Robotic Coating Applicator Tool Head for Wind Turbine Blade Repair
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Solution Overview
Problem
Conventional methods for repairing wind turbine blades, such as disassembly or manual rope access, are time-consuming and costly, leading to significant power production losses and delays, while existing automated systems are not reliable or efficient for use on blades connected to the rotor and hub.
Innovation Solution
A robotic maintenance device equipped with a coating applicator tool head that includes a tool head body, feed tube, roller brush, and nozzle, which applies a coating directly onto the blade to repair damage without disassembly or manual intervention, using a supply container with mixable components and adjustable actuators to ensure precise and even coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual rope access or disassembly methods are used for blade repair, then repair can be performed, but the process is time-consuming and costly leading to significant power production losses
Solution Approach 1:
The robotic maintenance device enables automated repair operations on the wind turbine blade without requiring manual rope access technicians or disassembly of the blade from the tower. The system performs inspection, preparation, and coating application autonomously, transforming manual service into self-service automation that eliminates downtime associated with conventional repair methods
Solution Approach 2:
The patent replaces manual mechanical repair operations with an automated robotic system equipped with specialized tool heads. The robotic device uses automated coating applicators with roller brushes and spray nozzles to apply repair materials, substituting the mechanical actions of human technicians with programmable robotic mechanisms that operate more efficiently and consistently
2Productivity
If manual rope access technicians are used for repair, then repair can be performed, but the cost is high and power production is disrupted
Solution Approach 1:
The robotic maintenance device is designed as a multi-functional system that can perform multiple repair operations including inspection, surface preparation, and coating application using different tool heads. This universal device replaces multiple specialized manual operations, improving efficiency while the modular tool head design manages system complexity through standardized interfaces
Solution Approach 2:
The system uses adjustable actuators with multiple degrees of freedom to precisely control the position and orientation of tool heads relative to the blade surface. By programmatically changing spatial parameters rather than relying on manual positioning, the system achieves high repair efficiency while managing complexity through automated control systems
3Extent of automation
If existing automated systems are used on blades connected to rotor and hub, then automation is achieved, but reliability and efficiency are insufficient
Solution Approach 1:
The robotic maintenance device is segmented into modular components including interchangeable tool heads (coating applicator, inspection, preparation) that can be independently selected and replaced. This segmentation improves reliability by allowing the most suitable tool head to be used for each specific repair task while maintaining high automation levels through standardized mounting and control interfaces
Solution Approach 2:
The system employs dynamic, adjustable actuators with multiple degrees of freedom that can adapt the tool head position and orientation in real-time during operation. This dynamic capability enhances reliability by allowing precise accommodation of varying blade geometries and damage locations while maintaining consistent automated performance
4Manufacturing precision
If coating is applied to repair damage, then blade integrity is restored, but uneven coverage reduces repair quality
Solution Approach 1:
The coating applicator tool head uses a roller brush as an intermediary between the spray nozzle and the blade surface. The nozzle applies coating material onto the roller brush, which then transfers it evenly to the blade as it rotates. This intermediary mechanism ensures uniform coating distribution while maintaining high application speed, resolving the contradiction between precision and productivity
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 solution enables rapid, precise, and cost-effective repair of wind turbine blades while minimizing downtime and eliminating the need for rope access technicians, ensuring consistent and high-quality maintenance without disrupting power production.
Implementation Method 1
The feed tube is configured to receive a flow of a coating from a supply container, delivering this flow of the coating to the nozzle, which is located adjacent the roller brush. The nozzle spreads the flow of the coating along a width of the roller brush and then applies the coating directly onto the roller brush.
Implementation Method 2
The roller brush is configured to be rolled along surfaces of the wind turbine blade, thereby transferring the coating by the roller brush onto the surfaces of the wind turbine blade
Implementation Method 3
The roller brush is configured to be rolled along surfaces of the wind turbine blade, thereby transferring the coating by the roller brush onto the surfaces of the wind turbine blade
Data Source
AI summary
A coating applicator tool head configured for use with a robotic maintenance device includes a tool head body with a frame, a supply container, a drive for actuating delivery of flow of coating from the supply container, a feed tube, a nozzle receiving flow from the feed tube, and a spreading tool such as a roller brush or a spatula receiving flow from the nozzle. The coating applicator tool head is moved by an articulated arm of the maintenance device over surface of a wind turbine blade containing damage such that the roller brush or spatula can apply layers of the coating to cover and fill in the damage. The nozzle directly supplies coating continuously onto the roller brush or the spatula, and the drive can be configured to independently adjust supply of two or more different components in the supply container that may be mixed to form the coating.