Wind Turbine Blade Repair Robot With Shielded Curing Zone
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Solution Overview
Problem
Conventional methods for repairing wind turbine blade damage are time-consuming, costly, and expose the repair process to environmental conditions, leading to inefficiencies and potential structural damage due to the need for manual labor and lack of shielding during automated repairs.
Innovation Solution
A robotic maintenance device with an applicator head and environmental control module, featuring a deployable tent to shield the curing zone from environmental conditions, allowing for automated repairs without the need for rope access technicians or permanent structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual rope access technicians are used for repairs, then repair quality can be maintained, but repair time and cost increase significantly
Solution Approach 1:
The robotic maintenance device performs repairs autonomously without requiring human operators to physically access the blade. The device includes an applicator head that automatically applies coating material to the leading edge, and an environmental control module that self-regulates temperature and humidity conditions, enabling the system to service itself during the repair process.
Solution Approach 2:
The patent replaces manual mechanical repair operations with an automated robotic system. The robotic device uses controlled material application mechanisms and environmental control systems to substitute for the manual skills and physical actions of rope access technicians, achieving consistent repair quality through automated processes.
2Loss of time
If automated repair devices are used, then repair time is reduced, but environmental conditions interfere with coating curing
Solution Approach 1:
The environmental control module creates a controlled micro-environment around the repair area that shields the coating material from adverse external weather conditions. This controlled atmosphere maintains optimal temperature and humidity levels necessary for proper coating curing, effectively isolating the repair zone from the external environment.
Solution Approach 2:
The system prepares and maintains optimal environmental conditions for coating curing before and during the application process. The environmental control module pre-establishes the necessary temperature and humidity parameters to ensure proper curing occurs immediately as the coating is applied, preventing environmental interference from compromising the repair.
3Ease of operation
If blade is removed from tower for repair, then repair access is improved, but downtime and operational losses increase
Solution Approach 1:
The maintenance device is divided into separable components that can be independently deployed and positioned on the blade while it remains mounted on the tower. The robotic device, applicator head, and environmental control module can be independently controlled and positioned to access different areas of the leading edge without requiring blade removal.
Solution Approach 2:
The patent transitions from ground-based repair operations to in-situ repairs on the mounted blade. By deploying the robotic device directly onto the blade surface while it remains on the tower, the system eliminates the need for vertical disassembly and reassembly operations, performing repairs in the original three-dimensional context where the blade is already positioned.
4Reliability
If permanent shielding structures are built for repairs, then environmental protection is improved, but device complexity and cost increase
Solution Approach 1:
The environmental control module is designed as a dynamic, movable structure rather than a permanent fixed installation. The module can be deployed, positioned, and retracted as needed for different repair operations on different blades, adapting to varying repair requirements without requiring permanent structural modifications to the wind turbine.
Solution Approach 2:
The environmental control module is designed to be universally applicable to multiple repair scenarios and different blade locations. Rather than building dedicated shielding structures for each repair location, this single multi-functional module can be deployed wherever repairs are needed, serving multiple purposes across different blades and repair situations.
Data Source
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AI summary
A robotic maintenance device (40) and method for repairing damage (26) around the leading edge (22) of a wind turbine blade (20) are provided. The maintenance device (40) includes a main chassis (42) that is configured to be mounted on the wind turbine blade (20), an applicator head (46) for applying a coating material (32) onto an exterior surface (30) of the blade (20) to cover and fill in damaged areas (26), and an environmental control module (60). The environmental control module (60) is located proximate the applicator head (46) and includes a tent (62) that selectively deploys over a portion of the leading edge (22) of the blade (20) behind operations of the applicator head (46) to define a curing zone. The coating material (32) within the curing zone can cure on the wind turbine blade (20) to complete the repair while remaining shielded from local environmental conditions such as wind and rain around the wind turbine blade (20). For example, the tent (62) can be configured to extend over a fixed length and move over that length behind the moving robotic maintenance device (40), or the tent (62) can be configured to secure on the blade (20) and be extended as the maintenance device (40) moves and conducts repair operations, with the tent (62) being retractable at the end of the maintenance process.