UAV-Supported Blade Repair Robot for Low-Downtime 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 operational downtime due to the need for disassembly, manual repairs by rope access technicians, or the use of inefficient automated systems that require assembly on the turbine.
Innovation Solution
A robotic maintenance device secured to an unmanned aerial vehicle (UAV) performs repairs on the wind turbine blade while remaining connected, allowing for semi-autonomous operations with minimal downtime, without the need for a fixed interface or rope access technicians.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual repairs by rope access technicians are used, then repair flexibility and adaptability are improved, but productivity is worsened due to time-consuming manual operations
Solution Approach 1:
The robotic maintenance device performs repairs autonomously without requiring human operators to physically access the blade. The system self-navigates along the blade using sensors and automated control, applying repair materials through robotic applicators, thereby eliminating the need for rope access technicians while maintaining repair quality
Solution Approach 2:
Manual mechanical repair operations by technicians are replaced with an automated robotic system that uses sensors, automated navigation, and robotic applicators to perform the same repair functions, significantly reducing repair time while maintaining adaptability through programmable control
2Productivity
If automated repair systems are used, then productivity is improved through faster operations, but device complexity is worsened due to assembly requirements on the turbine
Solution Approach 1:
The robotic maintenance device is divided into modular functional units including navigation sensors, robotic applicators, and support structures that can be independently assembled and maintained. This segmentation allows for simpler assembly procedures while maintaining the automated repair capabilities
Solution Approach 2:
The robotic maintenance device is designed as a multi-functional platform that can perform various repair tasks including surface preparation, material application, and inspection. This universality reduces the need for multiple specialized devices, thereby simplifying overall system complexity while enhancing productivity
3Manufacturing precision
If blade disassembly and ground-based repair are used, then manufacturing precision is improved through accessible repair conditions, but loss of time is worsened due to disassembly and reassembly operations
Solution Approach 1:
The robotic maintenance device performs preliminary surface preparation including cleaning and roughening of the repair area before material application. This preliminary action ensures optimal adhesion and repair quality while eliminating the need for time-consuming disassembly operations, as the robot can access and prepare the surface in-situ
Solution Approach 2:
The robotic system acts as an intermediary between the repair materials and the blade surface, applying materials with precise control through automated applicators. This intermediary approach ensures uniform material distribution and optimal bonding while maintaining operational efficiency by eliminating disassembly-reassembly cycles
Data Source
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AI summary
A repair device and method for repairing damage around the leading edge of a wind turbine blade (20) are provided. The repair device includes a robotic maintenance device (40) and an unmanned aerial vehicle (UAV) (62) that can move the maintenance device (40) between a storage position and an operation position, the former being mounted on a blade (20) of the wind turbine (10). The UAV (62) hovers and remains connected to the maintenance device (40) during operations at the blade (20) to minimize a total operational downtime needed to conduct the repair actions. The UAV (62) is secured to the maintenance device (40) by at least one support line (68) that carries the weight load of the maintenance device (40) and at least two control lines (72) that prevent undesired rotations of the maintenance device (40), thereby improving precision and accuracy of UAV-driven movements of the maintenance device (40). A transport container (24) may also be provided to define the storage position, the transport container (24) including an elongated slot (70) for guiding movement of the lines (68, 72) and the maintenance device (40) during movements into and out of a storage space within the container (24).