Wind Turbine Blade Internal Inspection Robot HZBR-60Pro

Quick answer

The HZBR-60Pro Blade Internal Inspection Robot is a vacuum-adhesion wall-climbing robot that inspects the inside of wind turbine blades. Weighing 12 kg and climbing on 650 N of suction, it carries a 4K 10x zoom gimbal camera plus four 5 MP inspection cameras and uses an AI image platform to recognise cracks, wrinkles, whitening and delamination. It covers 70% of the blade interior, inspects a 95 m blade cavity in 60 minutes or less, and generates inspection reports automatically.

Technical Specifications

Parameter	Value
Dimensions	523 x 300 x 205 mm
Weight	12 kg
Travel speed	0.15 m/s
System power	400 W
Battery endurance	0.5 h
Operating temperature	-10 to 50 C
Gimbal camera	8 MP 4K, 10x optical zoom
Inspection cameras	5 MP x 4
Wall curvature	>= R75 cm
Communication	Wireless WiFi

Overview

Manual internal blade inspection means a technician crawling through a dark, confined composite shell with a torch and a camera, judging defects by eye and hoping the documentation is consistent. Coverage is patchy, results depend on who did the inspection, and every hour inside the blade is an hour of confined-space risk.

The HZBR-60Pro replaces that process with a repeatable robotic survey. The robot adheres to the blade's inner surface by vacuum, drives along the shell at 0.15 m/s, and streams 4K gimbal video to an operator at the blade root. An AI image-processing platform flags cracks, wrinkles, whitening and delamination in real time, and the system assembles an inspection report automatically. Operators can drive it manually or switch to automatic inspection, with 100 m wireless remote control and an integrated 100 m drag-chain power cable and safety rope.

How it works

Insert: the robot is placed inside the blade cavity through the root access hatch.
Climb: vacuum adhesion of at least 650 N holds it to the inner shell, on curvatures down to R75 cm.
Capture: a 4K 10x zoom gimbal camera plus four 5 MP cameras record the internal surface.
Recognise: the AI image platform identifies cracks, wrinkles, whitening and delamination.
Report: an inspection report is generated automatically, with defect position and classification.

Key features

Vacuum adhesion with suction force of at least 650 N
Covers 70% of the blade interior
AI recognition of cracks, wrinkles, whitening and delamination
Manual and automatic dual-mode inspection
95 m blade cavity inspected in 60 minutes or less
Wireless remote control with a communication range of at least 100 m
Integrated 100 m drag-chain power cable plus safety rope

Applications

Routine internal blade inspection

Scheduled 60-minute cavity surveys that replace manual crawls and produce consistent, comparable reports year over year.

Post-storm and lightning-strike assessment

Rapid internal assessment after a suspected strike or extreme gust event, without waiting for rope-access teams.

Blade warranty claims

Geotagged defect images and AI classifications provide the evidence package manufacturers require for warranty adjudication.

Offshore and remote sites

A 12 kg two-person-portable unit reduces vessel time and eliminates confined-space entry on offshore campaigns.

Frequently asked questions

What defects can the HZBR-60Pro detect inside a wind turbine blade?

The AI image-processing platform recognises cracks, wrinkles, whitening and delamination on the internal blade surface. These are the defect classes most commonly associated with structural blade failures and with bonding-line degradation at the shear web and spar cap.

How much of the blade interior can the robot inspect?

The robot covers approximately 70% of the blade interior. It cannot reach the extreme tip section, which is typically sealed or too narrow for the 523 x 300 x 205 mm chassis.

How long does it take to inspect one blade?

A 95 m blade cavity is inspected in 60 minutes or less. The robot travels at 0.15 m/s and can run in either manual or automatic mode.

How does the robot stay attached to the blade surface?

It uses vacuum adhesion generating at least 650 N of suction force, and can operate on internal wall curvatures of R75 cm or greater. An integrated 100 m drag-chain power cable and safety rope provide fall protection.

Is the robot suitable for offshore wind farms?

Yes. At 12 kg the unit is portable by two technicians, which matters when vessel or helicopter time is charged by the hour, and it removes the need for confined-space entry inside the blade.