Case Study: Internal Wind Turbine Blade Inspection Using Nexxis Crawler & Elios 3
Client
Confidential — Multinational Renewable Energy Provider
Project Location
South Australia — Onshore Wind Farm
Project Overview
The client required a full internal inspection of wind turbine blades to evaluate structural integrity, detect early-stage damage, and prevent costly failures.
Traditional methods—such as rope access—posed safety risks, restricted access, and led to extended turbine downtime.
Our mission was to deliver a safer, faster, and more comprehensive inspection using advanced robotics and drone technology.
Scope of Work
- Conduct detailed visual and LiDAR inspections inside 60m+ blade structures.
- Capture high-resolution imagery, 3D maps, and defect analytics.
- Minimise turbine downtime and technician risk.
- Provide structured reporting for long-term asset lifecycle planning.
Technology Deployed
Nexxis Pipe Crawler (Modified for Blade Access)
- Dual side-mounted GoPro 360s + forward-facing 64MP camera.
- High-output Cree LED lighting system.
- Integrated Raspberry Pi control & Livox 3D LiDAR mapping.
- Remote operation from outside the blade structure.
Elios 3 Drone (Flyability)
- Supplementary mapping in tight blade curves.
- Real-time SLAM LiDAR mapping.
- Collision-tolerant carbon cage design.
- Dust-resistant lighting & payload for confined interiors.
Key Achievements
- 100% internal coverage across turbines — zero human entry.
- Complete 3D geometry mapping for structural modelling.
- Zero incidents, with data fully integrated into the GE Asset Management platform.
Deliverables
- 3D Blade Interior Point Cloud Models (Elios 3 LiDAR & Crawler LiDAR).
- Annotated HD imagery of all defects with timestamped metadata.
- Condition rating per blade — 1–5 scale with RAG status.
- Engineering-ready reports for maintenance planning.
