BladeBUG

BladeBUG Limited is a UK-based technology company that develops advanced robots for the inspection, maintenance, and repair of wind turbine blades without requiring rope access. The company was founded in 2014 by Chris Cieslak, a chartered mechanical and composites materials engineer with extensive experience in wind turbine blade design. Cieslak identified a market gap for a proactive, robotic solution to maintain blades once they are operational, aiming to prevent minor defects from escalating into larger, more expensive problems.

The company's core product is a six-legged, insect-like crawling robot that uses a vacuum adhesion system to walk directly on the curved surfaces of turbine blades. This platform is designed to be modular, capable of carrying various tool payloads for different tasks. Its capabilities include detailed visual inspections, non-destructive testing (NDT) such as subsurface ultrasonic scans, lightning protection system checks, and repairs like resurfacing damaged areas. The robot can be operated remotely by technicians from a safe location, reducing the significant health and safety risks associated with traditional rope access methods, especially in harsh offshore environments.

BladeBUG has engaged in multiple collaborative projects, often funded by Innovate UK, and has worked closely with partners like the Offshore Renewable Energy (ORE) Catapult, Imperial College London, and FORCE Technology. A significant milestone was achieved in November 2020 when the robot performed the world's first blade walk on an offshore wind turbine. Subsequent tests have demonstrated its ability to reduce deployment time by up to 50% compared to human technicians and to perform tasks beyond the visual line of sight. The business model is centered on providing the robot as a tool to the industry, including training for operators, rather than solely acting as a service provider. The company serves wind farm operators and owners, aiming to increase asset lifetime, improve operational efficiency, and lower overall maintenance costs for both onshore and offshore turbines.

Keywords: wind turbine maintenance, robotic inspection, blade repair, offshore wind, non-destructive testing, NDT, robotics, renewable energy, asset management, composite materials, crawler robot, rope access alternative, preventative maintenance, remote operations, lightning protection systems, leading-edge erosion, O&M, wind energy technology, clean tech, automation