Volume 8, Issue 9, September – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Innovative Approaches for Boosting Precision and
Productivity in Wind Tower Sand Blasting and
Painting System
Somil Nishar1*
1Engineering, Colorado State University Pueblo, 2200 Bonforte Blvd, Pueblo, 81001,
Colorado, United States.
Abstract:- In the realm of wind tower coating, the quest
for innovative solutions has led to the development of the
semicircular wind tower blasting and painting system.
This research paper explores the transformative potential
of this novel system in revolutionizing the traditional
approach to wind tower coating. Through a comparative
analysis with robotic arms, the paper highlights the
advantages of the semicircular system in terms of
efficiency, cost-effectiveness, and speed. The system,
specifically designed to match the cylindrical structure of
wind towers, utilizes automatic nozzles, precision spray
tools, and an integrated dust collection system to achieve
uniform application and enhance worker safety. This
approach not only extends the lifespan of wind towers but
also reinforces the fundamental strength of sustainable
energy. By reevaluating benchmarks for efficiency and
innovation in the field of automation, this research
contributes to the ongoing discourse on advancing wind
tower coating practices. As the wind energy industry
continues to grow, the combination of the semicircular
system and robotic arms holds promise as the ideal
solution for sand blasting and painting wind turbines,
driving the industry towards a more efficient and
sustainable future.
Keywords:- Wind Turbine Towers, Semicircular System,
Industrial Robot Painting, Efficiency and Cost Savings,
Automation Technologies.
I. INTRODUCTION
In the realm of automation, there’s an enduring belief
that intricate designs yield the most efficient outcomes. This
axiom has steered a considerable chunk of R&D funds
towards creating systems that, in their complexity, promise
unparalleled precision and productivity. Robotic arms,
especially, have emerged as a testament to this belief. Lauded
for their precision, especially in nuanced tasks like painting,
they’ve often been the go-to solution for industries
demanding meticulousness. However, as technological
horizons expand, there’s a burgeoning debate about whether
such intricate systems invariably ensure the best results.
Stepping into this discourse, our research spotlights the semi-
circular blaster system. While it may appear rudimentary the
system stands as an embodiment of innovation, cost-
efficiency and speed. By comparing the robotic arm’s
technical prowess with the simplicity and efficiency of the
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semi-circular system, this paper doesn’t merely present
empirical findings but also intertwines insights from
concurrent research endeavors thus offering a robust scaffold
for an in-depth analysis. As we navigate the evolving land-
scape of automation, it’s imperative to reassess and possibly
recalibrate our benchmarks for what truly constitutes
efficiency and innovation.
II. AIMS AND OBJECTIVES
In this research, I aim to critically assess and juxtapose
the efficiency of robotic arms and the semi-circular blaster
system within the automation domain, particularly in painting
applications. Initially, I will explore prevailing beliefs and
practices regarding robotic arms in precision-centric
industries, determining their main advantages and potential
drawbacks. Simultaneously, I intend to provide an in-depth
insight into the semi- circular blaster system, emphasizing its
design principles and the perceived benefits of its simplicity,
such as cost and speed efficiency. I will undertake an
empirical analysis, comparing real-world performances of
both systems, especially in nuanced tasks like painting.
Integrating findings from related current research, I will
further contextualize my results. Lastly, this study seeks to
reconsider and potentially reshape the conventional metrics of
efficiency and innovation in automation, while also offering
forward-looking recommendations for industries and
stakeholders venturing into automation technologies.
III. THE SEMICIRCULAR WIND TOWER
BLASTING AND PAINTING SYSTEM
The growth of the renewable energy industry has
increased the need for efficient production and maintenance
solutions, especially for wind towers. These towers are
essential for wind installations, which face extreme
environmental conditions and therefore require a durable and
stable protective coating. This paper introduces a semicircular
wind tower painting and sandblasting system to meet this
demand. This innovative system, de- signed to match the
cylindrical structure of the wind tower, allows for uniform
application through automatic nozzles, precision spray tools
and an integrated dust collection system. This approach offers
a number of benefits such as increased efficiency, improved
quality, cost savings, reduced environmental impact and
increased worker safety. Although the system is designed for
wind towers, it can also be used in the painting of other
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Volume 8, Issue 9, September – 2023 International Journal of Innovative Science and Research Technology
cylindrical structures. Therefore, this system not only
increases the life of the wind tower but also ensures
reinforcement of the fundamental strength of sustainable
energy and this promises a better future for the wind energy
industry (Airblast, 2020).
For example, while Jennifer Seward was working on a
project to improve the efficiency of blasting and painting of
wind towers, the idea of using ROBOT TABLETOP with its
ingenious edge detection sparked a new perspective. The
round shape of the wind towers and their relatively simple
design are eye-opening. The new perspective revealed that
there may be a more efficient alternative to complex robotic
arms and that is through using a semicircular multi-jet system
which involves a robot managing single tower section while
multiple sprayers are used for different sections and this
would speed up the process. The approach therefore
challenges the use of conventional robotic arms, which are
better suited for complex tasks and designs. This comparison
has similarities to NASA and ISRO, where achieving the
same results more efficiently and at a lower cost becomes the
primary focus. Therefore, choosing a more efficient and cost-
effective semicircular system may be the optimal choice
instead of a robotic arm for simple designs such as wind
towers (Seward, 2023).
IV. PRINCIPLES AND MECHANISM OF THE
SEMI-CIRCULAR BLASTER SYSTEM
The semicircular blaster system is a testament to the
age-old adage that simplicity of- ten trumps complexity. This
can be juxtaposed with conventional robotic arms which can
sometimes be prone to trouble in operation due to the sheer
complexity of their design. At a basic level semicircular
blower system are based on simple design principles. First,
instead of relying on multifaceted mechanical movements it
uses a semicircular layout where the setup involves placing
the sprayer at evenly spaced points along the curve ensuring
that each part has its own designated area to cover. This
geometric configuration is critical in achieving one of the
system’s key benefits of broad and consistent cover- age
(Ghazavi and Papini, 2019). This aspect becomes even more
evident in industrial tasks such as painting, where quality
often depends on achieving a consistent finish, with- out
overlaps or gaps. Another ingenious aspect of the semi-
circular blower system is its inherent rotation. Instead of
having to adjust multiple parts to fit different angles or con-
tours of the target surface, the system’s semi-circular swivel
design allows it to simply rotate. This means that whether the
surface is flat, angled or even slightly curved, the sprayer or
sprayer can be controlled to maintain the optimal application
angle. The result is a seamless and unified application,
regardless of the target’s diverse terrain (Ghazavi and Papini,
2019). Below is a cross-sectional view of the system as in
figure 1.0.
The semicircular paint spraying system, has made
waves in the paint industry. How- ever, simply classifying it
as a painting tool would be an understatement of its
versatility. While its effectiveness in painting is undeniable,
the system’s broader applications are equally compelling. For
IJISRT23SEP1737 www.ijisrt.com
ISSN No:-2456-2165
example, cleaning jobs, especially in industrial environments,
often require the removal of stubborn residues from large
areas. The semi-circular system, with extended coverage, can
facilitate faster and more effective cleaning. Sandblasting,
another industrial process in which surface material is
meticulously cleaned or smoothed by spraying sand particles,
is expected to yield enormous benefits from continuous
spraying operations, over a wide range of systems (Ghazavi
and Papini, 2019).
In manufacturing scenarios, uniformity is often the
deciding factor in product quality. Whether applying
protective coatings, adhesives or even decorative finishes, the
consistency provided by a semicircle system can be
invaluable. Its wide range ensures that products flow through
the assembly line with uniform handling methods,
minimizing errors and maximizing production efficiency. A
notable feature of the semicircular blaster system is its
adaptability. Different processes require different spray
density, particle size and material viscosity. The system’s
compatibility with a wide range of nozzles means it can be
tailored to the specific needs of each task. Whether it’s the
fine mist needed to create a delicate finish or the more
powerful spray for intense cleaning, the system can be
modified as needed. This adaptability, combined with stable
performance, makes it a versatile asset across a variety of
industries (Ghazavi and Papini, 2019).
Fig 1: Versatility of the Semi-Circular Blaster System
When comparing this system, to the robot arm in
painting, let’s take a situation where a robot arm takes 30
minutes to paint 50 square meters and the semicircular
system with 5 sprayers can paint the same area within 6 mins
and there its 5 times faster as shown below:
 Robot Arm:
Time taken to paint 50 square meters = 30 minutes
Semicircular System with 5 Sprayers:
Time taken to paint 50 square meters = 6 minutes (30/5).
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Volume 8, Issue 9, September – 2023 International Journal of Innovative Science and Research Technology
Therefore, using the semicircular system with 5 sprayers
would take 6 minutes to paint 50 square meters and this
maximizes efficiency and reduce painting time in generally.
V. ROBOTIC ARM FOR PAINTING
Over the years, wind turbines have become an essential
part of the global transition to renewable energy and since
these massive structures are exposed to extreme environ-
mental conditions, their protective coating must be flawless
and capable of holding the harshness. This has triggered
innovations when it comes to painting the wind turbines and
the use of robotic arms demonstrates the industry’s
commitment to efficiency, safety and sustainability. As the
demand for wind energy increases gradually, the integration
of advanced technologies such as robotic arms ensure the
infrastructure is not only energy- sustainable but also
enhanced maintenance and life-span of the turbines.
Therefore, it is only a matter of time before automation
solutions become the industry standard to serve these
renewable energy giants considering technology continues to
advance (Room, 2023).
Fig 2: Semicircular Wind Tower Blasting and Painting
System
Fig 3: Robot Painting for Wind Tower [Source: (Room,
2023)]
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ISSN No:-2456-2165
For example, the article “Industrial Painting with
Robots” examines the growing importance of industrial
painting robots in manufacturing and painting. Emphasizing
the pursuit of perfection, these robots consistently achieve
outstanding finishes, while ensuring profitability and
environmental responsibility. They represent a combination of
art and science in the field of industrial coatings. The
development of robotic coating technology is not limited to
major OEMs but even smaller industries are exploiting these
robots due to the demand for quality, efficiency and cost
reduction. The paper challenges the assumption that more
complex processes necessarily produce superior results,
highlighting the application of robots in industries as diverse
as automobiles, such as consumer electronics, medical
devices and aeronautical technology. These robots not only
provide adaptability and precision, but thanks to an integrated
system, they provide real-time monitoring and traceability,
ensuring optimal performance. As technological
advancements continue, the horizon for robotic coating
technology is widening, promising transformations not only
in traditional industries but also in advanced areas such as
additive manufacturing. Essentially, the article highlights the
pivotal role these robotic marvels play in revolutionizing the
coatings industry, improving efficiency, and pursuing the
ultimate goal of perfection (Anandan, 2013)
According to another study, "Design and manufacture of
robotic arm for spray painting application with 5 DOF", it is
clear that the robot arm is perfect and easy to manage and
operate. The main objective of the work has been achieved
and the particular arm un- der consideration can accommodate
a spray gun with a payload of 500g and even meet the demand
for applications such as paint spraying. The research tried to
cover all aspects of structural design and analysis in their
work, but there is still great opportunity for machine
improvement and thus the arm can be further developed by
using the best technology, perfectly designed and made to
order for people with disabilities in their work (Aniket et al.,
2021).
VI. CONCLUSION
In conclusion, the research conducted sheds light on the
innovative solution of wind tower coating through the
implementation of the semicircular wind tower blasting and
painting system. Through a thorough evaluation and
comparison with robotic arms, it is evident that the
semicircular system offers several advantages and
transformative potential in the field of wind tower coating.
The semicircular system, specifically designed to match the
cylindrical structure of wind towers, provides consistent
coverage with minimal human intervention, ensuring
efficiency, cost-effectiveness, and worker safety. The
system’s automatic nozzles, precision spray tools, and
integrated dust collection system contribute to uniform
coating application, reduced coating time, and improved
quality. Moreover, by extending the lifespan of wind towers,
it reinforces the efficiency and sustainability of the wind
energy industry.
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Volume 8, Issue 9, September – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
While the initial investment in the semicircular system Overall, the semicircular system stands as an innovative
may be higher compared to robotic arms, its long-term solution that has the potential to transform wind tower coating
benefits and effectiveness make it a promising solution for practices, providing significant benefits to the industry and
wind tower coating. On the other hand, robotic arms reinforcing the fundamental strength of sustainable energy.
demonstrate flexibility, precision, and adaptability, but may
be better suited for complex tasks and designs. The choice REFERENCES
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AUTHOR BIOGRAPHY

Somil Nishar I am a Lead Automation Engineer at Quality Design Services, Inc. (QDS), a company
that provides customized automation solutions for various industries. I have more than 7+ years of
experience industrial and automation engineering, with a focus on designing, leading, and innovating
projects that increase efficiency, quality, and productivity. I have a Master of Science in Engineering
specialized in Mechatronics, Robotics and Automation from Colorado State University Pueblo.

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