ThermoFly

The goal of this collaborative research project is to develop a drone-based inspection system capable of automatically performing simultaneous 3D reconstruction and detecting both depth and surface defects in wind turbines by combining different optical sensing technologies, namely active thermography and laser measurement systems. The measurement setup consists of a lighting unit that directs energy onto the surface under investigation and an infrared camera that captures the thermal response of the object’s boundary layer. In this way, active thermography enables the detection of subsurface damage from short distances and at a significantly higher resolution than passive ground-based systems. The use of a tethered flight system ensures a direct energy supply during the measurement, thereby reducing the total inspection time. Through experimental investigations and a physical simulation of thermal propagation, the measurement uncertainty in defect localization and the sensitivity of defect classification will be examined and evaluated. The airworthy demonstrator and the validation of active thermography provide the foundation for commercial deployment by the industrial partners. The airborne measurement system offers advantages over existing solutions and services for the technical inspection and maintenance of wind turbines. To ensure efficient transfer to industry, key partners from across the entire value chain are already involved in the project.