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Drone based rotor blade inspections and lightning protection testing system
At TOPseven, a high tech company specializing in globally patented solutions for autonomous drone inspections, we have opened a new chapter in wind turbine inspection. With our advanced drone based blade inspection, including an innovative method for lightning protection system testing, we are setting new standards for operational efficiency and precision. In this article, we outline the key elements of the technology and explain how it is shaping the future of the wind energy industry.
Katja Weissbach
Head of Sales
Table of contents
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Drone based rotor blade inspection is transforming how wind turbines are maintained.
At TOPseven, a high tech company specializing in globally patented solutions for autonomous drone inspections, we have opened a new chapter in wind turbine inspection. With our advanced drone based blade inspection, including an innovative method for lightning protection system testing, we are setting new standards for operational efficiency and precision.
In this article, we outline the key elements of the technology and explain how it is shaping the future of the wind energy industry.
Hardware: DJI Matrice 350/400 and the TOPseven SIGHT 61 MP camera
Our approach is built on the integration of state of the art hardware. The DJI Matrice 350 RTK, known for its reliability and precision, serves as the backbone of our system. It is paired with our in house developed 61 MP TOPseven camera, enabling us to capture high resolution, highly detailed images of rotor blades.
This powerful combination delivers inspection grade visual data in real time and ensures that even the smallest irregularities and damages can be detected and documented with confidence.
Software: The backbone of the inspection workflow
Software is the foundation of our inspection process. We have developed a comprehensive web interface that allows customers to manage inspection tasks, reports, and statistics in one place.
The TOPseven platform provides seamless integration with our cloud storage solution, while TOPseven Inspector is used for mission planning, data analysis and report creation. Together, they form a unified evidence pipeline that turns raw imagery into structured, review ready results.
Calibration: Precise flight paths and consistent data capture
Drone calibration is automated using a model from our database. Photographs of the hub and blade tips, combined with photogrammetry, form the basis for highly accurate flight path calculations and ensure consistent, high precision data capture.
This enables autonomous flight execution without relying on a specialized pilot, while maintaining repeatability across turbines and campaigns.
Visual inspection: Enhanced by AI
Our visual inspections benefit from patented AI assisted camera alignment and exposure control. This ensures consistent image quality and supports accurate damage detection.
As our AI is trained on manual damage detection, marking, and categorization, the analysis becomes more reliable over time. The outcome is not just better images, but clearer findings that are easier to review, validate and act on.
Lightning protection: Precise localization of anomalies
Drone based lightning protection testing provides a decisive advantage: the exact localization of anomalies.
Our innovative method allows the entire rotor blade to be inspected quickly and thoroughly, with safety, reduced turbine downtime, and lower operational cost as the top priorities. Instead of slow, contact based procedures, the inspection can be completed efficiently while still delivering actionable technical insight.
Reporting: Clear analysis and complete documentation
Every inspection concludes with a detailed report containing comprehensive information about the condition of the rotor blades and the lightning protection system.
These findings are critical for maintenance planning and contribute directly to long term performance, safety, and availability of wind turbines. Most importantly, the report is built to be reviewed and defended, helping teams move from field work to desk ready evidence faster.
Conclusion
TOPseven’s drone based rotor blade inspection, including lightning protection system testing, represents the leading edge of innovation in the wind industry.
By combining advanced drones, precision sensing, and intelligent software, we are setting new standards for inspection accuracy and operational efficiency. Our mission is to help operators run wind turbines more safely and cost effectively, while extending asset lifetime and supporting long term reliability.
At TOPseven, we are proud to be at the forefront of this technological shift.
