Coating applicator tool head used with automated device for repairing leading edge damage on wind turbine blade

Abstract

A coating applicator tool head configured for use with a robotic maintenance device includes a tool head body with a frame, a supply container, a drive for actuating delivery of flow of coating from the supply container, a feed tube, a nozzle receiving flow from the feed tube, and a spreading tool such as a roller brush or a spatula receiving flow from the nozzle. The coating applicator tool head is moved by an articulated arm of the maintenance device over surface of a wind turbine blade containing damage such that the roller brush or spatula can apply layers of the coating to cover and fill in the damage. The nozzle directly supplies coating continuously onto the roller brush or the spatula, and the drive can be configured to independently adjust supply of two or more different components in the supply container that may be mixed to form the coating.

1 . A coating applicator tool head configured to be used with a robotic maintenance device for repairing damage around a leading edge of a wind turbine blade, the coating applicator tool head characterized by:
 a tool head body including a frame and an interface element configured to mechanically and electrically couple with a corresponding interface provided on an articulated arm of the robotic maintenance device;   a feed tube configured to receive a flow of a coating from a supply container;   a roller brush rotatably mounted on the frame and configured to be rolled along surfaces of the wind turbine blade; and   a nozzle located adjacent the roller brush and connected to the feed tube so as to spread the flow of the coating along a width of the roller brush and then apply the coating directly onto the roller brush, such that the coating is then transferred by the roller brush onto the surfaces of the wind turbine blade to apply layers of the coating to cover and repair the damage on the wind turbine blade.   
     
     
         2 . The coating applicator tool head of  claim 1 , characterized in that the nozzle comprises:
 a nozzle body extending transversely along the width of the roller brush between opposing ends supported by the frame of the tool head body;   an inlet located centrally between the opposing ends of the nozzle body; and   an outlet defined by an elongate slot cut into the nozzle body to extend between the opposing ends and face towards the roller brush, the elongate slot configured to dispense the coating along the width of the roller brush.   
     
     
         3 . The coating applicator tool head of  claim 2 , characterized in that the nozzle body is defined by an at least partially flexible material such that pressure in the flow of the coating from the inlet expands the elongate slot at a central portion as compared to portions proximate the opposing ends, thereby causing a higher dispense flow rate of coating onto a center of the roller brush than at opposite ends thereof. 
     
     
         4 . The coating applicator tool head of  claim 1 , further characterized by:
 a supply container supported on the tool head body and defining a storage volume for holding the coating to be applied to the wind turbine blade; and   a drive operatively engaged with the supply container and actuated to deliver the flow of the coating from the supply container to the feed tube, which is connected to the supply container.   
     
     
         5 . The coating applicator tool head of  claim 4 , characterized in that the supply container defines at least two chambers configured to retain different components that can be mixed together to form the coating, the drive includes independent actuators associated with each of the at least two chambers, and the coating applicator tool head is further characterized by:
 a mixing element connected to the supply container and the feed tube, the mixing element configured to receive the different components from the at least two chambers and mix them into the coating to deliver the flow of the coating into the feed tube.   
     
     
         6 . The coating applicator tool head of  claim 5 , further characterized by:
 a control system operatively connected to the drive, the control system operating the independent actuators at independently adjustable speeds to supply each of the different components at a mix ratio adapted to produce the coating when mixed at the mixing element.   
     
     
         7 . The coating applicator tool head of  claim 6 , characterized in that the control system varies speed of the independent actuators to vary a flow rate of coating being dispensed at the nozzle onto the roller brush, the flow rate being adjusted in accordance with a movement speed of the roller brush so as to continuously apply the coating onto the roller brush during operation of the coating applicator tool head. 
     
     
         8 . The coating applicator tool head of  claim 5 , characterized in that the independent actuators of the drive are defined by pistons each configured to move relative to one of the at least two chambers to force flow of an associated component out of the chamber and into the mixing element, and the drive also includes independently actuated motors engaged with each of the pistons. 
     
     
         9 . The coating applicator tool head of  claim 5 , characterized in that the mixing element is defined by a static mixer configured to mix the different components as the different components flow through an elongate length of the static mixer. 
     
     
         10 . The coating applicator tool head of  claim 5 , further characterized by:
 a drain container connected to the mixing element; and   a valve operatively connected to the mixing element, the drain container, and the feed tube, the valve controlling flow of the coating exiting the mixing element to be delivered into either the drain container or the feed tube,   characterized in that the valve initially directs the coating to flow into the drain container until a mixing rate of the different components has reached a desired threshold, and then the valve directs the coating to flow into the feed tube for delivery to the nozzle and to the roller brush.   
     
     
         11 . The coating applicator tool head of  claim 1 , further characterized by:
 a curing means mounted on the frame at a position spaced apart from the roller brush, the curing means configured to apply heat energy and/or light towards the coating after application on the surfaces of the wind turbine blade to help cure and solidify a repaired area covered by the coating.   
     
     
         12 . A coating applicator tool head configured to be used with a robotic maintenance device for repairing damage around a leading edge of a wind turbine blade, the coating applicator tool head characterized by:
 a tool head body including a frame and an interface element configured to mechanically and electrically couple with a corresponding interface provided on an articulated arm of the robotic maintenance device;   a spreading tool mounted on the frame and configured to be moved along surfaces of the wind turbine blade to spread a coating thereon;   a supply container defining at least two chambers configured to retain different components that can be mixed together to form a coating to be dispensed onto the spreading tool for application to the wind turbine blade;   a drive operatively engaged with the supply container and actuated to deliver a flow of the coating from the supply container, the drive including independent actuators associated with each of the at least two chambers;   a mixing element connected to the supply container, the mixing element configured to receive the different components from the at least two chambers and mix them into the coating; and   a control system operatively connected to the drive, the control system operating the independent actuators at independently adjustable speeds to supply each of the different components at a mix ratio adapted to produce the coating when mixed at the mixing element.   
     
     
         13 . The coating applicator tool head of  claim 12 , characterized in that the control system varies speed of the independent actuators to vary a flow rate of coating being dispensed onto the spreading tool, the flow rate being adjusted in accordance with a movement speed of the spreading tool so as to continuously apply the coating onto the spreading tool during operation of the coating applicator tool head. 
     
     
         14 . The coating applicator tool head of  claim 12 , characterized in that the independent actuators of the drive are defined by pistons each configured to move relative to one of the at least two chambers to force flow of an associated component out of the chamber and into the mixing element, and the drive also includes independently actuated motors engaged with each of the pistons. 
     
     
         15 . The coating applicator tool head of  claim 12 , characterized in that the mixing element is defined by a static mixer configured to mix the different components as the different components flow through an elongate length of the static mixer. 
     
     
         16 . The coating applicator tool head of any of  claim 12 , further characterized by:
 a drain container connected to the mixing element; and   a valve operatively connected to the mixing element, the drain container, and the spreading tool, the valve controlling flow of the coating exiting the mixing element to be delivered into either the drain container or the spreading tool,   characterized in that the valve initially directs the coating to flow into the drain container until a mixing rate of the different components has reached a desired threshold, and then the valve directs the coating to flow into the spreading tool.   
     
     
         17 . The coating applicator tool head of  claim 12 , characterized in that the spreading tool is a spatula comprising:
 a flexible extrusion plate having a front edge, a rear edge, opposed side edges, an outer surface, and an inner surface, the extrusion plate further having a central region defined by a central axis; and   one or more spacers positioned proximate the inner surface of the extrusion plate, wherein the one or more spacers are configured to define a gap between an outer surface of the wind turbine blade and the inner surface of the extrusion plate; and   a feed tube for supplying a coating material to the spatula,   wherein the spatula is configured to shape the coating material into a coating over a damaged area of the wind turbine blade.   
     
     
         18 . The coating applicator tool head according to  claim 17 , wherein the one or more spacers define a height profile that corresponds to the shape of the coating from the applicator tool. 
     
     
         19 . The coating applicator tool head according to  claim 18 , wherein the height profile has a maximum adjacent the central region of the extrusion plate and decays to substantially zero adjacent the side edges of the extrusion plate. 
     
     
         20 . The coating applicator tool head according to  claim 17 , wherein the extrusion plate is selectively movable relative to the one or more spacers. 
     
     
         21 . The coating applicator tool head according to  claim 20 , wherein relative movement between the extrusion plate and the one or more spacers varies the height profile. 
     
     
         22 . The coating applicator tool head according to  claim 17 , wherein the one or more spacers include a plurality of ribs coupled to the inner surface of the extrusion plate and extending from the front edge toward the rear edge, and wherein the plurality of ribs defines grooves between adjacent ribs. 
     
     
         23 . The coating applicator tool head according to  claim 22 , wherein a height of the plurality of ribs varies, and wherein the height of the plurality of ribs is at a maximum adjacent the central region of the extrusion plate and decreases in height away from the central region and toward the side edges. 
     
     
         24 . The coating applicator tool head according to  claim 17 , wherein the one or more spacers include one or more spines having a front edge, a rear edge, an upper edge, and a lower edge. 
     
     
         25 . The coating applicator tool head according to  claim 24 , wherein the lower edge is angled relative to the upper edge by an acute angle, and wherein the lower edge is configured to engage the outer surface of the wind turbine blade. 
     
     
         26 . The coating applicator tool head according to  claim 24 , wherein the one or more spines is separate from the extrusion plate. 
     
     
         27 . The coating applicator tool head according to  claim 24 , wherein the one or more spines is positioned proximate the inner surface of the extrusion plate about the central region, and wherein the one or more spines extends in a direction generally parallel to the central axis. 
     
     
         28 . The coating applicator tool head according to  claim 24 , wherein the extrusion plate is coupled to a rigid support, wherein the one or more spines is coupled to the feed tube, and wherein the rigid support is slidable relative to the feed tube. 
     
     
         29 . The coating applicator tool head of  claim 12 , characterized in that the spreading tool is a roller brush rotatably coupled to the frame, the roller brush is mounted on the frame at opposing ends in such a manner to enable free rotation of the roller brush relative to the frame, and rotation of the roller brush is actuated by movement of the coating applicator tool head by the articulated arm back and forth along the surfaces of the wind turbine blade. 
     
     
         30 . The coating applicator tool head of any of  claim 12 , further characterized by:
 a curing means mounted on the frame at a position spaced apart from the spreading tool, the curing means configured to apply heat energy and/or light towards the coating after application on the surfaces of the wind turbine blade to help cure and solidify a repaired area covered by the coating.   
     
     
         31 . A method for automatically repairing damage around a leading edge of a wind turbine blade connected to a wind turbine, the method characterized by:
 coupling a coating applicator tool head to an articulated arm of a robotic maintenance device that has been positioned along the leading edge of the wind turbine blade such that the articulated arm can move the coating applicator tool head into position around a location containing damage on the wind turbine blade;   actuating a drive associated with a supply container operatively connected with the coating applicator tool head to move independent actuators of the drive relative to corresponding chambers of the supply container which contain different components that can be mixed together to form a coating for the wind turbine blade, to thereby deliver a flow of the different components into a mixing element;   mixing with the mixing element the flow of the different components to produce a flow of the coating which is delivered to a spreading tool;   moving the coating applicator tool head with the articulated arm so that the spreading tool moves along surfaces of the wind turbine blade to apply layers of the coating to the surfaces of the wind turbine blade, thereby covering and repairing the damage on the wind turbine blade; and   controlling the independent actuators of the drive to move at independently adjustable speeds to supply the different components at a desired mix ratio adapted to produce the coating when mixed at the mixing element.   
     
     
         32 . The method of  claim 31 , further characterized by:
 varying a speed of the independent actuators of the drive to vary a flow rate of the coating being delivered to the spreading tool, the flow rate being adjusted in accordance with a movement speed of the spreading tool so as to continuously apply the coating onto the spreading tool during operation of the coating applicator tool head.   
     
     
         33 . The method of  claim 31 , characterized in that the spreading tool is a spatula comprising:
 a flexible extrusion plate having a front edge, a rear edge, opposed side edges, an outer surface, and an inner surface, the extrusion plate further having a central region defined by a central axis; and   one or more spacers positioned proximate the inner surface of the extrusion plate, wherein the one or more spacers are configured to define a gap between an outer surface of the wind turbine blade and the inner surface of the extrusion plate; and   a feed tube for supplying a coating material to the spatula,   wherein the spatula is configured to shape the coating material into a coating over a damaged area of the wind turbine blade and the method if further characterized by:   engaging the applicator tool to the outer surface of the wind turbine blade;   supplying the coating material to the applicator tool;   moving the applicator tool along the outer surface of the wind turbine blade; and   dispensing the coating material from the applicator tool to form the coating over the damaged area of the wind turbine blade.   
     
     
         34 . The method of  claim 31 , characterized in that the spreading tool is a roller brush rotatably coupled to a frame of the coating applicator tool head, the coating applicator tool head further includes a nozzle located adjacent the roller brush and connected to the mixing element to receive the flow of the coating, and the method if further characterized by:
 spreading, by the nozzle, the flow of the coating along a width of the roller brush; and   dispensing the flow of the coating directly from the nozzle onto the roller brush while the roller brush is rolled along the surfaces of the wind turbine blade.   
     
     
         35 . The method of  claim 34 , characterized in that the step of dispensing the flow of the coating directly from the nozzle onto the roller brush further comprises:
 dispensing a higher dispense flow rate of the coating onto a center of the roller brush than at opposite ends along the width of the roller brush.   
     
     
         36 . The method of any of  claim 31 , further characterized by:
 applying heat energy and/or light towards the coating after application on the surfaces of the wind turbine blade to help cure and solidify a repaired area covered by the coating.   
     
     
         37 . The method of any of  claim 31 , characterized in that the coating applicator tool head further includes a drain container connected to the mixing element and a valve operatively connected to the mixing element, the drain container, and the spreading tool, and the method is further characterized by:
 controlling the flow of the coating with the valve to initially be directed from the mixing element into the drain container until a mixing rate of the different components has reached a desired threshold; and   actuating the valve to switch the flow of the coating to be directed from the mixing element to the spreading tool after the mixing rate has reached the desired threshold.