Mobile X-Ray Inspection for Wind Turbine Blade Defect Depth
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Solution Overview
Problem
Large structures like wind turbine blades are difficult to inspect for defects post-installation due to their size and operational constraints, with existing technologies only capable of pre-installation defect detection.
Innovation Solution
A defect inspection system utilizing an X-ray generator and detector, moved by transporting means such as drones or rails, which includes a control unit to control the X-ray output based on the structure's thickness and location, allowing for defect detection and depth calculation using a method involving multiple X-ray images and geometric calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection methods are used for large structures like wind turbine blades, then inspection cost and time are reduced, but inspection coverage and defect detection capability deteriorate due to inaccessibility of certain areas
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated X-ray imaging system. The system uses X-ray generators and detectors mounted on movable platforms (drones, rails, or jibs) to automatically capture images of the blade's internal structure, eliminating the need for manual inspection while significantly improving defect detection capability in hard-to-reach areas.
Solution Approach 2:
The patent introduces X-ray radiation as an intermediary to penetrate the blade material and reveal internal defects. The X-ray generator emits radiation that passes through the blade, and the detector captures the transmitted radiation pattern, allowing indirect visualization of internal structures without physical contact or disassembly.
2Measurement precision
If X-ray output is increased to improve defect detection in thick sections, then measurement precision improves, but radiation exposure and safety risks worsen
Solution Approach 1:
The patent applies local quality by adjusting X-ray output parameters based on the local thickness and material composition of different blade sections. The system uses pre-acquired CT data to determine optimal X-ray settings for each specific location, applying higher output only where necessary for thick sections and lower output for thinner areas, thereby maintaining detection precision while minimizing overall radiation exposure.
Solution Approach 2:
The patent implements feedback control by using initially acquired CT data to inform subsequent X-ray inspection parameters. The system analyzes the blade's internal structure from initial scans, then uses this information to optimize X-ray output settings for targeted defect detection, avoiding unnecessary high-radiation exposure while maintaining precision where defects are most likely to occur.
3Measurement precision
If multiple X-ray images are captured from different positions to calculate defect depth, then measurement precision improves, but inspection time and complexity worsen
Solution Approach 1:
The patent applies preliminary action by first acquiring comprehensive CT data of the entire blade before performing targeted defect detection. This initial 3D mapping provides a structural framework that reduces the number of additional X-ray images needed for defect depth calculation, as the pre-acquired data contains information about blade geometry and density that aids in interpreting subsequent defect-specific images.
Solution Approach 2:
The patent segments the inspection process into distinct phases: initial comprehensive CT scanning of the entire blade, followed by targeted defect detection in specific regions of interest. This segmentation allows the system to focus computational and imaging resources only on areas where defects are detected or suspected, reducing the total number of images required compared to exhaustive full-blade scanning at high resolution.
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
Enables effective detection and depth analysis of defects in large structures like wind turbine blades during operation, improving maintenance efficiency and safety by providing a non-invasive inspection method.
Implementation Method 1
an X-ray generator that generates X-ray to be irradiated to a structure
Implementation Method 2
an X-ray detector that detects the X-ray generated by the X-ray generator and transmitted through the structure
Data Source
AI summary
A defect inspection system includes an X-ray generator that generates X-ray to be irradiated to a structure, and an X-ray detector that detects the X-ray generated by the X-ray generator and transmitted through the structure. In particular, the X-ray generator is configured to be moved by a first transporting means, and the X-ray detector is configured to be moved by a second transporting means. The system further includes a control unit configured to control and operate the first transporting means and the second transporting means.