RENEWABLE ENERGY
Before repair (left), after cleaning and sanding
(middle), after final coating (right)
Rope Robotics’ robot can work precisely even at 130m height
Te core of the system is a robot
carrying visual sensors, which operates repair tools using a flexible arm, with technicians monitoring the robot from any location, onsite or remotely.
ROBOT HOISTED BY ROPES AND GRIPPING BLADE WITH VACUUM SYSTEM On site, the 150kg robot is first attached to ropes that have been anchored in the nacelle before it is hoisted some 100m from the ground onto the damaged blade, which has been fixed in a vertical position. A vacuum system allows the robot to attach itself firmly while motors enable movement across the blade. Using its onboard high- resolution camera and laser scanner, the robot inspects the surface, sending images to the remote operator, who diagnoses the damage and initiates the repair process in real time.
CLEANING, SANDING AND RESTORING BLADE Te three-phase repair process starts with sanding the damaged area, applying appropriate speed and force to create a pattern ensuring surface roughness and geometry. A second tool cleans the surface using a brush and alcohol to remove dirt and grease. Te patented dosing tool applies the leading-edge protective (LEP) material while the spreader tool, also patented, rebuilds the optimal aerodynamic blade shape, smoothening the material to pre-defined standards. Controlled remotely on-screen by a technician viewing live images, the robot performs each step with high precision and consistency, thus ensuring quality. All images are recorded and serve as documentation, a global requirement for wind turbine maintenance. Awarded two patents covering the
robot system, the method, the spreading tool and the dosing tool, the robot took five years to develop and was launched in 2021. “Perhaps surprisingly, the biggest challenge was to develop a functioning spreader and dosing tool that can apply viscous material both accurately and flexibly to fit different blade types. Tere are so many variables to consider like temperature, humidity and fluid dynamics. Implementing that into a fully functioning robot that is now working on wind farms around the world was an arduous but fulfilling task,” concludes Huus Bjerge.
EXTENDED WEATHER WINDOW AND PRIOR TRAINING After leading-edge damage has been established, typically by drones, the wind farm or service provider contracts Rope Robotics, which supplies the robot along with technician training and support on site.
Te robot has been proven in the field at wind speeds of up to 14m per second, relative humidity of up to 80% and temperatures from 0 to 40°C. Using results from the over 150 blade repairs already performed worldwide, Rope Robotics is investing in artificial intelligence (AI) to offer autonomous repairs in the future.
Patented spreader tool rebuilding and smoothing after preparation of blade
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