SYSTEM WITH AN APPARATUS ON A WIRE, METHOD OF ITS OPERATION, USE THEREOF AND A TOOL KIT

Abstract

A system, a method and a tool kit are provided including an apparatus on a wire, for example for cleaning or repairing a wind turbine blade. The apparatus includes a base and an arm, the arm extending from the base and including a remote end, the remote end and the base, each including an attachment device for securing to a surface.

Claims

1. A method of operating a system at an operation site, the operation site comprising an anchor location and a surface below the anchor location; the system comprising an apparatus and at least one wire, the at least one wire being dimensioned to carry the weight of the apparatus while attached to the anchor location and extending downwards from the anchor location at a level above the apparatus; the system further comprising a length adjustment mechanism for adjusting the length of the at least one wire between the apparatus and the anchor location; the apparatus comprising a base attached to the at least one wire; the apparatus further comprising an arm extending from the base and comprising a remote end, the arm being configured for movement of the remote end relatively to the base; wherein the remote end of the arm comprises an arm attachment device configured for securing the remote end stationary to the surface by contact of the arm attachment device with the surface; wherein the base comprises a base attachment device, different from the arm attachment device, for securing the base stationary to the surface by contact of the base attachment device with the surface; wherein method comprises adjusting an elevation level of the apparatus by adjusting the length of the wire by the length adjustment mechanism; securing the base stationary at a stationary position on the surface by the base attachment device; while the base is in contact with the surface and secured stationary to the surface, moving the remote end of the arm to an attachment point on the surface, the attachment point being distant from the secured base, securing the remote end stationary to the surface at the attachment point, while the remote end is still secured stationary at the attachment point and, detaching the base attachment device from its stationary position on the surface and moving the base relatively to the attachment point by moving the arm relatively to the base or by changing the elevation level of the base by the length adjustment mechanism or by a combination thereof.

2. The method according to claim 1, wherein the base comprises a dragging unit configured for dragging the base along the at least one wire; the method comprising activating the dragging unit and moving the base along the at least one wire and as a consequence causing a change of elevation of the base.

3. The method according to claim 1, wherein the apparatus comprises a control unit for electronically controlling the operation of the arm; the method comprising establishing a data connection between the control unit and a remote control station remote from the operation site, wherein the remote control station is at a distance remote from a line of sight to the operation site; transmitting operation signals from the remote control station to the control unit and operating the arm by the operation signals from the remote control station.

4. The method according to claim 3, wherein the apparatus comprises a video camera and the method comprises imaging the operation site by the video camera, transmitting the signals from the video camera to the remote control station and at the remote control station inspecting the operation site by the video camera.

5. The method according to claim 1, wherein the base comprises a magazine with a tool; the magazine comprising a magazine coupling and the tool comprising a first tool coupling configured for cooperation with the magazine coupling for securing the tool in the magazine; wherein the remote end of the arm or a remote end of a further arm comprises an arm coupling and the tool comprises a second tool coupling for cooperation with the arm coupling for securing the tool to the remote end of the arm or the further arm; wherein the method comprises driving the remote end of the arm or further arm to the magazine adjusting the arm coupling to an orientation and position where the arm coupling and the second tool coupling are in a mating orientation; locking the arm coupling to the second tool coupling, releasing the first tool coupling from the magazine coupling and removing the tool from the magazine by the arm or further arm; finally operating the tool with the arm or further arm.

6. The method according to claim 5, wherein the arm attachment device is detachable from the arm or further arm and comprises couplings identical to the first and second tool coupling and wherein the method comprises moving the arm attachment device to the magazine and transferring it to the magazine prior to coupling the tool from the magazine to the arm or further arm.

7. The method according to claim 1, wherein the operation site is a wind turbine with a wind turbine blade, and the surface is a surface of the wind turbine blade; wherein the method comprises fastening the at least one wire to a nacelle or central part of a rotor of the wind turbine and letting the wire extend downwards therefrom; while the base is attached to the at least one wire, increasing the elevation of the apparatus by the length adjustment mechanism until the apparatus is abutting the surface of the wind turbine blade.

8. The method according to claim 7, wherein the tool is a turbine blade surface repair tool, and the method comprises inspecting the blade surface with the video camera at the control centre and finding surface damage on the blade surface, repairing the surface damage by remotely operating the arm or further arm with the surface repair tool by electronic commands from the control centre to the control unit.

9. The method according to claim 3, wherein the operation site is an offshore wind turbine and the control center is at an onshore location.

10. The method according to claim 9, wherein the method comprises connecting the control unit electronically to a data signal cable extending from the offshore wind turbine to the onshore location and transmitting the control signals between the control unit and the control centre through the data signal cable.

11. A system comprising an apparatus and at least one wire, the at least one wire being dimensioned to carry the weight of the apparatus while extending downwards from an anchor location at a level above the apparatus; the system further comprising a length adjustment mechanism for adjusting the length of the at least one wire between the apparatus and the anchor location; the apparatus comprising a base attached to the at least one wire; the apparatus further comprising arm extending from the base and comprising a remote end, the arm being configured for movement of the remote end relatively to the base; wherein the remote end of the arm comprises an arm attachment device configured for securing the remote end stationary to the surface by contact of the arm attachment device with the surface; wherein the base comprises a base attachment device for securing the base stationary to the surface by contact of the base attachment device with the surface; wherein the system is configured for a sequence of operations comprising, adjusting an elevation level of the apparatus by adjusting the length of the wire by the length adjustment mechanism; securing the base stationary to the surface by the base attachment device; while the base is in contact with the surface and secured stationary to a stationary position the surface, moving the remote end of the arm to an attachment point on the surface, the attachment point being distant from the secured base, securing the remote end stationary to the surface at the attachment point, while the remote end is still secured stationary at the attachment point on the surface, detaching the base attachment device from its stationary position on the surface and moving the base relatively to the attachment point by moving the arm relatively to the base or by changing the elevation level of the base by the length adjustment mechanism or by a combination thereof.

12. A system according to claim 11, wherein at least one of the base attachment device or the arm attachment device comprises a suction cup, a dry adhesive pad, an electromagnetic pad, or an electrostatic pad configured for securing to the surface.

13. The system according to claim 11, wherein the adjustment mechanism comprises a dragging unit as part of the base, the dragging unit being configured for attachment to the at least one wire and configured for dragging the base along the at least one wire.

14. The system according to claim 11, wherein the base comprises a magazine with a tool; the magazine comprising a magazine coupling, and the tool comprising a first tool coupling configured for cooperation with the magazine coupling for securing the tool in the magazine; wherein the remote end of the arm or the remote of a further arm comprises an arm coupling and the tool comprises a second tool coupling for cooperation with the arm coupling for securing the tool to the remote end of the arm or further arm.

15. The system according to claim 14, wherein the magazine comprises multiple magazine couplings configured for holding multiple tools, and wherein the multiple couplings hold multiple tools of different type.

16. A tool kit for a system according to claim 5, the tool kit comprising a grinding tool for grinding a surface, a dispenser tool for dispensing filling material to the surface, and a spatula tool for shaping the filling material on the surface.

17. The system according to claim 11 for cleaning, painting or repairing a vertical surface or an inclined surface.

18. The system according to claim 18, wherein the surface is a wall of a building.

Description

BRIEF DESCRIPTION

[0043] Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denote like members, wherein:

[0044] FIG. 1 is a sketch of an embodiment of the invention on a wind turbine;

[0045] FIG. 2a illustrates mounting of the wire;

[0046] FIG. 2b illustrates mounting of the apparatus to the wire;

[0047] FIG. 2c illustrates lifting of the apparatus along the wire;

[0048] FIG. 3 illustrates the apparatus with a grinding tool on the leading edge of the blade;

[0049] FIG. 4 illustrates an embodiment of the apparatus in greater detail with an attachment device on the blade;

[0050] FIG. 5a illustrates an apparatus without an attachment device on the arm;

[0051] FIG. 5b illustrates with an attachment device on the arm;

[0052] FIG. 6 is an example of couplings for coupling tools to the base;

[0053] FIG. 7 illustrates a remote-control station; and

[0054] FIG. 8 illustrates a dragging unit.

DETAILED DESCRIPTION

[0055] FIG. 1 is an illustrative embodiment of the invention. A wind turbine 1 comprises a tower 2 and a nacelle 3 onto which a rotor 4 is rotationally coupled. The rotor 4 comprises a plurality of rotor blades 5 secured to a centre 6 of the rotor 4. A system 7 comprises an apparatus 8 and a wire 9 to which the apparatus 8 is attached. The wire 9 is secured to the centre 6 of the rotor 4 and/or to the nacelle 3 and extends downwards towards the base region 10 of the wind turbine. On the base region 10 of the wind turbine 1, a ground station 11 is provided for operation of the apparatus 8. For example, the ground station 11 provides electricity in case that the apparatus 8 is not provided with a battery system. In addition, or alternatively, it provides at least one of the following: water, cleaning liquid, compressed air for cleaning and/or for pneumatic driving of tools, hydraulic fluid, paint for painting.

[0056] Furthermore, the ground station 11 comprises a transceiver, wired or wireless, for data communication with the apparatus 8.

[0057] For example, the ground station 11 is wired by a first cable 12A to the apparatus 8 and a second cable 12B through a port 13 in the tower 2 in order to receive electrical power and/or to communicate with a remote-control station through a wired data transfer cable connection. The latter is particularly advantageous in case where the wind turbine 1 is an offshore installation where no sufficient wireless data connection is available.

[0058] An example of a method for installation is illustrated in FIG. 2a. A person or a team of persons, in the following for simplicity called the installer 14, installs the two wires 9 at the turbine top and lets the wires 9 hang down while one of the blades 5 is oriented vertically downwards. As illustrates in FIG. 2b, the installer 14 mounts the apparatus 8 onto the wires 9. The apparatus 8 is provided with dragging units through which the wires 9 extend and in which they are held in place. The dragging units are configured for running along the wires 4 and thereby drag the apparatus 8 along the wires 9 in an upwards or downwards direction as illustrated in FIG. 2c. Thereby, the dragging unit provide a length adjustment mechanism for adjusting the length of the at least one wire 9 between the apparatus 8 and the anchor location for thereby lifting or lowering the apparatus 8.

[0059] FIG. 3 illustrates an apparatus 8 in operation. The apparatus 8 comprises a base 15 from which an arm 16 extends. The arm 16 comprises seven rotational couplings 17a-g as illustrated best in FIG. 5a, giving the arm seven degrees of freedom for motion relatively to the base 15. The illustrated number of actuators is exemplary and could be different from seven. The base 15 is secured to the blade 5 while the arm 16 is provided with a grinding tool 18 for grinding the leading edge 5 of the blade 5. Such grinding is used prior to filling possible damages with adequate filler as part of the repair of the blade surface 5. In addition, the arm 16 comprises a video camera 40 for inspecting the site and for controlling the actions.

[0060] As an alternative to the illustrated embodiment, the wires 9 are rolled onto rollers which are part of the base 15. In this case, the wires 9 do not hang further down that the apparatus 8. As a further alternative, the apparatus 8 is secured to the wires, for example to the end of the wires, and a hoist is provided at the top of the wind turbine which is used to lift the apparatus up and down. Such exemplary embodiments are illustrated in FIG. 4.

[0061] As illustrated on FIG. 4, a base attachment device 20 is provided, for example a plurality of base suction cups, as part of the base 15 for securing the base 15 to the blade 5 surface 5. The base suction cups are exemplary and the base attachment device 20 could be provided by other means as mentioned in the description above.

[0062] In this particular illustration, the arm 16 is provided with an arm attachment device 21, for example an arm suction cup, for securing the remote end 22 of the arm 16 to an attachment point 23 on the blade surface 5. The arm suction cup is exemplary and the arm attachment device 20 could be provided by other means as mentioned in the description above.

[0063] When the base attachment device 20 is released from the blade surface 5, the arm 16 can drag the base 15 towards the attachment point 23. For sake of illustration on FIG. 4, the arm 16 is directed partly downwards and partly to the side such that a drag would be skew downwards. In many situations, however, the arm 15 would be placed more sideways relatively to the base 16 such that the vertical adjustment of the position against gravity is determined by interaction with the wire 9, whereas the sideways movement is determined by drag from the arm 16 on the base 15.

[0064] FIGS. 5a and 5b illustrate the apparatus 8 in further detail, where FIG. 5a illustrated the arm 16 without tool and FIG. 5b illustrates an arm attachment device 21 coupled to the remote end 22. The base 15 comprises a magazine 24 for a plurality of tools, for example in particular for working the surface. The magazine 24 comprises a plurality of magazine couplings 25 for coupling of tools to the magazine couplings 25, in the present illustration three magazine couplings, although the number can be different depending on the requirements.

[0065] An example of a coupling with two coupling counterparts 26A, 26B is illustrated in FIG. 6. The coupling counterparts 26A, 26B are operated electrically through a connector 27 such that after mating, electrical power activates a locking mechanism 28, in this case a recess 29 into which an expandable ring of balls 30 is secured.

[0066] As illustrated in FIG. 1, optionally, the ground station 11 is wired for data transfer through a data transfer cable 9. Such cable is useful for offshore wind turbines 1 as wireless data networks are typically inadequate offshore. However, wind turbines 1 are typically connected by electrical cables for transport of electrical power as well as connected by data transfer cables to onshore stations. Such data cables are advantageously extended for transferring data between the apparatus and an onshore control station as illustrated in FIG. 7. In the remote-control station 31, an operator 32 is remotely operating the offshore located apparatus 8, for example by watching display screens 33 and operating a control panel 34. The operation of the control panel 34 causes transmission of operational command data to the control unit 35 of the offshore-located apparatus 8, the control unit 35 illustrated in FIG. 3. The control unit 35 comprises a cable connector socket 41. For simplicity, the cable itself is not shown in FIG. 3. With reference to FIG. 7, the display screens 33 can be used to watch the video sequence recorded by a video camera on the arm.

[0067] As a further option, the apparatus 8 can be operated using virtual reality tools, similar to those used for corresponding computer games. For example, the operator 32 is provided with special an operational unit, the movement of which by the operator's arm causes the arm 16 to move correspondingly.

[0068] FIG. 8 illustrates an example of a dragging unit 36, which optionally is part of the base 8. The wire 9 runs through pairs of rollers 37 which squeeze the wire 9 in between them such that rolling of the pairs of rollers 37 drags the dragging unit 36 along the wire 9, even in lifting action against gravity. The wire 9 also move around a brake roller 28, which in squeezing cooperation with a brake shoe 39 secures the wire at a predetermined position. This way, the apparatus 8 is secured against falling.

[0069] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

[0070] For the sake of clarity, it is to be understood that the use of a or an throughout this application does not exclude a plurality, and comprising does not exclude other steps or elements. The mention of a unit or a module does not preclude the use of more than one unit or module.

REFERENCE NUMBERS

[0071] 1 wind turbine

[0072] 2 tower

[0073] 3 nacelle

[0074] 4 rotor

[0075] 5 blades

[0076] 5 blade surface

[0077] 5 blade leading edge

[0078] 6 center of rotor 4

[0079] 7 system

[0080] 8 apparatus

[0081] 9 wire

[0082] 10 base region of the wind turbine 1

[0083] 11 ground station

[0084] 12A first cable between ground station 11 and apparatus 8

[0085] 12B second cable between ground station and data transfer cable to a remote control station 31

[0086] 13 port in the tower 2 for the second cable 12B

[0087] 14 installer

[0088] 15 base

[0089] 16 arm

[0090] 17 a-g rotational actuators on arm 16

[0091] 18 grinding tool

[0092] 19 platform

[0093] 20 base attachment device

[0094] 21 arm attachment device

[0095] 22 remote end of the arm 16

[0096] 23 attachment point on the blade surface 5

[0097] 24 magazine for tool

[0098] 25 magazine coupling

[0099] 26A, 26B coupling counterparts

[0100] 27 electrical connector of coupling counterparts 26A, 26B

[0101] 28 locking mechanism of coupling counterparts 26A, 26B

[0102] 29 recess of coupling counterparts 26A, 26B

[0103] 30 expandable ring of balls of coupling counterparts 26A, 26B

[0104] 31 remote control station

[0105] 32 operator

[0106] 33 display screens

[0107] 34 control panel

[0108] 35 control unit of apparatus 8

[0109] 36 dragging unit

[0110] 37 pairs of rollers

[0111] 38 brake roller

[0112] 39 brake shoe interacting with brake roller

[0113] 40 video camera

[0114] 41 cable socket in base 15