment system according to any of the preceding claims further includes a docking station for docking when the mobile deployment unit is idle.

8. The robot deployment system of claim 7, wherein the docking station is disposed on the support unit and / or on one or more cables connected to the support unit.

9. The robot deployment system according to any of the preceding claims includes multiple mobile deployment units, each of which is connected to a support unit via an auxiliary cable and can operate independently.

10. The robot deployment system according to any of the preceding claims, wherein the mobile deployment unit further comprises one or more of the following: Sensor components for sensing their position and / or attitude, the sensor components including one or more of accelerometers, gyroscopes, rangefinders, GPS sensors and displacement sensors; A controller, configured to control one or more propulsion units based on the sensor signals, wherein the controller is optionally configured for closed-loop control; and One or more attachment devices for detachably attaching the mobile deployment unit to the surface of a wind turbine blade, the attachment devices including a vacuum adsorption device and / or an electromagnetic device.

11. The robot deployment system according to any of the preceding claims, wherein the propulsion unit is configured to generate thrust along a plurality of horizontal directions to achieve translational motion in the horizontal direction and / or rotational motion about an arbitrary axis; The propulsion unit may optionally include: A set of main propulsion units, each configured to generate thrust along a first horizontal axis; A set of secondary propulsion units, each configured to generate thrust along a second horizontal axis perpendicular to the first horizontal axis.

12. The robot deployment system according to any of the preceding claims, wherein the propulsion unit is configured to generate thrust along a plurality of axes to achieve translational motion in any direction and / or rotational motion about any axis.

13. The robot deployment system according to any of the preceding claims, wherein the one or more propulsion units are rotatably mounted on the mobile deployment unit to adjust the direction of the generated thrust.

14. The robot deployment system according to any of the preceding claims, wherein the auxiliary cable is used to support the operation of the mobile deployment unit via power supply, pneumatics, vacuum supply, and optical / data communication.

15. The robot deployment system according to any of the preceding claims further includes an auxiliary winch or a rewind spring winch for adjusting the length of the auxiliary cable.

16. The robot deployment system according to any of the preceding claims, wherein the mobile deployment unit is configured to acquire a payload for servicing wind turbine blades from the support unit and return the payload to the support unit after the task is completed.

17. The robot deployment system according to any of the preceding claims, wherein the support unit is configured to carry service personnel and raise and lower them to a target height.

18. The robot deployment system according to any one of claims 3 to 17, wherein the first cable includes a cable for powering the support unit.

19. A method for deploying a robot deployment system according to any one of claims 1 to 18, comprising the following steps: The support unit is moved to a height close to the target operating position of the wind turbine blades by the first cable, thereby suspending it in the air; The mobile deployment unit is moved to a height close to the service location of the wind turbine blades by a second cable, thereby suspending it in the air; Control one or more propulsion units of the mobile deployment unit to drive it toward the wind turbine blades.

20. The method for deploying the robot according to claim 19, wherein the control step further comprises: Release the mobile deployment unit from the docking station before operation; and / or After the operation is completed, the mobile deployment unit is docked back to the docking station.

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