A wind power blade active infrared detection device

Abstract

The utility model discloses a kind of active infrared detection devices of wind power blade, the device includes inspection robot, six degrees of freedom mechanical arm, detection executor module;Detection executor module includes pedestal, laser heater, infrared thermal imager, laser range finder, laser heater is fixed in the middle of pedestal, irradiation direction is vertically downward, infrared thermal imager is located laser heater left side, infrared thermal imager is fixed in the bottom of pedestal by support inclination, laser range finder is located laser heater right side, laser range finder is vertically downward setting.The utility model carries out wind power blade defect detection using active infrared thermal imaging technology, heating is carried out to wind power blade by laser heater, the temperature distribution of blade surface is detected using infrared thermal imager, to find the defect possibly existing in blade interior.

Description

Technical Field

[0001] This utility model relates to the field of non-destructive testing technology for wind power equipment, specifically an active infrared detection device for wind turbine blades. Background Technology

[0002] As a core component of wind turbines, the quality of wind turbine blades directly affects power generation efficiency and equipment safety. Currently, large wind turbine blades are constructed with fiberglass skin and a main beam. During manufacturing, due to process limitations, structural defects such as cavitation, cracks, insufficient adhesive, and poor curing inevitably occur in blind spots of blade fabrication. Under long-term alternating loads, these defects will continuously expand and develop into fatigue damage. With the increasing trend towards larger and more practical wind turbines, blade lengths are constantly increasing, placing higher demands on blade quality. Therefore, it is particularly important to detect defects early through effective detection methods during blade manufacturing, testing, and transportation.

[0003] Traditional methods for detecting defects in wind turbine blades include visual inspection and tapping. While these methods are simple to operate, they are difficult to accurately detect defects, rely heavily on worker experience, have a false negative rate as high as 40%, and are inefficient. Unmanned aerial vehicle (UAV) external wall inspection technology can only detect surface damage and is ineffective against internal structural defects. Passive infrared imaging technology is severely affected by environmental temperature differences; its sensitivity drops by 70% in winter, making it unable to detect deep defects and resulting in a false negative rate exceeding 30%. Utility Model Content

[0004] This invention addresses the aforementioned problems with existing wind turbine blade defect detection equipment by providing an active infrared detection device for wind turbine blades, utilizing active infrared thermal imaging technology for wind turbine blade defect detection.

[0005] To achieve the above objectives, the present invention adopts the following technical solution.

[0006] This utility model provides an active infrared detection device for wind turbine blades, comprising: The inspection robot includes a main body compartment and a set of walking wheels. The walking wheels are installed at the bottom of the main body compartment. The main body compartment contains a walking wheel drive motor for driving the walking wheels, a lithium battery pack for power supply, and a main controller. A six-degree-of-freedom robotic arm, the lower end of which is mounted on top of the inspection robot; The detection actuator module includes a base, a laser heater, an infrared thermal imager, and a laser rangefinder. The laser heater is fixed in the middle of the base with the irradiation direction vertically downward. The infrared thermal imager is located to the left of the laser heater and is tilted and fixed to the bottom of the base by a bracket. The laser rangefinder is located to the right of the laser heater and is set vertically downward. The main controller is connected to the laser heater, infrared thermal imager, laser rangefinder, walking wheel drive motor and six-degree-of-freedom robotic arm respectively.

[0007] Furthermore, a wireless communication module is installed inside the main cabin, through which the main controller transmits data to a remote terminal.

[0008] Furthermore, a heat insulation baffle is provided between the laser heater and the infrared thermal imager, and the heat insulation baffle is fixed on the base.

[0009] Preferably, the heat insulation baffle is made of alumina ceramic material with a thickness of 6mm.

[0010] Furthermore, the optical axis of the infrared thermal imager forms a 15° angle with the optical axis of the laser heater.

[0011] Furthermore, the horizontal distance between the center point of the infrared thermal imager and the center point of the laser rangefinder is 50mm.

[0012] Furthermore, the laser heaters are arranged in four groups in a diamond shape to form a laser heater array.

[0013] Furthermore, heat dissipation fins are provided on the top of the base, and the heat dissipation fins are located above the laser heater.

[0014] Compared with the prior art, the beneficial technical effects of this utility model are as follows: This utility model discloses an active infrared detection device for wind turbine blades. It utilizes active infrared thermal imaging technology to detect defects in wind turbine blades. A laser heater heats the blade, and an infrared thermal imager detects the surface temperature distribution, thereby identifying potential internal defects. Active thermal excitation reveals minute defects, improving the defect detection rate. A laser rangefinder can acquire the distance between the infrared thermal imager and the blade in real time, ensuring that the laser heater and the infrared thermal imager are at an appropriate working distance. An inspection robot equipped with a set of wheels and a wheel drive motor enables autonomous movement, facilitating inspection work on the wind turbine blades. The six-degree-of-freedom robotic arm allows the inspection actuator module to flexibly adjust its position and attitude to adapt to the inspection needs of wind turbine blades at different positions and angles. The main controller is connected to the laser heater, infrared thermal imager, laser rangefinder, walking wheel drive motor, and the six-degree-of-freedom robotic arm, enabling unified control and coordinated operation of all components. The main controller can transmit inspection data to a remote terminal in real time via a wireless communication module, allowing staff to promptly understand the inspection status and make decisions. A heat insulation baffle between the laser heater and the infrared thermal imager effectively reduces thermal interference from the laser heater, ensuring the accuracy of the infrared thermal imager. Heat dissipation fins on the top of the base help dissipate the heat generated by the laser heater during operation, ensuring its normal operation and extending its service life. Attached Figure Description

[0015] Figure 1 This is a perspective view of an active infrared detection device for wind turbine blades according to the present invention. Figure 2 This is a front view of an active infrared detection device for wind turbine blades according to the present invention. Figure 3 This is a block diagram illustrating the control principle of this utility model; Reference numerals: 1-Inspection robot, 101-Main cabin, 102-Walking wheel, 103-Walking wheel drive motor, 104-Main controller, 105-Wireless communication module, 2-Six-DOF robotic arm, 3-Base, 4-Laser heater, 5-Infrared thermal imager, 6-Laser rangefinder, 7-Heat dissipation fins, 8-Bracket, 9-Heat insulation baffle. Detailed Implementation

[0016] To more clearly illustrate the technical solution and effects of this utility model, the present utility model will be clearly and completely described below with reference to the accompanying drawings and embodiments. It should be understood that the embodiments described herein are merely some embodiments of this utility model, not all embodiments, and the technical features involved in the various embodiments of this utility model described below can be combined with each other as long as they do not conflict with each other.

[0017] It should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this utility model. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0018] It should be noted that, unless otherwise explicitly specified and limited, the terms “installation,” “connection,” “linking,” and “setting” should be interpreted broadly. For example, they can refer to fixed connection or setting, detachable connection or setting, or integral connection or setting; they can refer to direct connection or indirect connection through an intermediate medium; and they can refer to the internal connection of two components.

[0019] Example 1 Please see Figure 1-3 As shown, this embodiment provides an active infrared detection device for wind turbine blades, including: Inspection robot 1 includes a main body compartment 101 and a set of walking wheels 102. The set of walking wheels 102 is installed at the lower part of the main body compartment 101. The main body compartment 101 is equipped with a walking wheel 102 drive motor for driving the walking wheel 102 set, a lithium battery pack for power supply, and a main controller 104. A six-degree-of-freedom robotic arm 2, the lower end of which is mounted on the top of the inspection robot 1; The detection actuator module includes a base 3, a laser heater 4, an infrared thermal imager 5, and a laser rangefinder 6. The laser heater 4 is fixed in the middle of the base 3 with the irradiation direction vertically downward. The infrared thermal imager 5 is located to the left of the laser heater 4 and is tilted and fixed to the bottom of the base 3 by a bracket 8. The laser rangefinder 6 is located to the right of the laser heater 4 and is set vertically downward. The main controller 104 is connected to the laser heater 4, the infrared thermal imager 5, the laser rangefinder 6, the drive motor of the walking wheel 102, and the six-degree-of-freedom robotic arm 2.

[0020] In this embodiment, the six-degree-of-freedom robotic arm 2 is an AUBO i5, the infrared thermal imager 5 is a FLIR A655sc, the laser rangefinder 6 is a SICK LMS511, and the main controller 104 is an Advantech ARK-3530. The base 3 is made of aluminum alloy.

[0021] Specifically, a wireless communication module 105 is installed inside the main cabin 101, and the main controller 104 transmits data to a remote terminal through the wireless communication module 105. The wireless communication module 105 uses a Quectel EC25 5G module with a transmission rate of ≥100Mbps.

[0022] Specifically, a heat insulation baffle 9 is provided between the laser heater 4 and the infrared thermal imager 5. The heat insulation baffle 9 is fixed on the base 3. The heat insulation baffle 9 is made of alumina ceramic material with a thermal conductivity of 24 W / m·K and a thickness of 6 mm.

[0023] Specifically, the optical axis of the infrared thermal imager 5 forms a 15° angle with the optical axis of the laser heater 4 to avoid laser reflection interference. The horizontal distance between the center point of the infrared thermal imager 5 and the center point of the laser heater 4 is 50mm.

[0024] Specifically, the laser heaters 4 are arranged in four groups in a rhomboid pattern, forming an array of laser heaters 4. The laser heaters 4 use Raycus RFL-C1000 fiber lasers (200W×4).

[0025] Specifically, the base 3 is provided with heat dissipation fins 7 on its top, and the heat dissipation fins 7 are located above the laser heater 4.

[0026] The wind turbine blade active infrared detection device in this embodiment has a minimum defect detection rate of Φ2mm, a blade root area detection rate of up to 98%, and a single blade detection time of 35 minutes.

[0027] This invention relates to an active infrared detection device for wind turbine blades, which achieves precise detection through a closed-loop "thermal excitation-imaging-feedback" process. Based on the distance data from the laser rangefinder 6, the main controller 104 dynamically adjusts the pose of the six-degree-of-freedom robotic arm 2 using a PID control algorithm, maintaining the distance to the heating point at 0.5±0.1m. The main controller 104 controls the laser heater 4 to start and adjust its power: 50±5W at the blade root and 30±3W at the blade tip. After the laser is turned off for 500±10ms, the thermal imager and laser rangefinder 6 are triggered sequentially. The data collected by the thermal imager and laser rangefinder 6 are transmitted to a remote terminal via the wireless communication module 105 through the main controller 104.

[0028] The above description is a preferred embodiment of the present utility model, used to explain the technical solution of the present utility model, and is not intended to limit the present utility model. Those skilled in the art can make conventional modifications, equivalent substitutions and improvements within the spirit and principles of the present utility model, all of which are still included within the protection scope of the present utility model.

Claims

1. An active infrared detection device for wind turbine blades, characterized in that, include: The inspection robot includes a main body compartment and a set of walking wheels. The walking wheels are installed at the bottom of the main body compartment. The main body compartment contains a walking wheel drive motor for driving the walking wheels, a lithium battery pack for power supply, and a main controller. A six-degree-of-freedom robotic arm, the lower end of which is mounted on top of the inspection robot; The detection actuator module includes a base, a laser heater, an infrared thermal imager, and a laser rangefinder. The laser heater is fixed in the middle of the base with the irradiation direction vertically downward. The infrared thermal imager is located to the left of the laser heater and is tilted and fixed to the bottom of the base by a bracket. The laser rangefinder is located to the right of the laser heater and is set vertically downward. The main controller is connected to the laser heater, infrared thermal imager, laser rangefinder, walking wheel drive motor and six-degree-of-freedom robotic arm respectively.

2. The active infrared detection device for wind turbine blades according to claim 1, characterized in that: The main cabin is equipped with a wireless communication module, through which the main controller transmits data to a remote terminal.

3. The active infrared detection device for wind turbine blade according to claim 1, characterized in that: A heat insulation baffle is installed between the laser heater and the infrared thermal imager, and the heat insulation baffle is fixed on the base.

4. The active infrared detection device for wind turbine blade according to claim 3, characterized in that: The heat insulation baffle is made of alumina ceramic material with a thickness of 6mm.

5. The active infrared detection device for wind turbine blades according to claim 1, characterized in that: The optical axis of the infrared thermal imager forms a 15° angle with the optical axis of the laser heater.

6. The active infrared detection device for wind turbine blade according to claim 1, characterized in that: The horizontal distance between the center point of the infrared thermal imager and the center point of the laser rangefinder is 50 mm.

7. The wind turbine blade active infrared detection device according to claim 1, wherein: The laser heaters consist of four groups arranged in a diamond shape to form a laser heater array.

8. The active infrared detection device for wind turbine blade according to claim 1, characterized in that: The base is equipped with heat dissipation fins on top, which are located above the laser heater.

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