Crane and method for erecting a tower

Abstract

The present disclosure relates to a crane (200) for erecting a tower comprising a plurality of tower segments (171, 72, 173, 174, 175), the crane (200) comprising: a telescopic mast (210) and a boom (230) rotatably mounted relative to the telescopic mast (210) and comprising lifting equipment (240). The telescopic mast (210) comprises a lower mast segment (211) having one or more lower clamping assemblies (202, 204) for selectively clamping a part of the tower; and a roller assembly (300) for rolling along the tower and comprising one or more additional mast segments (212, 213, 214, 215, 216) having upper clamping assemblies (206) for selectively clamping a part of the tower, the additional mast segments (212, 213, 214, 215, 216) being slidable relative to the lower mast segment (211). The present disclosure also relates to a method for climbing a tower using the crane (200) and a method for installing a wind turbine tower.

Description

Technical Field

[0001] The present disclosure relates to a crane for erecting a tower including a plurality of tower segments. And in particular, the present disclosure relates to a crane for erecting a wind turbine tower. The present disclosure further relates to a method for climbing a crane on a tower and a method for erecting a wind turbine tower. Background Art

[0002] Modern wind turbines are typically used to supply electricity to the power grid. This type of wind turbine generally includes a tower and a rotor disposed on the tower. The rotor, which typically includes a hub and a plurality of blades, begins to rotate under the influence of the wind on the blades. The rotation generates torque, which is typically transmitted directly or through a gearbox to a generator via a rotor shaft. In this way, the generator generates electricity that can be supplied to the power grid.

[0003] Known methods for installing a wind turbine include the step of transporting different components to the site of the wind turbine. The wind turbine tower typically includes a plurality of tower segments that are installed or stacked on top of each other. The tower segments can be connected to each other at tower flanges.

[0004] A large crane can be used to lift subsequent tower segments and stack them on top of each other. After assembling the tower segments, the same large crane can be used to lift the wind turbine nacelle and install it on top of the tower. Then, the crane can be used to lift the wind turbine rotor hub and install it on the rotor shaft and / or the nacelle.

[0005] In addition, one or more blades are installed on the wind turbine rotor hub. The rotor hub generally includes a plurality of annular mounting flanges having openings. The blades can include a plurality of fasteners, such as bolts, pins or studs, at their blade roots. During installation, these fasteners should be fitted into the openings in the mounting flanges.

[0006] It is also known to lift a complete rotor assembly (i.e., a hub with a plurality of blades) and install it on, for example, a nacelle. However, in order to install a complete rotor assembly, a large surface area is required, which is typically not achievable in the case of an offshore wind turbine, for example.

[0007] It is also known to install an incomplete rotor assembly on a nacelle, such as a hub with two blades, and then install the remaining blades. In these cases, the rotor with two blades is typically installed in a manner such that the two blades point upwards (i.e., the "rabbit ears" configuration). Since the third blade can be installed vertically from below, there is no need to rotate the wind turbine rotor. However, in order to be able to perform these operations, the main wind speed must be below a predetermined value for an extended period of time. This period of time depends on the expected length of the installation steps and the safety factor to be considered.

[0008] It is also known to mount each of the plurality of blades in a substantially horizontal orientation or a substantially vertical orientation. This means that the individual installation steps may take less time and can be performed in stronger winds, thus increasing the time window available for installation.

[0009] Typically, in order to mount a blade to a wind turbine hub, a large crane previously used for installing, for example, a tower, nacelle, and rotor hub can be operated to lift the blade relative to the rotor hub. Unfortunately, operating such a large crane is expensive. In fact, the cost of using such a large crane currently represents a significant portion of the overall cost associated with wind turbine installation. For offshore applications, special vessels capable of carrying the large crane are required. [[ID=***]] [[ID=***]]

[0010] There is a clear trend in the art towards increasing the size of wind turbines. Wind turbine towers are being built taller and blades are becoming longer. For example, current tower designs have heights exceeding 80m, 100m, and even over 120 meters. The weights and sizes of wind turbine components such as blades, nacelles, and rotor hubs are increasing. [[ID=***]] [[ID=***]]

[0011] In order to mount tower segments on top of each other and then lift the nacelle, etc., increasingly large cranes are required. In addition, larger counterweights are needed for these large cranes. [[ID=***]] [[ID=***]]

[0012] There are many disadvantages associated with the use of large cranes. The platform or pad for the crane increases with the size of the crane. The transportation of crane components becomes increasingly complex and expensive. And large cranes are also more sensitive to wind loads. [[ID=***]] [[ID=***]]

[0013] Taking these disadvantages into account, self - lifting or self - climbing cranes have been proposed. Such self - climbing cranes offer several potential advantages, such as including easier transportation of the crane and, regardless of the height of the tower, there is no need to increase the length of the crane. The lifting structure attached to the tower will also be less sensitive to wind loads. Moreover, when using such self - lifting or climbing cranes, the surface area required for installation remains substantially constant, regardless of the height of the tower. [[ID=***]] [[ID=***]]

[0014] WO 2018 / 132010 discloses a method for erecting a vertical structure, particularly a part of a windmill, onshore or offshore. In this prior art document, each of the tower segments carries guiding means depicted as tracks along which a crane can be guided. [[ID=***]] [[ID=***]]

[0015] US2018 / 0282314 discloses a hoisting system for installing a wind turbine, wherein the hoisting system includes means for achieving a load-bearing connection to the wind turbine tower and means for moving the hoisting system up and down along the tower, and wherein the hoisting system is arranged to install or remove any one of the tower segments, nacelle, generator, hub, and blades in one or more combined hoists or in a single hoist when it is fixed to the already installed part of the wind turbine tower by the load-bearing connection.

[0016] Examples of the present disclosure provide methods and systems for erecting a tower (and particularly a wind turbine tower) that have reduced complexity and / or require fewer modifications to the tower structure. Examples provide methods and systems for erecting a wind turbine. Summary of the Invention

[0017] Technical Solution 1. A crane for erecting a tower including a plurality of tower segments, the crane comprising: a telescopic mast configured to vary at least between a retracted state and an extended state, and

[0018] a boom rotatably mounted relative to the telescopic mast and including lifting equipment, wherein

[0019] the telescopic mast includes

[0020] a lower mast segment having one or more lower clamp assemblies for selectively gripping a portion of the tower; and a roller assembly for rolling along the tower; and

[0021] one or more additional mast segments having upper clamp assemblies for selectively gripping a portion of the tower, the additional mast segments being slidable relative to the lower mast segment.

[0022] Technical Solution 2. The crane according to Technical Solution 1, wherein the telescopic mast is configured to vary between a retracted state and one or more extended states, and wherein the telescopic mast is configured to climb the tower by selectively releasing the upper clamp assembly or the lower clamp assembly and varying between the retracted state and the extended state.

[0023] Technical Solution 3. The crane according to Technical Solution 1 or 2, wherein the additional mast segments include an upper mast segment and one or more intermediate segments.

[0024] Technical Solution 4. The crane according to Technical Solution 3, wherein the upper mast segment includes the upper clamp assembly, and optionally wherein the upper clamp assembly is disposed at or near the upper end of the upper mast segment.

[0025] Technical solution 5. The crane according to any one of technical solutions 1 to 4, wherein one or more of the lower clamp assembly and the upper clamp assembly include

[0026] a first arm, which includes a first clamp disposed at the distal end of the first arm, and

[0027] a second arm, which includes a second clamp disposed at the distal end of the second arm, and optionally wherein the first arm and the second arm are telescopic arms.

[0028] Technical solution 6. The crane according to technical solution 5, wherein one or more of the lower clamp assembly and the upper clamp assembly are configured to change the distance between the first arm and the second arm.

[0029] Technical solution 7. The crane according to any one of technical solutions 1 to 6, wherein one or more of the lower clamp assemblies include an intermediate clamp assembly and a bottom clamp assembly for selectively gripping a part of the tower.

[0030] Technical solution 8. The crane according to any one of technical solutions 1 to 7, wherein the roller assembly includes a first roller arm and a second roller arm, the first roller arm includes a first set of wheels disposed at the distal end of the first roller arm, the second roller arm includes a second set of wheels disposed at the distal end of the second roller arm, and optionally wherein the first roller arm and the second roller arm are telescopic.

[0031] Technical solution 9. The crane according to technical solution 8, wherein the first set of wheels includes a first wheel support, wherein the first wheel support is capable of rotating relative to the first roller arm about a substantially vertical axis.

[0032] Technical solution 10. The crane according to technical solution 9, wherein the first wheel support is capable of rotating relative to the first roller arm about a substantially horizontal transverse axis.

[0033] Technical solution 11. The crane according to technical solution 9 or 10, wherein the roller assembly further includes: an upper bracket for carrying an upper set of wheels; and a lower bracket for carrying a lower set of wheels, wherein

[0034] the upper bracket and the lower bracket are mounted on the first wheel support, and optionally wherein

[0035] the upper bracket and the lower bracket are rotatably mounted relative to the first wheel support.

[0036] Technical solution 12. A method for climbing a tower using a crane, comprising:

[0037] Position the first tower section;

[0038] Attach a crane with a telescopic mast to the first tower section via a lower clamp assembly that grips a sole plate on the outer side of the first tower section;

[0039] Stack one or more additional tower sections on top of the first tower section;

[0040] An upper clamp assembly of the telescopic mast grips a sole plate on the outer side of one of the additional tower sections;

[0041] Release the lower clamp assembly; and

[0042] Retract the telescopic mast from at least a partially extended state, whereby roller assemblies of a lower mast section roll along the outer side of the first tower section.

[0043] Technical solution 13. The method according to technical solution 12, characterized in that the method further comprises a lower clamp assembly of the telescopic mast gripping a sole plate on the outer side of one of the additional tower sections.

[0044] Technical solution 14. The method according to technical solution 12 or 13, characterized in that the crane comprises a boom rotatably mounted relative to the telescopic mast and including lifting equipment, and stacking one or more additional tower sections on top of the first tower section comprises using the lifting equipment to lift one of the additional tower sections.

[0045] Technical solution 15. The method according to any one of technical solutions 12 to 14, characterized in that the method further comprises:

[0046] Release the upper clamp assembly;

[0047] Extend the telescopic mast; and

[0048] The upper clamp assembly grips another sole plate on the outer side of one of the additional tower sections.

[0049] In a first aspect of the present disclosure, a crane for erecting a tower including a plurality of tower segments is provided. The crane includes a telescopic mast and a jib rotatably mounted relative to the telescopic mast and including lifting equipment. The telescopic mast includes a lower mast segment having one or more lower clamp assemblies for selectively gripping a portion of the tower and a roller assembly for rolling along the tower. The telescopic mast further includes one or more additional mast segments having upper clamp assemblies for selectively gripping a portion of the tower, the additional mast segments being slidable relative to the lower mast segment.

[0050] According to this aspect, the crane is provided with a telescopic mast. When the telescopic mast retracts or extends, the roller assembly guides the telescopic mast. Further, due to the telescopic structure, the mast segments of the telescopic mast guide each other. The crane can move up (and down) relative to the tower without specific guide rails or guiding structures on the outside of the tower.

[0051] In another aspect, a method for climbing a tower using a crane is provided. The method includes positioning a first tower segment and attaching the crane having a telescopic mast to the first tower segment by a lower clamp assembly that grips a base on the outside of the first tower segment. The method further includes stacking one or more additional tower segments on top of the first tower segment and causing an upper clamp assembly of the telescopic mast to grip a base on the outside of one of the additional tower segments. Then, the method includes releasing the lower clamp assembly and retracting the telescopic mast from at least a partially extended state, whereby the roller assembly of the lower mast segment rolls along the outside of the first tower segment.

[0052] In yet another aspect, a method for erecting a wind turbine tower is provided. The method includes positioning a bottom tower segment and attaching a crane including a telescopic mast to the bottom tower segment by a bottom clamp set of the lower mast segment that grips a bottom mount at the outside of the bottom tower segment and an intermediate clamp assembly of the lower mast segment that grips another mount at the outside of the bottom tower segment. Then, the method includes using the crane to lift one or more additional tower segments and installing the additional tower segments on top of the bottom tower segment to build a tower segment stack and telescopically extending the telescopic mast. Then, the method includes causing an upper clamp assembly of another mast segment to grip a mount at the outside of one of the additional tower segments and releasing the bottom clamp assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 A perspective view showing an example of a wind turbine is presented;

[0054] Figure 2 Shows Figure 1Simplified internal view of an example nacelle of a wind turbine;

[0055] Figures 3A-3C An example of a crane mounted on a tower segment and a wind turbine is schematically shown;

[0056] Figures 4A-4N A series of steps according to an example method for installing a wind turbine are schematically shown;

[0057] Figures 5A-5D An example of a roller assembly that can form part of a crane according to an example of the present disclosure is schematically shown;

[0058] Figures 6A-6C An example of a handle that can be used in an example of the present disclosure is schematically shown; and

[0059] Figure 7A and 7B An example of a method for erecting a crane is schematically shown. Detailed Description

[0060] Embodiments of the present invention will now be described in detail, one or more examples of which are shown in the drawings. Each example is provided by way of illustration of the present invention, and not as a limitation thereof. Indeed, those skilled in the art will appreciate that various modifications and variations can be made to the present invention without departing from the scope or spirit thereof. For example, features shown or described as part of one embodiment can be used with another embodiment to yield yet another embodiment. Accordingly, it is intended that the present invention cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0061] Figure 1 A perspective view of an example of a wind turbine 160 is shown. As shown, the wind turbine 160 includes a tower 170 extending from a support surface 150, a nacelle 161 mounted on the tower 170, and a rotor 115 coupled to the nacelle 161. The rotor 115 includes a rotatable hub 110 and at least one rotor blade 120 coupled to the hub 110 and extending outwardly therefrom. For example, in the illustrated embodiment, the rotor 115 includes three rotor blades 120. However, in alternative embodiments, the rotor 115 may include more or fewer than three rotor blades 120. Each rotor blade 120 may be spaced about the hub 110 to facilitate rotation of the rotor 115 such that kinetic energy from the wind can be converted into useful mechanical energy and subsequently into electrical energy. For example, the hub 110 may be rotatably coupled to a generator 162 ( Figure 2 ) located within the nacelle 161 to permit the generation of electrical energy.

[0062] Figure 2shows Figure 1 A simplified internal view of an example of the nacelle 161 of the wind turbine 160 is shown. As shown, the generator 162 may be disposed within the nacelle 161. Generally, the generator 162 may be coupled to the rotor 115 of the wind turbine 160 to generate electric power from the rotational energy generated by the rotor 115. For example, the rotor 115 may include a rotor shaft 163 coupled to the hub 110 for rotation therewith. Then, the generator 162 may be coupled to the rotor shaft 163 such that rotation of the rotor shaft 163 drives the generator 162. For example, in the illustrated embodiment, the generator 162 includes a generator shaft 166 that is rotatably coupled to the rotor shaft 163 via a gearbox 164.

[0063] It should be appreciated that the rotor shaft 163, the gearbox 164, and the generator 162 may generally be supported within the nacelle 161 by a support frame or platen 165 located at the top of the wind turbine tower 170.

[0064] The nacelle 161 is rotatably coupled to the tower 170 by a yaw system 20 such that the nacelle 161 is capable of rotating about the yaw axis YA. The yaw system 20 includes a yaw bearing having two bearing members configured to rotate relative to each other. The tower 170 is coupled to one of the bearing members, and the bottom plate or support frame 165 of the nacelle 161 is coupled to the other bearing member. The yaw system 20 includes a ring gear 21 and a plurality of yaw drives 22 having a motor 23, a gearbox 24, and a pinion 25 for engaging the ring gear 21 to rotate one of the bearing members relative to the other.

[0065] The blade 120 is coupled to the hub 110 by a pitch bearing 100 between the blade 120 and the hub 110. The pitch bearing 100 includes an inner ring and an outer ring. The wind turbine blade may be attached at the inner bearing ring or the outer bearing ring, while the hubs are connected to each other. When the pitch system 107 is actuated, the blade 120 may perform a relative rotational movement with respect to the hub 110. The inner bearing ring may thus perform a rotational movement with respect to the outer bearing ring. Figure 2 The pitch system 107 includes a pinion 108 that engages a ring gear 109 provided on the inner bearing ring to cause the wind turbine blade to start rotating about the pitch axis PA.

[0066] Figures 3A-3C An example of a crane 200 mounted on a tower segment 171 and a wind turbine is schematically shown. A crane 200 for erecting a tower including a plurality of tower segments 171-175 is disclosed. The crane 200 includes a telescopic mast 210 and a boom 230 that is rotatably mounted relative to the telescopic mast 210 and includes lifting equipment 240.

[0067] The telescoping mast 210 includes a lower mast segment having one or more clamp assemblies 202, 204 for selectively gripping a portion of the tower and a roller assembly 300 for rolling along the tower, and further includes one or more additional mast segments having an upper clamp assembly 206 for selectively gripping a portion of the tower, the additional mast segments being slidable relative to the lower mast segment.

[0068] In particular, the telescoping mast can be configured to vary between a retracted state and one or more extended states, and the telescoping mast 210 can be configured to climb the tower by selectively releasing the upper clamp assembly 206 or the lower clamp assemblies 202, 204 and switching between the retracted state and the extended state. This will be further shown herein.

[0069] The retracted state of the telescoping mast can be understood herein to refer to the fully retracted state of the telescoping mast, i.e., the mast segments are slid into each other to the greatest extent possible and the telescoping mast is at its minimum length. The extended state can be understood herein to be a partially extended state or a fully extended state. The fully extended state is the state in which the mast segments have slid out of each other to the greatest extent possible. In the fully extended state, the telescoping mast is at its maximum length. The partially extended state can be understood herein to refer to any configured state of the mast that is not fully extended or fully retracted.

[0070] In Figure 3A the case of, a tower segment 171 is shown. The tower segment can be a segment of a wind turbine tower. In other examples, other towers can be erected in accordance with the systems and methods disclosed herein.

[0071] In Figure 3A it, the lower clamp assembly grips a portion of the tower segment 171, and in particular a portion from the outer side of the tower segment 171. The telescoping mast includes a plurality of segments that are slidable relative to each other (particularly shown in FIG. 4). The telescoping mast can increase its length by extending the telescoping mast, and the mast segments slide away from the lower mast segment. The telescoping mast can then decrease its length by retracting the segments.

[0072] When the telescoping mast retracts and extends to climb the tower (and descend from the tower after installation), the released clamp assemblies move with the moving mast segments, i.e., there is no relative movement of the mast segments relative to one or more of their clamp assemblies. Because there is no such relative movement, a complex braking mechanism is not required.

[0073] The telescopic mast may include one or more hydraulic mechanisms for extending and retracting the telescopic mast. The telescopic mast may further include a locking mechanism to lock the mast segments in different positions such that the length of the telescopic mast can be temporarily fixed.

[0074] In this example, the boom 230 includes a base plate 232 which is rotatably mounted relative to the upper mast segment of the telescopic mast. The boom 230 may further include a base 234 which includes a hydraulic actuator 233 that can tilt the upper portion 237 of the base 230. The upper portion 237 of the arm 236 carrying the boom 230 is hingedly mounted (hinge 235) relative to the base 234.

[0075] The boom 230 includes lifting equipment. For example, at or near the distal end of the boom 230, a suitable lifting device 240 (a part thereof) may be provided. The lifting equipment may include a hoisting mechanism and a plurality of pulleys. The hoist may be positioned at other locations of the boom 230. In one example, the pulleys and rollers may be provided within the arm 236, and the hoist may be provided on top of the base 230.

[0076] Figure 3C The same crane 200 mounted on a complete wind turbine is shown, where the telescopic mast is in a fully extended state. The tower may include a plurality of additional segments 172 - 175 which include the upper mast segment 175 and one or more intermediate segments 172 - 174.

[0077] In the example of FIG. 3, the upper mast segment includes an upper clamp assembly 206, and more precisely, the upper clamp assembly 206 may be arranged at or near the upper end of the upper mast segment. In the example of FIG. 3, the upper clamp assembly 206 is attached to the upper mast segment 175.

[0078] Figures 4A-4N A series of steps according to an example of a method for installing a wind turbine tower and a wind turbine is schematically shown.

[0079] An example of a method for erecting a wind turbine tower is shown in FIG. 4. The method includes positioning the bottom tower segment 171. The crane 200 including the telescopic mast 210 is attached to the bottom tower segment 171 by a bottom clamp assembly 202 of the lower mast segment 211 which grips the bottom seat outside the bottom tower segment 171. The crane 200 is also attached by an intermediate clamp assembly 204 of the lower mast segment 211 which grips another seat outside the bottom tower segment.

[0080] An example of attaching the crane 200 to the bottom tower segment 171 is shown in FIG. 7 and will be described in further detail with reference to FIG. 7.

[0081] The method may further include using a crane 200 to lift one or more additional tower sections 172, 173 and installing the additional tower sections 172, 173 on top of the bottom tower section 171 to construct a tower section stack. This can be seen in Figure 4B and 4C . To lift the tower sections, the cantilever can be rotated and lifting equipment on the cantilever can be used to lift the tower sections from the ground surface and place them on top of the previously installed section stack. The individual tower sections can be attached to each other, for example, by bolts at the mounting flanges.

[0082] The method may further include telescopically extending the telescopic mast 210. This can be seen in Figure 4D . The upper clamp assembly 206 of another mast section can grip a seat at the outside of one of the other tower sections. Then the bottom clamp assembly 202 can be released.

[0083] Even if the bottom clamp assembly 202 is released, a reliable attachment can still be maintained by the intermediate clamp assembly 204 and the upper clamp assembly 206.

[0084] In an example, as shown in Figure 4D and 4E , the method may further include: after releasing the bottom clamp assembly 202, using a crane 200 to lift another tower section 174 and installing the another tower section 174 on top of the tower section stack.

[0085] In Figure 4E , the telescopic mast 210 has not been fully extended. In the next step of this example, the telescopic mast 210 can be further extended. Before this further extension, the upper clamp assembly 206 can be released. After increasing the length of the telescopic mast, the upper clamp assembly can grip the seat at the tower section 174.

[0086] In an example, the bottom clamp assembly 202, the intermediate clamp assembly 204 and the upper clamp assembly 206 can grip the tower simultaneously. For lifting the tower sections, in most cases, two clamp assemblies will be sufficient. To increase stability, all the shown clamp assemblies can be enabled simultaneously.

[0087] In Figure 4F , the telescopic mast may be substantially fully extended. The intermediate clamp assembly 204 is attached at the lower tower section 171, and the upper clamp assembly is attached at a seat in the fourth tower section. In this case, the telescopic mast cannot be further extended. To install additional tower sections and other wind turbine components, the crane can climb the tower.

[0088] On the one hand, a method for climbing a tower using a crane 200 is provided. The method includes positioning at least a first tower segment 171; attaching the crane 200 with a telescopic mast 210 to the first tower segment 171 by gripping a lower clamp assembly of a shoe (or pedestal) at the outer side of the first tower segment 171; and stacking one or more other tower segments 172-174 on top of the first tower segment 171.

[0089] The upper clamp assembly 206 of the telescopic mast can then grip a shoe on the outer side of one of the additional tower segments. The lower clamp assembly can then be released, and the telescopic mast 210 can be retracted from an at least partially extended state ( Figure 4G ), whereby the roller assembly 300 of the lower mast segment 211 rolls along the outer side of the first tower segment 171 (and optionally along the additional tower segments 172, 173).

[0090] When the telescopic mast is retracted from a fully or partially extended state to a more retracted state, due to the telescopic structure of the mast 210, the lower mast segments 211-214 are guided by the higher segments 215, 216. The roller assembly 300 can roll upward on the tower without any fixed guides or rails on the tower. Thus, the method can be implemented "unguided" and on a tower without any guiding structure on its outer side. Nor is a locking or braking mechanism for the roller assembly 300 required.

[0091] The lower clamp assembly may herein refer to the bottom clamping assembly 202 and / or the intermediate clamping assembly 204.

[0092] In some examples, a single hydraulic cylinder can be used to extend the various mast segments. This can result in weight reduction. In other examples, multiple hydraulic cylinders can be used, such as one hydraulic cylinder for each mast segment.

[0093] The segments of the mast can be locked in different positions. After extending or retracting the mast to a desired length, the segments can be locked in their respective positions so as to maintain that length without the provision of hydraulic pressure.

[0094] In one example, the total length of the mast of the crane can be between 60 and 85 meters, particularly between 70 and 80 meters. In one example, the mast can have five segments. These segments can be between 20 meters and 10 meters in length. In an example, the lower mast segment can be longer than the subsequent mast segments. In an example, the length of the mast segments decreases with each higher mast segment.

[0095] In some examples, the method may further include a lower clamp assembly of the telescopic mast 210 (here the intermediate clamp assembly 204) that grasps a base on the outer side of one of the additional tower segments, such as a base disposed near the upper end of the tower segment 173. The base or pedestal may project from the tower segment.

[0096] In the example shown, another tower segment 175 may be lifted by the crane 200 and placed on top of the stack. Then, in some examples, the method may further include releasing the upper clamp assembly 206, extending the telescopic mast 210, and the upper clamp assembly 206 grasping another base (in FIG. 4l, the base 190) that projects from one of the additional tower segments.

[0097] Then, Figures 4J-4N Schematically shows how the same lifting equipment of the crane 200 is used to lift other components of the wind turbine. In Figure 4J shown, the nacelle 161 has been placed on top of the wind turbine tower. A yaw bearing may be provided between the tower and the nacelle 161. Subsequently, the hub 110 may be lifted and attached at the windward side of the nacelle 161. This is shown in Figure 4K shown.

[0098] Then, the blades 120 may be lifted one by one. As can be seen from Figure 4L shown, the first blade 120 is attached in a substantially horizontal manner. The blade 120 may be attached to the hub 110 via a pitch bearing. After installing the first blade, the hub 110 may be rotated so that subsequent blades 120 can be installed ( Figure 4M ). After installing the second blade 120, the hub may be rotated again so that the third blade can also be installed in a substantially horizontal orientation.

[0099] Rotation of the hub may involve the use of additional tools. Such additional tools may drive the shaft of the gearbox. Similarly, a crane and a suitable grasping assembly for the blade may be used to rotate the hub.

[0100] Even in this example, where the blades are installed separately from the hub and all blades are installed horizontally, it should be clear that other installation processes may be used in other examples. It may be possible to lift the hub with one or more pre-installed blades. It may also be possible to install the blades at a position relative to the horizontal plane, for example +30° or -30°.

[0101] Furthermore, it should be clear that suitable lifting equipment may be used, which may be partially or fully inside or outside the crane 200. For example, in one embodiment, a grasping unit that grasps the blade near the center of gravity may be lifted. In other examples, slings may be used. Suitable attachments for lifting may be provided for different components. These attachments may be different for the nacelle than for the hub and for the blades.

[0102] In this particular example, five tower segments are stacked on top of each other, but in other examples, a different number of tower segments may be used. Similarly, in other examples, the lengths of the different tower segments may vary, and the shapes of the tower segments may vary.

[0103] After installing the tower, wind turbine tower, or a complete wind turbine, the telescopic mast may be lowered from the tower. Lowering from the tower may also include selectively releasing the clamp assembly and appropriately extending and retracting the telescopic mast in a manner that is substantially opposite to the method used for climbing.

[0104] Figures 5A-5D An example of a roller assembly 300 and a bottom clamp assembly 202 that may form part of a crane 200 according to an example of the present disclosure is schematically shown. In this example, the lower end of the lower mast segment may incorporate rollers or wheels for rolling along the tower and a bottom handle for gripping a portion of the tower, as has been shown, for example, in FIG. 4.

[0105] The roller assembly 300 may be disposed at or near the bottom of the lower mast segment 211. The bottom clamp assembly 202 may include a bottom clamp 308 for selectively gripping a portion of the tower. The bottom clamp 308 may include one or more clamps that may be actively controlled for clamping (and thus fixing the mast segment 211 relative to the tower in place) and for releasing (such that the mast segment 211 may move relative to the tower). The clamps disclosed herein may include hydraulic or pneumatic or electric mechanisms for clamping. Any suitable clamp may be used for firmly gripping or gripping tightly enough to maintain the holding of the tower portion.

[0106] The bottom clamp assembly 202 may include a first arm 302 and a second arm 304, the first arm including a first clamp 308 disposed at the distal end of the first arm 302, the second arm including a second clamp disposed at the distal end of the second arm 304, and optionally wherein the first arm 302 and the second arm 304 are telescopic arms. A hydraulic actuator 306 may be arranged such that the segments of the arms may slide out or slide back into another segment of the hydraulic telescopic arm.

[0107] In this example, the roller assembly 300 includes a first roller arm and a second roller arm, the first roller arm including a first set of wheels 310 disposed at the distal end of the first roller arm, the second roller arm including a second set of wheels disposed at the distal end of the second roller arm. This may be seen in Figure 5B this.

[0108] The first roller arm and the second roller arm can be telescopic to change the distance between the rollers 315 - 318 and the mast segment 211. A hydraulic mechanism (not shown) can be used to change the length of the telescopic arm 340. The tower segment may not be completely cylindrical and may, for example, taper with a decreasing diameter towards the top of the tower segment. For example, the tower segment can be frustoconical or partially conical. For example, in FIG. 4l, it can be seen that the tower segment 175 is conical, but this is merely an example.

[0109] In some examples (e.g., see Figure 5C and 5D ), the first set of wheels 310 includes a first wheel support 330, where the first wheel support 330 can rotate relative to the first roller arm about a substantially vertical axis 342. Rotation about the vertical axis 342 enables changing the distance between the sets of wheels 310. The roller assembly 300 can thus be adapted to different diameters of the tower segment.

[0110] Rotation about the vertical axis 342 can be established by a pin that extends through alignment holes in brackets mounted to the arm 340 and the wheel support 330.

[0111] In some examples, the first wheel support 330 can rotate relative to the first roller arm about a substantially vertical axis 342 and about a substantially horizontal transverse axis 344. Rotation about the transverse axis 344 can be useful for a conical tower segment, such that the upper wheels 315, 316 and the lower wheels 317 and 318 can maintain contact with the tower.

[0112] In the example shown, the roller assembly can further include an upper bracket 322 that carries the wheels 315, 316 of the upper set 312 and a lower bracket 324 that carries the wheels 317, 318 of the lower set 314. The upper bracket 322 and the lower bracket 324 are mounted on the first wheel support 330, and optionally, the upper bracket 322 and the lower bracket 324 can be rotatably mounted relative to the first wheel support 330. As Figure 5D shown, the upper bracket 322 and the lower bracket 324 can rotate about axes 346, 348 that can be substantially parallel to the transverse axis 344 and substantially perpendicular to the longitudinal axis of the first roller arm.

[0113] Rotation about the axes 346 and 348 enables the wheels to adapt to, for example, flanges or other variations or irregularities along the outer surface of the tower (e.g., a wind turbine tower).

[0114] In the example shown, the wheels 315 - 318 are shown. In other examples, different wheels, rollers, or rolling elements can be used.

[0115] <> Figures 6A-6CAn example of a handle that can be used in an example of the present disclosure is schematically shown. In this particular example, the intermediate clamp assembly 204 of the lower mast section 211 is shown, but a similar arrangement and mechanism can be provided for the upper clamp assembly 206. Similarly, the bottom clamp assembly 202 can be the same as or similar to the intermediate clamp assembly shown here.

[0116] One of the lower clamp assemblies 202, 204 and the upper clamp assembly 206 can include a first arm and a second arm. The first arm includes a first clamp disposed at the distal end of the first arm, and the second arm includes a second clamp disposed at the distal end of the second arm. And optionally, the first arm and the second arm are telescopic arms. The hydraulic actuator 404 can be arranged such that the section 403 can slide out or slide back into another section of the hydraulic telescopic arm. As previously mentioned, the distance between the telescopic mast and the clamp 410 can be changed to accommodate different diameters of different sections of the tower, so that the saddle can be reached even for higher tower sections, and the tower sections may change in size and shape.

[0117] In Figure 6A What is shown in a slightly more detailed manner is the saddle. The saddle can take any suitable form such that it can be grasped or clamped. The saddle can have the shape of a lug, a base or a plate. Multiple plates or bases can be provided. The saddle can be attached to the tower section individually or can be integrally formed with it. Generally, as shown in FIG. 4, the saddle can be provided at or near the bottom end and the upper end of the tower section.

[0118] Generally speaking, if the distance between the lower handle and the upper handle increases, the load during lifting may be lower. However, depending on the particular tower design and the particular telescopic mast, the situation of the saddle can change.

[0119] In some examples, one or more of the clamp assemblies can be configured to change the distance between the first arm and the second arm. In the example shown, a hydraulic actuator 412 is shown, which can adapt the distance between the arms.

[0120] In some examples, the assembly of the arm 402 can pivot relative to the mast section. The load between the arm and the corresponding saddle can be balanced using such a pivot. If the crane is carrying a load and the boom rotates relative to the mast, the loads on different saddles may become unbalanced. Pivoting can avoid or reduce such imbalance.

[0121] Figure 7A and 7B An example of a method for erecting the crane 200 is schematically shown.

[0122] It can be seen that the mast can be transported separately from the boom. This can facilitate transportation. The crane can be assembled on site.

[0123] The truck 500 can tow the flatbed trailer 510. The telescopic mast of the crane 200 can be arranged substantially horizontally, i.e., lying flat on the trailer 510. The mast may be in the fully retracted position for transportation. In an example, the length of the telescopic mast can be 20 meters or less.

[0124] Figure 7A The bottom clamp assembly 202 and the roller assembly 300, the intermediate clamp assembly 204 with the clamp 410, and the upper clamp assembly 206 are shown.

[0125] The bottom tower section may have been previously positioned and installed on a suitable foundation. The mast can be brought near the tower section.

[0126] By using one or more hydraulic actuators 530, the mast can be raised straight up. The telescopic mast can pivot relative to the rear end of the trailer 510.

[0127] Then, the bottom clamp assembly 202 and the intermediate clamp assembly 204 can clamp a portion of the bottom tower section. In a subsequent step, the jib can be lifted and placed on top of the mast. After assembling the jib with the telescopic mast, the installation can continue according to other examples disclosed herein.

[0128] This written description uses examples (including preferred embodiments) to disclose the invention and also enables any person skilled in the art to implement the invention, including making and using any device or system and performing any incorporated method. The patent scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. If such other examples have structural elements that are not different from the written language of the claims or if they include equivalent structural elements that are not materially different from the written language of the claims, then such other examples are intended to fall within the scope of the claims. Aspects from the various embodiments and other known equivalent forms for each such aspect can be mixed and matched by those of ordinary skill in the art to form additional embodiments and techniques in accordance with the principles of this application. If reference numerals associated with the drawings are placed in parentheses in the claims, they are only used to attempt to increase the intelligibility of the claims and should not be construed as limiting the scope of the claims.

Claims

1. A crane (200) for erecting a tower comprising a plurality of tower segments, the crane comprising: a telescoping mast (210) configured to move between at least a retracted state and an extended state, and A boom (230) rotatably mounted relative to the telescopic mast (210) and comprising a lifting device (240), wherein the telescopic mast (210) comprises a lower mast section (211) having one or more lower clamp assemblies (202, 204) for selectively gripping portions of the tower; and a roller assembly (300) for rolling along the tower; and One or more further mast segments (212, 213, 214, 215, 216) having an upper clamp assembly (206) for selectively gripping portions of the tower, the further mast segments (212, 213, 214, 215, 216) being slidable relative to the lower mast segment.

2. The crane according to claim 1, characterized in that The telescoping mast (210) is configured to move between a retracted state and one or more extended states, and wherein The telescoping mast (210) is configured to climb the tower by selectively releasing the upper clamp assembly (206) or the lower clamp assembly (202, 204) and changing between the retracted state and the extended state.

3. The crane according to claim 1 or 2, characterized in that: The further mast segments (212, 213, 214, 215, 216) include an upper mast segment (216) and one or more intermediate segments (212, 213, 214, 215).

4. The crane according to claim 3, characterized in that The upper mast segment (216) includes the upper clamp assembly (206), and optionally wherein the upper clamp assembly (206) is disposed at or near an upper end of the upper mast segment (216).

5. The crane according to claim 1 or 2, characterized in that: One or more of the lower clamp assembly (202, 204) and the upper clamp assembly (206) include a first arm comprising a first clamp disposed at a distal end of the first arm, and A second arm comprising a second clamp arranged at a distal end of the second arm, and optionally wherein the first arm and the second arm are telescopic arms.

6. The crane according to claim 5, characterized in that One or more of the lower clamp assembly (202, 204) and the upper clamp assembly (206) are configured to change a distance between the first arm and the second arm.

7. The crane according to claim 1 or 2, characterized in that: The one or more lower clamp assemblies (202, 204) include a middle clamp assembly (204) and a bottom clamp assembly (202) for selectively gripping a portion of the tower.

8. The crane according to claim 1 or 2, characterized in that: The roller assembly (300) includes a first roller arm including a first set of wheels (310) arranged at a distal end of the first roller arm and a second roller arm including a second set of wheels (310) arranged at a distal end of the second roller arm, and optionally wherein the first roller arm and the second roller arm are retractable.

9. The crane according to claim 8, characterized in that The first set of wheels (310) includes a first wheel support (330), wherein the first wheel support (330) is rotatable relative to the first roller arm about a substantially vertical axis.

10. The crane according to claim 9, characterized in that The first wheel support (330) is rotatable relative to the first roller arm about a substantially horizontal transverse axis (344).

11. The crane according to claim 9 or 10, characterized in that The roller assembly further comprises: an upper bracket (322) for carrying an upper set of wheels (315, 316); and a lower bracket for carrying a lower set of wheels (317, 318), wherein The upper bracket (322) and the lower bracket are mounted on the first wheel support (330), and optionally wherein the upper bracket (322) and the lower bracket are rotatably mounted relative to the first wheel support (330).

12. A method for climbing a tower using a crane (200), comprising: Positioning a first tower segment (171); attaching a crane (200) having a telescoping mast (210) to the first tower segment (171) via a lower clamp assembly (202, 204) that grips a shoe (190) on the outside of the first tower segment (171); stacking one or more additional tower segments (172, 173, 174) on top of the first tower segment (171); The upper clamp assembly (206) of the telescoping mast (210) grasps a shoe on the outside of one of the additional tower segments (172, 173, 174); releasing the lower clamp assembly (202, 204); and The telescopic mast (210) is retracted from an at least partially extended state, whereby the roller assembly (300) of the lower mast segment (211) rolls along the outside of the first tower segment (171).

13. The method according to claim 12, characterized in that The method further comprises The lower clamp assembly (202, 204) of the telescoping mast (210) grasps a shoe (190) on the outside of one of the additional tower segments (172, 173, 174).

14. The method according to claim 12 or 13, characterized in that The crane (200) comprises a boom (230) rotatably mounted relative to the telescopic mast (210) and comprising a lifting device (240), wherein stacking one or more additional tower segments (172, 173, 174) on top of the first tower segment (171) comprises lifting one of the additional tower segments (172, 173, 174) using the lifting device (240).

15. The method according to any one of claims 12 to 14, characterized in that The method further comprises: releasing the upper clamp assembly (206); extending the telescopic mast (210); and The upper clamp assembly (206) grasps another shoe on the outside of one of the additional tower segments.

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