System and method for wind blade inspection, repair and upgrade

A method including positioning a modular robotic component proximate an area of interest on a surface of a wind turbine. The modular robotic component including a plurality of modules that perform a plurality of tasks. The method further including inspecting the area of interest with the modular robotic component for an indication requiring at least one of repair or upgrade and operating the modular robotic component to perform the plurality of tasks sequentially as the modular robotic component moves along the surface of the wind turbine. A modular robotic component and system including the modular robotic component are disclosed.

BACKGROUND

The embodiments described herein relate generally to wind turbines, and more specifically, to systems and methods for inspecting, repairing and/or upgrading wind turbines.

Wind turbine blades are typically precisely designed and manufactured to efficiently transfer wind energy into rotational motion, thereby providing the generator with sufficient rotational energy for power generation. Blade efficiency is generally dependent upon blade shape and surface smoothness. Unfortunately, during operation, debris (e.g., dirt, bugs, sea salt, etc.) is collected on the blades, thereby altering the shape and degrading the smoothness. In addition, rocks or other fragments may scratch or erode the blades upon contact. Furthermore, the presence of leading edge erosion and lightning damage may affect blade shape and surface smoothness, thus having an impact on blade efficiency.

Therefore, regular inspection, repair and/or performance upgrades, such as providing protection to the blades in the form of protective coatings, tapes or caps, may serve to maintain wind turbine efficiency. Typically, blade inspection, repair and/or upgrading is performed manually by via rope access, baskets or cranes. For example, using ropes, a blade technician is hoisted to a position adjacent to each blade via suspension from the tower, the hub, or a proximately located crane. The person then inspects, cleans, provides upgrading and/or repairs the blade. For example, the person may take pictures of the blades for later analysis or perform additional tests to determine a current condition of the blade surface. In addition, the person may proceed with any repair or upgrading deemed necessary. However, manual blade maintenance is time consuming and expensive, and is therefore generally performed at longer than desired time intervals. Consequently, wind turbines may operate in an inefficient manner for significant periods. In addition, environmental conditions may preclude the ability for humans to access the wind turbine to perform such tasks.

Accordingly, there is a need for a system and method for inspection, repair and/or upgrade of a wind turbine that requires minimal human intervention. Additionally, an inspection, repair and/or upgrade system and method that can perform in a wide variety of environmental conditions would be desired. Further, there is a need for a system and method for inspection, repair and/or upgrade of a wind turbine that are relatively fast and efficient.

BRIEF DESCRIPTION

In one aspect, a method is provided. The method including positioning a modular robotic component proximate an area of interest on a surface of a wind turbine. The modular robotic component comprising a plurality of modules that perform a plurality of tasks. The method further including inspecting the area of interest with the modular robotic component for an indication requiring at least one of repair or upgrade and operating the modular robotic component to perform the plurality of tasks sequentially as the modular robotic component moves along the surface of the wind turbine.

In another aspect, a system is provided. The system includes one or more cables positioned in draping engagement with a portion of a wind turbine, each of the one or more cables anchored to a base location at opposing ends and a modular robotic component configured to ascend the one or more cables to a position proximate an area of interest on a surface of the wind turbine. The modular robotic component includes an access module, an inspection module coupled to the access module and at least one additional module coupled to the inspection module. The access module includes a drive mechanism to drive the modular robotic component along the surface of a wind turbine. The inspection module includes one or more sensors to inspect the surface of the wind turbine and validate the area of interest on the surface of the wind turbine. Each module of the at least one additional module is configured to perform a task. The access module, the inspection module and the at least one additional module are cooperatively engaged to enable movement along the surface of the wind turbine to sequentially perform the tasks at an indication.

In yet another aspect, a modular robotic component is disclosed. The modular robotic component includes an access module, an inspection module coupled to the access module and at least one additional module coupled to the inspection module. The access module includes a drive mechanism to drive the modular robotic component along the surface of a wind turbine. The inspection module includes one or more sensors to inspect the surface of the wind turbine and validate the area of interest on the surface of the wind turbine. Each module of the at least one additional module is configured to perform a task. The access module, the inspection module and the at least one additional module are cooperatively engaged to enable movement along the surface of the wind turbine to sequentially perform the tasks at an indication.

DETAILED DESCRIPTION OF THE DISCLOSURE

Embodiments of the present disclosure may minimize the need for human intervention in the inspection, repair and/or upgrade of wind turbines. As a result, the disclosed modular robotic component, system and method may significantly lower costs by enabling certain inspection, repair and/or upgrade operations to be robotically performed.

Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present disclosure without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. Although exemplary embodiments of the present disclosure will be described generally in the context of a land-based wind turbine, for purposes of illustration, one of ordinary skill in the art will readily appreciate that embodiments of the present disclosure may be applied to any wind turbine structure, such as offshore wind turbines, and is not intended to be limiting to land based structures.

Referring now to the drawings, wherein identical numerals indicate the same elements throughout the figures,FIG. 1provides a schematic side view of an exemplary wind turbine10. In the exemplary embodiment, wind turbine10is a horizontal-axis wind turbine. Alternatively, the wind turbine10may be a vertical-axis wind turbine. In the exemplary embodiment, the wind turbine10includes a tower mast12extending from and coupled to a supporting surface14. The tower mast12may be coupled to the supporting surface14with a plurality of anchor bolts or via a foundation mounting piece (neither shown), for example. A nacelle16is coupled to the tower mast12, and a rotor18is coupled to the nacelle16. The rotor18includes a rotatable hub20and a plurality of rotor blades22coupled to the hub20. In the exemplary embodiment, the rotor18includes three rotor blades22. Alternatively, the rotor18may have any suitable number of rotor blades22that enables the wind turbine10to function as described herein. The tower mast12may have any suitable height and/or construction that enables the wind turbine10to function as described herein.

The rotor blades22are spaced about the rotatable hub20to facilitate rotating the rotor18, thereby transferring kinetic energy from a wind force24into usable mechanical energy, and subsequently, electrical energy. The rotor18and the nacelle16are rotated about the tower mast12on a yaw axis26to control a perspective, or azimuth angle, of the rotor blades22with respect to the direction of the wind24. The rotor blades22are mated to the hub20by coupling a blade root portion28to the rotatable hub20at a plurality of load transfer regions30. Each load transfer region30has a hub load transfer region and a blade load transfer region (both not shown inFIG. 1). Loads induced to the rotor blades22are transferred to the hub20via load the transfer regions30. Each rotor blade22also includes a blade tip32.

In the exemplary embodiment, the rotor blades22have a length of between approximately 30 meters (m) (99 feet (ft)) and approximately 120 m (394 ft). Alternatively, the rotor blades22may have any suitable length that enables the wind turbine10to function as described herein. For example, the rotor blades22may have a suitable length less than 30 m or greater than 120 m. As wind24contacts the rotor blade22, blade lift forces are induced to the rotor blade22and rotation of the rotor18about an axis of rotation32is induced as the blade tip22is accelerated.

As the rotor blades22are rotated and subjected to centrifugal forces, the rotor blades22are also subjected to various forces and moments. As such, the rotor blades22may deflect and/or rotate from a neutral, or non-deflected, position to a deflected position. A pitch angle (not shown) of the rotor blades22, i.e., an angle that determines the perspective of the rotor blade22with respect to the direction of the wind24, may be changed by a pitch assembly (not shown inFIG. 1). Increasing a pitch angle of rotor blade22decreases blade deflection by reducing aero loads on the rotor blade22and increasing an out-of-plane stiffness from the change in geometric orientation. The pitch angles of the rotor blades22are adjusted about a pitch axis34at each rotor blade22. In the exemplary embodiment, the pitch angles of the rotor blades22are controlled individually. Alternatively, the pitch angles of the rotor blades22are controlled simultaneously as a group.

During operation of wind turbine10, the pitch assembly may change the pitch of rotor blades22such that rotor blades22are moved to a feathered position, such that the perspective of at least one rotor blade22relative to wind vectors provides a minimal surface area of rotor blade22to be oriented towards the wind vectors, which facilitates reducing a rotational speed of rotor18and/or facilitates a stall of rotor18.

In the exemplary embodiment, control system36is shown as being centralized within nacelle16, however, control system36may be a distributed system throughout wind turbine10, on support surface14, within a wind farm, and/or at a remote control center. Control system36includes a processor38configured to perform the methods and/or steps described herein. Further, many of the other components described herein include a processor. As used herein, the term “processor” is not limited to integrated circuits referred to in the art as a computer, but broadly refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. It should be understood that a processor and/or a control system can also include memory, input channels, and/or output channels.

The wind turbine10of the present disclosure may, during fabrication, assembly, operation, or otherwise, incur various indications. An indication40may be, for example, a crack, erosion, fouling, lightening damage or other defect on a surface of the wind turbine10, such as in a rotor blade22, tower12, or other component of the wind turbine10. The indication40, if not recognized and repaired, or the blade, or portions thereof, upgraded, may cause damage to the various components of the wind turbine10or cause them to fail. For example, indications40in high load areas of the rotor blades22may, in some instances, need to be repaired before growing past approximately 50 millimeters (“mm”) in length, while indications40in low load areas of the rotor blades22may need to be repaired before growing past approximately 3 meters (“m”) in length.

To provide such inspection for indications, repair of indications and/or upgrade to the wind turbine, disclosed herein is a modular robotic component52and a system50that provides for use of the modular robotic component52to access the blade22or other part of the wind turbine10. In the embodiment ofFIGS. 1 and 2, the system50utilizes a vertical, external, rappelling system to position the modular robotic component52proximate the blade22. In the embodiment ofFIGS. 3 and 4, the modular robotic component52is positioned proximate the wind turbine10, and more particularly, the blade22utilizing manual positioning, or any other suitable means of positioning.

As illustrated inFIG. 1, in one embodiment the system50includes a vertical, external, rappelling system54to position the modular robotic component52proximate the blade22. The vertical, external, rappelling system54is generally comprised of one or more cables56, to position the modular robotic component52at the location for inspection, repair and/or upgrade of the indication40. In this particular embodiment, the modular robotic component52is configured to climb the vertical, external, rappelling system54. One or more coordinated base located robots58running in slave mode ensure that the modular robotic component52is able to apply the right contact forces at the right position to ensure task performance. The system50may perform a variety of tasks to provide fast, efficient, accurate inspection, repair and/or upgrade of the wind turbine10. Such tasks may include, but are not limited to, real-time inspection, cleaning, sanding, grinding, coating application, filler application, tape application, or the like.

In an embodiment, the system50may include initial deployment of one or more pilot lines (not shown) to aid in placement of the vertical, external, rappelling system54. In an alternative embodiment, the system50may include initial deployment of the one or more cables56on the wind turbine10, that form the vertical, external, rappelling system54, without the use of pilot lines, and more particularly utilizing a delivery component such as an unmanned aerial vehicle (UAV), and more particularly a drone, a balloon, such as, but not limited to, a helium balloon, a hot air balloon, a hydrogen balloon, a ballistic mechanism, a catapult, or any other delivery component that is capable of deploying the one or more pilot lines or the one or more cables56relative to the wind turbine10. By positioning the cables56about a component of the wind turbine10in such a manner, and by doing so through the use of the delivery component (not shown), human intervention in the form of a climber that anchors the one or more cables56to the wind turbine10, such as to the top of the nacelle16, is not required. The one or more cables56are configured to traverse the wind turbine10in draping engagement. For example, in one embodiment, the one or more cables56may be configured to traverse the hub20or any other components of the wind turbine10, such as the rotor blades22or the nacelle16. In an embodiment, after positioning the one or more cables56as desired, the one or more cables56are anchored to the one or more coordinated base located robots58. Further information regarding the inclusion of the vertical, external, rappelling system54are disclosed in copending patent application, entitled, “SYSTEM AND METHOD FOR WIND BLADE INSPECTION, REPAIR AND UPGRADE”, filed on the same day herewith, and assigned to the same assignee as here, which application is incorporated herein by reference in its entirety.

As illustrated inFIG. 1, in this particular embodiment, the modular robotic component52ascends the vertical, external, self-rappelling system54, and more particularly, the one or more cables56to the portion of the wind turbine10, such as the blade22, where the indication40is present. As the modular robotic component52ascends, the one or more cables56are modulated, such as by adjusting tension on the cables to produce desirable forces through pulling, moving, steering, or the like, using the one or more coordinated base located robots58as a slave-system to assist in positioning the modular robotic component52proximate the blade22, and more particularly, the indication40on the blade22. In an alternate embodiment, the one or more cables56are modulated using a manually driven ground base system.

As illustrated by enlargement inFIG. 2, the modular robotic component52is comprised of a plurality of modules60,62,64,66,68,70,72,74,76,78coupled one to another to form a train-like structure. It should be understood that although nine modules are illustrated in the figures, any number of modules required to perform the tasks may be included in the modular robotic component52. It should further be understood that although the plurality of modules60,62,64,66,68,70,72,74,76,78are illustrated as substantially the same shape and size, varying shapes and sizes may be included to form the modular robotic component52.

In an embodiment, the modular robotic component52is comprised of at least two modules. Each of the modular robotic components60,62,64,66,68,70,72,74,76,78is configured to perform a task, or a combination of tasks, that relate to inspection, repair and/or upgrade of the wind turbine blade22. Such tasks may include, but are not limited to, inspection, various repairs including application of filler material(s), coating(s), tape(s), or the like. The modular robotic component52is reconfigurable based on the task at hand. In an embodiment, an inspector or repair crew member can remotely monitor and control the modular robotic component52to assist with the required task at hand (e.g. repair).

In the embodiment ofFIG. 2, the modular robotic component52, comprised of a first module60, a second module62, a third module64, a fourth module66, a fifth module68, a sixth module70, a seventh module72, an eighth module74, a ninth module76and a tenth module78is configured to provide for inspection, repair and application of a coating. More particularly, subsequent to positioning proximate the wind turbine10, and in this particular embodiment the blade22, the modular robotic component52traverses the blade22in a continuous or incremental manner dependent upon the task being performed. The modular robotic component52inspects an area of interest21on the surface of the blade22for any indications40, such as damage to the blade surface due to normal wear and tear or abnormal wear and tear, such as indications as a result of a lightning strike, etc. During the inspection process, the first module60provides access and mobility to the surface the blade22, and more particularly to the area of interest in need of upgrade and/or repair. The first module60will always be present as an access module, and subsequent interchangeable modules will follow the access module. The first, or access, module60may include a built-in camera61for positioning and a drive mechanism (described presently) to provide movement along the wind turbine surface. As the modular robotic component52progresses along the surface of the blade22, the second module62provides inspection of the surface of the blade22to validate the area for repair and/or upgrade or determine the need to repair, monitor the area during upgrade or repair and to validate the repair/upgrade is complete at the end of the process. In an embodiment, the second module62may comprise one or more sensors63that utilize visual sensing or ultrasonic-based non-destructive testing (NDT) to provide such inspection. As the modular robotic component continues to progress along the surface of the wind turbine10, and as illustrated the blade22, the third module64is positioned proximate the identified indication40and provides cleaning of the area. As the third module64is cleaning, the second module62may be inspecting another area of interest on the surface of the blade22and identifying additional indications40in need of repair or the like. As the modular robotic component52continues to progress along the surface of the blade22, the fourth module66performs sanding of the area of interest21. The modular robotic component52continues progressing along the surface of the blade22in a manner to position the fifth module68proximate the now sanded area of interest21and provide an additional cleaning step to the area of interest21. The modular robotic component52continues progressing along the surface of the blade22in a manner to position the sixth module70proximate the now sanded and cleaned area of interest21and deposits a filler material or coating in the identified indication40(crack, hole, etc.). The modular robotic component52continues progressing along the surface of the blade22in a manner to position the seventh module72proximate the now filled identified indication40and provides curing of the filler material, and or subsequent steps to the surface of the blade22. As the seventh module72is curing the deposited fill material, the upstream modules, and more specifically the first module60, the second module62, the third module64, the fourth module66, the fifth module68, and the sixth module70may be inspecting, identifying, cleaning, sanding and filling yet another location on the surface of the blade22. As the modular robotic component52continues to progress, the eighth module74is positioned proximate the now filled and cured indication40and may provide a final shaping (e.g. sanding) of the filled area. As the modular robotic component52continues to progress along the surface of the blade22, the ninth module76is positioned proximate the now filled, cured and shaped area of interest21, and provides for deposition of an optional coating material to the filled area of interest21. Finally, as the modular robotic component52continues to progress along the surface of the blade22, the tenth module78is positioned proximate the area of interest21and provides for the application of a tape along the surface of the blade. As previously mentioned, the progression of the modular robotic component52via the first module60to align each module proximate the indication40provides for continued inspection by the second module62, cleaning by the third module64, sanding by the fourth module66, cleaning by the fifth module68, deposition of fill material by the sixth module70, curing of the fill material by the seventh module72, final shaping by the eight module74, coating by the ninth module76and tape application by the tenth module78at locations proximate each module60,62,64,66,68,70,72,74,76,78. In an embodiment, the modular robotic component52moves at a consistent velocity, resulting in a complete repair by the time the modular robotic component52leaves the area of interest21on the surface of the blade22.

At a given time, each module60,62,64,66,68,70,72,74,76,78is performing a task on a different location on the blade22, but as the modular robotic component52moves, each module60,62,64,66,68,70,72,74,76,78visits the entire area of interest21. As a result, the repair and/or upgrade process is continuous, as opposed to piecewise. It should be understood that as previously described, the modular robotic component52traverses the blade22in a continuous or incremental manner dependent upon the task being performed. More specifically, while the movement is described as continuous, versus piece-wise, instances in which a portion of the blade requires a longer length of time in which to inspect, repair and/or upgrade may require the modular robotic component52to pause, as if to move incrementally, so as to properly complete the task. This is not intended to include step-wise movement whereby the modular robotic component52is stopped and moved to another area to complete a task.

It should be understood that while specific tasks have been identified in the previous description, the tasks performed by the modular robotic component52as identified with respect toFIG. 2are merely exemplary, and are not intended to be limiting, or indicate performance in a specific order. As intended, any number of tasks in any sequential order may be performed by the modular robotic component52as required.

In an embodiment, the first module60may further comprise a drive mechanism82. The drive mechanism82may be configured to drive the modular robotic component82. For example, the drive mechanism82may be coupled to a traction apparatus84, and may drive the traction apparatus84, causing the first module60, and in response the complete modular robotic component52, to traverse the surface of the wind turbine10and/or the vertical, external, self-rappelling system54. Alternatively, the drive mechanism82may be independent of the traction apparatus84and may independently cause the first module60, and in response the complete modular robotic component52, to traverse the surface of the wind turbine10and/or the vertical, external, self-rappelling system54. The drive mechanism82may be, for example, a direct drive mechanism including a motor, or may include a gearbox, belt, chain, rack and pinion system, or any other suitable drive component.

As illustrated inFIG. 2, in an embodiment, the modular robotic component52may be tethered to the base location with a tether cable80configured to provide one or more of power, communications, grounding, supplies, distance calculation from a specific point, such as a root of blade, or the like. More particularly, the tether cable80may provide any suitable components or systems for operating the modular robotic component52.

Subsequent to reaching the desired location for inspection, repair or upgrade of the blade22, the modular robotic component52performs one or more tasks in the area of interest21. In an embodiment, during this task performance the modular robotic component52is configured to perform continuous or incremental movement along the blade22via the first module60, and more particularly the drive mechanism82and the traction apparatus84. Upon completion of the inspection, repair and/or upgrade of the wind turbine10, the modular robotic component52descends the vertical, external, self-rappelling system54, and more particularly, the one or more cables56. Similar to during the ascending of the modular robotic component52, the one or more cables56are modulated using the one or more coordinated base located robots58, as a slave-system to assist the modular robotic component52or manually modulated as previously described. The modular robotic component52is subsequently removed from the wind turbine10and the one or more cables56are removed from the wind turbine10in a simple pulling action by the one or more coordinated base located robots58or human intervention.

The modular robotic component52and/or the one or more coordinated base located robots58may further include a processor86for operating the modular robotic component52. The modular robotic component52, such as the drive mechanism82, the traction apparatus84, and/or any other components or systems of the modular robotic component52, may be communicatively coupled to the processor86. The communicative coupling of the various components of the modular robotic component52and the processor86may be through a physical coupling, such as through a wire or other conduit or umbilical cord, including tether cable80, or may be a wireless coupling, such as through an infra-red, cellular, sonic, optical, or radio frequency-based coupling. In an embodiment, the processor86may be incorporated into a suitable control system (not shown), such as a handheld remote, a personal digital assistant, cellular telephone, a separate pendant controller, or a computer. The modular robotic component52may be operated manually through the processor86by a human operator or may be partially or fully automated through the use of suitable programming logic incorporated into the processor86.

The modular robotic component52may be configured to inspect for indications40and/or repair indications40, provide upgrades to the blades22, and any other wind turbine10components, such as the tower12. For example, in an exemplary embodiment, the modular robotic component52may traverse the wind turbine10via the vertical, external, self-rappelling system54, to a blade22and inspect the blade22for indications40. The modular robotic component52may thereafter perform task to repair the indication40and/or report the indication40for future repair.

In an embodiment, the modular robotic component52may include any variety of modules for inspecting, repairing and/or upgrading the wind turbine10. For example, the modular robotic component52may, in exemplary embodiments, include a locating apparatus to determine the location of an indication40detected on the rotor blade22by providing information regarding the location of the modular robotic component52when the indication40is detected, and converting this information to information regarding the respective location of the indication40along the length of the rotor blade22. The modular robotic component52may, in exemplary embodiments, include a measuring apparatus configured to measure the size of any indications40detected on the wind turbine10, such as on a rotor blade22. The modular robotic component52may, in exemplary embodiments, include a metering device. The metering device may indicate the distance that the modular robotic component52is from the rotatable hub20, the ground, or any other wind turbine10component, when the indication40is detected. The modular robotic component52may, in exemplary embodiments, include a global positioning system (“GPS”) device or transmitter configured to utilize location data to determine the location of the modular robotic component52, when the indication40is located.

In an exemplary embodiment, the vertical, external, self-rappelling system54of the present disclosure may include safety features connecting the modular robotic component52to the wind turbine10or tether cable80. In the event that the modular robotic component52, while traversing the vertical, external, self-rappelling system54, loses traction and becomes disengaged from the wind turbine10, and/or the cables56, the safety features may prevent the modular robotic component52from falling to the ground and becoming damaged or broken, a safety risk or damaging the tower.

In further exemplary embodiments, the safety features may include features that reduce the apparent weight of the modular robotic component52. For example, the safety features may include, for example a tensioning system, such as a spring tensioning system, or a counterweight for offsetting the weight of the modular robotic component52. Further, the tensioning system or counterweight may, in some embodiments, increase the force applied to offset the weight of the modular robotic component52as the modular robotic component52moves up the cables56or to offset the weight of any tethered cables, such as tether cable80, including wires, conduits, or additional umbilical cords that are associated with the vertical, external, self-rappelling system10.

Referring now toFIGS. 3 and 4, illustrated is an embodiment of the wind turbine10in which the modular robotic component52is utilized for leading edge erosion repair. In this particular embodiment, the modular robotic component52is comprised of a first module90, a second module92, a third module94, a fourth module96, a fifth module98and a sixth module100, each providing any necessary tasks for repair of a leading edge23of the blade22, such as previously described with regard toFIGS. 1 and 2. In this particular embodiment, the modular robotic component52is positioned proximate the wind turbine10, and more specifically the blade22, without the need for the vertical, external, self-rappelling system54(FIGS. 1 and 2). More particularly, the modular robotic component52may be positioned manually or through the use of pilot lines102, or the like.

Referring now toFIG. 5, the present disclosure is further directed to a method100for inspecting, repairing and/or upgrading a wind turbine for indications, such as the blade or other components of the wind turbine for indications. The method may include, for example, manually positioning a modular robotic component proximate an area of interest on a blade, in an initial step102. Alternatively, one or more cables may be initially positioned proximate the wind turbine to assist with the step of positioning the modular robotic component, in a step104. The one or more cables are then modulated to position the modular robotic component as it ascends the one or more cables to a position proximate an area of interest on the blade, in a step106.

Next, in a step108, the modular robotic component is operated to perform a plurality of tasks in a sequential manner as the modular robotic component moves continuously and incrementally along a surface of the wind turbine. The tasks are performed by at least two modules that comprise the modular robotic component. Subsequent to completion of all tasks, or at a desired time, the modular robotic component is manually removed from the wind turbine, in a step110. Alternatively, the one or more cables are modulated, in a step112, to position the modular robotic component as it descends the one or more cables. Upon the modular robotic component reaching the base location, the modular robotic component and the one or more cables are removed or disengaged from the wind turbine, in a step114.

As discussed above, the wind turbine10of the present disclosure may include a tower12and at least one rotor blade22. In exemplary embodiments, the modular robotic component52may be operated to inspect, repair and/or upgrade a surface of the wind turbine10, and more particularly a surface of the rotor blade22, or alternatively the tower12or other wind turbine10component, for indications40.

In further exemplary embodiments, the method of the present disclosure may include various steps involving positioning the rotor blade22prior to positioning of the modular robotic component52. For example, the method may include the step of rotating the rotor blade22such that the rotor blade22is approximately parallel to and proximate the tower12. For example, the rotor blade22may be rotated about the axis of rotation32(FIG. 1) until the rotor blade22is in a generally downward position. The rotor blade22may then be rotated and positioned such that it is approximately parallel to the tower12. Thus, the modular robotic component52disposed on the wind turbine10may be in an optimal position for inspecting the rotor blade22.

The method may further include the step of rotating the nacelle16about the yaw axis26. For example, while the modular robotic component52of the present disclosure may advantageously inspect, repair and/or upgrade a rotor blade22in a wide variety of environmental conditions, the use of incident light to inspect the rotor blade22may still be beneficial. Thus, if incident light is available, or if other desired conditions are present, the nacelle16may be rotated about the yaw axis26to optimally position the rotor blade22as desired.

The method may further include the step of rotating the rotor blade22about the pitch axis34. For example, a rotor blade22of the present disclosure may include a pressure side, a suction side, a leading edge, and a trailing edge, as is known in the art. Each side and edge of the rotor blade22must be inspected, repaired and/or upgraded. To achieve such, the side or edge must be in the line-of-sight of the modular robotic component52. For example, when the rotor blade22is positioned such that the pressure side, leading edge, and trailing edge are in the line-of-sight of the modular robotic component52, the suction side may not be analyzed. Thus, during the inspection, repair and/or upgrade of the rotor blade22by the modular robotic component52, after analyzing portions of the rotor blade22that are in the line-of-sight of the modular robotic component520, the rotor blade22may be rotated about the pitch axis34such that other portions of the rotor blade22are placed in the line-of-sight of the modular robotic component52. The modular robotic component52may then continue to inspect, repair and/or upgrade the rotor blade22.

It should be understood that the modular robotic component52and method of the present disclosure may be optimized for fast, efficient inspection, repair and/or upgrade of a wind turbine10. For example, the modular robotic component52and method of the present disclosure may be utilized to quickly and efficiently inspect, repair and/or upgrade the various rotor blades22of a wind turbine10. Additionally, it should be understood that the modular robotic component52and method of the present disclosure eliminate human intervention and reduce human errors previously associated with the inspection, repair and/or upgrade of wind turbines10. Further, it should be understood that the modular robotic component52and method of the present disclosure can perform in a wide variety of environmental conditions.

Exemplary embodiments of the system for inspecting, repairing and upgrading a wind turbine, and more particularly the modular robotic component is described in detail above. The modular robotic component is not limited to use with the specified land-based wind turbines described herein, but rather, the modular robotic component52can be utilized with offshore wind turbines. In such an off-shore application, the base location may include a manned or unmanned ocean-based vehicle, or the like. Moreover, the present disclosure is not limited to the embodiments of the modular robotic component, system and method described in detail above. Rather, other variations of the modular robotic component, system and method may be utilized within the spirit and scope of the claims.