Modular Blade Repair Robot for Internal Wind Turbine Cracks
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Solution Overview
Problem
Current repair technologies for wind turbine blades are limited to repairing cracks on one-third of the blade's length, leaving the remaining two-thirds prone to catastrophic failure, and existing methods require lengthy downtimes and expose operators to hazardous conditions.
Innovation Solution
A modular robot with interchangeable machining and patching modules, equipped with traction systems, cameras, and a remote control system, allows for internal repairs of cracks and fissures without removing the blade, using interchangeable modules for machining and patching operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operator access is used for repair, then repairs can be performed on the blade, but only cracks up to one third of the total length can be reached and repaired
Solution Approach 1:
The robot is divided into multiple modular segments including a front module, rear module, and interchangeable intermediate module. This segmentation allows the robot to navigate through the blade's internal structure and reach areas that are inaccessible to operators, thereby extending repair coverage to two-thirds of the blade length while maintaining operational feasibility through modular design.
2Reliability
If current repair technologies are used, then cracks in accessible areas can be repaired, but cracks in the remaining two-thirds of the blade cannot be repaired leading to potential catastrophic failure
Solution Approach 1:
The robot acts as an intermediary device that enters the blade's internal structure through an access hole and performs repair operations from within. This intermediary approach allows the system to reach and repair cracks in previously inaccessible areas (two-thirds of blade length) without requiring external operator access, thereby improving blade safety while managing system complexity through a self-contained robotic platform.
3Reliability
If blade removal is performed for repair, then internal cracks can be accessed, but the blade must be removed from its operating position and lowered to ground level
Solution Approach 1:
The robot extracts the repair function from the traditional blade removal process. Instead of removing the blade to access internal cracks, the robot is inserted through a small access hole and performs machining and patching operations internally. This extraction principle allows repairs to be conducted in-situ, eliminating the need for blade removal and significantly reducing downtime while maintaining reliable access to internal cracks.
4Ease of manufacture
If operators perform repairs manually, then repairs can be carried out, but operators are exposed to working at heights, in confined spaces and harmful environments
Solution Approach 1:
The robotic system performs repair operations autonomously or under remote control, making the system self-service rather than relying on human operators to enter hazardous environments. The robot navigates, machines, and patches cracks independently, eliminating operator exposure to working at heights, confined spaces, and harmful environments while maintaining full repair capability through automated machining and patching modules.
Data Source
AI summary
A robot includes front and rear traction modules to circulate throughout the inside of a wind turbine blade; two intermediate modules able to be inserted between the front module and the rear module, which include an intermediate machining module to machine fissures and cracks from within the blade; and an intermediate patching module to apply, compact and cure repair patches on the fissures and cracks; and a remote control system to monitor parameters and control the repair actions.