System and method for repairing leading edge damage on a wind turbine blade

A method for repairing damage around a leading edge of a wind turbine blade on a wind turbine, the method including:

• operating the wind turbine to move one of the wind turbine blades to a generally horizontal orientation;
• and pitching the wind turbine blade in the generally horizontal orientation such that the leading edge of the blade is oriented to face vertically upward;
• the method characterized by:
• providing a robotic maintenance device and an unmanned aerial vehicle (UAV);
• securing the robotic maintenance device to the UAV with at least one support line extending therebetween;
• moving the robotic maintenance device with the UAV from a storage position to an operation position in which the robotic maintenance device is mounted on the wind turbine blade proximate the leading edge;
• performing repair actions with the robotic maintenance device as the robotic maintenance device moves along a length of the wind turbine blade, the UAV remaining connected with the robotic maintenance device by the at least one support line during the performing of repair actions;
• and
• moving the robotic maintenance device with the UAV off of the wind turbine blade following the repair actions and returning the robotic maintenance device back to the storage position,
• the method further characterized by:
• mounting a power supply for the UAV on the robotic maintenance device;
• and
• transmitting operating power, using a cable associated with the at least one support line, from the power supply on the robotic maintenance device to the UAV whenever the UAV is secured to the robotic maintenance device, thereby reducing a total load to be carried by the UAV when the robotic maintenance device is mounted on the wind turbine blade.

A repair system for repairing damage around a leading edge of a wind turbine blade on a wind turbine, the system characterized by:

• a robotic maintenance device configured to move along a longitudinal length of the wind turbine blade, to optionally abrade an exterior surface of the wind turbine blade around the damage with a sander, and to apply a coating material over the exterior surface of the wind turbine blade to perform repair actions by filling in and covering up any damage around the leading edge of the wind turbine blade;
• and
• an unmanned aerial vehicle (UAV) including at least one support line that is removably secured to the robotic maintenance device to allow the UAV to move the robotic maintenance device, and also including at least two control lines that are secured to different portions of the robotic maintenance device to control rotations of the robotic maintenance device about a vertical axis when moving the robotic maintenance device between a storage position and an operation position mounted on the wind turbine blade,
• the system further characterized by:
• a power supply for the UAV, the power supply being mounted on the robotic maintenance device;
• and
• a cable associated with the at least one support line, the cable configured to transmit operating power from the power supply on the robotic maintenance device to the UAV whenever the UAV is secured to the robotic maintenance device, thereby reducing a total load to be carried by the UAV when the robotic maintenance device is mounted on the wind turbine blade.

A repair system for repairing damage around a leading edge of a wind turbine blade on a wind turbine, the system characterized by:

• a robotic maintenance device configured to move along a longitudinal length of the wind turbine blade, to optionally abrade an exterior surface of the wind turbine blade around the damage with a sander, and to apply a coating material over the exterior surface of the wind turbine blade to perform repair actions by filling in and covering up any damage around the leading edge of the wind turbine blade;
• an unmanned aerial vehicle (UAV) including at least one support line that is removably secured to the robotic maintenance device to allow the UAV to move the robotic maintenance device, and also including at least two control lines that are secured to different portions of the robotic maintenance device to control rotations of the robotic maintenance device about a vertical axis when moving the robotic maintenance device between a storage position and an operation position mounted on the wind turbine blade,
• a transport container sized to contain the robotic maintenance device and the UAV during transport and delivery to the wind turbine, and characterized in that the storage position is within the transport container,
• wherein the transport container is further characterized by:
• an enclosed storage space including a rear door opening at one longitudinal end thereof and a roof at a top end thereof;
• and
• at least one elongated slot in the roof which extends longitudinally from the rear door opening, the at least one elongated slot sized to receive the at least one support line and/or the at least two control lines such that UAV-driven movement of the robotic maintenance device is guided during movement into and from the transport container,
• characterized in that the transport container defines a longitudinal length L1, the at least one elongated slot defines a length L2, and L1>L2 such that at least a portion of space within the transport container does not receive the robotic maintenance device, thereby providing a safe location away from the robotic maintenance device for an operator controlling the UAV while standing within the transport container.