Intelligent robot reduces wind turbine blade repair costs by up to 66%

Intelligent Robot Reduces Wind Turbine Blade Repair Costs by Up to 66%

Challenge

Damage occurs on the surfaces of wind turbine blades after extended operation. These damages primarily arise because raindrops strike the leading edge of the blade with great force, as the blades rotate at high speeds.

In addition to the gradual erosion of the surface, the damage generates noise, which can be a significant nuisance for people living near wind turbines. Until now, inspection and repair of wind turbine blades have been done manually, which involves safety risks, is time-consuming, and entails high costs.

Solution

In the innovation project Leading Edge Repair, a new automated technique has been developed for inspecting and repairing damage to wind turbine blade leading edges. The innovation project has resulted in reduced Lost Time Incidents (LTI), increased safety, and cost savings for companies working with wind turbine repairs. Additionally, less noise contributes to improved conditions for social acceptance.

Result

Based on the project’s results, calculation models have been developed to provide guidance for proper inspection and durable repairs. Using the collected data, an intelligent robot has been developed to replace manual repairs by autonomously carrying out the repair work. It uses data intelligently by focusing on the damages with the highest priority.

The robot and its underlying technology enable up to 66% cost reduction by more efficiently prioritizing the scope of repairs on blade leading edges. Furthermore, Lost Time Incidents (LTI) have been reduced by 90–100%, as project partners have nearly eliminated the need for human rope access technicians on wind turbines—a job that is otherwise very risky and physically demanding.