Development of a Robotic System for Wind Turbine Tower Bolt Inspection and Maintenance

Mrunal Vemuganti, Shaik Mahaboob Abdul Rehman

Abstract: Manual inspection and tightening of tower section studs with nuts in wind turbines is a labour-intensive and high-risk task, often performed at significant heights under challenging environmental conditions. This process not only consumes considerable amounts of time but also exposes technicians to potential safety hazards. To address these challenges, a Robotic Tower Bolt Inspection and Tightening is proposed. This system is designed to autonomously navigate to the interface of tower sections, identify and assess the tightness of section bolts using integrated torque sensors and vision-based inspection modules, and perform corrective tightening where necessary. Equipped with advanced mobility mechanisms, the robot can operate in vertical and confined spaces, ensuring comprehensive coverage of all the bolt locations. Real-time data acquisition and wireless communication enable remote monitoring and control, reducing the need for human intervention. The system enhances operational safety, improves maintenance efficiency, and ensures consistent bolt tensioning, which is critical for the structural integrity and longevity of wind turbines. This paper presents the design, functionality, and advantages of the robotic system, maintenance practices in the wind energy sector through automation, and intelligent inspection.

Keywords: Robotic inspection, Bolt tightening, Torque sensors, Vision-based inspection, Autonomous navigation, Real-time data acquisition, Wireless communication, Advanced mobility mechanisms, Vertical and confined space operation, Remote monitoring and control

How to Cite?: Mrunal Vemuganti, Shaik Mahaboob Abdul Rehman, "Development of a Robotic System for Wind Turbine Tower Bolt Inspection and Maintenance", Volume 14 Issue 10, October 2025, International Journal of Science and Research (IJSR), Pages: 319-326, https://www.ijsr.net/getabstract.php?paperid=SR25923152556, DOI: https://dx.doi.org/10.21275/SR25923152556