Wind Turbine Blade Imaging With Gimbal-Based Defect Tracking
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Solution Overview
Problem
Conventional methods for inspecting wind turbine rotor blades are either unsafe, time-consuming, or result in inaccurate imaging due to the large size and curvature of the blades, making it difficult to identify minor damage.
Innovation Solution
A multi-axis gimbal mounted on the exterior of the wind turbine, equipped with a camera and an image analysis unit, adjusts its orientation based on image analysis output to capture accurate images of the rotor blade, allowing for automated and precise inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a conventional camera is used to capture an entire rotor blade, then the field of view covers the whole blade, but the resolution is too poor to identify minor damage
Solution Approach 1:
The rotor blade imaging is divided into multiple sequential image sections captured by moving the camera along the blade length. Each section is captured with high resolution, and then stitched together to form a complete high-resolution image of the entire blade, resolving the contradiction between field of view and resolution.
Solution Approach 2:
The camera is mounted on a multi-axis gimbal that enables movement along the longitudinal axis of the rotor blade, adding a new dimension of motion. This allows the camera to capture multiple high-resolution images at different positions along the blade, which are then combined to achieve both comprehensive coverage and high detection precision.
2Measurement precision
If a person visually inspects the rotor blade, then detailed damage can be identified, but the inspection is time-consuming and involves significant downtime
Solution Approach 1:
The system enables automated inspection by mounting the camera on the rotating rotor blade itself, which serves as the mounting structure. The blade's own rotation and structure are utilized to position and orient the camera, eliminating the need for external support structures or manual intervention, thereby reducing inspection time while maintaining high detection accuracy.
Solution Approach 2:
The inspection is performed continuously during the rotor blade's normal rotation without requiring the turbine to shut down. The camera captures images at multiple positions during the rotation cycle, enabling uninterrupted inspection and eliminating the significant downtime associated with manual inspections.
3Area of stationary object
If a drone-based system is used to image the rotor blade, then access to the entire blade is achieved, but accumulated positioning errors lead to large discrepancies in defect location
Solution Approach 1:
A multi-axis gimbal with known geometric relationships between its axes serves as an intermediary reference system. The gimbal's structured mechanical framework provides stable, traceable positioning information that mediates between the camera and the rotor blade, enabling accurate spatial registration and defect location without the accumulated errors of satellite-based positioning.
Solution Approach 2:
The system replaces unstable aerial vehicle positioning with a controlled mechanical gimbal mounting system attached to the rotor blade. The gimbal's mechanical structure provides stable, repeatable positioning with known geometric relationships, substituting the error-prone satellite-based positioning of drones with a reliable mechanical reference system.
4Strength
If the rotor blade is pre-bent, then structural integrity is maintained, but imaging the complete blade becomes more difficult
Solution Approach 1:
The camera mounting system utilizes the dynamic rotation of the rotor blade during operation. By capturing images at multiple rotational positions, the system adapts to the blade's pre-bent shape and captures the complete surface area. The dynamic imaging approach accommodates the blade's curved geometry without requiring complex static positioning mechanisms.
Data Source
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AI summary
The invention describes a wind turbine rotor blade imaging arrangement (1), comprising a multi-axis gimbal (10) mounted to the exterior of the wind turbine (2) and configured to adjust its orientation in response to one or more received settings (10_α, 10_β, 10_Υ); a camera (11) mounted on the multi-axis gimbal (10) and arranged to capture images 11i) of a rotor blade (20); an image analysis unit (110) configured to analyse the captured images (11i); and a camera orientation controller (100) configured to compute updated gimbal settings (10_α, 10_β, 10_Υ) on the basis of the image analysis output (110_out).