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Research Paper | Renewable and Sustainable Energy | Volume 15 Issue 6, June 2026 | Pages: 461 - 472 | India
Design and Development of a Robotic System for Wind Turbine Tower Bolts
Abstract: Ensuring structural integrity in utility?scale wind turbines requires consistent and reliable inspection of tower fastening systems. The proposed system is a fully automated mechatronic platform designed to perform intra?tower bolt inspection and retorquing without manual intervention. The device utilizes a multi?degree?of?freedom mechanical architecture mounted on a central rotary plate, ena-bling continuous 360? circumferential coverage within the confined tower passage. A cable?driven motor-pulley hoisting system pro-vides precise vertical positioning, while a rack?and?pinion?based stabilization flange firmly braces the device against the tower wall, eliminating sway and ensuring a rigid operational environment during tightening. The articulated arm assembly consisting of prima-ry, secondary, and tertiary arms-supports a torque?application end?effector capable of delivering controlled, repeatable tightening according to predefined torque setpoints. The ECU governs all subsystems under a deterministic, real?time control framework, se-quencing hoisting, stabilization, rotation, arm deployment, bolt alignment, and torque application in a tightly coordinated manner. Mechanical compliance elements integrated into the device help absorb vibration during operation, preventing misalignment and ensuring consistent tool?to?bolt engagement. The system?s modular three?plate structure allows individual plates, motors, and tools to be upgraded or serviced independently, improving long?term maintainability. By standardizing bolt?inspection and tightening proce-dures, the platform minimizes human involvement, shortens maintenance cycles, and ensures repeatable torque delivery across all tower segments. This automated architecture enhances operational continuity and ensures reliable, fleet?level bolt?maintenance quality with high repeatability and structural consistency.
Keywords: Automated Bolt Inspection, Wind Turbine Maintenance, Mechatronic Platform, 360 ° Rotary Coverage, Cable-Driven Hoisting System, Rack-and-Pinion Stabilization, Articulated Robotic Arm, Torque-Controlled Tightening, Real-Time ECU Control, Modular Structural Design
How to Cite?: Mrunal Vemuganti, G Yuvanesan, "Design and Development of a Robotic System for Wind Turbine Tower Bolts", Volume 15 Issue 6, June 2026, International Journal of Science and Research (IJSR), Pages: 461-472, https://www.ijsr.net/getabstract.php?paperid=SR26526121652, DOI: https://dx.dx.doi.org/10.21275/SR26526121652