Infrared Adhesive Layer Inspection for Wind Turbine Blade LEP Bonds

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Solution Overview

Problem

Existing methods for inspecting the adhesive bond between a leading-edge protector (LEP) and a wind turbine rotor blade are inaccurate, time-consuming, and dependent on human skill, ambient light levels, and fail to detect defects consistently, leading to false negatives or positives.

Innovation Solution

An infrared imaging system with a heating assembly and displacement means to inspect the adhesive layer by detecting temperature anomalies using infrared imaging, allowing for automated and efficient detection of defects in the adhesive layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual inspection techniques are used to detect adhesive layer defects, then inspection can be performed without special equipment, but inspection accuracy and consistency deteriorate due to dependence on human skill and concentration

Engineering Contradiction:

Improveinspection capabilityVSAvoiddefect detection accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent replaces manual mechanical inspection (hand触摸, visual inspection) with an automated optical inspection system using a camera and image processing. The system captures images of the adhesive layer and automatically analyzes them to detect defects, eliminating dependence on human skill and concentration while maintaining ease of implementation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Extent of automation

If 3D scanning is used to inspect the adhesive layer, then automated inspection is achieved, but measurement precision deteriorates due to sensitivity to ambient light variations

Engineering Contradiction:

Improveinspection automationVSAvoiddefect detection accuracy

Core Design Contradiction:

Extent of automationVSMeasurement precision

Solution Approach 1:

The patent replaces 3D scanning with a simplified 2D image capture system using a camera. This approach is less sensitive to ambient light variations while still achieving automated inspection. The system uses standard imaging rather than complex 3D scanning, making the automation more robust to environmental conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a visual copy (image) of the adhesive layer surface and analyzes this copy to detect defects. By working with 2D images rather than 3D data, the system reduces complexity and sensitivity to lighting conditions while maintaining automated defect detection capability.

Inventive Principle:

Principle #26Copying

3Extent of automation

If ultrasound inspection is used to detect air cavities, then automated inspection is achieved, but measurement precision deteriorates because similar acoustic impedance of LEP and adhesive layer prevents detection of defects without air pockets

Engineering Contradiction:

Improveinspection automationVSAvoidair cavity detection accuracy

Core Design Contradiction:

Extent of automationVSMeasurement precision

Solution Approach 1:

The patent replaces ultrasound inspection with optical imaging. Instead of using acoustic waves that cannot distinguish between LEP and adhesive layer, the system uses light to capture visual images of the adhesive layer surface. This allows detection of surface irregularities and defects through image analysis without being limited by similar acoustic impedance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If manual inspection is performed to ensure high quality adhesive bonding, then inspection can be adapted to various LEP shapes, but productivity deteriorates due to time-consuming procedures and need for consistent high concentration

Engineering Contradiction:

Improveinspection flexibilityVSAvoidinspection speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces manual inspection with automated image capture and analysis. The camera system can quickly capture images of the adhesive layer, and automated image processing algorithms analyze the images to detect defects. This dramatically increases inspection speed and productivity while maintaining adaptability to different LEP shapes and configurations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The inspection system performs self-analysis through automated image processing algorithms that automatically detect and classify defects without human intervention. The system serves itself by capturing images, processing them, and generating inspection results autonomously, eliminating the need for human concentration and time investment.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method provides accurate and rapid detection of adhesive layer defects, eliminating the need for human intervention and ensuring consistent results, reducing the risk of false positives or negatives.

Implementation Method 1

a heating assembly configured to direct heat at a portion of the adhesive layer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an infrared imaging means arranged to obtain an infrared image of the heated portion

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Data Source

PatentEP4419797B1Method of inspecting an adhesive layer

Publication Date: 2026.03.25 SIEMENS GAMESA RENEWABLE ENERGY AS

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AI summary

The invention describes an apparatus (1) for inspecting an adhesive layer (30) applied about the leading edge (20PLE, 20SLE, 2LE) of a wind turbine rotor blade (2), which apparatus (1) comprises a heating assembly (1H) configured to direct heat at a portion (P, Phot) of the adhesive layer (30) between the outer edges (30P, 30S) of the adhesive layer (30); an infrared imaging means (1IR) arranged to obtain an infrared image (11IR) of a heated portion (Phot); and a displacement means (13, 14) adapted to move the inspection apparatus (1) alongside the rotor blade (2) during operation of the heating assembly (1H) and the infrared imaging means (1IR) to facilitate infrared imaging of the adhesive layer (30).