Robotic vehicle for measuring flanges of wind power towers and measuring method using said vehicle

Abstract

Robotic vehicle (11) for measuring flanges (FL) of wind power towers, comprising: a support structure (13); a drive unit (15) equipped with motorized locomotion members and associated with the support structure (13); a tilt sensor (19) capable of generating a signal indicative of the tilt angle of a plane of the sensor along a pair of mutually perpendicular axes; a profile-measuring device (21) capable of generating a signal indicative of dimensional features of a surface relative to which the vehicle (11) moves by means of the motorized locomotion members; a local electronic control unit (23) associated with the support structure (13) and capable of controlling the operation of the drive unit (15) and processing the signals coming from said tilt sensor (19) and said profile-measuring device (21).

Description

[0001] “Robotic vehicle for measuring flanges of wind power towers and measuring method using said vehicle ”

[0002] DESCRIPTION

[0003] Technical Field

[0004] The invention relates to a robotic vehicle for measuring flanges of wind power towers, more particularly, though not exclusively, wind power towers for offshore installations. The invention further relates to a measuring method employing said vehicle.

[0005] More generally, the invention relates to an automated device used for inspection or dimensional measurement tasks in the monitoring of wind turbine towers.

[0006] The main object of the device is to measure flanges, which are flat, circular components used to join pipes, valves, pumps, and other equipment in the engineering and construction fields.

[0007] Offshore in this context indicates that the device is designed to operate also in marine environments, typically far from the coast, but more generally in harsh environments.

[0008] Background Art

[0009] A wind power tower flange is a critical component used in the construction of wind turbines.

[0010] These flanges are essential elements for the assembly and structural integrity of wind turbines. Their design and material selection are crucial to ensuring that the turbines can withstand harsh conditions, especially in offshore environments, providing a reliable source of renewable energy.

[0011] As is known, a flange is generally a type of connector used to join two sections of a structure, and, in the context of wind turbines, the flange is used to connect together various sections of the wind power tower, such as the foundation at the base of the tower, or the different tower sections. These flanges are typically made of high-strength steel to withstand the harsh marine environment and the loads imposed by the wind turbine. These flanges are also generally circular and have bolt holes arranged in a predetermined pattern to ensure a secure and stable connection and are designed to match the diameter of the tower sections they connect. Offshore wind turbine flanges are large, given the scale of the turbines, and must support significant weight and stress.

[0012] The flange ensures the stability and structural integrity of the wind turbine, particularly important in the dynamic marine environment where wind, waves and currents impose variable forces, and allows the disassembly and reassembly of turbine components for maintenance or upgrades. The flange must withstand significant mechanical loads and vibrations resulting from turbine operation and therefore these flanges require precise manufacturing to ensure they fit perfectly and can be bolted securely without causing misalignments.

[0013] Typical uses of the flanges measured by the vehicle according to the present invention include:

[0014] - connecting the single-pile foundation to the base of the wind power tower, in the context of single-pile foundations for wind turbines;

[0015] - connecting the segments of the wind power tower, to enable the modular construction of tall wind power towers;

[0016] - connecting the floating base to the wind power tower, ensuring stability in a highly dynamic environment, in the context of floating wind turbines.

[0017] Currently, non-contact laser measuring instruments, known as "laser trackers," are used to measure the surface dimensional features of flanges for wind power towers, particularly offshore ones. These instruments are portable apparatuses that are carried and used on the flange by human personnel who perform the measurement operations manually.

[0018] The operation of these laser measuring instruments is based on the optical principles of laser light which has an accuracy of the order of 10 pm / meter and a range of over 100 meters.

[0019] CN217980086 (U) describes an example of a device and detection system for measuring the center distance and degree of localization of the inclined hole of the flange of wind power towers.

[0020] Evidently, using human personnel for this type of measurement involves significant risks and inconveniences and therefore there is a strong need to solve the problem of how to measure flanges with minimal use of human personnel and above all while avoiding the need to perform the measurement by manually intervening directly on the flange.

[0021] This problem is even more acute in the energy engineering and wind power generation sector, where, in recent years, actual wind energy parks, also known as wind farms, have been developed. These wind farms consist of a collection of wind turbines or wind power towers, located in a limited area and generally interconnected, which generate electricity by exploiting the energy of wind. Electricity power generation varies depending on the wind and the generating capacity of the wind turbines.

[0022] In these contexts, the wind conditions most favorable to electricity generation are, at the same time, the most unfavorable for the installation and maintenance of wind power towers. Furthermore, when dealing with offshore installations or any installations in harsh environments, human intervention is more difficult and risky due to adverse weather and sea conditions. The use of special vessels and adequate safety measures, however, do not completely eliminate the risk of accidents and in any case lead to an increase in the costs of interventions for the assembly and maintenance of wind turbines. Not the least drawback of the known art derives from the fact that the particular conditions in which wind power towers are installed can sometimes make the tower itself substantially inaccessible in certain periods of the year or when particularly adverse weather conditions occur, with consequent inevitable lengthening of installation and maintenance times.

[0023] Furthermore, the use of instruments such as laser trackers requires the flange to be equipped with safety devices, specifically special scaffolding, to prevent a person from falling overboard. Scaffolding construction is a laborious operation that can take several days, forcing the vessel to remain close to the tower at all times. Vessel rental costs are very high, and time therefore plays a key role in containing the costs of missions for installing wind power towers.

[0024] A first object of the invention is therefore to avoid having to wait for the scaffolding and other safety structures to be set up before carrying out the inspection of the tower flange.

[0025] A further object of the invention is to solve the problem of how to carry out the measurement of the flanges of wind power towers in an automated manner.

[0026] A still further object of the invention is to provide a solution to the aforementioned problem, which also allows for a measurement that provides "denser" results, i.e. a greater number of points on the flange surface than other traditionally used systems that exploit the presence of a human operator.

[0027] Not least, the invention has the object to provide a solution to the aforementioned problem that is simple and economical, and therefore suitable for industrial production at low cost.

[0028] These and other objects are achieved with vehicle and method as claimed in the appended claims.

[0029] Summary of Invention

[0030] The robotic vehicle for measuring flanges of wind power towers according to the invention essentially comprises: a support structure, a drive unit equipped with motorized locomotion members and associated with the support structure, a tilt sensor capable of generating a signal indicative of the tilt angle of a plane of the sensor along a pair of mutually perpendicular axes, a profile-measuring device capable of generating a signal indicative of dimensions of a surface relative to which the vehicle moves by means of the motorized locomotion members, a local electronic control unit associated with the support structure and capable of controlling the operation of the drive unit and processing the signals coming from said tilt sensor and said profile-measuring device.

[0031] Preferably, said local control unit is capable of communicating, through a wireless connection, with a remote electronic control unit for exchanging control signals with said remote unit and transmitting data relating to the performed measurements.

[0032] In a preferred embodiment of the invention, the support structure is functional for hooking the vehicle to a crane and the vehicle further includes landing members associated with the support structure and capable of taking a rest configuration and a working or landing configuration.

[0033] In this preferred embodiment, the support structure of the vehicle according to the invention essentially comprises a frame preferably equipped with hooking means adapted to allow lifting the vehicle by means of a lifting member such as a lifting rope or a lifting sling. The frame can be made, for example, by means of a combination of plates and boxshaped tubular elements, joined together using screws or welding. The frame preferably has a vertical extension when the vehicle is in its operational configuration and a substantially double-pitched shape with a pair of parallel plates of approximately trapezoidal shape, placed at the opposite side flanks of the frame and joined together by parallel box-shaped tubular elements.

[0034] Superiorly, the frame preferably includes an eyebolt attached to an upper tubular element of the frame, which element serves as a support beam. The eyebolt is preferably of the rotating type, to allow free yaw rotation, preventing twisting of the lifting sling.

[0035] The support structure further comprises a housing having a substantially parallel epipedal shape and located at the base of the frame and joined thereto.

[0036] Alternatively, the vehicle can be without a support structure like the one described above for lifting, for example, when the vehicle can be positioned onto the flange manually, or by other means that do not require such a support structure. In this case the support structure can consist of a suitable frame, for example a horizontally extending frame, and / or the housing itself can form the support structure.

[0037] Preferably, the drive unit associated with the support structure and equipped with the motorized locomotion members whose movement is imparted by electro-mechanical members, is received within the housing.

[0038] The motorized locomotion members are preferably independent of one another and can consist of corresponding wheels. A gearmotor or electric motor is preferably provided for at least one pair of wheels located on the same flank of the vehicle, while the remaining wheels can be idle wheels.

[0039] Preferably, the drive wheels are the internal ones, i.e., those facing the inside of the flange to be measured and therefore traveling the shortest circumferential path, whereas the external wheels will preferably be idle. Advantageously, this preferred choice allows the internal wheels of the vehicle to abut onto the inner diameter of the inner flange and distribute any play only between the shoulders of the external wheels and the outer diameter of the flange.

[0040] Preferably, at least two wheels are provided per each side of the vehicle. The axes of the wheels will also preferably be non-parallel to each other and converging towards the vehicle side flank facing the inside of the flange when the vehicle is operating thereon, whereby the planes in which the wheels rotate are substantially tangent to the inner perimetral edge of the flange and to a circumference external to the flange and concentric with the center of the flange.

[0041] The landing members are associated with the support structure and capable of taking a rest configuration and a landing configuration. The rest configuration is the configuration in which the vehicle is ready to be transported or stored inside a housing or container.

[0042] The landing configuration is the configuration in which the vehicle is ready to land on the flange so as to be able to measure the surface features thereof.

[0043] The configuration in which the landing members are at rest is used for transporting the vehicle, for the measurement step and the step of moving the vehicle over the flange, whereas the landing configuration, in which the landing members are in their operational configuration, is used essentially only for the step of landing of the vehicle on the flange.

[0044] In a preferred embodiment of the invention, the landing members comprise a front landing cylinder and a rear landing cylinder. Alternatively, the cylinders can be replaced by a plurality of parallel coaxial wheels, thus reducing friction when in contact with the flange. The two cylinders are arranged with their axes parallel to each other and are supported by corresponding U-shaped oscillating levers hinged with their arms to the opposite flanks of the support structure. A pair of springs, for example, air springs, is preferably provided for each lever arm, said springs being hinged to connecting plates rotatably attached the support structure. In the illustrated embodiment, the connecting plates of the two front and rear levers that are located on the same flank of the vehicle are rotatably attached to a common pin. In addition, the axis of the pin provided on a flank is coaxial with the axis of the pin provided on the opposite flank and can slide vertically by means of an actuator. Also, at their ends opposite to the connecting plate, the air springs are hinged, at a middle region, to the oscillating arms. The connecting plates are further articulated by means of levers hinged to the lateral plates of the support structure at a specific hinge pin.

[0045] In this way, the oscillating arms, the air springs, the levers and the connecting rod define an oscillating structure that supports the landing cylinders and can take a rest configuration, in which the cylinders are lifted upwards, and an operating or landing configuration, in which the cylinders are lowered.

[0046] The sliding upwards of the hinge axis of the connecting plates causes the reaching of the rest configuration, whereas the sliding downwards allows reaching the operational configuration.

[0047] According to the invention, the contact surfaces of the cylinders, when said cylinders are in their landing configuration and are therefore lowered, lie in a plane substantially parallel to the plane tangent to the contact surface of the locomotion members of the vehicle, but arranged at a lower height, so that, when the vehicle is made to land onto the flange to be measured, the cylinder meet the flange surface in advance of said locomotion members, consisting, for example, of corresponding wheels. This provision allows, by means of special sensors, to control the phase of descent of the vehicle on the flange, stopping the vehicle travel when the wheels come into contact with the flange surface. Additional sensors also allow monitoring of the landing by providing a visual indication through a light turret, and via telemetry. At this point, an operator located at a remote monitoring station can act on the remote control to bring the landing members into the rest configuration and bring the vehicle into the measurement configuration.

[0048] According to the invention, the landing cylinders or the corresponding plurality of wheels are preferably provided, on the side intended to face the outside of the flange to be measured, with respective eyebolts or pulley arrangements for corresponding handling ropes for controlling front and rear yaw.

[0049] The tilt sensor comprises a device capable of generating a signal indicative of the tilt angle of a plane of the sensor with respect to a pair of mutually perpendicular axes.

[0050] The profile-measuring device, or profile gauge or profilometer, comprises a device capable of generating a signal indicative of the shape or profile of a surface relative to which the vehicle moves by means of the motorized locomotion members.

[0051] The profilometer can generate a high-resolution profile of the scanned surface and thus provide data on the surface features that can be compared with the expected ones in order to ascertain the existence and extent of defects, typically in the order of a hundredth of a mm.

[0052] The vehicle can comprise one or more of such measuring devices, depending on the width of the flange to be measured. The measuring device, or a battery of measuring devices, is firmly fixed to a shelf or plate which is cantilevered to the rear part of the vehicle in a plane parallel to the surface of the flange to be measured when the vehicle is operating on the flange. This plate has a substantially rectangular shape and is oriented so that the rear long side is substantially parallel to the radius of the circumference defining the perimeter of the flange on which the vehicle has to operate.

[0053] Preferably, according to the invention, the tilt sensor is also associated with said plate and measures the tilt of the plane of the plate with respect to a pair of perpendicular axes passing through the sensor. The tilt sensor is advantageously fixed to the plate with one of said axes being substantially tangent to the path travelled by the vehicle as it advances on the flange during the measurement step.

[0054] Advantageously, in this way, roll and pitch, i.e., rotation around axes perpendicular to the radius and around the radius itself, respectively, are measured.

[0055] In addition, advantageously, the use of a tilt sensor, preferably associated with the plate, also allows the vehicle to obtain the measurement of the average inclination of the flange with respect to the plane of gravity, thereby allowing, for example, to evaluate the correct installation of the pile to which the flange is fixed.

[0056] The electronic control unit is preferably programmable, is associated with the support structure and is capable of controlling the operation of the drive unit and of communicating, though a wireless connection, with a remote electronic control unit, to exchange control signals with said remote unit. Preferably, said electronic control unit is also capable of transmitting data relative to the measurements carried out by the sensors. The electronic control unit can be equipped with storage means in which the data relative to the performed measurements can be stored for future transfer, for example, when the vehicle is stored on a vessel or at a fixed station.

[0057] According to the invention, more generally there are preferably provided a remote control system to manage movement and a telemetric monitoring and control system to get a signal indicative of: state of the sensors; state of the vehicle; state of the landing members; number of steps performed by the measurement cycle; check of the scanning system and download of data.

[0058] According to the invention, the vehicle is preferably equipped with a centering system comprising a pair of centering members arranged on the opposite side flanks of the vehicle and associated with the support structure. The centering system has the function of guiding the vertical downward movement during landing and the vertical upward movement during detachment from the flange. In a preferred embodiment, the centering system is essentially configured like a saddle, so that the vehicle is lowered on the flange like a saddle on the back of a horse.

[0059] The centering system preferably comprises a pair of 'U'-shaped tubes attached to a corresponding pair of support brackets extending vertically downwards when the vehicle has landed on the flange to be measured and is in its operational configuration. Preferably, the pair of tubes are removable and can have a different extension in a vertical direction, i.e. the tube on the inner side extends vertically downwards more than the outer one, when the vehicle is in the operational configuration.

[0060] The 'U'-shaped tubes are advantageously mounted with the 'longer' 'U'-shaped tube on the inner side of the flange and the 'shorter' U'-shaped tube on the outer side of the flange, to facilitate the centering phase and make it reliable.

[0061] Preferably, moreover, the U'-shaped tubes have a different coloring conferred for example by a checkered red-black pattern on the outer flank and a checkered red-yellow pattern on the inner flank, to facilitate identification of the flank of the vehicle that has to remain inside or outside the flange during measurement operations.

[0062] Preferably, the profile-measuring device is a laser profilometer of the 'strip-laser' 2D type, capable of performing 2D measurements with a single sensor. Still according to the invention, it is also possible to provide for the use of 3D profilometers.

[0063] According to the invention, the vehicle can comprise a plurality of profile-measuring devices, depending on the width of the flange to be measured, for covering the whole width, i.e., the difference between the outer radius and the inner radius, of the circular crown defining the flange surface on which the vehicle operates.

[0064] According to a particular embodiment of the invention, the vehicle comprises a system intended for treating the flange surface and provided with a treatment member capable of modifying the quality of the surface during the measurement operation performed by the vehicle.

[0065] This treatment system comprises, in combination or in alternative, a motorized wiper and / or an air-blowing assembly. The treatment system is arranged frontally associated with the support structure so as to meet the surface to be measured in advance of the profile-measuring device.

[0066] In a preferred embodiment, the system comprises a wiper actuating member frontally associated with the support structure. The actuating member is provided with an electric motor for controlling the alternating movement of the arm carrying the rubber blade of the wiper. The actuating member is received inside a casing attached to the support structure. The casing is preferably made so that protection against rain and water splashes is ensured to the apparatuses and members contained therein.

[0067] A pair of blown air ducts is provided astride the casing of the actuating element and ends at an air diffuser arranged transversely to the vehicle so as to be substantially oriented perpendicular to the direction of progress of the vehicle on the flange to be measured. Upstream of the air ducts there is provided a corresponding blower which communicates with a respective duct and withdraws air from the outside environment in order to send it to the diffuser through the duct. Preferably, the ducts are 'L'-shaped and have, when the vehicle is in its operational configuration, the inlet opening arranged in a substantially vertical plane and an outlet opening arranged associated with the inlet of an air conveyor. The air conveyor in turn preferably has an air outlet arranged at a diffuser located at approximately 45° with respect to the surface of the flange to be measured.

[0068] Advantageously, the treatment system allows removing, from the flange surface, moisture and dirt caused by greases and powder, which might jeopardize the movement of the vehicle and the measurement of the flange profile.

[0069] The vehicle is preferably further provided with a rechargeable battery for actuating the electronic or electro-mechanical members. In particular, when the vehicle is a vehicle used for measuring flanges of offshore wind power towers, the battery can be recharged when the vehicle is stored on a vehicle. On board the vehicle there is also preferably provided a computer equipped with specific software that essentially performs the following functions:

[0070] - initializing the vehicle;

[0071] - starting the measurement step;

[0072] - downloading the acquired data;

[0073] - analyzing the data;

[0074] - generating reports;

[0075] - checking telemetry.

[0076] The vehicle can also preferably be connected to an external PC. Data can be downloaded from the vehicle to the external PC via LAN, with a direct LAN connection, or with a radio link between pairs of antennas. These are the same antennas used to access the telemetry.

[0077] In a particular embodiment of the invention, the vehicle can advantageously be equipped with a support structure, or framework, to which the vehicle can be reversibly attached. Such a framework is preferably made of beams joined together. The framework serves to hold the vehicle in position during the vehicle set-up phase before it is brought onto the flange to be measured. The vehicle is positioned on the frame in order to attach thereto the centering devices, if any.

[0078] According to the invention, the vehicle can advantageously be equipped with a flange lighting lamp which can be attached to the plate to which the profile-measuring device is fixed to the inner side of the plate facing the inside of the flange when the vehicle is in operation.

[0079] In addition, preferably, the vehicle is equipped with a defect identification video camera that can be attached to the plate to which the profile-measuring device is fixed to the outer side of the plate facing away from the flange when the vehicle is in operation.

[0080] Even more preferably, the vehicle is equipped with two video cameras, one of which faces the flange surface and is mounted to the same plate with which the profilometers are associated. This first video camera allows visual inspection of the flange for the detection of macroscopic defects through processing using Al systems. A second video camera is associated with the landing members and is positioned to view the inside of the flange to monitor for possible defects.

[0081] A pair of light towers can be provided at the front and rear of the vehicle to signal the operating status of the vehicle to remote observers by means of lights with specific colors.

[0082] The measurement method for measuring flanges of wind power towers according to the invention essentially comprises: a first step in which the vehicle is brought onto the surface of a flange to be measured; a second step in which the vehicle is moved over the flange while simultaneously performing the measurement of the surface profile of the flange by means of the instruments mounted on board the vehicle, in particular the tilt sensor and the profile-measuring device.

[0083] Optionally, a step may be provided which precedes the measurement step and in which the vehicle is brought, by means of the drive unit with which it is equipped, to a reference associated with said flange, i.e. it is aligned to a reference known as 'marker', which determines a starting position; in this case, preferably, the measurement is completed when the vehicle reaches said 'marker' reference again.

[0084] Typically, the reference or 'marker' consists of a colored line or mark that runs radially across the flange surface and extends vertically along the outer surface of the flange itself.

[0085] Preferably, according to the invention, the first step is carried out by means of a crane which lifts the vehicle from the platform of a means of transport, such as a vessel when the flange belongs to an offshore wind power tower. The vehicle is hooked up using a lifting rope or lifting sling appropriate for the vehicle load. Typically, the lifting sling can support a nominal load of two tons and is approximately ten meters long, to allow a crane to lift and move the vehicle above the flange to be measured and to maintain a constant connection between the vehicle and the crane throughout the work cycle.

[0086] In this step, the vehicle is in its landing configuration, i.e., with the landing cylinders lowered so that they encounter the flange surface in advance of the motorized locomotion members during the vehicle descent phase.

[0087] In this descent phase, the centering system for centering the vehicle with respect to the flange intervenes advantageously, when provided for.

[0088] After the start of the vehicle movement over the flange surface by means of the drive unit, the vehicle generally completes at least one complete rotation, i.e. a travel of at least 360° to return again to the reference associated with the flange.

[0089] The typical diameter of a flange for wind power towers varies remarkably according to the height, capacity and location, onshore (on land) or offshore (at sea), of the turbine.

[0090] For onshore wind power towers, a flange diameter can range from about 1.5 meters to 3 meters or more. Flanges for offshore wind power towers tend to be larger, often exceeding 3 meters in diameter. In some cases, they can reach up to 4 meters or more, considering that offshore turbines are generally larger and more powerful than onshore ones.

[0091] Furthermore, it is not uncommon to find wind power towers with an external diameter of 7500 mm and an internal diameter between 6400 and 6700 mm.

[0092] The time required to make the vehicle according to the invention perform a complete inspection round around the entire flange (360°) therefore varies according to the flange diameter. Advantageously, with the vehicle according to the invention this time is short and can be estimated to be around 45 minutes on average. At the end of this time interval, the crane operator can pick up the vehicle and return it to the base, for example on the deck of a vessel.

[0093] Advantageously, the data collected by the vehicle while it is on the flange allows determining whether the measurement step can be considered complete or whether a new measurement is necessary. This verification step can also include statistical monitoring to determine whether the measurements are consistent with environmental factors, such as the wind present during the measurement.

[0094] Once the vehicle is safely on land or on the deck of a vessel, the data acquired and stored on board of the vehicle can be transferred to an electronic processing unit. Furthermore, the vehicle can be stored as it is or disassembled into its main components and stored in a special protective container.

[0095] Advantageously, the vehicle according to the invention allows a measurement cycle to be performed without an operator on board the flange on which the measurement is being performed. The vehicle according to the invention therefore replaces the operator, performs the measurement autonomously, and can be brought to or removed from the flange using a crane, generally smaller than the one used for the operations of assembling the wind power tower.

[0096] Advantageously, the vehicle according to the invention allows for accurate and precise measurement, and it can also perform multiple measurement cycles by moving along the flange surface until the desired acquisition is completed. Advantageously, therefore, compared to the prior art, the vehicle according to the invention allows for the acquisition of a large amount of data, greater than that which can typically be acquired with known manual means.

[0097] Advantageously, the data collected by the vehicle according to the invention can be processed using a specially developed program that manages the entire measurement flow and raw data and also allows data manipulation up to the final processing generally performed with commercial inspection software, which has the purpose of performing the analysis and generating the final report and which can reside in a remote electronic processor.

[0098] The transfer of the data acquired by the vehicle can take place via a wireless connection, preferably after the measurement process. The data can be stored in a memory device provided on the vehicle and connected to the electronic control unit, to be transferred to a computer when the vehicle is stored. However, real-time transfer as the data is acquired is also possible.

[0099] Brief Description of Drawings Some preferred embodiments of the invention will be provided by way of nonlimiting examples with reference to the annexed drawings, in which:

[0100] Fig.1 is a view of the right side, or inner side, of the vehicle according to the invention in a preferred embodiment, with the landing members in the rest configuration;

[0101] Fig.2 is a view similar to Fig.l, with the landing members in the landing configuration;

[0102] Fig.3 is a top view of the vehicle of Fig.l, with the landing members in the rest configuration;

[0103] Fig.4 is a view similar to Fig.3, with the landing members in the landing configuration.

[0104] Description of Embodiments

[0105] Referring to the annexed figures, the robotic vehicle for measuring flanges of wind power towers according to the invention has been indicated as a whole by reference numeral 11.

[0106] According to the invention, the vehicle 11 essentially comprises a support structure 13, a drive unit 15, a tilt sensor 19, a profile-measuring device 21 and a local electronic control unit 23.

[0107] In the illustrated embodiment, the vehicle 11 further comprises landing members 17 and a centering system 81 which will be described in more detail later in the description.

[0108] Still referring to the illustrated embodiment, the support structure 13 of the vehicle 11 comprises a frame 25 equipped with hooking means 27 adapted to allow lifting the vehicle 11 by means of a lifting member such as the lifting sling of a crane. In the illustrated embodiment, the hooking means 27 comprise an eyebolt 29.

[0109] In this illustrated preferred embodiment of the invention, the frame 25 is made by means of a combination of plates and box-shaped tubular elements, joined together using screws. The frame 25 has an overall vertical extension when the vehicle 11 is in the operational working configuration and a substantially double-pitched shape with a pair of parallel plates 31,33 of approximately trapezoidal shape, placed at the opposite side flanks of the frame 25. The plates 31,33 and joined together by parallel box-shaped tubular elements 35a,35b,35c.

[0110] Still referring to the illustrated embodiment, the support structure 13 further comprises a housing 37 having a substantially parallelepipedal shape and located at the base of the frame 25 and joined thereto by means of screws. Superiorly, the frame 25 includes the eyebolt 29 attached to the central upper tubular element 35b of the frame 25, which element serves as a support beam for the vehicle during transportation thereof, for example, by means of a crane, from the storage site, such as the deck of a boat, to the work site, such as the flange of an offshore wind power tower.

[0111] The drive unit 15 associated with the support structure 13 is received inside the housing 37, said drive unit being equipped with motorized locomotion members 39 whose movement is imparted by electro-mechanical members.

[0112] In the illustrated embodiment, the motorized locomotion members 39 are independent of one another and comprise corresponding wheels 39a, 39b, 39c, 39d.

[0113] A gearmotor or electric motor is provided for the pair of wheels 39a, 39d located on the flank of the vehicle 11 that is inside the flange FL when the vehicle is operating thereon, i.e., the wheels which, being arranged on the internal circumference of the circular crown 'Ll' defining the flange FL, travel the shortest circumferential path.

[0114] Also, the front axis Sant and rear axis Spost of the wheels, 39a, 39b and 39c, 39d, respectively, are non-parallel to each other and converge towards the vehicle 11 side flank intended to face the inside of the flange FL to be measured, when the vehicle is operating thereon, whereby the planes in which the wheels 39a, 39b, 39c, 39d rotate are substantially tangent to a circumference concentric with the center of the flange throughout the entire progress of the vehicle over the flange.

[0115] In the illustrated embodiment, the wheels 39a, 39b, 39c, 39d have a cylindrical shape with a central cylindrical body 41 provided with an external safety shoulder 43. The central cylindrical body 41 of each wheel 39a, 39b, 39c, 39d is intended to come into abutment, with its revolution surface, preferably covered by a tire or the like, onto the surface of the flange to be measured, whereas the lateral surface of the shoulder 43 facing the flange FL forms a lateral confinement abutment. More precisely, the tread of the tire with which all the wheels 39a, 39b, 39c, 39d are preferably equipped and which envelops the central cylindrical body 41 is in contact with the horizontal surface of the flange FL, whereas the shoulders 43 of the internal wheels 39a and 39d are tangent to the inner diameter of the flange and the shoulders 43 of the wheels 39b and 39c are slightly spaced from the outer diameter of the flange, to accommodate, during progress of the vehicle 11 over the circular crown defined on the flange, the play deriving from the manufacturing tolerance of the flange itself. Accordingly, the shoulders 43 of the wheels 39a, 39d of the vehicle 11 that are within the flange FL are substantially in abutment against the inner diameter of the flange, whereas any play is distributed only in the area between the shoulders of the external wheels 39b, 39c and the outer diameter of the flange FL. When the vehicle 11 is in operation, said axes Sant and Spost are therefore essentially coplanar and convergent substantially towards the center of the flange on which the vehicle 11 is performing the measurement.

[0116] The landing members 17 are associated with the support structure 13 and are capable of taking a rest configuration (Figs. 1 and 3) and a landing configuration (Figs. 2 and 4). The rest configuration is the configuration in which the vehicle 11 is ready to be transported or stored inside a housing or container and also to the configuration in which the vehicle is ready to perform the measurement while moving over the flange surface. The landing configuration is the configuration in which the vehicle 11 is ready to land on the flange of a wind power tower.

[0117] In the illustrated preferred embodiment of the invention, the landing members 17 comprise a front landing cylinder 45 and rear landing cylinder 47. The two cylinders 45,47 are arranged with their respective axes parallel to each other and supported by corresponding oscillating front and rear 'U'-shaped levers 48a, 48b, respectively, hinged with their arms 49a, 49b, 49c, 49d to the opposite side flanks of the support structure 13. For each arm 49a, 49b, 49c, 49d of the levers 48a, 48b there is provided a pair of air springs 5 la, 5 lb, 5 lc,5 Id hinged at 52 to corresponding connecting plates 53 rotatably attached to the support structure 13 and articulated by means of levers 54 to the side plates 31,33 of the support structure 13 at a pin 56. In the illustrated embodiment, the connecting plates 53 of the arms 49a, 49b, 49c, 49d of the front 48a and rear 48b levers that are located on the same flank of the vehicle 11 are rotatably attached to a common pin 55. In addition, the axis of the pin 55 provided on a side flank is coaxial with the axis of the pin 55 provided on the opposite side flank and can slide vertically by means of an actuator 50. Also, the air springs 51a,51b,51c,51d are hinged, at their ends opposite to the connecting plates 53, to a pin 57, which in turn is associated, at a middle region, with the oscillating arms 49a, 49b, 49c, 49d of the levers 48a, 48b. In this way, the oscillating arms 49a, 49b, 49c, 49d, the air springs 51a,51b,51c,51d and the connecting plates 53 define together with the relative hinge pins 55,56,57 an oscillating structure that supports the landing cylinders 45,47 and can take a rest configuration, in which the cylinders 45,47 are lifted upwards (Fig.1 and 3), and an operating or landing configuration, in which the cylinders 45,47 are lowered (Fig.2 and 4).

[0118] The vertical sliding upwards of the common hinge axis passing through the pin 55 of the connecting plates 53 causes the landing members 17 to reach the rest configuration, whereas the vertical sliding downwards allows said landing members 17 to reach the operational configuration. Such sliding takes place by means of the actuator 50.

[0119] The abutment surface of the landing cylinders 45,47, when said cylinders are in the landing configuration, lies in a plane Pinf substantially parallel to a plane PSUp that is tangent to the abutment surface of the locomotion members, i.e., the wheels 39a, 39b, 39c, 39d in the illustrated embodiment, and located at a lower height, so that, when the vehicle 11 is brought onto the flange FL to be measured, the cylinders 45,47 encounter the surface of the flange in advance with respect to said locomotion members. By abutment surface of the landing cylinders 45,47 and of the locomotion members 39 it is meant the respective surface that comes into contact with the surface of the flange FL when the vehicle is brought onto said flange by lowering it vertically from above. This provision allows, by means of special sensors, to control the descent phase of the vehicle 11 on the flange, stopping its travel when the wheels have reached a pre-established height due to contact with the flange surface.

[0120] In this illustrated embodiment of the invention, the landing cylinders 45,47 are provided, on the side intended to face the outside of the flange to be measured, with a respective eyebolt 61,63, provided for attaching a corresponding rope for controlling front and rear yaw.

[0121] The tilt sensor 19 comprises a device capable of generating a signal indicative of the tilt angle of a plane of the sensor, with respect to a pair of mutually perpendicular axes.

[0122] The profile-measuring device 21 comprises a device capable of generating a signal indicative of the shape or profile of the surface relative to which the vehicle 11 moves by means of the motorized locomotion members. In the illustrated embodiment, there is provided a battery of three measuring devices 21 firmly fixed to the underside of a plate 22 which is cantilevered to the rear part of the vehicle 11 in a plane parallel to the rotation axes of the wheels 39a, 39b, 39c, 39d. The plate 22 has a substantially rectangular shape and is oriented so that the rear long side 22a is substantially parallel to the rotation axis Spost of the rear wheels 39c, 39d.

[0123] The profile-measuring device 21 is a 2D laser profilometer, capable of performing measurements such as height, width or angle difference, with a single sensor.

[0124] According to the invention, the vehicle can comprise a plurality of profile-measuring devices, depending on the width of the flange FL to be measured. In this way, it is possible to cover the whole width LI of the flange FL, i.e., the difference between the outer radius and the inner radius of the circular crown defining the flange surface on which the vehicle 11 operates. In this specific illustrated embodiment, there are provided three profilemeasuring devices 21 arranged side by side, so as to scan the entire width of flange FL of standard type for offshore wind power towers.

[0125] The vehicle 11 further comprises a local electronic control unit 23 associated with the support structure 13 and capable of controlling the operation of the drive unit 15 and processing the signals coming from the sensor 19 and the measuring device 21.

[0126] The control unit 23 is also capable of communicating, through a wireless connection, with a remote electronic control unit for exchanging control signals with said remote unit. A battery power unit is also provided to power the vehicle equipment and the drive unit. Said local electronic unit 23 associated with the vehicle 11 also receives signals from the sensor 19 and the measuring devices 21 and is adapted to transmit and / or store the data relating to the measurements performed by the tilt sensor 19 and the profile-measuring devices 21. The electronic control unit 23 can be equipped with storage means in which the data relative to the performed measurements can be stored for future transfer to an external processing unit in which specific software is provided that will process the acquired data according to known techniques to produce a specific report.

[0127] Still referring to the illustrated embodiment, the vehicle 11 is equipped with a centering system 81 comprising a pair of centering members 83a, 83b arranged on the opposite side flanks of the vehicle 11 and associated with the support structure 13. The centering system 81 has the function of guiding the vertical downward movement of the vehicle 11 on the flange FL during landing and the vertical upward movement of the vehicle 11 during detachment from the flange FL.

[0128] The centering system 81 preferably comprises a pair of 'U'-shaped tubes 85a, 85b secured to a corresponding pair of support brackets 87 which in turn are secured to the support structure 13, said brackets extending vertically downwards when the vehicle 11 has landed on the flange and is in its operational configuration. The pair of tubes 85a, 85b are removable and have an extension in a different vertical direction, i.e. the tube 85a on the inner side intended to face the inside of the flange FL when the vehicle 11 is operating thereon, extends vertically downwards, when the vehicle 11 is in the operational configuration, more than the outer tube 85b intended to face the outside of the flange FL when the vehicle 11 is operating thereon. This arrangement allows the vehicle 11 to be kept stably balanced and in the desired position during the measurement step on the flange FL.

[0129] In the illustrated embodiment, the 'U'-shaped tubes 85a, 85b have a different coloring conferred for example by a checkered red-black pattern on the outer flank of the vehicle 11 and a checkered red-yellow pattern on the inner flank, to facilitate identification of the flank of the vehicle 11 that has to remain inside or outside the flange FL during the measurement operations.

[0130] In this illustrated embodiment of the invention, the vehicle 11 comprises a treatment system 91 intended for treating the flange surface and provided with a treatment member 93 capable of modifying the quality of the surface during the measurement operation performed by the vehicle 11. Specifically, the system 91 has the function of removing, from the flange surface, moisture and dirt, which might jeopardize a correct dimensional measurement.

[0131] This treatment system comprises a motorized wiper 95 and an air-blowing assembly 97.

[0132] The treatment system 91 is arranged frontally on the vehicle 11 and is associated with the support structure 13 so as to meet the surface of the flange on which the vehicle is operating in advance of the profile-measuring devices 21.

[0133] Said treatment system 91 comprises a wiper actuating member 99 frontally associated with the support structure 13. The actuating member 99 is provided with an electric motor for controlling the alternating movement of the arm 101 carrying the rubber blade 103 of the wiper 95. The actuating member 99 is received inside a casing 105 attached to the support structure 13.

[0134] A pair of blown air ducts 105a, 105b is provided astride the casing 105 of the actuating element 99 and ends at an air diffuser 107 open downwardly and arranged transversely to the vehicle 11 so as to be substantially oriented perpendicular to the direction of progress of the vehicle on the flange to be measured. Said diffuser 107 is configured to cause an air blade oriented substantially at 45° to the surface of the FL flange encountered as the vehicle 11 moves forward. Upstream of the air ducts 105a, 105b there is provided a corresponding blower 109a, 109b which communicates with a respective duct 105a, 105b and withdraws air from the outside environment to send it to the diffuser 107 through the corresponding duct. Preferably, the ducts 105a, 105b are 'L'-shaped and have, when the vehicle 11 is in the operational configuration, the inlet opening arranged in a substantially vertical plane and the outlet opening arranged in a substantially horizontal plane at the inlet of the diffuser 107.

[0135] The measurement method for measuring flanges of wind power towers using the described vehicle essentially comprises:

[0136] - a step of providing a vehicle 11 made according to any one of claims 1 to 8;

[0137] - a step in which the vehicle 11 is brought onto the surface of a flange FL to be measured;

[0138] - a step in which the vehicle 11 is moved over the flange surface by means of the drive unit 15 while simultaneously performing the measurement of the surface profile of the flange by means of the tilt sensor 19 and the profile-measuring device 21.

[0139] In addition, the method preferably further comprises the steps of: causing the vehicle 11 to take a landing configuration;

[0140] - bringing the vehicle 11 onto the flange FL to be measured; causing the vehicle 11 to take an operational configuration; causing the vehicle to move forward over the surface of the flange FL; acquiring the signals generated by the tilt sensor 19 and the profile-measuring device 21; removing the vehicle 11 from the flange; storing the vehicle 11 ; processing said signals and generating a report containing all the dimensional features of the flange FL.

[0141] Even more preferably, the method further comprises, prior to the measurement step, a step in which the vehicle 11 is brought, by means of the drive unit with which it is equipped, to a reference MK associated with the flange FL, i.e. it is aligned to a starting position called 'marker' represented by a known reference, for example, a colored line provided on the flange and radially crossing the flange; in this case, preferably, the measurement is completed when the vehicle reaches said 'marker' reference again.

[0142] The invention as described and illustrated is susceptible to numerous variations and modifications falling within the same inventive principle.

Claims

CLAIMS1. Robotic vehicle (11) for measuring flanges (FL) of wind power towers, comprising:- a support structure (13);- a drive unit (15) equipped with motorized locomotion members and associated with the support structure (13);- a tilt sensor (19) capable of generating a signal indicative of the tilt angle of a plane of the sensor along a pair of mutually perpendicular axes;- a profile-measuring device (21) capable of generating a signal indicative of dimensional features of a surface relative to which the vehicle (11) moves by means of the motorized locomotion members;- a local electronic control unit (23) associated with the support structure (13) and capable of controlling the operation of the drive unit (15) and processing the signals coming from said tilt sensor (19) and said profile-measuring device (21).

2. Vehicle according to claim 1, wherein landing members (17) are provided associated with the support structure (13) and capable of taking a rest configuration for allowing transport and storage of the vehicle and a landing configuration for allowing the vehicle to land on the flange (FL) to be measured.

3. Vehicle according to claim 2, wherein the landing members (17) comprise a front landing cylinder (45) and a rear landing cylinder (47) which are arranged with their respective axes parallel to each other and are secured to an oscillating structure articulated to the support structure (13).

4. Vehicle according to claim 3, wherein the abutment surface of the landing cylinders (45,47), when said cylinders are in the landing configuration, lies in a plane (Pinf) substantially parallel to a plain (Psup) tangent to the abutment surface of the locomotion members and located at a lower height, so that, when the vehicle (11) is brought onto the flange (FL) to be measured, the cylinders (45,47) encounter the surface of the flange in advance with respect to said locomotion members.

5. Vehicle according to any one of the preceding claims, wherein a centering system (81) is further provided comprising a pair of centering members (83a, 83b) arranged on the opposite side flanks of the vehicle (11) and associated with the support structure (13), said centering system (81) being capable of guiding the vertical downward movement of the vehicle (11) onto the flange (FL) to be measured, during landing, and the vertical upward movement of the vehicle (11), during detachment of the vehicle (11) from the measured flange (FL).

6. Vehicle according to claim 5, wherein the centering system (81) comprises a pair of 'U'-shaped tubes (85a, 85b) secured to a corresponding pair of support brackets (87) extending vertically downwards when the vehicle (11) has landed on the flange (FL) to be measured and is in an operational configuration capable of performing the measurement of the flange.

7. Vehicle according to any one of the preceding claims, wherein the profile-measuring device (21) is a 2D laser profilometer.

8. Vehicle according to any one of the preceding claims, wherein a treatment system (91) is provided intended for treating a surface and provided with a treatment member capable of changing the quality of a surface during the measurement operation to be performed by the vehicle (11), said treatment system (91) comprising, in combination or in alternative, a motorized wiper (95) and / or an air-blowing assembly (97).

9. Measurement method for measuring flanges of wind power towers, comprising:- a step of providing a vehicle (11) made according to any one of claims 1 to 8;- a step in which the vehicle (11) is brought onto the surface of a flange (FL) to be measured;- a step in which the vehicle (11) is moved over the flange surface by means of the drive unit (15) while simultaneously performing the measurement of the surface profile of the flange by means of the tilt sensor (19) and the profile-measuring device (21).

10. Method according to claim 9, wherein the following steps are further provided: causing the vehicle (11) to take a landing configuration;- bringing the vehicle (11) onto the flange (FL) to be measured; causing the vehicle (11) to take an operational configuration; causing the vehicle to move forward over the surface of the flange (FL); acquiring the signals generated by the tilt sensor (19) and the profile-measuring device (21); removing the vehicle (11) from the flange; storing the vehicle (11); processing said signals and generating a report containing all the dimensional features of the flange (FL).

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