WO2021121524A1 - Dispositif de maintenance robotique et procédé utilisant un système de vision pour balayer un endommagement de bord d'attaque sur une pale d'éolienne - Google Patents

Dispositif de maintenance robotique et procédé utilisant un système de vision pour balayer un endommagement de bord d'attaque sur une pale d'éolienne Download PDF

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Publication number
WO2021121524A1
WO2021121524A1 PCT/DK2020/050394 DK2020050394W WO2021121524A1 WO 2021121524 A1 WO2021121524 A1 WO 2021121524A1 DK 2020050394 W DK2020050394 W DK 2020050394W WO 2021121524 A1 WO2021121524 A1 WO 2021121524A1
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WO
WIPO (PCT)
Prior art keywords
wind turbine
turbine blade
control system
maintenance device
blade
Prior art date
Application number
PCT/DK2020/050394
Other languages
English (en)
Inventor
Ivar J.B.K. JENSEN
Aksel PETERSEN
Asger Bloksma KROGSTRUP
Original Assignee
Vestas Wind Systems A/S
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vestas Wind Systems A/S filed Critical Vestas Wind Systems A/S
Publication of WO2021121524A1 publication Critical patent/WO2021121524A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • F03D80/50—Maintenance or repair
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • F03D80/50—Maintenance or repair
    • F03D80/55—Cleaning
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2230/00—Manufacture
    • F05B2230/90—Coating; Surface treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/60—Properties or characteristics given to material by treatment or manufacturing
    • F05B2280/6011—Coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • This application relates generally to wind turbines, and more particularly, relates to an automated robotic device and method for repairing damage along the leading edge of a wind turbine blade without necessitating removal of the blade from the tower of the wind turbine or manual repairs by rope access technicians.
  • Wind turbines are used to produce electrical energy using a renewable resource and without combusting a fossil fuel.
  • a wind turbine converts kinetic energy from the wind into electrical power.
  • a conventional wind turbine installation includes a foundation, a tower supported by the foundation, and an energy generating unit positioned atop of the tower.
  • the energy generating unit typically includes one or more nacelles to house several mechanical and electrical components, such as a generator, gearbox, and main bearing, and the wind turbine also includes a rotor operatively coupled to the components in the nacelle through a main shaft extending from the nacelle.
  • the rotor includes a central hub and a plurality of blades extending radially therefrom and configured to interact with the wind to cause rotation of the rotor.
  • the rotor is supported on the main shaft, which is either directly or indirectly operatively coupled with the generator which is housed inside the nacelle. Consequently, as wind forces the blades to rotate, electrical energy is produced by the generator. Wind power has seen significant growth over the last few decades, with many wind turbine installations being located both on land and offshore.
  • blades interact with the wind to generate mechanical rotation of the rotor, which can then be converted into electrical energy.
  • the blades move at varying speeds through the ambient environment surrounding the wind turbine, but often this movement is at high speed. Consequently, the blades will typically experience erosion and damage over time in operation as a result of friction from the air as well as potential impacts from particulate matter or other items in the air, especially along the leading edge facing the direction of movement through the wind.
  • the erosion or damage along the leading edge of the blade adversely affects the aerodynamic qualities of the blade, resulting in lower power production for given incoming wind speeds.
  • Such erosion and damage on the blades can be corrected by routine maintenance and repair procedures.
  • the blades are typically formed from a shell of fiber composite, aluminum, or similar material with an outer skin defined by a series of layers of coatings (polymeric elastomers, paint, etc.) surrounding and covering an outer surface of the shell.
  • the outer skin is defined by several different layers of material, including at least an outermost topcoat, a second layer underneath the outermost topcoat, and a third layer underneath the second layer. Other layers are typically present underneath the third layer as well.
  • the topcoat, second layer, and third layer may be formed from different colors of material so as to more easily reveal how deep an erosion or damaged portion goes into the outer skin of the blade.
  • Damage to the blade outer skin can be categorized into several different levels of severity based on which layer the damage extends to, e.g., an erosion to the third layer would be a "category 2" level of severity, which would be higher than a cut to the second layer, which would be a "category 1" level of severity.
  • an erosion to the third layer would be a "category 2" level of severity, which would be higher than a cut to the second layer, which would be a “category 1" level of severity.
  • For low levels of damage or erosion such damage can be repaired by depositing/painting a coating onto the area to fill in the damage and restore the blade to the original condition along the leading edge thereof.
  • WO2018/113875 One example of such a repair system is shown in PCT International Patent Publication No. WO2018/113875, owned by the original Applicant of the present application. It will be understood that other types of repair or maintenance actions can also be taken to correct these types of damage on the wind turbine blade.
  • a repair action can be taken by an operator on a platform hoisted into position adjacent the blade on the wind turbine, either extending from the nacelle or hub of the wind turbine or extending from a cherry picker or boom- style lift.
  • the wind turbine must be stopped and locked for the time period of repair, and as such, significant power production losses are experienced by wind turbine operators for these necessary maintenance and repair actions. This may lead some operators to delay or procrastinate in making such repairs, which can lead to more significant structural damage and even longer delays when more thorough repairs are necessary at the wind turbine blade.
  • embodiments of the invention are directed to a robotic maintenance device for repairing damage around a leading edge of a wind turbine blade of a wind turbine.
  • the maintenance device includes a main body, an articulated arm connected to the main body, a vision system, and a control system.
  • the main body is configured to engage with the wind turbine blade along the leading edge.
  • the articulated arm includes an interface element at a free end thereof for selectively engaging with one or more tool heads used for conducting maintenance and repair actions on the wind turbine blade.
  • the vision system is configured to scan a surface of the blade adjacent the damage, so as to determine the surface profile of the blade. To do this, the vision system includes a laser for conducting scans of the profile defined by the blade.
  • the control system is operatively coupled to the vision system the scans of the profile from the laser.
  • the control system uses the scans of the profile to calculate a robot working line that is subsequently used when operating the articulated arm to move the one or more tool heads along the robot working line when conducting maintenance and repair actions on the blade.
  • Such scanning automatically enables the repair to be conducted without reliance on input from human operators, thereby making the automated repair more precise and reliable.
  • the control system operates the articulated arm and the vision system such that a plurality of point scans are taken by the laser for an individual cross-section of the blade.
  • the control system combines these point scans to approximate a section profile of the individual cross-section of the blade.
  • the control system operates the articulated arm and the vision system to repeat this process of taking point scans and combining into section profiles along at least three individual cross-sections of the wind turbine blade spaced apart along a longitudinal direction of the blade.
  • the control system then approximates lines between these section profiles to define the robot working line for the robotic maintenance device to follow along the longitudinal direction.
  • the robot working line may help calculate a movement path for the tool heads later used by the articulated arm for conducting maintenance and repair actions.
  • the laser captures between three and ten point scans for each individual cross-section to be combined by the control system to approximate the section profile.
  • control system operates the articulated arm and the vision system such that a line scan is taken by the laser to determine a section profile of an individual cross-section of the blade.
  • the section profile resulting from the line scan is generally more accurate than the approximations made by combining a plurality of point scans in other embodiments.
  • the control system operates the articulated arm and the vision system to repeat this process of taking line scans to determine section profiles along at least three individual cross-sections of the wind turbine blade spaced apart along a longitudinal direction of the blade. The control system then approximates lines between these section profiles to define the robot working line for the robotic maintenance device to follow along the longitudinal direction.
  • the vision system is configured to both scan and image a surface of the blade adjacent the damage, so as to both determine the surface profile of the blade as well as the severity of the damage.
  • the vision system includes a laser for conducting scans of the profile defined by the blade and a scanning camera for imaging the surface of the blade.
  • the control system is operatively coupled to the vision system and receives the images from the scanning camera of the surface of the blade as well as the scans of the profile from the laser.
  • the control system uses the scans of the profile to calculate a robot working line that is subsequently used when operating the articulated arm to move the one or more tool heads along the robot working line when conducting maintenance and repair actions on the blade.
  • Such scanning automatically enables the repair to be conducted without reliance on input from human operators, thereby making the automated repair more precise and reliable.
  • control system uses color recognition on the images of the surface from the scanning camera to evaluate a severity of the damage at the surface and to thereby determine a level of repair needed to correct the damage with application of a coating to the surface using the robotic maintenance device.
  • the vision system further includes an overview camera mounted on a mast extending upwardly from the main body of the maintenance device.
  • an operator reviews images from the overview camera to optionally provide additional guidance for the maintenance device.
  • the images may be used to verify the determination of the level of repair needed to correct the damage as provided by the control system. In some circumstances this second level of review will be desirable, even though the automated determination of repair tends to be more precise and accurate than operator determinations.
  • the maintenance device includes a coating applicator tool head selectively engaged with the articulated arm and configured to apply a coating to the surface.
  • the control system operates the scanning camera of the vision system to image the surface of the blade after applying the coating to the surface with the coating applicator tool head.
  • the control system uses color recognition on the images to automatically assess a quality of repair performed by the maintenance device.
  • the maintenance device includes a cleaning/abrading tool head selectively engaged with the articulated arm and configured to sand and clean the surface to condition the surface of the wind turbine blade for application of the coating.
  • the control system operates the scanning camera of the vision system to image the surface of the wind turbine blade after conditioning the surface with the cleaning/abrading tool head. The control system then uses color recognition on the images to confirm that the surface is ready to receive the coating to repair the damage.
  • the wind turbine blade is defined by layers of coating materials having different colors, including a top coat of a first color, a second material layer underneath the top coat of a second color, and a third material layer underneath the second material layer of a third color.
  • the first, second, and third colors are distinguishable to allow the control system to automatically evaluate severity of damage or quality of repair based on color recognition of images taken with the scanning camera.
  • Embodiments of the invention are also directed to a method for automatically evaluating and repairing damage around a leading edge of a wind turbine blade on a wind turbine.
  • the method includes operating the wind turbine to move one of the wind turbine blades to a generally horizontal orientation, and pitching the wind turbine blade in the generally horizontal orientation such that the leading edge of the blade is oriented to face vertically upward.
  • the method also includes positioning a robotic maintenance device having a main body, an articulated arm configured to engage with tool heads that conduct maintenance and repair actions, a vision system including a laser, and a control system onto the wind turbine blade along the leading edge. The articulated arm is thus positioned to move into position at a location containing damage on the blade.
  • the method further includes using the articulated arm and the tool heads to apply a coating to the surface of the blade to repair the damage, with the articulated arm moving the tool heads in accordance with the robot working line that was calculated.
  • the automated repair is fast, precise, and reliable.
  • the step of operating the laser also includes operating the laser to produce a plurality of point scans for an individual cross-section of the blade.
  • the control system combines the point scans to approximate a section profile of the individual cross- section of the blade.
  • the step of operating the laser further includes repeating these steps of taking point scans and combining into section profiles along at least three individual cross-sections of the wind turbine blade spaced apart along a longitudinal direction of the blade.
  • the control system then approximates lines between these section profiles to define the robot working line for the robotic maintenance device to follow along the longitudinal direction.
  • the laser captures between three and ten point scans for each individual cross-section to be combined by the control system to approximate the section profile.
  • the step of operating the laser also includes operating the laser to produce a line scan for an individual cross-section of the blade, the line scan defining a section profile of the individual cross-section.
  • the step of operating the laser further includes repeating these steps of taking a line scan along at least three individual cross- sections of the wind turbine blade spaced apart along a longitudinal direction of the blade. The control system then approximates lines between these section profiles to define the robot working line for the robotic maintenance device to follow along the longitudinal direction.
  • the method includes a vision system including a scanning camera and operating the scanning camera of the vision system to image a surface of the wind turbine blade.
  • the method further includes evaluating the images from the scanning camera of the surface of the blade with the control system by using color recognition to determine a severity of damage at the surface and thereby determine a level of repair needed to correct the damage.
  • the method includes operating an overview camera of the vision system, which is mounted on a mast extending upwardly from the main body, to provide images showing a complete overview of operations of the robotic maintenance device to an operator.
  • the operator can optionally provide feedback based on images from the overview camera to the control system to verify the determination of the level of repair needed to correct the damage.
  • the step of using the articulated arm and the tool heads further includes coupling a cleaning/abrading tool head to the articulated arm and using the cleaning/abrading tool head to sand and clean the surface of the blade.
  • This step also includes coupling a coating applicator tool head to the articulated arm and using the coating applicator tool head to apply layers of the coating to the surface of the blade to thereby repair the damage.
  • the method further includes operating the scanning camera to image a surface of the wind turbine blade after use of the cleaning/abrading tool head and/or after use of the coating applicator tool head. The images from the scanning camera are evaluated using color recognition to determine whether the functions performed by the tool head(s) is sufficient and accurate.
  • Fig. 1 is a perspective view of a wind turbine according to one embodiment of the invention.
  • Fig. 2 is a front view of a wind turbine blade of the wind turbine of Fig. 1 , showing various levels of erosion-type damage along a leading edge that is pitched upwardly.
  • Fig. 3 is a top perspective view of a robotic maintenance device including a vision system in accordance with embodiments of the present invention, the maintenance device being mounted in position on the leading edge of the wind turbine blade of Fig. 2 with an articulated arm moving over a surface containing the damage to scan and/or image the blade.
  • Fig. 3A is a detailed side view of a free end of the articulated arm of the robotic maintenance device of Fig. 3, showing further details of the vision system including a scanning camera and a laser.
  • Fig. 4A is a front view schematically illustrating the laser of the vision system of Fig. 3 imaging one portion of a cross-section of the wind turbine blade in accordance with operational steps of the invention.
  • Fig. 4B is a front view similar to Fig. 4A, but schematically illustrating the laser of the vision system imaging a different portion of the cross-section of the blade.
  • Fig. 4C is a front view similar to Fig. 4B, but schematically illustrating the laser of the vision system imaging yet another different portion of the cross-section of the blade.
  • Fig. 5A is a geometric perspective representation of data points collected when a plurality of point scans are conducted by the laser of the vision system of Fig. 3, with approximations of section profiles being drawn in between the point scans by a control system of the maintenance device.
  • Fig. 5B is a geometric perspective representation of data points collected when scans of different cross-sections of the blade are taken by the laser of the vision system of Fig. 3, similar to Fig. 5A, and with approximations of a longitudinal profile being drawn in between the cross-sections by the control system.
  • Fig. 5C is a front view schematically illustrating operation of the articulated arm and the laser of the vision system to generate a line scan to determine a section profile of the wind turbine blade at the individual cross-section shown.
  • Fig. 6A is a simulated top view image that represents image data that the scanning camera of the vision system of the maintenance device of Fig. 3 may produce before a repair action is conducted along the leading edge of the wind turbine blade.
  • Fig. 6B is a simulated top view image similar to Fig. 6A, but showing image data that the scanning camera may produce after the repair action is conducted.
  • a robotic maintenance device having a vision system for scanning/imaging a wind turbine blade and a method for automatically repairing damage around a leading edge of the blade are shown in detail.
  • the maintenance device is configured to repair so-called category-1 and category-2 damage to the outer coatings of a wind turbine blade, such as by scanning the blade to image the damaged area, sanding down a surface of the blade around the damaged area and cleaning the same, and then applying layers of coating by painting or the like to repair the damage.
  • the vision system uses a laser to scan the profile of the blade to allow for accurate calculations of a robot working line for the tool heads of the robot to operate along when performing repair actions.
  • the vision system also uses one or more cameras to image the blade, with a control system then using color recognition on the images to automatically evaluate the damaged or repaired status of the blade.
  • This robotic maintenance device and operational method produces a high quality and precise repair of damage on wind turbine blade in an automated manner and while the blade remains connected to the remainder of the wind turbine, which helps minimize operational downtime, while also avoiding the need for rope access technicians and the associated safety and timing problems of manual repairs.
  • the correction of erosion damage on wind turbine blades is typically referred to as a "repair” of those damages.
  • “damage” refers to more significant damages to the blade (perhaps beyond what is described as “category-1” and “category-2” damage herein), and so the operation of the maintenance device may be deemed a routine maintenance action that occurs before a blade is “damaged” in such contexts.
  • the maintenance device is capable of providing preventative maintenance to remove wear and erosion effects before such effects cause "damage” that must be repaired on the wind turbine blade, and the maintenance device is also capable of providing more thorough repairs after damage is caused on the blade.
  • a wind turbine 10 is shown to include a tower 12, a nacelle 14 disposed at the apex of the tower 12, and a rotor 16 operatively coupled to a generator (not shown) housed inside the nacelle 14.
  • the rotor 16 of the wind turbine 10 includes a central hub 18 and a plurality of wind turbine blades 20 that project outwardly from the central hub 18 at locations circumferentially distributed around the hub 18.
  • the rotor 16 includes three wind turbine blades 20, but the number of blades 20 may vary from one wind turbine to another.
  • the wind turbine blades 20 are configured to interact with air flow to produce lift that causes the rotor 16 to spin generally within a plane defined by the wind turbine blades 20.
  • the robotic maintenance device of this invention improves the repair process and can completely automate this process to make it more precise, accurate, and less time-consuming as will be set forth in detail below.
  • one or more of the wind turbine blades 20 may experience erosion from prolonged, continuous exposure to the environment.
  • erosion damage 26 is shown in Fig. 1 and better shown in the detailed view of Fig. 2. While not being particularly limited to any source, erosion damage 26 may occur due to particulates in the air that abrade the leading edge 22 of the wind turbine blade 20 during operation. Erosion therefore may occur in an erosion zone that includes the leading edge 22, but it may also occur in other areas in the surface 30 of the blade 20.
  • the robotic maintenance device is configured to repair damage and move along the leading edge 22, this device is also capable of conducting maintenance and repair actions anywhere along the outer surface of the blades 20.
  • Erosion damage 26 is generally characterized as a loss of material from the wind turbine blade 20. Material loss may be uniformly distributed but is often non-uniform across the leading edge 22 or any other surface of the wind turbine blade 20. Rather than losing a uniform skin of material from a surface, erosion may include localized surface imperfections, such as random pitting and shallow gouges or crack-like features that may be a result of localized, connected pitting (as a result of impacts with debris or other matter in the environment). In any case, if erosion damage 26 is not repaired in a timely fashion, the wind turbine blade 20 becomes less efficient at rotating the rotor 16 and ultimately, the structural integrity of the wind turbine blade 20 may be significantly impaired. With reference to the detailed view in Fig.
  • the erosion damage 26 may define differing levels of severity based on how deep the damage extends inwardly into the material layers defining the outer shell of the blade 20.
  • the erosion damage 26 includes some areas with an erosion or cut of material through the outer topcoat layer into a second layer of material underneath the topcoat, which is categorized as a "category 1" level of severity, and further areas with an erosion or cut of material through the outer topcoat layer and the second later of material into a third layer of material underneath the second layer, which is categorized as a "category 2" level of severity.
  • deeper cuts and erosions defining more significant damage is typically categorized at higher levels such as category 3, 4, or 5.
  • the topcoat is shown at 28a
  • the revealed areas of second layer are shown at 28b
  • the revealed areas of third layer are shown at 28c.
  • These various layers 28a, 28b, 28c of material may be different in color, which can help with the identification of damage severity and repair confirmation after the repair is completed with the maintenance device. By identifying and correcting such lower levels of erosion damage 26 promptly, more significant damage of the blade 20 can be avoided along with higher operational downtime caused by the more significant damage.
  • Fig. 3 provides an overview of the robotic maintenance device 40 that includes the vision system 56 in accordance with embodiments of this invention.
  • the maintenance device 40 includes a main body 42 having a first body portion 44 and a second body portion 46 extending towards opposite sides of the leading edge 22 of the blade 20 when the maintenance device 40 is mounted atop the leading edge 22 of the blade 20 as shown in this Figure. It will be appreciated that the wind turbine 10 is halted with the blade 20 to be worked upon in a generally horizontal orientation with the blade 20 pitched so that the leading edge 22 faces upwardly when the maintenance device 40 is placed upon the blade 20.
  • the maintenance device 40 can be moved onto the blade 20 in various manners without departing from the scope of this invention, including by crane and/or by flying vehicle.
  • the main body 42 generally defines a framework for other components of the maintenance device 40 to be mounted on, as set forth in the following description.
  • an articulated arm 48 is connected to the main body 42 so as to project outwardly beyond a front of the remainder of the maintenance device 40.
  • the articulated arm 48 is defined by a series of arm portions 50 connected together at rotational joints 52 in this embodiment. Movement of the arm portions 50 at the joints 52 enable a free end 54 of the articulated arm 48 to move all around the periphery and surface of the wind turbine blade 20. To this end the free end 54 is capable of accessing any portion on the surface of the blade 20 to conduct inspection or maintenance and repair actions in this embodiment (or any portion within the physical range defined by the articulated arm 48).
  • the free end 54 of the articulated arm 48 also carries elements defining part of a vision system 56 for the maintenance device 40.
  • the vision system 56 may include a laser 110 and/or a scanning camera 58 configured to image the surface 30 in the vicinity of the leading edge 22 and/or damaged areas on the blade 20.
  • the maintenance device 40 also includes in this embodiment a mast 60 that projects upwardly from the main body 42 to a position well above the remainder of the maintenance device 40.
  • the vision system 56 also includes an overview camera 62 mounted on the mast 60.
  • the overview camera 62 images the remainder of the maintenance device 40 to provide a complete overview of the operational status and actions of the maintenance device 40.
  • Such an overview can be desirable when the maintenance device 40 is at least partially monitored and/or controlled from a location offsite, including on the ground surface rather than on the blade 20. More or fewer camera devices may be provided in other embodiments to allow for visual feedback to be provided to the maintenance device 40 and/or to an operator.
  • the operation of these components of the vision system 56 are described in further detail below with reference to Figs. 3A through 6B.
  • the main body 42 serves as a support for one or more tool heads that may be selectively engaged by the articulated arm 48 to conduct the necessary repair and maintenance actions.
  • two exemplary tool heads are provided on the maintenance device 40.
  • the first is a cleaning/abrading tool head 70 that is configured to sand down the surface of the wind turbine blade 20 containing damage and then clean that surface to prepare it for repair.
  • the second is the coating applicator tool head 80 that is configured to apply layers of coating material onto the surface of the blade 20 to fill in damaged areas and thereby repair the blade 20.
  • the free end 54 of the articulated arm 48 includes an interface element 64 that can mechanically and electrically couple with corresponding interface elements 66 located on each of the tool heads 70, 80.
  • the maintenance device 40 also includes a control system 90 shown schematically in Fig. 3 and implemented on known hardware and software platforms.
  • the control system 90 is operatively connected to the other portions of the maintenance device 40, including the articulated arm 48, the vision system 56, and a movement drive 100, to thereby operate these elements.
  • the control system 90 is capable of responding to inputs from the vision system 56 and/or from an offsite operator to modify the actions taken by the maintenance device 40 based on the repair or maintenance needed on the blade 20.
  • the movement drive 100 is further illustrated in Fig. 3.
  • the main body 42 includes first and second body portions 44, 46 that extend towards opposite sides of the leading edge 22 of the blade 20 when the maintenance device 40 is mounted atop the leading edge 22.
  • the movement drive 100 is defined by a plurality of elements located along longitudinal rails 102 extending along a length of the maintenance device 40 at the free ends defined by the first and second body portions 44, 46.
  • a plurality of idler wheels 104 connected to an undersurface of the main body 42 between the first and second body portions 44, 46 sit directly on the leading edge 22 of the blade 20, two of such idler wheels 104 being visible in Fig. 3.
  • the idler wheels 104 can freely rotate along the surface of the blade 20 in response to movements of the maintenance device 40 generated by the movement drive 100 as will be described.
  • the idler wheels 104 help support a weight of the maintenance device 40 on the blade 20 such that the entire weight is not applied to the movement drive 100 and its elements.
  • These idler wheels 104 may be formed from a plastics material or any other suitable material, typically a low-friction material to help avoid any damage upon engagement with the blade 20.
  • the movement drive 100 includes a plurality of clamping actuators 106a, 106b, 106c that extend from the longitudinal rails 102 into selective clamped engagement with the opposite sides of the wind turbine blade 20.
  • the idler wheels 104 and the clamping actuators 106a, 106b, 106c define the points of direct contact between the maintenance device 40 of this embodiment and the blade 20. It will be understood that only one idler wheel 104 or any number of idler wheels 104 may be provided in other embodiments.
  • the movement drive 100 includes three pairs of actuators in the plurality of clamping actuators 106a, 106b, 106c.
  • the plurality of clamping actuators includes a front pair of clamping actuators 106a located at one longitudinal end of the main body 42, a middle pair of clamping actuators 106b, and a rear pair of clamping actuators 106c located at another longitudinal end of the main body 42.
  • the middle pair of clamping actuators 106b is positioned between the front and rear pairs.
  • the movement drive 100 is configured to move one pair of the clamping actuators at a time relative to the other pairs to produce movements in either direction along the leading edge 22 of the blade 20.
  • the plurality of clamping actuators 106a, 106b, 106c is configured to produce a steady crawling-like movement along the blade 20 as the maintenance device 40 is positioned for conducting repair and maintenance actions.
  • the movement drive 100 may include more than three pairs of clamping actuators without departing from the scope of the invention.
  • This design of the movement drive 100 allows for both movement of the maintenance device 40 and rigid engagement in position during repair method steps in order to make repair actions more precise and accurate (e.g., without generating unnecessary additional vibrations), thus helping minimize operational downtime for the repair.
  • the free end 54 includes an interface element 64 configured to engage with corresponding interface elements 66 on a tool head 70, 80, but no tool heads are shown attached to the articulated arm 48 in these Figures for simplicity of illustration. It will be appreciated that the scanning and imaging steps described below may be conducted both when the articulated arm 48 is in this state shown in Figs. 3 and 3A, or alternatively, when one of the tool heads 70, 80 is connected to the articulated arm 48.
  • the articulated arm 48 includes a support body 112 that is connected to the free end 54 just above the interface element 64 in this embodiment.
  • the support body extends away from the articulated arm 48 and defines a framework upon which the laser 110 is mounted as shown in these Figures.
  • the laser 110 is mounted so that an outlet 114 of the laser 110 points away from the articulated arm 48 and is unobstructed by the support body 112 and any further elements attached to same.
  • one of those further elements includes a camera boom 116 that is connected to the support body 112 and extends laterally away from the support body 112 as most clearly shown in the perspective view provided in Fig. 3.
  • the camera boom 116 is connected at one end to the support body 112, and the scanning camera 58 is mounted on the opposite end of the camera boom 116.
  • the scanning camera 58 is therefore mounted in a position generally out of the path of any tool head 70, 80 that may also be connected to the free end 54 of the articulated arm 48 during operation of the maintenance device 40.
  • the scanning camera 58 of this embodiment is of conventional design and includes a camera body 118 connected to the camera boom 116 and a lens 120 extending away from the camera body 118.
  • both the scanning camera 58 and the laser 110 are of known commercially-available designs and may be replaced with alternative designs without departing from the scope of the invention.
  • control and/or power wires typically extend between the laser 110 and scanning camera 58 and the articulated arm 48 so as to provide a communication path between the control system 90 of the maintenance device 40 and these components of the vision system 56.
  • Control signals can also be wirelessly delivered between these elements in still further embodiments.
  • Figs. 4A through 4C schematically illustrate several scanning steps that may be performed by the vision system 56 during the repair process for the wind turbine blade 20.
  • the vision system 56 In order for the repair and maintenance of erosion damage 26 to be fully automated, the vision system 56 must provide the control system 90 with accurate information on the current shape of the blade 20 and the amount of damage around the leading edge 22.
  • One embodiment of the maintenance device 40 thus uses the laser 110 of the vision system 56 to scan the blade 20 at varying points and cross-sections in order to determine a surface profile of the blade 20 both in cross-section and longitudinally. With this information on the current shape of the blade 20 along the surface 30, the control system 90 can then calculate appropriate movement paths for the articulated arm 48 to move the tool heads 70, 80 along to provide any necessary repair actions in a precise and accurate manner.
  • the focus of the vision system 56 and its operation in this invention are to provide input data to allow for an automated calculation of robot working lines to be used in this process.
  • the articulated arm 48 moves the vision system 56 such that the laser 110 is directed with its outlet 114 pointed towards one side of the leading edge 22 of the wind turbine blade 20.
  • the laser 110 captures a scan of one or more points on this side of the blade 20.
  • the point scans may determine the current position of an outer surface profile of the blade 20 at a single position by evaluating reflection and bounce-back of the laser beam emitted from the laser 110. Such a position may vary based on how much erosion damage 26 is present on the blade 20.
  • Such information is communicated to the control system 90 for further combination with other scan data as described in further detail below.
  • the articulated arm 48 may be further programmed to move the laser 110 to a number of different points on this side of the blade 20 to provide a series of point scans identifying points on the surface profile or individual cross-section of the blade 20.
  • the articulated arm 48 has moved to a different position such that the laser 110 is scanning the leading edge 22 of the blade in a "head on” manner from a position directly above the leading edge 22, shown by the scan profile 126 schematically in this view.
  • the scan profile 126 schematically in this view.
  • the laser 110 is now moved by the articulated arm 48 to an opposite side of the blade 20 to take point scans of one or more surface profile points on the opposite side, shown by the scan profile 128 in this view.
  • the scan profiles 124, 126, 128 in these views are schematically shown as covering a span of area, it will be appreciated that the laser 110 may also simply be drawn as a line drawn between the outlet 114 and the point on the surface 30 being evaluated. Three or more of these point scans will be taken for each cross-section being evaluated so that the point scans can be combined to help approximate a section profile of the blade 20 at this individual cross-section.
  • the point scans include 4 different point scans on one side of the blade, another point scan at the leading edge 22, and 4 more different point scans on the opposite side of the blade, resulting in 9 total point scans. It will be appreciated that any number of points scans (e.g., such as between 3 and 10) may be used in embodiments of the invention.
  • the point scans communicated to the control system 90 may effectively be geometrically plotted by the control system 90 as shown in Fig. 5A.
  • Each of the point scans (nine in total in this illustration) is plotted on a transverse plane based on the scan data received from the point scans of the laser 110.
  • the control system 90 then combines these point scans into a first section profile 132 by approximating lines between the points to thereby create an approximation of the first section profile 132 defined by the surface 30 of the blade 20 at this individual cross- section.
  • FIG. 4A through 4C is then repeated for additional cross-sections along the longitudinal length of the blade 20.
  • at least three individual cross-sections are scanned by the laser 110 so that additional (second and third) section profiles 134, 136 can be approximated for each of these cross-sections.
  • two additional sets of point scans and approximated section profiles 134, 136 are shown in Fig. 5A spaced apart along a longitudinal axis in the geometric plot from the first section profile. More scans and cross-sections may be evaluated in further embodiments consistent with the scope of this invention.
  • the laser 110 thus communicates scans of the blade 20 to the control system 90 in such a manner that the control system 90 can generally determine the section profile currently defined by the blade 20 at different cross-sections.
  • variations in the surface profile from the expected airfoil shape of the wind turbine blade 20 can be determined by this plot done by the control system 90, likely caused by damage 26 on the surface 30 of the blade 20.
  • the severity of the damage 26 can also thus be determined from this scan data.
  • the tool heads 70, 80 of the maintenance device 40 typically work in this embodiment by moving longitudinally along the surface 30 of the wind turbine blade 20, this movement actuated by the articulated arm 48.
  • the control system 90 In order to assure that the tool heads 70, 80 are operating on the surface 30 accurately, the control system 90 must determine one or more robot working lines from the scan information described above. In this regard, the control system 90 will further approximate lines between corresponding points of the plurality of section profiles 132, 134, 136 such as shown by the longitudinal profile line 138 added in the geometric plot at Fig. 5B. Further longitudinal profile lines will be drawn/approximated by the control system 90 at each of the sets of corresponding point scans, e.g., 9 total longitudinal profile lines would be drawn by the control system 90 in the example shown in these Figures.
  • the longitudinal profile lines 138 and the section profiles 132, 134, 136 in total approximate the current shape of the surface 30 of the blade 20, and as such, robot working lines for the maintenance device 40 to follow are determined by this approximation of the current shape of the blade 20.
  • the robot working lines are used specifically to calculate movement paths for the articulated arm 48 to move the tool heads 70, 80 along during subsequent steps of the automated repair process. Consequently, repair actions can be made in a precise manner on the actual/current surface profile of the blade 20, regardless of the severity and extent of the damage 26 present on the blade 20.
  • the definition of the section profiles 132, 134, 136 of the blade 20 may be improved from those approximated using point scans as set forth above.
  • control system 90 in further embodiments operates the articulated arm 48 and the laser 110 (or a modified version of laser 110 for linear scanning) to take line scans of the individual cross-sections rather than a series of point scans.
  • a line scan is schematically illustrated in Fig. 5C.
  • the articulated arm 48 again moves the laser 110 to be directed towards one side of the blade 20, but in this case, the articulated arm 48 moves the laser 110 in a generally arc-shaped movement shown by arrows 142 around the leading edge 22 of the blade 20 until the laser 110 reaches the opposite side from where the scanning process began.
  • the laser 110 continually scans the surface 30 of the blade 20 as shown in scan profile 144 to determine the section profile of the blade 20 at that particular cross-section.
  • This section profile will be similar to the ones generated from the point scans and discussed above relative to Figs. 5A and 5B, but the line will be based on the actual line scan rather than approximated lines between several point scans. It will be understood that while the movement of the articulated arm 48 is more complex and must be more precise in this embodiment to conduct the line scan, the resulting section profile is typically more accurate than the estimated/approximated version using the point scans. Regardless, both types of scanning embodiments operate to allow automated repair of blade damage in a precise and accurate manner.
  • the control system 90 will operate the articulated arm 48 and the laser 110 to conduct a series of line scans to define section profiles along multiple individual cross-sections spaced apart along the longitudinal direction of the blade 20. At least three section profiles will be determined by line scans in this fashion, and then the control system 90 will approximate lines between corresponding points of the plurality of section profiles similar to the process shown in the geometric plot at Fig. 5B and described above. Any number of longitudinal profile lines can be drawn across the section profiles, as will be understood by those skilled in the art. The longitudinal profile lines and the section profiles in total approximate the current shape of the surface 30 of the blade 20, and as such, robot working lines for the maintenance device 40 to follow are determined by this approximation of the current shape of the blade 20. This enables the automated repair process to be conducted in a precise and accurate manner based on actual scanned information showing the current shape of the blade 20 and the extent of damage 26 on the blade 20.
  • the vision system 56 of the robotic maintenance device 40 may also be configured to automatically evaluate the severity of damage 26 and the sufficiency of repair actions taken during the repair process described herein.
  • the scanning camera 58 of the vision system 56 is used to image areas of the surface 30 proximate the leading edge 22 and/or proximate the damage 26, and the control system 90 uses color recognition on these images to evaluate the damage 26.
  • the wind turbine blade 20 may be constructed by layers of coating materials at an outer portion thereof defining different colors to help with this color recognition assessment.
  • the different layers of coating materials may include a top coat 28a defining a first color such as gray, a second material layer 28b located underneath the top coat 28a and defining a second color such as white, and a third material layer 28c located underneath the second material layer 28b and defining a third color such as red.
  • the colors provided may vary from wind turbine to wind turbine, but as long as the colors of the various layers 28a, 28b, 28c are distinguishable from one another, the methods of the current invention will be enabled to their fullest extent.
  • the articulated arm 48 may move the scanning camera 58 so as to be directed towards different areas on the surface 30 to take images thereof (of course, the orientation of the free end 54 would be different than the one shown for directing the laser 110 at the surface 30 in those Figures).
  • Two example images 150, 152 from such a process are shown in Figs. 6A and 6B.
  • the image 150 shows the leading edge 22 of the blade 20 as well as some area on the opposing sides of the blade 20.
  • the different shading in the areas indicates different colors that appear in this image 150, and as such, the control system 90 using color recognition can immediately determine that erosion damage 26 is present on the blade 20 from this view in Fig. 6A.
  • the extent of the damage is visible, e.g., more severe category-2 damage is evident from the revealed third material layer 28c at and adjacent the leading edge 22, while less severe category-1 damage is evident from the revealed second material layer 28b on opposite sides of the category-2 damage.
  • the areas where top coat 28a are still at least partially intact are shown at 28a in this image 150 as well.
  • the severity of the damage 26 is identified to be at least category-2 damage, which will then determine how the downstream operation of the tool heads 70, 80 is performed by the control system 90.
  • a blade 20 showing category-2 damage will require more application of coating to repair the damage 26 than a similar blade 20 showing only category-1 damage.
  • the repair can be tailored to the areas needing repair so that the maintenance action is done with precision and accuracy, so as to re-establish the desired original airfoil shape of the blade 20 as much as possible.
  • an image taken by the scanning camera 58 of the same area as previously shown in Fig. 6A should look more like the image 152 shown in Fig. 6B.
  • the leading edge 22 of the blade 20 and all surrounding areas have the same color, specifically the color of the top coat 28a.
  • the category-1 damage and the category-2 damage has been filled in and repaired by application of coating to the surface 30 (or another similar repair method).
  • the vision system 56 acquires images which can be analyzed using color recognition by the control system 90 such that the severity of damage 26 and sufficiency/quality of repair can be automatically assessed, even without operator input or intervention.
  • a fully automated repair process that minimizes costs and operational downtime is achieved when using the robotic maintenance device 40 and methods of these embodiments.
  • the articulated arm 48 engages with the coating applicator tool head 80 and uses the same to apply a coating onto the surface 30 of the blade 20.
  • the control system 90 can operate the scanning camera 58 of the vision system 56 to image the surface 30 after applying the coating, to assess the current status and quality of the repair. If the image does not reveal solely the color of the top coat 28a, then further use of the coating applicator tool head 80 is necessary.
  • the articulated arm 48 engages with the cleaning/abrading tool head 70 to sand down and clean the surface 30, thereby conditioning the surface 30 to receive the coating.
  • the control system 90 can operate the scanning camera 58 of the vision system 56 to image the surface 30 after the sanding and cleaning steps. By using color recognition, the control system 90 can evaluate if the sanding and cleaning steps have properly conditioned the surface to receive the coating to repair the damage 26.
  • the imaging and analysis done with the robotic maintenance device 40 can assure precision and high quality throughout the repair process.
  • the vision system 56 uses the overview camera 62 mounted on the mast 60 to continually provide an overview of the operations being done by the maintenance device 40.
  • the operator can review these images from the overview camera 62 to verify that the determination of the level of repair needed was done properly by the control system 90.
  • the operator can provide guidance or further instructions based on these images to the control system 90 to modify or supplement the repair process being implemented.
  • operator feedback and control is optional and may be omitted so as to achieve a fully automated, high quality and precise repair of erosion damage 26 in the embodiments previously described.
  • the vision system 56 and the control system 90 on the robotic maintenance device 40 enables a fully automated repair to be conducted while the wind turbine blade 20 is still attached to the wind turbine 10. This process minimizes operational downtime as compared to conventional repair methods, especially those involving rope access technicians. Furthermore, the scanning and analysis done by the embodiments of this invention allow for routine monitoring of damage build-up on wind turbine blades 20 at more regular periodic intervals, which helps wind turbine operators stay more on top of damage issues so that they can be repaired promptly before more major damage or issues arise. The maintenance device 40 therefore improves the reliability of wind turbines 10 in the field as well as the associated repair and maintenance processes.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
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  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
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Abstract

L'invention concerne un dispositif de maintenance robotique et un procédé de réparation d'endommagement le long du bord d'attaque d'une pale d'éolienne. Le dispositif de maintenance comprend un corps principal, un bras articulé doté d'un élément d'interface pour venir en prise de manière sélective avec des têtes porte-outil, un système de vision conçu pour balayer une surface de la pale, et un système de commande. Le système de vision comprend un laser permettant d'effectuer des balayages d'un profil de pale, pour ainsi permettre le calcul de trajectoires de déplacement devant être utilisées par les têtes porte-outil dans le processus de réparation. Le système de commande utilise une reconnaissance de couleur sur les images pour évaluer une gravité d'endommagement sur la pale et pour évaluer une qualité de réparations effectuées après que le processus de réparation soit achevé. Ainsi, une réparation entièrement automatisée de la pale est permise avec ce dispositif de maintenance et ce système de vision.
PCT/DK2020/050394 2019-12-18 2020-12-18 Dispositif de maintenance robotique et procédé utilisant un système de vision pour balayer un endommagement de bord d'attaque sur une pale d'éolienne WO2021121524A1 (fr)

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DKPA201970792 2019-12-18

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2752621A2 (fr) * 2011-09-02 2014-07-09 Samsung Heavy Ind. Co., Ltd. Appareil pour la maintenance des pales d'éoliennes
WO2018113875A1 (fr) 2016-12-20 2018-06-28 Vestas Wind Systems A/S Procédés et systèmes pour réparer des pales d'éolienne
WO2019155234A1 (fr) * 2018-02-09 2019-08-15 Bladebug Limited Système d'inspection de pale d'éolienne
EP3540217A1 (fr) * 2018-03-15 2019-09-18 The Boeing Company Appareil et procédés d'entretien de pales d'éolienne

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2752621A2 (fr) * 2011-09-02 2014-07-09 Samsung Heavy Ind. Co., Ltd. Appareil pour la maintenance des pales d'éoliennes
WO2018113875A1 (fr) 2016-12-20 2018-06-28 Vestas Wind Systems A/S Procédés et systèmes pour réparer des pales d'éolienne
WO2019155234A1 (fr) * 2018-02-09 2019-08-15 Bladebug Limited Système d'inspection de pale d'éolienne
EP3540217A1 (fr) * 2018-03-15 2019-09-18 The Boeing Company Appareil et procédés d'entretien de pales d'éolienne

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LYNGBY RASMUS A ; ET AL: "General rights Copyright and moral rights for Autonomous surface inspection of wind turbine blades for quality assurance in production Creative Commons CC-BY-NC licence https Autonomous surface inspection of wind turbine blades for quality assurance in production", PROCEEDINGS OF9TH EUROPEAN WORKSHOP ON STRUCTURAL HEALTH MONITORING CITATION PROCEEDINGS OF9TH EUROPEAN WORKSHOP ON STRUCTURAL HEALTH MONITORING 9 TH EUROPEAN WORKSHOP ON STRUCTURAL HEALTH MONITORING JULY, 1 January 2018 (2018-01-01), pages 1 - 13, XP055788687, Retrieved from the Internet <URL:https://orbit.dtu.dk/files/194663672/0098_Lyngby.pdf> [retrieved on 20210323] *
SIEMENSGAMESA: "How a small robot innovates rotor blade inspection", 12 December 2018 (2018-12-12), pages 1, XP054981584, Retrieved from the Internet <URL:https://www.youtube.com/watch?v=JQ4I4q3gPyk> [retrieved on 20210323] *

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