Robotic Blade Coating Applicator for Uniform Leading Edge Repair
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Solution Overview
Problem
Conventional methods for repairing wind turbine blade damage are time-consuming, costly, and result in significant power production losses due to the need for disassembly, manual repairs, or stopping the turbine, while existing automated systems are inefficient and prone to uneven coatings.
Innovation Solution
An applicator tool for a robotic maintenance device that includes a spatula and chamfer arms to shape and apply coating material precisely along the leading edge, with a vision system for real-time correction and a multi-cartridge system for consistent material supply, ensuring accurate and efficient repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If manual repair by rope access technicians is used, then repair can be performed on the blade, but the process is time-consuming and costly
Solution Approach 1:
The robotic maintenance device enables the blade to be repaired autonomously without requiring human technicians to manually access the blade via rope access. The device applies coating material automatically, allowing the system to perform maintenance tasks on its own, thereby reducing both time and cost while maintaining repair capability
Solution Approach 2:
The patent replaces the manual mechanical repair process with an automated robotic system. The robotic device uses controlled mechanisms to apply coating material precisely to damaged areas, substituting human operators with automated machinery that operates more efficiently and consistently
2Ease of repair
If blade is disassembled from the tower for repair, then thorough repair can be performed, but the process becomes time-consuming and costly
Solution Approach 1:
The robotic maintenance device is designed to perform repairs in-situ on the installed blade without requiring disassembly from the tower. The device can access and repair damaged areas while the blade remains in its operational position, eliminating downtime associated with blade removal and reinstallation
Solution Approach 2:
The device prepares the repair area by cleaning and abrading the surface before applying coating material. This preliminary preparation ensures proper adhesion and quality repair outcomes without requiring blade disassembly, maintaining both repair quality and operational productivity
3Productivity
If automated coating system is used, then repair efficiency is improved, but coating uniformity becomes problematic
Solution Approach 1:
The spatula is designed with flexible support arms that allow it to dynamically adapt to the blade surface contours. The support arms can flex and adjust their position to maintain consistent spacing between the spatula and blade surface, ensuring uniform coating thickness even on curved or irregular surfaces while maintaining high repair efficiency
Solution Approach 2:
The system incorporates sensors and control mechanisms that monitor the coating application process in real-time. The flexible support arms provide feedback on spacing variations, allowing the system to adjust its position or coating rate to maintain uniform coating thickness, thereby achieving both efficiency and precision
4Ease of repair
If turbine is stopped for repair, then maintenance can be performed, but significant power production losses occur
Solution Approach 1:
The robotic maintenance device enables rapid in-situ repairs that can be performed while the turbine remains in service or with minimal shutdown time. The automated system can quickly assess damage, prepare the surface, and apply coating material without requiring extended turbine停机, thereby maintaining power production while providing necessary maintenance capability
Solution Approach 2:
The device performs preliminary assessment and preparation of the repair area before full turbine shutdown is required. By pre-positioning the device and preparing access points while the turbine is still operational, the actual repair can be completed rapidly with minimal energy loss
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 tool enables high-quality, precise, and efficient repair of wind turbine blade damage with minimal aerodynamic disruption, reducing downtime and maintenance costs.
Implementation Method 1
The flexible extrusion plate is configured to define a gap between the inner surface thereof and an exterior surface of the wind turbine blade
Implementation Method 2
a first chamfer arm and a second chamfer arm configured to engage the outer surface of the extrusion plate of the spatula adjacent the front edge to press the extrusion plate against the exterior surface of the wind turbine blade
Implementation Method 3
a first nozzle with a nozzle outlet located under the spatula to deliver a coating material into the gap as the robotic maintenance device moves the spatula along the leading edge of the wind turbine blade
Data Source
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AI summary
An applicator tool (42) is provided for use with a robotic maintenance device (40) for 5 repairing damage (26) around a leading edge (22) of a wind turbine blade (20) on a wind turbine (10). The applicator tool (42) includes a tool frame (70) and a spatula (76) defining a flexible extrusion plate (78) that is configured to be engaged with an exterior surface (34) of the wind turbine blade (20), and a nozzle (84) that delivers a coating material (30) into a gap (112) between the extrusion plate (78) and the blade 0 (20). At least two nozzles (84) and corresponding fluid supplies may be provided to extend a working capacity of the applicator tool (42). The applicator tool (42) also includes a first chamfer arm (80) and a second chamfer arm (82) each configured to engage an outer surface (100) of the extrusion plate (78) adjacent a front edge (94) thereof to press the extrusion plate (78) against the exterior surface (34) of the blade 5 (20) at two specific engagement locations. The spatula (76) is configured to shape the coating material (30) into a shaped coating as the coating material (30) spreads in the gap (112) to thereby fill in and cover the damage (26) on the wind turbine blade (20), and the first and second chamfer arms (80, 82) are configured to limit spread of the coating material (30) beyond the two specific engagement locations 0 such that the shaped coating applied to the wind turbine blade (20) extends only between a first chamfer line (36) and a second chamfer line (38) on opposite sides of the leading edge (22). The applicator tool (42) also includes a vision system (160) configured to image the blade (20) to detect whether the first and second chamfer lines (36, 38) are located at expected positions to determine if any overfill or underfill 5 condition needs corrected, as well as a repair verification scanner (180) that detects a coating layer thickness of the shaped coating to further confirm whether a repair is performed as expected.