Prime Engineering continues to break boundaries in the engineering field, offering innovative solutions across industries. In this case study, we explore an exciting collaboration focused on robotic innovation in wind turbine inspection.

Renewable energy is becoming increasingly central to achieving sustainability goals, which is why maintenance and inspection technologies are essential. Companies such as Prime Engineering and TSR Wind are driving safer, more efficient, and more reliable solutions for the wind energy sector. This collaboration showcases how strategic partnerships can overcome complex challenges, setting new standards for operational excellence in renewable energy infrastructure.

 

Project Overview: Robotic solutions for turbine maintenance

Partnering with an innovative engineering company

Our client, TSR Wind, provides advanced specialised maintenance solutions for the wind energy sector. With a strong commitment to enhancing safety and efficiency, they develop cutting-edge robotic technologies that optimise maintenance processes for wind turbines. They are well-known for their proprietary technologies, such as Eolos for external blade inspection, Cerberus for internal blade inspection, and Kratos for ultrasonic weld inspection.

To meet the demands of modern wind turbine maintenance, TSR Wind is developing four types of high-capacity robots. These robots are designed to conduct rigorous and detailed inspections of wind turbine towers, significantly enhancing productivity and safety. Among these, the main project where Prime Engineering is involved focuses on creating a robot that uses ultrasonic technology to detect potential cracks in turbine towers. This innovation aims to prevent structural issues and boost the overall efficiency of wind turbine maintenance.

 

The Challenge: Overcoming inspection obstacles

The project presented unique challenges, primarily ensuring that the robot’s magnets functioned flawlessly while navigating the wind turbine towers. Another critical aspect was guaranteeing the ultrasonic system’s accuracy and reliability during inspections.

Additionally, transitioning from magnetic-based inspection methods to a fully automated robotic solution required overcoming significant engineering and logistical hurdles.

Previously, inspections relied on magnetic systems to climb and descend turbine towers, but these methods proved less effective. With the collaboration of Prime Engineering, TSR Wind successfully built one of these robots, which is currently operating in Australia. The robot performs accurate inspections, ensuring a reliable process and paving the way for project success in other countries where TSR Wind operates.

The project focuses on developing a prototype robot capable of conducting precise weld inspections on wind turbine towers using ultrasonic technology. The initiative represents an important step towards improving the reliability and safety of these structures.

 

Our Solution: Engineering excellence in robotic development

Prime Engineering has been an integral part of the project since its inception in January 2024. Currently in the production phase, the project aims to deliver a fully functional solution by December 2025. This collaboration exemplifies our expertise in Team Extension, where we provide dedicated professionals to enhance the client’s capabilities.

Our two consultants are working alongside a total project team of seven specialists, focusing on hardware design, PCB optimisation, and wiring/routing the robot’s components. One of them works in electronic engineering, designing PCBs using Altium to ensure the robot’s systems receive and process signals accurately. The other consultant specialises in electromechanical engineering, assembling and installing all components of the robot to guarantee optimal performance.

Prime Engineering’s team brought a wealth of experience in electronic and technical engineering to this project. Using tools like Altium and KiCad, our consultants prioritised hardware design, optimising PCB layouts, and perfecting the cabling and routing of the robot’s components. Through this expertise, the first robot was successfully deployed and is already making a measurable impact in real-world conditions.

 

Why choose Prime Engineering for your engineering projects?

At Prime Engineering, we are committed to delivering tailored engineering solutions that align with our partners’ goals. Through our Team Extension service, we provide highly skilled professionals equipped with the tools and expertise to make a difference.

In addition to our contributions in robotics and hardware design, we support clients across industries with a range of services, including Managed Services, Custom Software, and Nearshore development.

Let’s collaborate and create? Share your vision with us and let’s make it a reality. To making happen, contact us to explore how we can support your next project!