Energy

BladeBUG robots can remotely perform tasks independently or assist technicians in inspecting, maintaining, and repairing turbine blades.

The rapid growth of offshore wind means new challenges and opportunities for remote maintenance and repair solutions. UK-based 

 advanced robots can remotely perform tasks independently or assist technicians in inspecting, maintaining, and repairing turbine blades. To ensure that the robot can withstand rough weather conditions and provide a good user experience for the operator, they asked EGGS for help.

Designing a robot that can operate in challenging environments

The initial stage dealt with understanding the overall user journey of BladeBUG, from preparation, transport, deployment, and operations, to removal. A subgoal of the RIMA project has been to focus on the usability and handling of the robot, to improve the experience of technicians and service providers operating the robot.

Illustration

EGGS has helped develop the industrial design of the robot's external casing and ensured it is robust enough to perform in challenging environments. The new aesthetics provide a sense of confidence that the robot is robust enough to manage the handling and environment of a wind turbine – on and offshore. Moreover, we have improved the user experience of handling or manoeuvring the robot.

A robust design and excellent user experience

Thanks to its new design, the robot feels more rugged and able to withstand tough treatment during transport, deployment, and operation upon the nacelle and blade of a turbine. The robotic solution answers several of the wind energy industry's future challenges, especially in the offshore environment: Health and safety of workers at sea and heights; skill shortage to maintain the number of expected turbines; and the cost of maintaining larger turbines further from shore.

The external design decisions have also impacted the robot's architecture, making adaptations and improvements on a larger scale than just aesthetic and superficial.

Functionality and improved internal architecture

The robot is now a manufactured prototype of an external shell, where all electronics and sensitive moving parts are entirely and partially enclosed with water-tight casing or panels.

Bladebug front

The leg structure and enclosing of electronics have been redeveloped as part of the casing design, and an internal enclosure has been added that protects the main electronics from any water or dust. Fixtures and updated placements have also greatly improved ease of use, particularly when removing and inserting elements, such as the lithium-power pack.

Bladebug perspective

An external casing covers all the previously exposed electronics, and sensitive moving parts are now nestled behind panels to reduce the risk of ingress from dust, water, oil, and salt. Sturdy handles on the top and sides allow for more flexible movement when carrying or moving the robot.

As beneficiaries of European Union funding of €150ks, part of the 

 Open Call 2, BladeBUG, and EGGS Design have 

 the robot in an operational environment. The funding is part of the RIMA (Robotics for Inspection and Maintenance) programme, which connects research, technology and service providers, industry sectors, and digital innovation hubs to SMEs (Small and Medium-sized Enterprises) looking to accelerate innovation.

With a ready prototype, BladeBUG is now planning for manufacturing, constructing, and assembling the detailed prototype.

Physical Prototyping and Piloting

Validation

Part of a ten-month EU-funded project

Sketching and early CAD prototyping provided mediums to explore and experiment with the different options for specific robot parts. It has also offered an opportunity to explore the overall visual impact and develop the look and feel in alignment with the brand direction. The collaboration and development have been remote, with EGGS' team split between Denmark and Norway and BladeBUG based in London in the UK.

Safe and efficient wind turbine inspection robot