SPREADER TOOL FOR SPREADING VISCOUS MATERIAL ONTO THE EDGE OF A WIND TURBINE BLADE

Abstract

A spreader tool is provided for spreading viscous material on the surface, for example an edge, of a wind turbine blade. The spreader tool comprises at least one bendable spreader wing, for example provided as a fin-ray construction, for pressing a flexible band against a curved section of the blade and for dragging viscous material along it by the flexible band during movement of the spreader tool along the blade surface. The spreader tool is advantageously part of a robot system used to work the surface of the blade.

Claims

1. A spreader tool comprising: a bendable spreader wing; and a bending mechanism that includes an actuator, the bending mechanism configured and arranged to deform the spreader wing into a variable curved structure and to adjust the bending curve of the spreader wing to the curvature of a curved section; the spreader tool configured for spreading viscous material on the surface of the curved section of a wind turbine blade while being attached to a remote end of an arm of an unmanned robot, and wherein the arm is extending from a base of the robot, and the remote end being configured for movement relative to the base.

2. The spreader tool according to claim 1, wherein the spreader wing includes a first strut and a second strut, in accordance with a fin-ray principle, the two struts constituting two long sides with an acute angle between the struts, and a plurality of support beams connect the first strut with the second strut in rotational connections; wherein the second strut is connected to the actuator, and the actuator is configured to force the fin-ray structure into a bending configuration by moving the second strut relative to the first strut.

3. The spreader tool according to claim 2, wherein the first and second struts are formed by a first and a second chain, respectively, wherein the actuator is connected to the second chain, and further configured and arranged to move the second chain by the actuator relatively to the first chain and force the first chain to bend in conformance with the curvature of the curved section.

4. The spreader tool according to claim 1, further including a flat flexible band attached to the spreader wing, the flat flexible band configured and arranged for abutting the curved section and for dragging viscous material along the curved section during movement of the spreader tool along the curved section.

5. The spreader tool according to claim 4, wherein the flat flexible band is attached to a first chain, and wherein the actuator is configured to bend the flexible band, in combination with the first chain, in conformance with the shape of the curved section.

6. The spreader tool according to claim 1, wherein the bendable spreader wing is configured for shifting between a bent configuration and a straight configuration for selectively spreading viscous material onto a bent or a straight surface.

7. The spreader tool of claim 1, further including a second spreader wing, the two spreader wings extend from a centre region in opposite directions, and each of the two spreader wings are connected to the bending mechanism; the bending mechanism further configured and arranged to adjust the bending curve of the combination of the two spreader wings to the curvature of the curved section; and wherein the spreader tool is further configured and arranged to be orientated relative to the curved section and to adjust the curvature of the spreader wings in combination to the curvature of the curved section.

8. The spreader tool of claim 7, where the spreader wing and the second spreader wing are configured and arranged to face each other when the centre region is positioned at the edge of the turbine blade while the two spreader wings are facing the surface of the turbine blade on either side of the edge for abutting the turbine blade when the spreader wings are bent around the blade edge by the bending mechanism, and drag viscous material along the edge during movement of the spreader tool along the edge.

9. The spreader tool of claim 1, wherein the spreader tool is configured and arranged to orient relative to the curved section, adjust the curvature of the spreader wing in combination to the curvature of the curved section via the actuator; and move along the curved section by the arm dragging the viscous material along the curved section and spreading the viscous material on the curved section.

Description

DESCRIPTION OF THE DRAWINGS

[0082] The invention will be explained in more detail with reference to the drawing, where

[0083] FIG. 1 is a sketch of an embodiment of the invention on a wind turbine with a base station on the ground;

[0084] FIGS. 2a-c illustrate a) mounting of the wire, b) mounting of the robot to the wire, lifting of the robot along the wire;

[0085] FIG. 3 illustrates the robot with a grinding tool on the leading edge of the blade;

[0086] FIG. 4 illustrates an embodiment of the robot in greater detail with an attachment device on the blade;

[0087] FIG. 5a-b illustrates a robot a) without and b) with an attachment device on the arm;

[0088] FIG. 6 is an example of couplings for coupling tools to the base;

[0089] FIG. 7 illustrates a remote control station;

[0090] FIG. 8 illustrates a dragging unit;

[0091] FIGS. 9a-b illustrate a dispenser tool in a) an overview drawing and b) with details;

[0092] FIGS. 10a-c illustrate a revolver-type dispenser tool in a) perspective view, b) cross sectional side view, and c) from view;

[0093] FIGS. 11a-c show a spreader tool a) on a wing, b) in enlarged view, and c) from the opposite side;

[0094] FIGS. 12a-b show the spreader tool in straight configuration a) in a view towards the flexible band and b) in a view towards the actuators.

DETAILED DESCRIPTION

[0095] 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 a robot 8 and a wire 9 to which the robot 8 is attached. The wire 9 is secured to the rotor 4, for example 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 1.

[0096] On the base region 10 of the wind turbine 1, a base station 11 is provided for assisting the operation of the robot 8. For example, the base station 11 provides electricity in case that the robot 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, and/or paint for painting. For this reason, the base station 11 is connected to the robot 8 by a line 12A comprising at least one cable and/or at least one flexible tube for a fluid. Optionally, the line 12A is a hose, also called an umbilical, inside which there is provided a plurality of fluid tubes or at least one cable and at least one fluid tube.

[0097] For example, the line 12A comprises a first cable, and the base station 11 is wired by this first cable to the robot 8 and by 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.

[0098] Optionally, the base station 11 comprises a transceiver, wired or wireless, for data communication with the robot 8. In case of wireless communication, the robot 8 comprises a corresponding wireless data transceiver 41, as illustrated in FIG. 3

[0099] As an alternative, the base station 11 is not provided at the base region 10 of the tower 2 but on a platform 19 of the tower 2, where the platform 19 is provided at a higher level than the base region 10 of the tower 2. As a further option, the base station 11 is provided on a vessel in case of offshore installations, such as offshore wind turbines.

[0100] 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 robot 8 onto the wires 9. It is pointed out that in this illustrated example, that the robot 8 is mounted onto the wires on a platform 19, however, it can also be mounted to the wire at the base 10 of the wind turbine.

[0101] For example, the robot 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 robot 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 robot 8 and the anchor location for thereby lifting or lowering the robot 8. An example of a dragging unit is illustrated in FIG. 8.

[0102] FIG. 3 illustrates a robot 8 in operation. The robot 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.

[0103] As an alternative to the illustrated embodiment, the wires 9 are rolled onto rollers (not shown) which are part of the base 15 and located inside the base 15. In this case, the wires 9 do not hang further down than the robot 8. Such exemplary embodiment with rollers that roll up the wires is also illustrated in FIG. 4. As a further alternative, the robot 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 robot up and down. Such exemplary embodiments are similar in appearance as the embodiments that are illustrated in FIG. 4 as the rollers are provided inside the base.

[0104] 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.

[0105] 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.

[0106] 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. Such movement of the arm would typically be assisted in change of the length of the wire by the length adjustment mechanism. 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.

[0107] FIGS. 5a and 5b illustrate the robot 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.

[0108] 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.

[0109] As illustrated in FIG. 1, optionally, the base station 11 is wired for data transfer through a data transfer cable 12B. 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 robot 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 robot 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 robot 8, the control unit 35 illustrated 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 or the base.

[0110] As a further option, the robot 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.

[0111] FIG. 8 illustrates an example of a dragging unit 36 for 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 robot 8 is secured against falling. Alternatively, the robot 8 comprises rollers for winding up the wires inside or on the base.

[0112] FIG. 9a shows a dispenser tool 42. Inside a housing 43, dispenser cartridges 44 are provided from which material, for example filler material or glue, is provided through corresponding nozzles 46. An access door 45 gives access to the cartridges 44 for exchange thereof. On a bracket 47, a coupling counterpart 26A is provided for receiving electricity for driving the tool and/or fluids as part of a pneumatic or hydraulic driving system for the dispensing action.

[0113] FIG. 9b is a detailed drawing of an example of such dispenser tool 42 where part of the housing 43 has been removed. The dispensers cartridges 44 or of the type with a nozzle 46 is screwed onto the cartridge 44, and the cartridge 44 comprises an end cap that is sliding inside the cartridge 44 wall such that pressing of the sliding end cap towards the nozzle 46 causes expelling of the content of the cartridge 44 out of the nozzle 46. This type of cartridge 44 is standard for glues and filler materials and optionally for one-time-use. The end cap (nor shown) is driven by a dispenser actuator 48 in which a spindle 49 is driven by an electrical motor 50 against the end cap inside the cartridge 44 housing 43. As illustrated, four dispenser actuators 48 with corresponding motors 50 and spindles 49 are provided for the four cartridges 44, however, the number can be different. Electricity for the motors 50 is provided through the coupling 26A. Proper control of the actuators 48 is achieved with the electronic boards 51 connected thereto.

[0114] Typically, only one of the dispensers 44 is used at a time. In order to properly control the dispensing from the corresponding nozzle 46 to the surface 5′, the arm that is holding the dispenser tool 42 through the coupling 26A is angled into a fitting orientation where only the predetermined dispenser nozzle 46 is in contact with the surface 5′ or so close to the surface 5′ that the dispensed viscous material is dispensed onto the surface 5′.

[0115] FIGS. 10a, 10b, and 10c illustrate an alternative embodiment, in which the cartridges 44 are provided in a rotational drum magazine 66 of a revolver type dispenser tool 42, where the rotational drum 66 is rotated by a motor 67 until one of the cartridges 44 is aligned with a dispenser actuator 48, for example similar to the type as illustrated in FIG. 9b with a spindle 49 and a motor 50 that drives the spindle 49 which in turn pushes the end cap 68 towards the nozzle 46. Due to the rotation with the drum 66, the nozzle 46 of the cartridge 44 that is aligned with the dispenser actuator 48 always has the same position. For this reason, the orientation of the dispenser tool 42 relatively to the blade surface 5″ is the same independent of the cartridge 44 which is to be used for dispensing.

[0116] Once, the material from the cartridge 44, such as glue or filler material, has been dispensed from the cartridge 44 through the respective nozzle 46 onto the surface 5′, a further tool is provided for properly spreading the dispensed viscous material on the surface 5′.

[0117] In some cases, the edge 5″ or another curved section of the surface 5′ of the blade 5 is repaired by dispensing a viscous filler material on the surface 5′ and subsequently spreading it properly by a spreader tool. An example of such spreader tool is illustrated in FIG. 11.

[0118] FIG. 11A shows a spreader tool 52 in operation. It has a flexible band 53 fastened to a bendable constructions 54 in order for the flexible band 53 to be used as a squeegee when abutting the surface 5′. When the spreader tool 52 is abutting the edge 5″ of the blade 5, the flexible band 53 is deformed into the shape of the blade 5 around the edge 5″ and abuts the surface 5′ tightly, which is illustrated in the enlarged drawing of FIG. 11b. Hydraulic or pneumatic spreader actuators 58 are used for a controlled deformation of the bendable construction 54. The spreader actuators 58 are provided with corresponding hydraulic or pneumatic tube connectors 65. Correspondingly, the flexible band 53 is deformed when spreading viscous material on other curved sections of the blade surface 5′.

[0119] FIG. 12a and FIG. 12b illustrate the spreader tool 52 when its flexible band 53 is in straight condition, for example during storage or when used for spreading viscous material on straight sections of the surface 5′ of the blade 5. The flexible band 53 has a flat side 55 directed away from the bendable construction 54 and is configured for contact with the blade surface 5′ and a blade edge 56 which is used for spreading the viscous material, for example filler, onto the surface.

[0120] When the spreader tool 52 is held inclined relatively to the surface 5′, such that the flexible band 53 is not resting with its flat side 55 against the blade surface 5′ but only with the blade edge 56 of the flexible band 53, the viscous material can be evenly spread by the spreader tool 52 over and along the edge 5″ surface 5′ when the spreader tool 52 is drawn along the edge 5″. This situation is illustrated in FIG. 11c, where it is readily recognised that there is a gap 57 between the surface 5′ and flat side 55 of the flexible band 53, while the band's blade edge 56 is close to abutting the surface 5′ in order to drag the viscous material from inside the gap 57 along the edge 5″ while spreading it around the edge 5″.

[0121] The spreader tool 52 comprises two couplings 26A which gives two possibilities for attachment to the arm of the robot 8. Alternatively, one is used for attachment of the spreader tool 52 to the arm of the robot 8 and another coupling 26A is used when the spreader tool 52 is stored in the toolbox, as it was explained in relation to FIG. 4. As a further alternative, the spreader tool 52 comprises only one coupling 26A.

[0122] For example, the coupling 26A is connected to the connectors 65 of the pair of hydraulic or pneumatic actuators 58. In this case, the provision of hydraulic or pneumatic fluid is provided through the robot arm.

[0123] When activated, the pair of actuators 58 bend the two sections 54A, 54B of the bendable construction 54, together with the flexible band 53, for example around the edge 5″, as illustrated.

[0124] As best illustrated in FIG. 12, the bendable construction 54 comprises two spreader wings 54A, 54B which are arranged on either side of a centre region 59, where the centre region in operation is positioned on the edge 5″ of the blade surface 5′, and the two spreader wings 54A, 54B extend in opposite directions and are bent into the profile of the blade's 5 edge 5″ onto opposite sides of the edge 5″.

[0125] The construction follows a fin-ray principle in which two flexible struts are inclined to each other and a plurality of support beams connect the struts at various locations along their lengths. When one strut is moved relatively to the other, the construction deforms into a curved structure.

[0126] In the exemplified embodiment of FIGS. 11 and 11, each spreader wing 54A, 54B comprises a double-chain structure 60 with two chains 60A, 60B as struts. Each chain can only bend in one plane, which is in a direction normal to the flat side 55 of the flexible band 53. When the two chains 60A, 60B are straightened, as illustrated in FIG. 12b, the two chains 60A and 60B are inclined relatively to each other and form an acute angle, typically in the range of between 15 and 45 degrees. A centre region 59 forms the base of a triangle with the two struts, formed by the chains 60A and 60B.

[0127] In more detail, a plurality of chain links 61A of one of the two chains 60A is connected to a corresponding plurality of chain links 61B of the other chain 60B by a corresponding plurality of support beams 62 which extends largely laterally from the chains 60A, 60B and which are individually rotationally coupled with their two ends to either of the two chain links 61A, 61B which they individually connect. Due to the two chains 60A, 60B being inclined to each other when straight, the support beams 62 have different sizes and are increasing in length along the double chain 60. The consequence of the triangular arrangement of the two chains 60A, 60B is a bending in a lateral direction, where the bending is not free but which is restricted to a smooth curve by the cooperation of the two chains 60A, 60B, which are linked to each other by the plurality of support beams 62. Whereas one chain 60A is attached to the flexible band 53, the two sections of the other chain 60B are covered by two covering bands 63.

[0128] The actuators 58 comprise an actuator rod 64 which is fastened to an end of the outer chain 61B. When the actuators 58 are extended, the actuator rod 64 pushes the outer chain away 61B from the actuator 58 and forces the two spreader wings 54A, 54B to bent around the centre region 59.

[0129] When the actuator 58 is retracted, the spreader wings 54A, 54B are extended into a straight configuration. Although, the spreader tool 52 has been developed especially for spreading viscous material around edges 5″ and is capable of bending correspondingly, the spreader wings 54A, 54B can also be used in straight configuration when filler, glue, or other viscous material is to be spread on the flat surface 5′ of the blade 5. For versatility, it is a great advantage that the spreader tool 52 can easily and quickly shift between abutment of the edge of the blade 5 and abutment of the quasi-plane surface 5′ at the flat side of the blade 5.

[0130] Although, two wings have been used for an exemplification that is suitable for the edge of the blade 5, a spreader tool 25 with only a single spreader wing 54A is also an option, especially, when surface sections with less curvature are repaired.

[0131] Although, the robot 8 and the specific tools have been explained in detail in relation to a wind turbine 1 and its blade 5 because of the special advantages at such type of operation site, the principles apply equally well when the robot 8 is used at other types of operation sites, for example other types of vertical or inclined walls, for example of buildings.

REFERENCE NUMBERS

[0132] 1 wind turbine [0133] 2 tower [0134] 3 nacelle [0135] 4 rotor [0136] 5 blades [0137] 5′ blade surface [0138] 5″ blade leading edge [0139] 6 centre of rotor 4 [0140] 7 system [0141] 8 robot [0142] 9 wire [0143] 10 base region of the wind turbine 1 [0144] 11 base station [0145] 12A first cable between base station 11 and robot 8 [0146] 12B second cable between base station and first cable to a remote control station 31 [0147] 13 port in the tower 2 for the second cable 12B [0148] 14 installer [0149] 15 base [0150] 16 arm [0151] 17a-g rotational actuators on arm 16 [0152] 18 grinding tool [0153] 19 platform [0154] 20 base attachment device [0155] 21 arm attachment device [0156] 22 remote end of the arm 16 [0157] 23 attachment point on the blade surface 5′ [0158] 24 magazine for tool [0159] 25 magazine coupling [0160] 26A, 26B coupling counterparts [0161] 27 electrical connector of coupling counterparts 26A, 26B [0162] 28 locking mechanism of coupling counterparts 26A, 26B [0163] 29 recess of coupling counterparts 26A, 26B [0164] 30 expandable ring of balls of coupling counterparts 26A, 26B [0165] 31 remote control station [0166] 32 operator [0167] 33 display screens [0168] 34 control panel [0169] 35 control unit of robot 8 [0170] 36 dragging unit [0171] 37 pairs of rollers [0172] 38 brake roller [0173] 39 brake shoe interacting with brake roller [0174] 40 video camera [0175] 41 wireless transceiver in base 15 [0176] 42 dispenser tool [0177] 43 housing of dispenser tool 42 [0178] 44 cartridge [0179] 45 access door to cartridge 44 [0180] 46 nozzle [0181] 47 bracket [0182] 48 actuator for dispensing from cartridge 44 [0183] 49 spindle of actuator 48 [0184] 50 electrical motor of actuator 48 [0185] 51 electronic boards 51 [0186] 52 spreader tool [0187] 53 flexible band [0188] 54 bendable construction [0189] 54A, 54B two opposite spreader wings of the bendable construction 54 [0190] 55 flat side of flexible band 53 [0191] 56 edge of flexible band 53 [0192] 57 gap between one edge of the flexible band while the opposite blade edge 56 is close to or abutting the surface 5′ [0193] 58 hydraulic or pneumatic spreader actuator [0194] 59 centre region [0195] 60A first chain carrying the flexible band 53 [0196] 60B second chain, inclined relatively to first chain 60A when straight [0197] 61A chain link of first chain 60A [0198] 61B chain link of second chain 60B [0199] 62 support beams that connect chain link 61A with chain link 61B at rotational connections [0200] 63 covering band for chain sections of second chain 60B [0201] 64 actuator rod [0202] 65 hydraulic or pneumatic connectors for spreader actuator 58 [0203] 66 drum of revolver type dispenser tool 42 [0204] 67 motor for rotation of drum 66 [0205] 68 end cap of cartridge 44