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Wind Turbine Repair Robot

Project description

Robots repair wind turbines safely and cheaply

Wind turbines are usually placed in areas with sustained winds to maximise the output of electrical energy. Repair works are currently carried out by specially trained rope technicians only in very good weather conditions. The EU-funded project WindTRRo is developing the first robot as proof of concept that takes over this cost- and labour-intensive job. This robot should be able to handle maintenance and repair of wind turbine blades reliably in all-weather conditions. In addition to increased safety benefits, the unique robotic repair solution will significantly reduce the time and costs required for gaining access to the blades.


Wind turbines are placed in high wind areas, and repairs can only be done at low wind speed, low humidity, low wave height and with no risk of lightning, leaving only 25% of the days in the repair season. Altogether, a typical manual repair costs €32,000, and is done by Rope Access Technicians hanging in ropes from the nacelle of the wind turbine.

Rope Robotics has invented and patented the world’s first robot for performing all the phases of wind turbine blade leading edge maintenance and repair fast and reliably without having people performing hazard task from ropes. The robot is able to do:
• Surface area inspection and documentation
• Sanding, grinding and filling
• Coating
• After repair inspection and documentation
All this is done while the robot attaches itself to the blade with vacuum, and it is done faster and with less requirements to more than doubling the available working days to 54%. A standard repair including inspection costs only €7,000.

EU intends to double the wind capacity by 2030 to reduce CO2 emissions. The global wind energy O&M market is expected to grow to €19bn by 2025 and the aging fleet in Europe represents the majority of this revenue opportunity. Leading edge repair represents approx. 50% of the repair market and is estimated to be €483m by MAKE Consulting.
Rope Robotics expects a turnover on sales of robots of €60m by 2022 and an explosive growth in the following years. Customers are producers such as Siemens Gamesa and Vestas, wind farm owners such as Vattenfall and Ørsted, and service providers as Totalwind.

A series of 6 robots will be prepared and integrated with tools and remote control to demonstrate to two key customers, Siemens Gamesa and Vestas, that the robots deliver as promised. A customer deployment program on commercial terms with a fleet of 25 robots will be developed to gain market acceptance with additional wind turbine owners.

Call for proposal


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Net EU contribution
€ 2 196 022,50
8230 Abyhoj

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The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.

Danmark Midtjylland Østjylland
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Total cost
€ 3 221 982,50