company
engineering firm
industry
Energy production (wind power)
country
Not specified
cost savings
50% (8 hours → 4 hours per tower)
Why does the company use inspection drones?
Our customer faced significant challenges when inspecting bolts on platforms and lift structures inside wind turbine towers. Traditional methods were laborious and dangerous.
Previously, inspectors had to climb each tower manually, which was not only physically demanding but also slowed down the entire process. The goal was to find a faster method that would eliminate the risk to personnel while increasing efficiency so that more facilities could be inspected in less time.
challenges
Manual climbing inspections:
A time-consuming process that slowed down operations and required considerable physical effort.
High safety risks:
Working at great heights and in confined, enclosed spaces posed a constant risk of falling and injury.
High personnel costs:
Traditional projects required up to 10 inspectors to maintain the maintenance intervals.
High costs:
At approximately $15,000 per tower, conventional inspections were very costly.
What is the solution with ASIO X?
The company used the ASIO X inspection drone to safely and efficiently inspect screw connections from the air.
Efficient inspection process
The drone navigates quickly through the tower sections and systematically checks bolts and structures. This halved the total inspection time from 8 hours to just 4 hours per tower.
Long flight times for complex towers
With a flight time of up to 24 minutes, ASIO was able to inspect the required sections (longest flight: 19 min.) in one go without time-consuming interruptions for battery changes.
Safety through technology
Since the drone takes over the work at height, technicians no longer have to climb the tower. The number of people at risk fell from 10 to just one operator on the ground.
Precision through 4K & lighting
High-resolution videos and the powerful lighting system make it possible to reliably identify even the smallest signs of wear on the bolts.
Why the ASIO X was suitable for this application
Long flight time
24 minutes of flight time enable complete inspections without frequent battery changes.
Precise navigation
The ASIO X moves safely through complex tower structures and can even reach hard-to-access areas.
single-person operation
Reduction from 10 inspectors to 1 operator – significantly lower personnel costs and coordination requirements.
Instant data visualization
With ASIO Explore, inspection data can be evaluated directly on site, enabling quick decisions and response times.
results
50% faster inspections
The inspection time per tower was reduced from 8 hours to 4 hours.
50% cost savings
Inspection costs fell from $15,000 to $7,500 per tower—a saving of $7,500 per tower.
Drastically increased security
The number of inspectors working at dangerous heights fell from 10 to 1 operator on the ground. The risk of accidents was massively reduced.
Improved data accuracy
High-resolution images enable the detection of even the smallest signs of wear and tear and more precise maintenance planning.
Optimized use of resources
The reduced personnel costs enabled a more effective distribution of the workforce and optimized project processes.
Experience ASIO X in action
Book a drone demonstration
Integration of drones into industrial inspection processes
The example from the wind power industry shows that the use of inspection drones enables significant gains in efficiency and safety. The elimination of dangerous work at height, shorter inspection times, and precise digital data collection are decisive factors.
