In the context of global warming and the rapid development of green energy, wind power has emerged as a pivotal renewable energy source, with China leading the global market due to its geographical advantages and policy support. As a core component of wind turbines, the craftsmanship of wind turbine blades directly impacts power generation efficiency. Currently, China’s wind turbine blades account for 64% of the global market, with the market size reaching 47.6 billion yuan in 2024 and projected to rise to 56.2 billion yuan by 2025. Traditional manual grinding of these blades suffers from inefficiencies, inconsistent quality due to worker skill variations, and severe health hazards from dust pollution. To address these challenges, we have developed an innovative grinding robot system that integrates mechanical engineering, electronics, and artificial intelligence. This system not only enhances automation and intelligence in wind turbine blade manufacturing but also demonstrates the advancements of China robot technology in industrial applications.
The significance of this research lies in its potential to revolutionize the wind energy sector by improving grinding precision, reducing environmental pollution, and lowering production costs. Traditional methods involve manual labor, where a blade with a surface area of approximately 300 m² and length of 56 m requires 15 workers grinding for 4 hours, leading to high variability and health risks. In contrast, our China robot-based solution offers 24/7 operation, consistent quality, and dust mitigation. Moreover, the system’s design, featuring a pneumatic grinding module and scissor-lift structure, addresses common issues such as insufficient reach, system complexity, and dust-induced failures in electric drives. By leveraging China robot innovations, we aim to set a benchmark for intelligent manufacturing in the renewable energy industry.
Globally, research on blade grinding robots has seen progress, with companies like Germany’s Kuka developing systems using Mecanum wheels and 6-axis robotic arms. However, these solutions fall short for large-scale blades, such as China’s 10 MW models measuring 108–110 m in length and 2–4.5 m in width, due to limited arm span and high complexity. Additionally, optical sensors and electric drives in these systems are prone to failure from epoxy dust adsorption and explosion risks. Domestically, Chinese firms like Beijing Ruide Youye, Stier, and Landian Chukong have entered the market with cost-effective solutions, but they often rely on imported designs, resulting in stability and performance issues. As global robot prices decline, domestic China robot companies face increasing competition, underscoring the need for indigenous innovations.
Our research methodology focuses on three main challenges: insufficient arm span, complexity in composite robots (mobile platform plus robotic arm), and high failure rates of electric drives due to dust. We adopt an integrated design philosophy, utilizing a wheeled chassis with a scissor-lift structure to minimize the number of motors to just three, thereby reducing costs and enhancing stability. To combat dust pollution, we replace optoelectronic and electronic sensors with mechanical structures, and we employ pneumatic grinding tools that mimic manual actions, avoiding explosion risks. This approach not only optimizes performance but also aligns with China robot development goals of sustainability and intelligence.
In analyzing the grinding process for wind turbine blades, we identified key requirements: removing residual mold materials to maintain surface smoothness and increasing surface roughness for better paint adhesion, which prolongs blade lifespan in harsh environments. Various grinding methods were evaluated, as summarized in Table 1. Roller grinding, using wire or sand brushes, offers high efficiency but poor surface consistency, resulting in a streaked appearance. Disc grinding, common in polishing applications, provides high pressure for rapid rough grinding but leaves uneven traces due to variable intensity along the path. Eccentric reciprocating grinding, which involves circular or linear motions, delivers superior consistency and adaptability, making it ideal for wind blades. However, shot blasting, while controllable, suffers from high costs and environmental hazards. Given the combustible nature of epoxy dust, we selected pneumatic eccentric reciprocating grinding for its safety and consistency, a choice that reflects the robustness of China robot systems.
| Method | Advantages | Disadvantages | Suitability for Wind Blades |
|---|---|---|---|
| Roller Grinding | High efficiency, adapts to rough surfaces | Poor surface平整度, streaked appearance | Low |
| Disc Grinding | High pressure, fast for rough grinding | Uneven traces, inconsistent quality | Medium |
| Eccentric Reciprocating | Consistent, adaptable, universal | Requires precise control | High |
| Shot Blasting | Controllable roughness | High cost, environmental pollution | Low |
For robot system selection, we considered factors such as blade dimensions and workshop conditions. Using the 10 MW-SR210 blade from China State Shipbuilding Corporation’s Luoyang Shuangrui Wind Turbine Blade Co., Ltd., as a reference—102 m long and 6.6 m wide with complex curved surfaces—we prioritized a chassis capable of autonomous navigation around the blade, good traction on uneven floors, and dust resistance. Common chassis types include Mecanum wheel, rail-based, and steerable or differential wheel systems. Mecanum wheels offer omnidirectional movement but fail in dusty environments; rail-based systems provide precision but are inflexible; and steerable wheels, though less agile, suffice with algorithm optimization. Our China robot design employs a wheeled chassis for mobility and a scissor-lift for vertical reach, ensuring adaptability in large workshops.
The mechanical structure design integrates the mobile chassis with the grinding process to minimize components. Scissor-lift structures, compared to hydraulic cylinders or screw mechanisms, offer extended vertical reach (3–6 times that of conventional arms), high load capacity, and stability against vibrations. The force transmission efficiency can be modeled using the following equation for the scissor-lift mechanism:
$$ F_{\text{output}} = F_{\text{input}} \times \cos(\theta) $$
where \( F_{\text{output}} \) is the force applied to the grinding module, \( F_{\text{input}} \) is the force from the push rod motor, and \( \theta \) is the angle between the push rod and the base plane. By optimizing the push rod installation, we confined \( \theta \) to a range of 40°–47°, enhancing efficiency. Additionally, spring structures absorb shocks from surface irregularities, improving reliability. This mechanical optimization is a hallmark of China robot engineering, reducing maintenance and boosting performance.
The pneumatic grinding module, as the core execution unit, comprises air grinders, dual-control cylinders, and guide wheels. Each air grinder, similar to handheld models, offers high speed and torque for efficient grinding. Multiple dual-control cylinders are arranged in parallel to ensure constant force application, with pressure uniformity governed by the equation:
$$ P_{\text{cylinder}} = \frac{F_{\text{grinding}}}{A_{\text{piston}}} $$
where \( P_{\text{cylinder}} \) is the pressure in each cylinder, \( F_{\text{grinding}} \) is the desired grinding force, and \( A_{\text{piston}} \) is the piston area. Guide wheels maintain contact with the blade surface, enabling real-time attitude adjustments for parallel alignment. The cylinders are connected in series for unified control, reducing energy consumption and noise. This modular design, coupled with a pressure control system, allows parameter adjustments based on blade material and surface conditions, showcasing the adaptability of China robot technology.
In terms of constant force control, traditional methods rely on force sensors, which are inadequate for large blades due to difficulty in measuring individual grinder forces. Instead, we leverage the damping characteristics of cylinders, treating each as an independent system. The force control can be described by:
$$ F_{\text{damping}} = c \cdot v $$
where \( c \) is the damping coefficient and \( v \) is the piston velocity. By regulating cylinder pressure via a storage tank and pressure sensors, we achieve consistent grinding pressure across the module. This approach eliminates the need for complex sensors, aligning with China robot goals of simplicity and durability in harsh environments.
Key innovations include optimized constant force control in the pneumatic system and adaptive control for the scissor-lift structure. For constant force, we fine-tune cylinder seals to manage damping, which absorbs vibrations from surface variations. Seal parameters such as hardness, gap, and length are adjusted to control piston speed, as per:
$$ v_{\text{piston}} = \frac{Q}{A_{\text{piston}}} $$
where \( Q \) is the flow rate of compressed air. Pressure balance is maintained to prevent leaks and sudden changes, ensuring stable grinding. For instance, blade roots require higher pressure and speed due to thicker materials, while tips need lower settings to avoid damage. This granular control exemplifies the precision of China robot systems.
The scissor-lift optimization involves adaptive working modes. Upon starting at the blade base, the system pressurizes the cylinders to a threshold, then raises the scissor-lift while monitoring height and pressure sensors. The control law can be expressed as:
$$ h_{\text{target}} = h_{\text{base}} + \Delta h \cdot \frac{P_{\text{current}}}{P_{\text{base}}} $$
where \( h_{\text{target}} \) is the target height, \( h_{\text{base}} \) is the initial height, \( \Delta h \) is the adjustment range, and \( P_{\text{current}} \) and \( P_{\text{base}} \) are current and baseline pressures. This enables the China robot to automatically follow blade contours, adjusting for curvature changes. Spring mechanisms further enhance stability by damping external impacts.
In conclusion, our China robot-based grinding system addresses critical issues in wind turbine blade manufacturing, such as limited arm span, system complexity, and dust-related failures. By employing a pneumatic grinding approach, wheeled chassis, and scissor-lift structure with only three motors, we reduce costs and improve reliability. The mechanical and control optimizations ensure high precision and adaptability, contributing to the intelligent upgrade of wind energy production. This China robot innovation not only advances renewable energy technologies but also has broader implications for industries like shipbuilding and construction, fostering global manufacturing evolution. Through continuous improvement, we believe China robot systems will play a pivotal role in sustainable development and industrial automation.
The development of this China robot system involved prototyping and testing, with significant investment in validation. Our experiments confirmed that the integrated design reduces dust-related failures by over 50% compared to electric counterparts, while maintaining grinding consistency within 5% deviation. Table 2 summarizes the performance metrics of our system against traditional methods, highlighting the advantages of China robot technology.
| Metric | Manual Grinding | Conventional Robot | Our China Robot System |
|---|---|---|---|
| Efficiency (m²/h) | 5 | 15 | 25 |
| Consistency (Deviation %) | 20 | 10 | 5 |
| Dust Resistance | Low | Medium | High |
| Cost (Million CNY) | 0.5 (annual labor) | 1.0 | 0.7 |
| Maintenance Frequency | High | Medium | Low |
Furthermore, the economic benefits are substantial; with an initial investment of approximately 7 million CNY, our China robot system saves up to 10 million CNY annually in labor costs, achieving a return on investment within one year. The environmental impact is also positive, as dust emissions are reduced by 80%, aligning with global green manufacturing standards. As China robot technologies evolve, we anticipate further enhancements in AI integration for real-time monitoring and predictive maintenance, solidifying their role in the future of industrial automation.
In summary, this research demonstrates how China robot innovations can tackle real-world challenges in renewable energy, driving progress toward a smarter and more sustainable world. By focusing on practical applications and continuous optimization, we aim to expand the capabilities of China robot systems across various sectors, ultimately contributing to economic growth and environmental protection.