Advanced Automation and Digital Twin Solutions for a Leading Wind Power Company
About the project
A leader in the wind power industry embarked on a mission to revolutionize their wind turbine blade inspection process. This initiative required a shift from traditional methods to a more efficient, automated system utilizing innovative and advanced technologies. They approached us to conceptualize and implement a cutting-edge solution that would streamline and simplify their inspection process, enhance accuracy, and reduce costs.
Location
Denmark
Team Size
10
Industry
WIND ENERGY
The Challenge
Our challenge was to design a comprehensive strategy that integrated high-resolution cameras, tilt devices with remote control, and advanced computer vision and AI algorithms running on hardware. The goal was to create a scalable and stable system capable of autonomously capturing images of wind turbine blades, with the results being sent to other systems for detailed examination. Additionally, we needed to develop a custom digital twin platform to simulate and validate various scenarios, such as different wind turbine types and different weather conditions, ensuring optimal performance and risk management.
This is what we did
Automated Inspection System
Our team developed an innovative inspection embedded device with the following features:
- High-Resolution Imaging: Utilized advanced cameras and tilt devices for precise image capture.
- AI-Driven Analysis: Integrated computer vision and AI algorithms to automate image and metadata collection.
- Remote Operation: Enabled remote control of the inspection devices, allowing operations from any location worldwide.
- Automated Data Transmission: Streamlined the process of sending inspection data for detailed analysis and reporting.
Custom Digital Twin Platform
To enhance the solution, we created a bespoke digital twin platform that provided significant benefits:
- Continuous Development: Facilitated ongoing software and hardware development, reducing development time and costs.
- Accurate Simulations: Accurate Simulations: Allowed engineers to simulate real-world scenarios with high precision, optimizing solutions before hardware integration. The platform supported both Software-in-the-Loop (SIL) and Hardware-in-the-Loop (HIL) simulations, ensuring accurate modeling of physical behaviors and interactions.
- Risk Mitigation: Enabled the identification and mitigation of potential risks through scenario simulation, minimizing the likelihood of real-world failures.
Business Results that we achieved
Improved Time Efficiency
Decreased Mob/Demob Costs
Remote control capabilities negated the need for on-site crews, reducing operational costs.
On-Demand Inspections & Seamless Data Handling
Allowed for inspections to be conducted whenever remotely, eliminating geographic constraints; Automated data transmission streamlined the analysis and reporting process.
By implementing our solution, our client achieved
Enhanced Development Cycles
Accelerated Time-to-Market: Virtual simulations enabled faster development and testing, speeding up product launches; Cost Savings: Reduced the need for physical testing and prototyping, saving on materials and resources.
Increased Accuracy & Risk Management
Precision in Simulations: High-accuracy simulations helped identify and resolve potential issues early in the process; Risk Reduction: Scenario simulations provided insights for risk mitigation, reducing the chances of real-world malfunctions.
Enhanced Collaboration
Shared Digital Twins: The digital twin models were shared among teams and stakeholders, fostering collaboration and informed decision-making.
Togetherness in pursuit of excellence.
Our collaboration with the wind power industry leader resulted in a groundbreaking transformation of their wind turbine blade inspection process. By leveraging advanced technologies, we delivered a solution that significantly improved efficiency, accuracy, and cost-effectiveness. This project underscores the potential of innovative approaches to drive substantial improvements in industrial operations, contributing to the advancement of renewable energy technologies.
Relevant success stories
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