Climbing ring robot for inspection of offshore wind turbines

A rapid expansion of wind turbine farms for sustainable electric power production is planned in Europe by 2020. At least in the UK, these will largely be located offshore to meet growing concerns about the visual intrusiveness and noise generation producedby onshore based farms. The necessary structural integrity inspection of offshore wind turbine blades poses tremendous problems of access, danger to human operatives and costs in the event of blades having to be taken out of service and transported on shore forschedules inspections. For these reasons robotic in-situ blade inspection of offshore wind turbines has been proposed and micro/nano focus computed axial X ray tomography (MNCAT) has been identified as the optimal if not the only solution for identification of safety critical defects in the thickest blade sections. The weight of such an inspection system is very high, typically 200kg and typical cross sectional scanner dimensions of 1 m × 2 m to encircle as blade, clearly involve very high destabilizing moments to be countered by the deployment robot. The solution is a climbing ring robot completely encircling a turbine tower, typically 3 meter in diameter, to provide the necessary adhesion forces and anti-destabilizing force moments. Because of the size and thus development costs of such a huge robot the optimal design path is to prototype a small scale model. First results on such a model are described and from its performance the load carrying capabilities of a full scale version can be computed and the scale model can then berefined by 'reverse engineering' to guarantee that a full scale construction is able tomeet requirements. The key design innovation is that the adhesive forces between the robot and climbing surface a provided entirely by mechanical means rather than by usingthe usual methods of vacuum suction or magnetic force, making the system much cheaper andeasier to manipulate. Furthermore the design is entirely modular. Copyright © 2008 by World Scientific Publishing Co. Pte. Ltd

Design and Development of a Mobile Climbing Robot for Wind Turbine Inspection

Wind turbines (WT) have become an essential renewable energy source as the contribution of WT farms has reached megawatts scale. However, wind turbine blades (WTB) are subjected to failure due to many loading effects such as aerodynamic, gravity and centrifugal loads and operation in harsh environments such as ultraviolet (UV) radiation, ice, hail, temperature variation, dirt, and salt. As a result, the blades suffer different types of damage. Consequently, a periodic inspection process is required to detect and repair defects before a catastrophic failure happens. This thesis presents a literature review of wall climbing robots to identify the most appropriate locomotion and adhesion method to use for a WT climbing machine that can take a large payload of non-destructive testing (NDT) sensors up to a blade and deploy them with scanning arms. A review of wind turbine blade construction, various loading effects on blades and types of damage in blades is followed by a review of the NDT techniques used for inspecting WTB. The above review determines the design requirements to achieve the aim of the current research which is to design a low-cost and reliable mobile robot which will be able to climb the WT tower and subsequently scan the blade surface to perform the inspection using various sensors to identify and classify damages. This robot system should be able to access all the critical areas of the blade structure in a stable and secure way. It should be stable enough to allow the various test sensors to scan the blade structure in the shortest possible time. The thesis describes the development of a tower climbing robot that uses magnetic adhesion to adhere to the WT. As a preliminary study, a simulation model is developed using COMSOL Multiphysics to simulate the magnetic adhesion force while climbing the tower. A test rig is designed and fabricated to measure the magnetic adhesion force experimentally to validate the simulation model. The response surface methodology (RSM) using Box-Behnken design (BBD) is used to design and perform experiments to optimise different independent variables i.e. air gap, the distance between magnets in an array and backplate (yoke) thickness that affect the magnetic adhesion force. A scaled-down prototype magnetic adhesion climbing robot has been designed and constructed for wind turbine blade inspection. The robot is 0.29 m long with two 1.0 m long arms, weighs 10.0 kg and can carry a maximum 2.0 kg payload of NDT sensors. Optimum design of a magnetic adhesion mechanism has been developed for the climbing robot prototype that maximises the magnetic adhesion force. The robot is equipped with two arms that can be extended by one meter to come close to the blade for inspection. Each arm is equipped with a gripper that can hold an inspection tool of weight up to one kilogram. A scaled-down wind turbine has been modelled using SolidWorks and a portion of it constructed to experimentally test the scaled-down climbing robot. To scale up the robot prototype for operation on a normal sized wind turbine, a 100 m tall wind turbine with three 76 m long blades has been modelled and the prototype robot scaled up based on these dimensions. The scaled-up robot is 3.0 m long, weighs 1135 kg and has two 10 m long arms. Static stress analysis and flow simulation have been carried out to check the durability of the scaled-up robot while climbing the wind turbine tower. The procedure for scaling up the adhesion mechanism to achieve equilibrium of the robot has been introduced based on the reaction force concluded from the static stress and flow simulation study. As a result, the maximum payload that each arm can carry has been calculated for both the scaled-down prototype (1 kg) and the scaled-up design (50 kg). This concludes the utility and robustness of the wall climbing robot as a robotic solution for wind turbine blade inspection

Analysis of Mechanical Adhesion Climbing Robot Design for Wind Tower Inspection

Maintenance of wind turbine farms is a huge task, with associated significant risks and potential hazard to the safety and well-being of people who are responsible for carrying the tower inspection tasks. Periodic inspections are required for wind turbine tower to ensure that the wind turbines are in full working order, with no signs of potential failure. Therefore, the development of an automated wind tower inspection system has been very crucial for the overall performance of the renewable wind power generation industry. In order to determine the life span of the tower, an investigation of robot design is discussed in this paper. It presents how a mechanical spring-loaded climbing robot can be designed and constructed to climb and rotate 360° around the tower. An adjustable circular shape robot is designed that allows the device to fit in different diameters of the wind generator tower. The rotational module is designed to allow the wheels to rotate and be able to go in a circular motion. The design further incorporates a suspension that allows the robot to go through any obstacle. This paper also presents a finite element spring stress analysis and Simulink control system model to find the optimal parameters that are required for the wind tower climbing robot

A robot design for wind generator support structure inspection

In recent time, the development of wind tower inspection has been very crucial for the overall performance of the wind turbine. In order to maintain, monitor and determine the life span of the tower, an investigation of robot design is discussed. It presents how to design and construct a robot that can climb the tower and rotate 360° . A ring system which is in a circular shape robot is designed that allows the device to fit in the structure of the wind generator tower. The rotational module is designed to allow the wheels to rotate and be able to go in a circular motion. Also it is designed with a suspension that allows the robot to go through any obstacle. This paper also presents the FEA spring stress analysis and Simulink control system model to find the optimal parameters that are required for the wind tower climbing robot

Keynote: Robotic Non Destructive Testing

This keynote paper aims to highlight the application of mobile robots to perform inspection and non destructive testing (NDT) in industries such as aerospace, large scale fabrication, pipelines, petro-chemical storage and power generation. It describes industrial tasks where regular inspection is essential to ensure the integrity of infrastructure such as storage tanks, pressure vessels, pipelines, aircraft, ships, etc, and to provide managers of capital assets with data to plan outages and to make decisions on the life span of their infrastructure. The development of robot prototypes is described for these industrial tasks. These robots deploy NDT systems by first providing access to large vertical structures or to test sites that are inaccessible to humans. They are designed to reduce outage time, or where possible, carry out the NDT online thus preventing costly outages

Maintenance Management of Wind Turbines

“Maintenance Management of Wind Turbines” considers the main concepts and the state-of-the-art, as well as advances and case studies on this topic. Maintenance is a critical variable in industry in order to reach competitiveness. It is the most important variable, together with operations, in the wind energy industry. Therefore, the correct management of corrective, predictive and preventive politics in any wind turbine is required. The content also considers original research works that focus on content that is complementary to other sub-disciplines, such as economics, finance, marketing, decision and risk analysis, engineering, etc., in the maintenance management of wind turbines. This book focuses on real case studies. These case studies concern topics such as failure detection and diagnosis, fault trees and subdisciplines (e.g., FMECA, FMEA, etc.) Most of them link these topics with financial, schedule, resources, downtimes, etc., in order to increase productivity, profitability, maintainability, reliability, safety, availability, and reduce costs and downtime, etc., in a wind turbine. Advances in mathematics, models, computational techniques, dynamic analysis, etc., are employed in analytics in maintenance management in this book. Finally, the book considers computational techniques, dynamic analysis, probabilistic methods, and mathematical optimization techniques that are expertly blended to support the analysis of multi-criteria decision-making problems with defined constraints and requirements

Non-Destructive Techniques for the Condition and Structural Health Monitoring of Wind Turbines: A Literature Review of the Last 20 Years

A complete surveillance strategy for wind turbines requires both the condition monitoring (CM) of their mechanical components and the structural health monitoring (SHM) of their load-bearing structural elements (foundations, tower, and blades). Therefore, it spans both the civil and mechanical engineering fields. Several traditional and advanced non-destructive techniques (NDTs) have been proposed for both areas of application throughout the last years. These include visual inspection (VI), acoustic emissions (AEs), ultrasonic testing (UT), infrared thermography (IRT), radiographic testing (RT), electromagnetic testing (ET), oil monitoring, and many other methods. These NDTs can be performed by human personnel, robots, or unmanned aerial vehicles (UAVs); they can also be applied both for isolated wind turbines or systematically for whole onshore or offshore wind farms. These non-destructive approaches have been extensively reviewed here; more than 300 scientific articles, technical reports, and other documents are included in this review, encompassing all the main aspects of these survey strategies. Particular attention was dedicated to the latest developments in the last two decades (2000–2021). Highly influential research works, which received major attention from the scientific community, are highlighted and commented upon. Furthermore, for each strategy, a selection of relevant applications is reported by way of example, including newer and less developed strategies as well

Mobile wall climbing and swimming robots to inspect aircraft, storage tanks, pressure vessels and large infrastructure

Non-destructive testing (NDT) of very large critical infrastructure that may be located in hazardous environments, poses the problem of first gaining access to the test site before the testing can be performed. Providing access usually constitutes the major part of the cost and time spent on the testing. Hence, a great deal of effort has been directed recently at developing mobile robotics that transports a payload of NDT sensors to the test site, preferably without taking the structure out of service. The paper describes a number of mobile, wall climbing, swimming and pipe climbing robots that have been designed by the authors to perform the non-destructive internal inspection of petrochemical storage tanks and nuclear pressure vessels, the inspection of the wings/fuselage of aircraft and the blades on wind turbines by climbing on their external surfaces

Non Destructive Testing With Mobile Wall Climbing And Swimming Robots (Abstract)

This keynote paper will describe the application of mobile climbing and swimming robots to perform Non Destructive Testing (NDT) of large safety critical infrastructure. Tools are required for the integrity management of structures such as storage tanks, pressure vessels, aircraft, ships, mooring chains, wind and tidal turbine towers/blades, subsea oil and gas pipelines and flexible risers, etc.[1, 2, 3]. The mobile robots are designed to provide access and deploy a variety of NDT techniques to test sites located on these structures. They obviate the need to carry out lengthy and expensive preparation such as the erection of scaffolding or the dangerous deployment of rope abseiling and platform systems. The aim is to reduce planned outage times by speeding up inspection and wherever possible to perform the NDT on-line thus preventing costly outages. In addition, intrusive robotic inspection systems are usually the only means to perform NDT of structures located in hazardous or difficult to access environments