US 2025/0001447 A1 · COATING APPLICATOR TOOL USED WITH ROBOTIC DEVICE FOR REPAIRING LEADING EDGE DAMAGE ON A WIND TURBINE BLADE

Abstract

An applicator tool (42) is provided for use with a robotic maintenance device (40) for 5 repairing damage (26) around a leading edge (22) of a wind turbine blade (20) on a wind turbine (10). The applicator tool (42) includes a tool frame (70) and a spatula (76) defining a flexible extrusion plate (78) that is configured to be engaged with an exterior surface (34) of the wind turbine blade (20), and a nozzle (84) that delivers a coating material (30) into a gap (112) between the extrusion plate (78) and the blade 0 (20). At least two nozzles (84) and corresponding fluid supplies may be provided to extend a working capacity of the applicator tool (42). The applicator tool (42) also includes a first chamfer arm (80) and a second chamfer arm (82) each configured to engage an outer surface (100) of the extrusion plate (78) adjacent a front edge (94) thereof to press the extrusion plate (78) against the exterior surface (34) of the blade 5 (20) at two specific engagement locations. The spatula (76) is configured to shape the coating material (30) into a shaped coating as the coating material (30) spreads in the gap (112) to thereby fill in and cover the damage (26) on the wind turbine blade (20), and the first and second chamfer arms (80, 82) are configured to limit spread of the coating material (30) beyond the two specific engagement locations 0 such that the shaped coating applied to the wind turbine blade (20) extends only between a first chamfer line (36) and a second chamfer line (38) on opposite sides of the leading edge (22). The applicator tool (42) also includes a vision system (160) configured to image the blade (20) to detect whether the first and second chamfer lines (36, 38) are located at expected positions to determine if any overfill or underfill 5 condition needs corrected. as well as a repair verification scanner (180) that detects a coating layer thickness of the shaped coating to further confirm whether a repair is performed as expected.

Claims23

Dependent claims

An applicator tool configured to be used with a robotic maintenance device for repairing damage around a leading edge of a wind turbine blade on a wind turbine, the applicator tool characterized by:

a tool frame configured to be connected at one end of the robotic maintenance device;
a spatula supported by the tool frame and configured to be engaged with an exterior surface of the wind turbine blade, the spatula including a flexible extrusion plate having a front edge, a rear edge facing the robotic maintenance device, an outer surface and an inner surface, wherein the flexible extrusion plate is configured to define a gap between the inner surface thereof and the exterior surface of the wind turbine blade;
a first nozzle including a nozzle outlet located under the spatula to deliver a coating material into the gap as the robotic maintenance device moves the spatula along the leading edge of the wind turbine blade;
and
a first chamfer arm and a second chamfer arm operatively coupled to the tool frame, and each engaging the outer surface of the extrusion plate of the spatula adjacent the front edge to press the extrusion plate against the exterior surface of the wind turbine blade at two specific engagement locations on opposing sides of the leading edge of the wind turbine blade,
the spatula being configured to shape the coating material into a shaped coating as the coating material spreads in the gap to thereby fill in and cover the damage on the wind turbine blade, and the first and second chamfer arms being configured to limit spread of the coating material beyond the two specific engagement locations such that the shaped coating applied to the wind turbine blade extends between a first chamfer line and a second chamfer line on opposite sides of the leading edge.

3 more elements

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

providing a robotic maintenance device onto the wind turbine blade, the robotic maintenance device including an applicator tool having a spatula, a first nozzle, and a first chamfer arm and a second chamfer arm located adjacent the spatula;
moving the robotic maintenance device along a working length at the leading edge of the wind turbine blade;
discharging a coating material from the first nozzle under the spatula and specifically into a gap defined between an extrusion plate of the spatula and an exterior surface of the wind turbine blade;
shaping the coating material into a shaped coating with the extrusion plate of the spatula as the coating material spreads in the gap and as the spatula moves along the working length, the shaped coating filling in and covering the damage on the wind turbine blade;
and
engaging the first and second chamfer arms with a drive cylinder to press the extrusion plate against the exterior surface of the wind turbine blade at two specific engagement locations on opposing sides of the leading edge of the wind turbine blade, thereby limiting spread of the coating material beyond the two specific engagement locations such that the shaped coating applied to the wind turbine blade extends between a first chamfer line and a second chamfer line on opposite sides of the leading edge.

3 more elements

Dependencies are inferred from the claim text.

Coating applicator tool used with robotic device for repairing leading edge damage on a wind turbine blade

Life of this patent

Coating applicator tool used with robotic device for repairing leading edge damage on a wind turbine blade

Life of this patent

Abstract

Claims23