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

The Problem of Adhesion Methods and Locomotion Mechanism Development for Wall-Climbing Robots

This review considers a problem in the development of mobile robot adhesion methods with vertical surfaces and the appropriate locomotion mechanism design. The evolution of adhesion methods for wall-climbing robots (based on friction, magnetic forces, air pressure, electrostatic adhesion, molecular forces, rheological properties of fluids and their combinations) and their locomotion principles (wheeled, tracked, walking, sliding framed and hybrid) is studied. Wall-climbing robots are classified according to the applications, adhesion methods and locomotion mechanisms. The advantages and disadvantages of various adhesion methods and locomotion mechanisms are analyzed in terms of mobility, noiselessness, autonomy and energy efficiency. Focus is placed on the physical and technical aspects of the adhesion methods and the possibility of combining adhesion and locomotion methods

Design and development of a pole climbing surveillance robot

The cost of installing, monitoring and servicing a fixed camera system can be high and not all areas are in need of constant surveying. The increase in crime in urban areas emphasizes the need for a more effective and efficient surveillance system, as a result could lead to fewer crimes. A temporary surveillance unit which is able to climb to gain an elevated view has great potential for both military and civilian application. This paper highlights how the patent pending climbing robotic system (PC-101) was developed to be used by London’s Metropolitan Police Forensic Department for analysing outdoor crime scenes especially that related to car accidents. When cars are involved in accidents in the Metropolitan area, depending on the scale of the incident, the road generally has to be shut off to traffic if there are serious casualties. Elevated images are required for cases which may be taken to court, which then the images are then used as evidence, therefore regulations on the quality and perspectives of the image have to be met. By climbing a range of existing street furniture such as street lamp post, a temporary platform eliminates the use of larger special vehicle which struggles to get to the crime scene as well as cuts down the duration of the road closure. 98% of London street lamps in the Metropolitan area are constructed out of steel structures which make the use of magnetic wheels for locomotion an ideal solution to the climbing problem. Once remote controlled to the top of the lamp post, the PC-101 makes use of its actuated camera arm/gimbal to take the required shot, which can be seen on the ground control unit. A surveillance tool of this sort can be used for many applications which include crowd/riot control, crime scene investigations, monitoring hostile environments and even the monitoring of nature within urban environment

UAV/UGV Autonomous Cooperation: UAV Assists UGV to Climb a Cliff by Attaching a Tether

This paper proposes a novel cooperative system for an Unmanned Aerial Vehicle (UAV) and an Unmanned Ground Vehicle (UGV) which utilizes the UAV not only as a flying sensor but also as a tether attachment device. Two robots are connected with a tether, allowing the UAV to anchor the tether to a structure located at the top of a steep terrain, impossible to reach for UGVs. Thus, enhancing the poor traversability of the UGV by not only providing a wider range of scanning and mapping from the air, but also by allowing the UGV to climb steep terrains with the winding of the tether. In addition, we present an autonomous framework for the collaborative navigation and tether attachment in an unknown environment. The UAV employs visual inertial navigation with 3D voxel mapping and obstacle avoidance planning. The UGV makes use of the voxel map and generates an elevation map to execute path planning based on a traversability analysis. Furthermore, we compared the pros and cons of possible methods for the tether anchoring from multiple points of view. To increase the probability of successful anchoring, we evaluated the anchoring strategy with an experiment. Finally, the feasibility and capability of our proposed system were demonstrated by an autonomous mission experiment in the field with an obstacle and a cliff.Comment: 7 pages, 8 figures, accepted to 2019 International Conference on Robotics & Automation. Video: https://youtu.be/UzTT8Ckjz1

Design and parametric investigations of permanent magnet adhesion mechanism for robots climbing on reinforced concrete walls

Wall Climbing Robots (WCRs) have found extensive applications in the past decade in numerous engineering fields, however, the design of efficient adhesion mechanism for robots climbing on concrete surfaces remains a challenge and attracts research attention. This paper proposes various designs of magnetic adhesion mechanism for concrete surfaces and investigates the adhesion force and payload capacities each design would accommodate for wall climbing robot applications. Permanent magnet is used as the magnetic adhesion mechanism and a yoke structure helps in holding the magnets and influences the adhesion characteristics of the mechanism. The effect of various structural designs of adhesion mechanisms on the adhesion force and payload capacity on the concrete surface is studied in this work. The adhesion forces against the different standoff distances which comprise the gap between the magnet and the concrete surface are also investigated therein. The results show that the developed adhesion mechanism can be applied for concrete walls generating the required adhesion forces and providing a better insight in choosing the best configuration, number of magnets and standoff distances for the design of adhesion mechanism against the required payload of WCR

An Autonomous Wall Climbing Robot for Inspection of Reinforced Concrete Structures: SIRCAUR

A wall climbing inspection robot has been designed to climb on safety critical concrete structures by adhering to reinforcement steel bars (rebars) using permanent magnets to generate the adhesion forces. Simulation and experimental validation has been performed to determine the optimum flux focusing magnet configurations with the robot operating on 30 to 35mm of concrete cover over rebars arranged in different patterns. The goal of adhesion force optimization is to be able to carry a ground penetrating radar (GPR) sensor which detects rebar corrosion, concrete delamination and concrete cover deterioration. The autonomous robot uses an ultra-wide band (UWB) localisation system and GPR data to control its motion trajectories to avoid regions where there is insufficient density of rebars. Non-destructive testing (NDT) inspection data acquired by GPR is transmitted wirelessly to a ground station for processing and monitoring by NDT technicians

A new family of magnetic adhesion based wall-climbing robots

This paper is devoted to climbing robots that adhere to the wall through permanent magnetic elements. If the surface on which they adhere is not ferromagnetic, it is necessary for the system to be composed of two subsystems (master and follower carts), arranged in a sandwich configuration, with the surface to climb interposed between the two. However, this configuration does not allow the robot to descend from the wall where it is climbing and to move freely on the floor (because of the presence of the follower). This paper shows how to remove this limitation. In fact, the system is able to automatically detach the follower when the robot has to move on the floor and recover it when it has to climb