A UAV-Mounted Sensor Network for Close-Range Inspection of Wind Turbine Rotor Blades
Authors: Jost Wittmann, Ahmed Abdullahi Hassan, Nils Kömpe, Andreas Nüchter
Abstract
Inspection of offshore wind turbine rotor blades is critical for predictive maintenance to maximise efficiency and extend operational lifetime. However, it remains a challenging task due to remote locations, large structural dimensions, and the limitations of current UAV-compatible sensor systems. While existing approaches can detect certain types of surface anomalies, reliable classification of defect types often remains a manual and error-prone process. This paper presents the design of a UAV-mounted multimodal sensor network combining an industrial RGB camera, a passive thermal infrared camera, and an in-house developed 3D scanner. All sensors are co-calibrated into a common coordinate frame, enabling spatial superimposition of geometric, colour, and thermal data. The system is designed to operate at close range, addressing three fundamental sensing challenges: platform motion, large field of view, and millimetre-level measurement accuracy. Preliminary laboratory results demonstrate synchronised multi-sensor acquisition and initial point cloud reconstructions, forming the basis for future airborne inspection trials.
Wind turbine blade defect detection remains highly challenging in real-world inspection scenarios due to limited on-site data and the subtle visual characteristics of defects. In practice, blade defects are often small-scale, low-contrast, and difficult to distinguish from complex backgrounds, which significantly limits the robustness of existing detectors. To address these challenges, we propose BladeYOLO, a defect detection framework for wind turbine blades. Specifically, we integrate a Vision Transformer (ViT) backbone initialized with DINOv3 self-supervised pre-trained weights into YOLOv12-L, enabling the transfer of large-scale generic visual priors to blade defect detection and improving feature representation under limited training annotations. To enhance the perception of subtle defects, we further develop a Mamba-guided Weak-Defect Enhancement module, which consists of a Detail-Enhanced Multi-scale Branch for preserving high-frequency structural cues and a Cross-Mamba module for progressively propagating high-level semantic guidance to shallow features. In addition, we introduce a lightweight Style-Injector module that captures environment-related style information via Fourier decomposition and injects it into selected ViT self-attention layers, thereby improving robustness against environment-induced appearance variations. Extensive experiments demonstrate that BladeYOLO achieves superior performance on the WTBlade-Defect dataset, with additional annotation-budget experiments showing its favorable performance under reduced training annotations. Evaluation on the public Wind Surface Defect dataset further provides supportive evidence for the cross-dataset robustness of BladeYOLO. In particular, on this public dataset, BladeYOLO outperforms the best competing method by 3.5% in mAP50 and 2.5% in mAP50−95.
The proliferation of unmanned aerial vehicles (UAVs) has created urgent demand for precise UAV monitoring. Existing RGB-based systems rely on spatial cues that degrade at small scales, particularly with high inter-type similarity, target-clutter ambiguity, and low contrast. Multispectral imaging (MSI) encodes material-aware spectral signatures, yet MSI-based fine-grained small-UAV detection remains underexplored due to lack of dedicated datasets. We introduce UAVNet-MS, the first multispectral dataset for fine-grained small-UAV detection, comprising 15,618 temporally synchronized RGB-MSI data cubes (1440x1080) with bounding box annotations. The dataset features challenging small objects (93.7% <= 32^2 pixels, average 18^2 pixels, ~0.02% image area) under low contrast. We propose MFDNet, a dual-stream baseline addressing array-induced parallax and spatial-spectral fusion. Extensive evaluation under RGB-only, MSI-only, and RGB+MSI protocols against 20 detectors shows MFDNet achieves +6.2% AP50 improvement over best RGB-only methods, demonstrating spectral cues provide complementary material evidence beyond spatial cues. This work provides foundational dataset, strong baseline, and benchmark for multispectral UAV monitoring research.
Close-proximity offshore wind turbine inspection requires strict clearance control around large cylindrical structures under wind and model mismatch. Nominal Nonlinear Model Predictive Control (NMPC) may violate safety constraints when mass, inertia, thrust effectiveness, drag, or wind conditions differ from nominal assumptions. We propose a sensitivity-based robust NMPC for a tilted multirotor that robustifies the tower-clearance constraint via online constraint tightening. First-order parametric state sensitivities provide a structured-uncertainty margin, while bounded gusts are handled by a stage-dependent additive margin. The formulation augments the nominal NMPC with sensitivity propagation and margin evaluation only, leaving the receding-horizon optimization structure unchanged. Monte-Carlo evaluation over 500 uncertainty realizations on a boundary-critical helical inspection trajectory shows that the proposed controller eliminates the clearance violations observed under nominal NMPC at the cost of a moderate increase in solve time.