A wind turbine blade surface defect detection device

Abstract

This utility model relates to the field of wind turbine blade inspection technology, specifically to a wind turbine blade surface defect detection device. It includes a drive assembly sleeved on the outside of the tower, the drive assembly being annular and concentric with the tower, capable of moving along the axial direction of the tower. The drive assembly consists of two arc-shaped units, which are detachably and fixedly connected. Each arc-shaped unit has an arc-shaped rack concentrically fixed to its upper end, forming a toothed ring. A slider is slidably engaged on the toothed ring, and a drive unit is provided on the slider to drive its circular motion on the toothed ring. An arc-shaped tile is fixedly connected to the slider. This utility model achieves breakthroughs in detection coverage, ease of operation, environmental adaptability, and system stability through the integration of modular mechanical structure, dynamic detection algorithm, and wireless control technology, making it particularly suitable for large-scale offshore wind farms and multi-unit grid-connected scenarios.

Description

Technical Field

[0001] This utility model relates to the field of wind turbine blade inspection technology, specifically to a wind turbine blade surface defect detection device. Background Technology

[0002] Wind turbine blades need to be inspected regularly for defects. Defects include: 1. Paint peeling off after wear; 2. Peeling at the fiberglass bonding points; 3. Black holes and spots after lightning strikes; 4. When the wind blows, the blades are subjected to stress, fatigue damage will cause wrinkles, and if the wrinkles are too large, they will bend and may eventually break.

[0003] Patent document CN218331260U discloses a device for detecting surface defects on wind turbine blades. This device extends the wind turbine blade along the long side of the top surface of a mounting base and clamps it vertically between two pairs of clamping mechanisms. A laser rangefinder measures the distance between the rangefinder and the blade surface, comparing the measured distance with a pre-tested standard distance to determine if there are bulges or pits on the blade surface. Because the blade is vertical and the laser rangefinder does not need to contact the blade, surface defects on both sides of the blade can be tested simultaneously. This device is suitable for inspecting wind turbine blades before they leave the factory; it cannot monitor wind turbine blades after installation.

[0004] Patent document CN219412806U discloses a surface defect detection device for wind turbine blade maintenance. When the wind turbine blades need maintenance, one blade is rotated to a position perpendicular to the ground. A camera device is mounted on a base, and then a rope wound around a pulley system is pulled, causing a sliding positioning ring to slide up and down along the wind turbine tower. Simultaneously, the base and the camera device on the base also rise and fall with the sliding positioning ring. The camera device captures the appearance of the blade and transmits the video to a playback device on the ground, allowing maintenance personnel to determine whether there are any defects on the blade's appearance. However, this device requires climbing to install the rope and pulley system, which is cumbersome. When using the camera device to inspect the blades, it cannot rotate circumferentially around the tower as needed, easily creating blind spots and failing to effectively perform a comprehensive inspection of the wind turbine blades. Utility Model Content

[0005] The main objective of this invention is to provide a detection device whose detection unit can rotate in the circumferential direction of the tower, enabling comprehensive detection of the blades. This detection device is easy to assemble and disassemble.

[0006] To achieve the above objectives, the technical solution provided by this utility model is as follows: A wind turbine blade surface defect detection device includes a drive assembly sleeved on the outside of the tower. The drive assembly is annular and concentric with the tower, capable of moving along the axial direction of the tower. The drive assembly consists of two arc-shaped units, which are detachably and fixedly connected. Each arc-shaped unit has an arc-shaped rack concentrically fixed at its upper end. The arc-shaped racks on the two arc-shaped units form a toothed ring, on which a slider is slidably engaged. The slider is equipped with a drive unit capable of driving the slider to move in a circular motion on the toothed ring. An arc-shaped tile is fixedly connected to the slider, which includes an outer arc-shaped part and an inner arc-shaped part. The outer arc-shaped part, the inner arc-shaped part, and the drive assembly are concentric. One end of the outer arc-shaped part and one end of the inner arc-shaped part are fixedly connected. The inner arc-shaped part is fixedly connected to the slider through multiple connecting rods. A camera assembly is fixedly mounted on both the inner and outer arc-shaped parts. When the blade is positioned between the outer and inner arc-shaped parts, the camera assembly can capture an image of the outer edge of the blade.

[0007] Specifically, the arc-shaped unit includes an arc-shaped plate, on which multiple square rods are slidably arranged. The length direction of the square rods is parallel to the radial direction of the arc-shaped plate. A drive wheel is rotatably connected to the end of the square rod facing the tower. A brake motor capable of driving the drive wheel is fixed on the square rod. A fixing plate is fixed to the end of the square rod away from the tower. The fixing plate is connected to the arc-shaped plate by a tension spring.

[0008] Specifically, each end of the arc-shaped plate is fixed with a lug, and the lugs of the two arc-shaped plates are fixedly connected by bolts.

[0009] Specifically, the drive unit includes a drive motor fixed on the slider, and a gear is concentrically fixed on the output shaft of the drive motor. The gear is located in the groove of the slider, and the gear ring part is located in the groove. The gear meshes with the gear ring part in the groove.

[0010] Specifically, the drive motor and the brake motor are electrically connected to the ground power supply via power lines, the brake motor and the drive motor are electrically connected to the controller, and the controller is electrically connected to the control handle on the ground via control cables.

[0011] Specifically, the drive wheel is a non-slip rubber wheel.

[0012] Specifically, the inner edge of the arc-shaped rack is fixed with an arc-shaped convex ring. After the two arc-shaped racks form a toothed ring, the two convex rings form a circular ring. An arc-shaped groove is opened on the slider, and the circular ring and the arc-shaped groove are slidably engaged.

[0013] Specifically, the camera assembly includes an industrial camera, which is electrically connected to the main control processor, and the main control processor is wirelessly connected to the handheld terminal via a router.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows: 1. Two arc-shaped units are bolted together and fitted onto the outside of the tower, eliminating the need for large hoisting equipment and reducing the difficulty of high-altitude operations. The combination of tension springs and drive wheels provides radial elastic pressure, ensuring that the anti-slip rubber wheels always adhere to the tower surface, adapting to the deformation and surface roughness of towers of different diameters.

[0015] 2. The coordinated design of the camera assembly and motion control system enables blind-spot-free detection of the blade surface. Industrial cameras symmetrically distributed on the inner and outer arc sections synchronously acquire images of the inner and outer edges of the blade, avoiding the visual blind spots of traditional single-sided detection. The drive motor drives the arc-shaped blade to rotate circumferentially along the toothed ring, and combined with the axial climbing of the device, forms a spiral scanning path that completely covers the blade surface.

[0016] 3. The handheld terminal can remotely adjust camera parameters, such as focal length and ISO, via wireless network, and receive H.264 encoded video streams in real time, enabling controllability and instant feedback in the detection process.

[0017] 4. The sliding engagement between the convex ring and the arc-shaped groove forms an axial limit, which, combined with the gear and gear ring meshing transmission, suppresses radial offset during the circumferential movement of the slider, reducing vibration amplitude. The brake motor provides constant torque output to prevent drive wheel slippage and ensure a smooth climbing process.

[0018] 5. The curved tile position can be quickly adjusted via the control handle, eliminating the need for reassembly or climbing when switching detection targets between adjacent blades, significantly reducing time consumption. When a blade needs replacement, the curved tile can be quickly rotated to the side of the tower to avoid interference with the rotating blade and ensure operator safety. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the present invention in operation.

[0020] Figure 2 for Figure 1 A magnified view of region C in the middle.

[0021] Figure 3 This is a rear view of the present invention in operation.

[0022] Figure 4 for Figure 3 Sectional view along the AA direction.

[0023] Figure 5 for Figure 4 A magnified view of region D in the middle.

[0024] Figure 6 for Figure 3 Sectional view along the BB direction.

[0025] The components in the attached diagram are named as follows: 1. Tower, 2. Generator set, 3. Blade, 4. Arc plate, 5. Arc rack, 6. Square rod, 7. Drive wheel, 8. Brake motor, 9. Fixing plate, 10. Tension spring, 11. Ear plate, 12. Slider, 13. Gear, 14. Drive motor, 15. Arc tile, 16. Camera assembly, 17. Connecting rod. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0027] Example 1: Refer to Figures 1-6 As shown, a wind turbine blade surface defect detection device includes a drive assembly sleeved on the outside of the tower 1. The drive assembly is annular and concentric with the tower 1. The drive assembly can move along the axial direction of the tower 1.

[0028] The drive assembly consists of two arc-shaped units, which are detachably and fixedly connected.

[0029] The arc-shaped unit includes an arc-shaped plate 4, on which multiple square rods 6 are slidably mounted. The length direction of the square rods 6 is parallel to the radial direction of the arc-shaped plate 4. A drive wheel 7, which is an anti-slip rubber wheel, is rotatably connected to the end of the square rod 6 facing the tower 1. A brake motor 8, capable of driving the drive wheel 7, is fixed to the square rod 6. A fixing plate 9 is fixed to the end of the square rod 6 away from the tower 1, and the fixing plate 9 is connected to the arc-shaped plate 4 by a tension spring 10. Ear plates 11 are fixed to both ends of the arc-shaped plate 4, and the ear plates 11 of two arc-shaped plates 4 are fixedly connected by bolts.

[0030] Each arc-shaped unit has an arc-shaped rack 5 concentrically fixed at its upper end. The arc-shaped racks 5 on the two arc-shaped units form a toothed ring. A slider 12 is slidably engaged on the toothed ring. The slider 12 is equipped with a drive unit that can drive the slider 12 to move in a circular motion on the toothed ring.

[0031] The drive unit includes a drive motor 14 fixed on the slider 12. A gear 13 is concentrically fixed on the output shaft of the drive motor 14. The gear 13 is located in the groove of the slider 12, and the gear ring part is located in the groove. The gear 13 meshes with the gear ring part in the groove.

[0032] An arc-shaped tile 15 is fixedly connected to the slider 12.

[0033] The arc-shaped tile 15 includes an outer arc-shaped part and an inner arc-shaped part. The outer arc-shaped part, the inner arc-shaped part and the drive assembly are concentric. One end of the outer arc-shaped part and one end of the inner arc-shaped part are fixedly connected. The inner arc-shaped part is fixedly connected to the slider 12 through multiple connecting rods 17. A camera assembly 16 is fixed on both the inner arc-shaped part and the outer arc-shaped part. After the blade 3 is located between the outer arc-shaped part and the inner arc-shaped part, the camera assembly 16 can capture an image of the outer edge of the blade 3.

[0034] The drive motor 14 and the brake motor 8 are electrically connected to the ground power supply via power lines. The brake motor 8 and the drive motor 14 are electrically connected to the controller. The controller is electrically connected to the control handle on the ground via control cables.

[0035] The camera assembly 16 includes an industrial camera, which is electrically connected to the main control processor, which is wirelessly connected to the handheld terminal via a router.

[0036] When inspecting the blades 3 of the wind turbine, two arc-shaped plates 4 are fitted onto the outside of the tower 1, and the lugs 11 of the two arc-shaped plates 4 are fixedly connected by bolts. At this time, the drive wheel 7 is pressed against the outer edge of the tower 1, and the tension spring 10 is stretched.

[0037] The brake motor 8 is started by controlling the handle. Multiple brake motors 8 rotate at the same speed and in the same direction, thereby driving the device to move upward on the outside of the tower 1.

[0038] When the blade 3 to be inspected is located on one side of tower 1 and parallel to tower 1, that is... Figure 3 As shown, activate the generator set's brakes and stop the rotation of blade 3.

[0039] After the device moves upward, the blade 3, which is parallel to the tower 1, is located inside the arc-shaped tile 15, that is, the blade 3 is located between the outer arc-shaped part and the inner arc-shaped part.

[0040] During the upward movement of this device, camera component 16 is activated. The industrial camera outputs raw image data in YUV422 format via the DVP parallel interface and transmits it to the main control processor, model XR872. The main control processor's built-in ISP unit performs automatic white balance and exposure adjustment, and compresses the data into an H.264 bitstream using a hardware encoder. The main control processor divides the compressed video stream into 1472-byte UDP packets and sends them to the router via a 2.4GHz / 5.8GHz dual-band WiFi module. The handheld terminal establishes an HTTP long connection with the router to request the video stream. After receiving the UDP packets, the handheld terminal reassembles the data, and the image information of the blade surface captured by the industrial camera is displayed on the handheld terminal's screen. The surface of blade 3 can be inspected using the image information displayed on the handheld terminal's screen.

[0041] Users can adjust industrial camera parameters, such as focal length and ISO, through the touch interface of the handheld terminal. Control commands are transmitted to the industrial camera via the TCP reverse channel, realizing two-way interaction.

[0042] When inspecting the surface of blade 3, the inspector can drive the drive motor 14 by controlling the handle. After the drive motor 14 is started, the arc-shaped tile 15 can rotate in the circumferential direction of the tower 1, thereby adjusting the position of the camera component 16 and realizing the overall inspection of the surface of blade 3.

[0043] When damage is detected in the center of blade 3, meeting the replacement criteria, the drive motor 14 is activated to rotate the arc-shaped tile 15 to one side of the tower 1. At this point, the tower 1 is positioned between the arc-shaped tile 15 and blade 3. Then, the brake of the generator set 2 is released, causing blade 3 to rotate. When another blade 3 rotates to be parallel to the tower 1, the brake of the generator set 2 is activated, and then the drive motor 14 is activated to rotate the arc-shaped tile 15. Once the blade 3 parallel to the tower 1 is located within the arc-shaped tile 15, it can be directly inspected. When blade 3 is damaged and meets the replacement criteria, this device can quickly separate the arc-shaped tile 15 from the inspected blade 3, facilitating rapid inspection of the next blade 3.

[0044] Example 2: Based on Example 1, an arc-shaped convex ring is fixed on the inner edge of the arc-shaped rack 5. After the two arc-shaped racks 5 form a toothed ring, the two convex rings form a circular ring. An arc-shaped groove is opened on the slider 12, and the circular ring slides and engages with the arc-shaped groove.

[0045] The ring consisting of two arc-shaped convex rings is slidably engaged with the slider 12, resulting in better stability and reduced vibration amplitude during the rotation of the slider 12.

[0046] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A wind turbine blade surface defect detection device, comprising a drive assembly sleeved on the outside of a tower (1), the drive assembly being annular and concentric with the tower (1), the drive assembly being movable along the axial direction of the tower (1), the drive assembly being composed of two arc-shaped units, the two arc-shaped units being detachably and fixedly connected, characterized in that, Arc-shaped racks (5) are concentrically fixed at the upper end of each arc-shaped unit. The arc-shaped racks (5) on the two arc-shaped units form a toothed ring. A slider (12) is slidably engaged on the toothed ring. A drive unit capable of driving the slider (12) to move in a circle on the toothed ring is provided on the slider (12). An arc-shaped tile (15) is fixedly connected to the slider (12). The arc-shaped tile (15) includes an outer arc-shaped part and an inner arc-shaped part. The outer arc-shaped part, the inner arc-shaped part and the drive component are concentric. One end of the outer arc-shaped part and one end of the inner arc-shaped part are fixedly connected. The inner arc-shaped part is fixedly connected to the slider (12) through multiple connecting rods (17). A camera component (16) is fixed on both the inner arc-shaped part and the outer arc-shaped part. After the blade (3) is located between the outer arc-shaped part and the inner arc-shaped part, the camera component (16) can capture an image of the outer edge of the blade (3).

2. The wind turbine blade surface defect detection device according to claim 1, characterized in that, The arc-shaped unit includes an arc-shaped plate (4), on which multiple square rods (6) are slidably arranged. The length direction of the square rods (6) is parallel to the radial direction of the arc-shaped plate (4). A drive wheel (7) is rotatably connected to the end of the square rod (6) facing the tower (1). A brake motor (8) that can drive the drive wheel (7) to rotate is fixed on the square rod (6). A fixing plate (9) is fixed to the end of the square rod (6) away from the tower (1). The fixing plate (9) is connected to the arc-shaped plate (4) by a tension spring (10).

3. The wind turbine blade surface defect detection device according to claim 2, characterized in that, Both ends of the arc plate (4) are fixed with ear plates (11), and the ear plates (11) of the two arc plates (4) are fixedly connected by bolts.

4. The wind turbine blade surface defect detection device according to claim 2, characterized in that, The drive unit includes a drive motor (14) fixed on the slider (12). A gear (13) is concentrically fixed on the output shaft of the drive motor (14). The gear (13) is located in the groove of the slider (12), and the gear ring part is located in the groove. The gear (13) meshes with the gear ring part in the groove.

5. The wind turbine blade surface defect detection device according to claim 4, characterized in that, The drive motor (14) and the brake motor (8) are electrically connected to the ground power supply via power lines. The brake motor (8) and the drive motor (14) are electrically connected to the controller. The controller is electrically connected to the control handle on the ground via control cables.

6. The wind turbine blade surface defect detection device according to claim 2, characterized in that, The drive wheel (7) is a non-slip rubber wheel.

7. The wind turbine blade surface defect detection device according to claim 1, characterized in that, The inner edge of the arc-shaped rack (5) is fixed with an arc-shaped convex ring. After the two arc-shaped racks (5) form a toothed ring, the two convex rings form a circular ring. The slider (12) is provided with an arc-shaped groove, and the circular ring and the arc-shaped groove are slidably engaged.

8. The wind turbine blade surface defect detection device according to claim 1, characterized in that, The camera assembly (16) includes an industrial camera, which is electrically connected to the main control processor, and the main control processor is wirelessly connected to the handheld terminal via a router.

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