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

Climbing and Walking Robots

With the advancement of technology, new exciting approaches enable us to render mobile robotic systems more versatile, robust and cost-efficient. Some researchers combine climbing and walking techniques with a modular approach, a reconfigurable approach, or a swarm approach to realize novel prototypes as flexible mobile robotic platforms featuring all necessary locomotion capabilities. The purpose of this book is to provide an overview of the latest wide-range achievements in climbing and walking robotic technology to researchers, scientists, and engineers throughout the world. Different aspects including control simulation, locomotion realization, methodology, and system integration are presented from the scientific and from the technical point of view. This book consists of two main parts, one dealing with walking robots, the second with climbing robots. The content is also grouped by theoretical research and applicative realization. Every chapter offers a considerable amount of interesting and useful information

Development of a Wall Climbing Robot and Ground Penetrating Radar System for NonDestructive Testing of Vertical Safety Critical Concrete Structures

This research aims to develop a unique adhesion mechanism for wall climbing robot to automate the technology of non-destructive testing (NDT) of large safety critical reinforced concrete structures such as nuclear power plants, bridge columns, dams etc. This research work investigates the effect of key design parameters involved in optimizing the adhesion force achieved from rare earth neodymium magnets. In order to penetrate a nominal concrete cover to achieve magnetic coupling with buried rebar and generate high enough adhesion force by using minimum number of permanent magnets, criteria such as distance between multiple magnets, thickness of flux concentrator are evaluated by implementing finite element analysis (FEA). The proposed adhesion module consists of three N42 grade neodymium magnets arranged in a unique arrangement on a flux concentrator called yoke. The preliminary FEA results suggest that, using two yoke modules with minimum distance between them generate 82 N higher adhesion force compared to a single module system with higher forceto-weight ratio of 4.36. Presence of multiple rebars in a dense mesh setting can assist the adhesion module to concentrate the magnetic flux along separate rebars. This extended concentration area has led to higher adhesion force of 135.73 N as well as enabling the robot to take turns. Results suggest that, having a 50×50 mm rebar meshing can sustain steep robot rotational movement along it’s centre of gravity where the adhesion force can fall as low as 150 N. A small, mobile prototype robot with on-board force sensor is built that exhibited 3600 of manoeuvrability on a 50×50 mm meshed rebars test rig with maximum adhesion force of 108 N at 35 mm air gap. Both experiment and simulationresults prove that the magnetic adhesion mechanism can generate efficient adhesion force for the climbing robot to operate on vertical reinforced concrete structures. In terms of the NDT sensor, an in-depth analysis of the ground penetrating radar (GPR) is carried out to develop a low cost operational laboratory prototype. A one-dimensional numerical framework based on finite difference time domain (FDTD) method is developed to model response behaviour of a GPR. The effects of electrical properties such as dielectric constant, conductivity of the media are evaluated. A Gaussian shaped pulse is used as source which propagates through the 1D array grid, and the pulse interactions at different media interfaces are investigated. A real life application of GPR to detect a buried steel bar in 1 m thick concrete block is modelled, and the results present 100% accurate detection of the steel bar along with measured depth of the concrete cover. The developed framework could be implemented to model multi-layer dielectric blocks with detection capability of various buried objects. Experimental models are built by utilizing a proposed antenna miniaturization technique of dipole antenna with additional radiating arms. The resultant reflection coefficient values indicate a reduction of 55% and 44% in length reduction compared to a conventional 100 MHz and 200 MHz dipole antenna respectively. The GPR transmitting pulse generator features an enhanced tuneable feature to make the GPR system more adaptable to various environmental conditions. The prototype pulse generator circuit can produce pulses with variable width from 750 ps to 10 ns. The final assembled robotic GPR system’s performance is validated by its capability of detecting and localizing an aluminium sheet and a rebar of 12 mm diameter buried under a test rig built of wood to mimic the concrete structure environment. The final calculations reveal a depth error of +0.1 m. However, the key focus of this work is to prove the design concept and the error in measurement can be addressed by utilizing narrower bandwidth pulse that the proposed pulse generator is capable of generating. In general, the proposed robotic GPR system developed in this research proves the concept of feasibility of undertaking inspection procedure on large concrete structures in hazardous environments that may not be accessible to human inspector

Optimal control of the heave motion of marine cable subsea-unit systems

One of the key problems associated with subsea operations involving tethered subsea units is the motions of support vessels on the ocean surface which can be transmitted to the subsea unit through the cable and increase the tension. In this paper, a theoretical approach for heave compensation is developed. After proper modelling of each element of the system, which includes the cable/subsea-unit, the onboard winch, control theory is applied to design an optimal control law. Numerical simulations are carried out, and it is found that the proposed active control scheme appears to be a promising solution to the problem of heave compensation

Development of a Chain Climbing Robot and an Automated Ultrasound Inspection System for Mooring Chain Integrity Assessment

Mooring chains used to stabilise offshore floating platforms are often subjected to harsh environmental conditions on a daily basis, i.e. high tidal waves, storms etc. Chain breakage can lead to vessel drift and serious damage such as riser rupture, production shutdown and hydrocarbon release. Therefore, integrity assessment of chain links is vital, and regular inspection is mandatory for offshore structures. Currently, structural health monitoring of chain links is conducted using either remotely operated vehicles (ROVs), which are associated with high costs, or by manual means, which increases the risk to human operators. The development of climbing robots for mooring chain applications is still in its infancy due to the operational complexity and geometrical features of the chain. This thesis presents a Cartesian legged magnetic adhesion tracked-wheel crawler robot developed for mooring chain inspection. The crawler robot presented in this study is suitable for mooring chain climbing in air and the technique can be adapted for underwater use. The proposed robot addresses straight mooring chain climbing and a misaligned scenario that is commonly evident in in-situ conditions. The robot can be used as a platform to convey equipment, i.e. tools for non-destructive testing/evaluation applications. The application of ultrasound for in-service mooring chain inspection is still in the early stages due to lack of accessibility, in-field operational complexity and the geometrical features of mooring systems. With the advancement of robotic/automated systems (i.e. chain-climbing robotic mechanisms), interest in in-situ ultrasound inspection has increased. Currently, ultrasound inspection is confined to the weld area of the chain links. However, according to recent studies on fatigue and residual stresses, ultrasound inspection of the chain crown should be further investigated. A new automated application for ultrasonic phased-array full-matrix capture is discussed in this thesis for investigation of the chain crown. The concept of the chain-climbing robot and the inspection technique are validated with laboratory-based climbing experiments and presented in this thesis

Design and Real Time Control of a Versatile Scansorial Robot

This thesis presents investigations into the development of a versatile scansorial mobile robot and real-time realisation of a control system for different configurations of the robot namely climbing mode, walking mode and steering mode. The mobile robot comprises of a hybrid leg and wheel mechanism with innovative design that enables it to interchange its configuration to perform the specific tasks of pole climbing in climbing mode, walking and step climbing in walking mode, and skid steering and inclined slope climbing in steering mode. The motivation of this research is due to the surrounding environment which is not always structured for exploration or navigation missions, and thus poses significant difficulty for the robot to manoeuvre and accomplish the intended task. Hence, the development of versatile scansorial robot with a flexible and interchangeable configuration can provide a broad range of applications and locomotion system and to achieve the mission objective successfully. The robot design consists of four arms/legs with wheel attached at each end-effector and has two link manipulation capability. In climbing mode, the arms are configured as grippers to grip the pole and wheels accelerate to ascend or descend. The climbing angle is monitored to retain the level of the robot while climbing. However, in walking mode, the arms are configured as legs and the wheels are disabled. By implementing a periodic walking gait, the robot is capable of performing stable walking and step climbing. In steering mode, the arms are configured as suspension and the wheels are used for manoeuvring. In this mode, the skid steering system is used to enable the robot perform the turn. The versatile scansorial robot’s configurations and locomotion capabilities are assessed experimentally in real time implementation using the physical prototype. The experiments provided demonstrate the versatility of the robot and successfully fulfill the aims and objectives of the research

Climbing and Walking Robots

Nowadays robotics is one of the most dynamic fields of scientific researches. The shift of robotics researches from manufacturing to services applications is clear. During the last decades interest in studying climbing and walking robots has been increased. This increasing interest has been in many areas that most important ones of them are: mechanics, electronics, medical engineering, cybernetics, controls, and computers. Today’s climbing and walking robots are a combination of manipulative, perceptive, communicative, and cognitive abilities and they are capable of performing many tasks in industrial and non- industrial environments. Surveillance, planetary exploration, emergence rescue operations, reconnaissance, petrochemical applications, construction, entertainment, personal services, intervention in severe environments, transportation, medical and etc are some applications from a very diverse application fields of climbing and walking robots. By great progress in this area of robotics it is anticipated that next generation climbing and walking robots will enhance lives and will change the way the human works, thinks and makes decisions. This book presents the state of the art achievments, recent developments, applications and future challenges of climbing and walking robots. These are presented in 24 chapters by authors throughtot the world The book serves as a reference especially for the researchers who are interested in mobile robots. It also is useful for industrial engineers and graduate students in advanced study

Aeronautical engineering: A continuing bibliography with indexes (supplement 233)

This bibliography lists 637 reports, articles, and other documents introduced into the NASA scientific and technical information system in November, 1988. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

Characterisation of a nuclear cave environment utilising an autonomous swarm of heterogeneous robots

As nuclear facilities come to the end of their operational lifetime, safe decommissioning becomes a more prevalent issue. In many such facilities there exist ‘nuclear caves’. These caves constitute areas that may have been entered infrequently, or even not at all, since the construction of the facility. Due to this, the topography and nature of the contents of these nuclear caves may be unknown in a number of critical aspects, such as the location of dangerous substances or significant physical blockages to movement around the cave. In order to aid safe decommissioning, autonomous robotic systems capable of characterising nuclear cave environments are desired. The research put forward in this thesis seeks to answer the question: is it possible to utilise a heterogeneous swarm of autonomous robots for the remote characterisation of a nuclear cave environment? This is achieved through examination of the three key components comprising a heterogeneous swarm: sensing, locomotion and control. It will be shown that a heterogeneous swarm is not only capable of performing this task, it is preferable to a homogeneous swarm. This is due to the increased sensory and locomotive capabilities, coupled with more efficient explorational prowess when compared to a homogeneous swarm

Miniature Mobile Systems for Inspection of Ferromagnetic Structures

Power plants require periodical inspections to control their state. To ensure a safe operation, parts that could fail before the next inspection are repaired or replaced, since a forced outage due to a failure can cost up to millions of dollars per day. Non-Destructive Testing (NDT) methods are used to detect different defects that could occur, such as cracks, thinning, corrosion or pitting. Some parts are inspected directly in situ, but may be difficult to access; these can require opening access holes or building scaffoldings. Other parts are disassembled and inspected in workshops, when the required inspection tools cannot be moved. In this thesis, we developed innovative miniature mobile systems able to move within these small and complex installations and inspect them. Bringing sensors to difficult-to-access places using climbing robots can reduce the inspection time and costs, because some dismantling or scaffolding can be eliminated. New miniature sensors can help to inspect complex parts without disassembling them, and reduce the inspection costs, as well. To perform such inspections, miniature mobile systems require a high mobility and keen sensing capabilities. The following approach was used to develop these systems. First, different innovative climbing robots are developed. They use magnetic adhesion, as most structures are made of ferromagnetic steel. Then, vision is embedded in some of the robots. Performing visual inspections becomes thus possible, as well as controlling the robots remotely, without viewing them. Finally, non-visual NDT sensors are developed and embedded in some of the robots, allowing them to detect defects that simple vision cannot detect. Achieving the miniaturization of the developed systems requires strong system integration during these three steps. A set of examples for the different steps has been designed, implemented and tested to illustrate this approach. The Tripillars robots, for instance, use caterpillars, and are able to climb on surfaces of any inclination and to pass inner angles. The Cy-mag3Ds robots use an innovative magnetic wheel concept, and are able to climb on surfaces of any inclination and to pass inner angles, outer angles and surface flips. The Tubulos robots move in tubes of 25 mm diameter at any inclination. All robots embed the required electronics, actuators, sensors and energy to be controlled remotely by the user. Wireless transmission of the commands signals allows the systems to maintain their full mobility without disturbing cables. Integrating Hall sensors near the magnetic systems allows them to measure the adhesion force. This information improves the security of the robots, since when the adhesion force becomes low, the robots can be stopped before they fall. The Tubulo II uses Magnetic Switchable Devices (MSDs) for adhesion. An MSD is composed of a ferromagnetic stator and one or more moving magnets; it has the advantage of requiring only a low force to switch on or off a high adhesion force. MSDs have the advantage of being easy to clean of the magnetic dust that is present in most real environments and that sticks strongly to magnetic systems. As an additional step toward inspection, a camera is embedded on the Cy-mag3D II and the Tubulos. It allows these robots to inspect visually the structures the robots move in, and to control them remotely. The perspective of a climbing robot in an unknown environment is often not enough to give the user a sense of its scale, and to move efficiently in it. A distance sensor is designed and embedded on the Cy-mag3D II, which increases the user's perception of the environment substantially; Finally, an innovative miniature Magnetic Particle Inspection (MPI) system was developed to inspect turbine blades without disassembling them. An MSD is used to perform the required magnetization. The system can automatically inspect a flat surface, performing all the required steps of MPI: magnetize, spray magnetic particles, record images under UV light and demagnetize. Thanks to the strong integration and miniaturization, the system can potentially inspect complex parts such as steam turbines