Method of mounting a blade to a rotor hub of a wind turbine

Abstract

A method (100) of installing a blade (22) to a rotor hub (20) of a wind turbine (10), the wind turbine (10) comprising a tower (12), a nacelle (16) mounted on the tower (12), a rotor hub (20) coupled to the nacelle (16), and a blade (22), each blade (22) comprising a blade root section (56) and a blade extension section (66), the method (100) comprising: installing a first blade root section (50) to the rotor hub (20); installing a second blade (72) to the rotor hub (20) after installing the first blade root section (50), the second blade (72) comprising a second blade root section (52) and a second blade extension section (62); and connecting the first blade extension section (60) to the first blade root section (50) after installing the second blade (72).

Description

Technical Field

[0001] This disclosure generally relates to wind turbines, and more particularly to a method of mounting blades to the rotor hub of a wind turbine. Background Technology

[0002] Wind power is considered one of the cleanest and most environmentally friendly energy sources available today, and wind turbines are receiving increasing attention in this area. A modern wind turbine typically consists of a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades capture kinetic energy from the wind using the known airfoil principle and transfer this kinetic energy through rotation to rotate a shaft that connects the rotor blades to the gearbox, or, if no gearbox is used, directly to the generator. The generator then converts the mechanical energy into electrical energy, which can be deployed to the public power grid.

[0003] The size of the rotor blades contributes to the energy efficiency of a wind turbine. In particular, increasing the rotor blade size can increase the energy output of a wind turbine. The economic benefits of increasing the size of a wind turbine or rotor blades must be weighed against the corresponding costs of manufacturing, transporting, assembling, or repairing the wind turbine. Typically, wind turbine assembly involves mounting the rotor hub to the nacelle on top of the tower, and using a crane to individually install each rotor blade onto the hub. To install individual blades, the hub is often rotated multiple times, for example, so that each blade can be installed in a horizontal orientation.

[0004] During such installation, the gearbox and other components are subjected to extreme torsional moments. Furthermore, a drive tool may be needed to rotate an incomplete rotor with only one or two blades to handle the extreme loads during the rotation of the incomplete rotor. Additionally, the blades may only be installed under very low wind conditions to prevent wind loads from increasing rotor imbalance in the incomplete rotor. However, as wind turbine or blade sizes increase, extreme loads increasingly drive the design and / or cost of the gearbox, the design and / or cost of other components subjected to extreme torsional moments during installation, or the design and / or cost of the drive tool. Moreover, installation may only be possible at even lower wind speeds, particularly limiting field operation to a narrow weather window.

[0005] Therefore, this disclosure relates to a method for mounting blades to the rotor hub of a wind turbine, which can provide response to extreme loads or extreme torsional moments during blade mounting and / or provide cost-effective blade mounting. Summary of the Invention

[0006] Aspects and advantages of the invention will be set forth in part in the description which follows, or may be apparent from the description, or may be learned by practice of the invention.

[0007] In one aspect, this disclosure relates to a method of mounting blades to the rotor hub of a wind turbine, the wind turbine including a tower, a nacelle mounted on the tower, a rotor hub coupled to the nacelle, and blades, each blade including a blade root section and a blade extension section. The method includes: mounting a first blade root section to the rotor hub; mounting a second blade to the rotor hub after mounting the first blade root section, the second blade including a second blade root section and a second blade extension section; and connecting the first blade extension section to the first blade root section after mounting the second blade. It should be understood that the method may also include any additional steps and / or features as described herein.

[0008] Technical Solution 1. A method (100) for mounting blades (22) to a rotor hub (20) of a wind turbine (10), the wind turbine (10) comprising a tower (12), a nacelle (16) mounted on the tower (12), the rotor hub (20) connected to the nacelle (16), and blades (22), each blade (22) comprising a blade root section (56) and a blade extension section (66), the method (100) comprising:

[0009] - The root section (50) of the first blade is mounted to the rotor hub (20);

[0010] - After installing the first blade root section (50), a second blade (72) is installed onto the rotor hub (20), the second blade (72) comprising a second blade root section (52) and a second blade extension section (62); and

[0011] - After the second blade (72) is installed, the first blade extension section (60) is connected to the first blade root section (50).

[0012] Technical solution 2. The method (100) according to technical solution 1 further includes:

[0013] - After the first blade root section (50) is installed and before the second blade (72) is installed, the third blade root section (54) is installed to the rotor hub (20).

[0014] Technical solution 3. The method (100) according to technical solution 2 further includes:

[0015] - After the second blade (72) is installed, the third blade extension section (64) is connected to the root section (54) of the third blade.

[0016] Technical Solution 4. The method (100) according to any one of Technical Solutions 1 to 3, wherein the first blade extension section (60) is connected to the first blade root section (50), and the first blade root section (50) is oriented downward at an angle of at least 50 degrees relative to the horizontal plane; and / or

[0017] The third blade extension section (64) is connected to the third blade root section (54), and the third blade root section (54) is oriented downward at an angle of at least 50 degrees relative to the horizontal plane.

[0018] Technical Solution 5. The method (100) according to any one of technical solutions 1 to 4, wherein installing the first blade root section (50) includes using a first crane to lift the first blade root section (50) to the rotor hub (20); and wherein connecting the first blade extension section (60) includes using a second crane to lift the first blade extension section (60) to the first blade root section (50), the second crane being different from the first crane.

[0019] Technical Solution 6. The method (100) according to any one of Technical Solutions 1 to 5, wherein the extension static moment of the blade extension section (66) of the blade (22) is at least 5% of the blade static moment of the blade (22) and / or the maximum 50% of the blade static moment of the blade (22).

[0020] Technical Solution 7. The method (100) according to any one of technical solutions 1 to 6, wherein at least one of the blades (22) is connected to the blade root section (56) of the blade (22) by a pitch angle offset relative to the pitch angle alignment line of the blade root section (56) and the blade extension section (66) in normal operation of the wind turbine (10).

[0021] Technical Solution 8. The method (100) according to Technical Solution 7, wherein the pitch angle offset is at least 90 degrees and / or at most 270 degrees.

[0022] Technical Solution 9. The method (100) according to any one of technical solutions 1 to 8 further includes:

[0023] - Install the hook connection device (88) to the extended end section (77) of the blade root section (56); and

[0024] - Hook the hook (96) of the lifting device (98) onto the hook connection device (88).

[0025] Technical solution 10. The method (100) according to technical solution 9 further includes:

[0026] - After the blade root section (56) is installed onto the rotor hub (20), the blade root section (56) is rotated relative to the rotor axis of the wind turbine (10), wherein the blade root section (56) is rotated using the lifting device (98).

[0027] Technical Solution 11. The method (100) according to any one of technical solutions 9 and 10, wherein the extended end section (77) includes a first connector member (78) configured for connection to a second connector member (84) of the blade extension section (66), and wherein mounting the hook coupling device (88) to the extended end section (77) includes connecting a coupling connector member (90) of the hook coupling device (88) to the first connector member (78) of the extended end section (77).

[0028] Technical Solution 12. The method (100) according to any one of technical solutions 9 to 11, wherein the hook coupling device (88) includes a remotely controllable locking device (94) configured to remotely controllably lock the hook (96) to the hook coupling device (88) and / or to remotely controllably release the hook (96) from the hook coupling device (88).

[0029] Technical Solution 13. The method (100) according to any one of Technical Solutions 9 to 12, wherein the hook connection device (88) is installed on the blade root section (56) before the blade root section (56) is installed on the rotor hub (20).

[0030] Technical Solution 14. The method (100) according to any one of technical solutions 9 to 13, wherein the lifting device (98) includes a connecting device (97) connected to the hook (96), and wherein rotating the root section of the blade (56) includes using the lifting device (98) to pull the connecting device (97) in a downward direction.

[0031] Technical Solution 15. The method (100) according to any one of technical solutions 9 to 14 further includes:

[0032] - The blade root section (56) is pre-tensioned in a first direction using a first connecting device connected to the hook connecting device (88) and in a second direction using a second connecting device connected to the hook connecting device (88), the first direction being different from the second direction.

[0033] These and other features, aspects, and advantages of the invention will be further supported and described with reference to the following description and the appended claims. The accompanying drawings, which are incorporated and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. Attached Figure Description

[0034] The complete and feasible disclosure of the invention, including its preferred mode, for those skilled in the art is set forth in the description with reference to the accompanying drawings, in which:

[0035] Figure 1 The illustration shows a perspective view of a wind turbine.

[0036] Figure 2 The illustration shows a simplified interior view of the nacelle of a wind turbine, with particular emphasis on the nacelle during normal operation.

[0037] Figure 3 The illustration shows a flowchart of a method according to an embodiment of the present disclosure;

[0038] Figures 4A-4E The illustration shows a schematic diagram of a wind turbine during blade installation according to an embodiment;

[0039] Figure 5 The figure shows a graph of the torque acting on the main shaft during conventional blade installation and during blade installation according to the embodiments described herein.

[0040] Figure 6A The figure shows a schematic cross-sectional view of a blade extension section connected to the blade root section according to an embodiment;

[0041] Figure 6B The figure shows a schematic cross-sectional view of a hook-connecting device connected to the root section of the blade according to an embodiment; and

[0042] Figures 7A-7B The figure shows a schematic diagram of the lifting device of the hook-to-hook connection device according to an embodiment. Detailed Implementation

[0043] Reference will now be made in detail to embodiments of the invention, one or more of which are illustrated in the accompanying drawings. Each example is provided by way of explanation rather than limitation of the invention. Indeed, it will be apparent to those skilled in the art that various modifications and variations may be made to the invention without departing from the scope or spirit thereof. For example, a feature illustrated or described in part as one embodiment may be used with another embodiment to produce yet another embodiment. Therefore, it is intended that the invention cover such modifications and variations and their equivalents as fall within the scope of the appended claims.

[0044] Now refer to the attached diagram, Figure 1 The figure shows a perspective view of a wind turbine 10 according to the present disclosure. As shown, the wind turbine 10 generally includes a tower 12 extending from a support surface 14 (e.g., the ground), a nacelle 16 mounted on the tower 12, and a rotor 18 coupled to the nacelle 16.

[0045] like Figure 1 As shown, rotor 18 includes a rotatable rotor hub 20 and at least one blade 22 coupled to and extending outward from the rotor hub 20. For example, in the illustrated embodiment, rotor 18 includes three blades 22. However, in alternative embodiments, rotor 18 may include more or fewer than three blades 22. Each blade 22 may be spaced apart around rotor hub 20 to facilitate rotation of rotor 18, thereby enabling kinetic energy to be converted from wind energy into usable mechanical energy, and subsequently into electrical energy. For example, rotor hub 20 may be rotatably coupled to generator 24 located within nacelle 16. Figure 2 This allows for the generation of electrical energy.

[0046] The wind turbine 10 may also include a wind turbine controller 26 centralized within the nacelle 16. However, in other embodiments, the controller 26 may be located within any other component of the wind turbine 10 or at a location outside the wind turbine 10. Furthermore, the controller 26 may be communicatively coupled to any number of components of the wind turbine 10 to control those components. Accordingly, the controller 26 may include a computer or other suitable processing unit. Therefore, in several embodiments, the controller 26 may include suitable computer-readable instructions that, when implemented, configure the controller 26 to perform various functions, such as receiving, sending, and / or executing wind turbine control signals.

[0047] Now for reference Figure 2 The illustration shows Figure 1A simplified internal view of the nacelle 16 of the wind turbine 10 shown is illustrated, with particular emphasis on its drivetrain components. More specifically, as shown, a generator 24 may be coupled to a rotor 18 to generate electricity from the rotational energy produced by the rotor 18. The rotor 18 may be coupled to a main shaft 34, which is rotatable via a main bearing (not shown). The main shaft 34 is then rotatably coupled to a gearbox output shaft 36 of the generator 24 via a gearbox 30. The gearbox 30 may include a gearbox housing 38 connected to a base plate 46 via one or more torque arms 48. More specifically, in some embodiments, the base plate 46 may be a forged component in which the main bearing (not shown) is housed, and through which the main shaft 34 extends. As generally understood, in response to the rotation of the rotor blades 22 and the rotor hub 20, the main shaft 34 provides a low-speed, high-torque input to the gearbox 30. Therefore, gearbox 30 converts low-speed, high-torque input into high-speed, low-torque output to drive gearbox output shaft 36, and thus drive generator 24.

[0048] Each blade 22 may also include a pitch adjustment mechanism 32 configured to rotate each blade 22 about its pitch axis 28 via a pitch bearing 40. Similarly, the wind turbine 10 may include one or more yaw drive mechanisms 42 communicatively coupled to the controller 26, wherein each pitch drive mechanism 42 is configured to change the angle of the nacelle 16 relative to the wind (e.g., by engaging the yaw bearing 44 of the wind turbine 10).

[0049] The installation of blades for the assembly or repair of wind turbines typically involves extreme torsional moments acting on gearboxes or other components, or extreme loads that will be handled by drive tools that move the rotor from one angular position to another. Accordingly, this disclosure relates to a method for mounting blades to the rotor hub of a wind turbine, which allows the use of drive tools, gearboxes, or other components designed for lower extreme loads or lower extreme torsional moments. In particular, the method according to the embodiments described herein can reduce torsional moments or rotor imbalance during installation. The embodiments can allow for cost-effective blade installation. For example, blade installation can be performed at higher wind speeds. Crane availability or more efficient utilization of cranes can be achieved.

[0050] According to embodiments of this disclosure, each blade 22 includes a blade root segment 56 and a blade extension segment 66, particularly one blade root segment 56 and at least one blade extension segment 66. In some embodiments, each blade 22 includes one blade root segment 56 and one blade extension segment 66, the blade extension segment 66 being particularly a blade tip segment. In other embodiments, each blade 22 may include one blade root segment 56 and two blade extension segments 66. In an embodiment, the blade root segment 56 includes the root of the blade 22. The root of the blade 22 may be configured to be mounted to a blade mounting position on the rotor hub 20. In an embodiment, the mass of the blade extension segment 66 is less than the mass of the blade root segment 56. For example, the mass of the blade extension segment may be a maximum of 50% of the mass of the blade root segment, particularly a maximum of 30% or a maximum of 20%, and / or a minimum of 1% of the mass of the blade root segment, particularly a minimum of 3% or a minimum of 5%.

[0051] According to an embodiment, the wind turbine 10 includes three blades 22, specifically a first blade 70 including a first blade root section 50 and a first blade extension section 60, a second blade 72 including a second blade root section 52 and a second blade extension section 62, and a third blade 74 including a third blade root section 54 and a third blade extension section 64.

[0052] According to embodiments of this disclosure, method 100 includes mounting a first blade root section 50 to a rotor hub 20. Mounting the first blade root section 50 may include lifting the first blade root section 50 from a support surface 14 to the rotor hub 20. The first blade root section 50, particularly the root of the first blade root section 50, may be connected to a blade mounting position on the rotor hub 20. Specifically, the first blade root section 50 may be mounted to the rotor hub 20 without the first blade extension section 60 being connected to it. The torque caused by the imbalance of the rotor 18 and acting on the main shaft of the wind turbine 10 can be reduced compared to the torque caused by mounting a complete blade to the rotor hub according to conventional blade mounting. Figure 3 A flowchart of method 100 according to an embodiment is shown. For example, in block 110, the root section 50 of the first blade is mounted to the rotor hub 20.

[0053] In some embodiments, at least one blade root segment 56 of blade 22 (particularly each of the blade root segments 56) may be connected to rotor hub 20, wherein the longitudinal blade root segment axis of the blade root segment 56 forms an angle of up to 45 degrees relative to the horizontal plane, particularly an angle of up to 30 degrees, 20 degrees, or 10 degrees. For example, the blade root segment 56 may be connected to rotor hub 20, wherein the longitudinal blade root segment axis is at least substantially oriented in the horizontal direction. In another embodiment, the blade root segment 56 may be connected to rotor hub 20, wherein the longitudinal blade root segment axis of the blade root segment 56 forms an angle greater than 45 degrees.

[0054] Figures 4A-4E The illustration schematically depicts the installation of blade 22 according to an embodiment. For example, in Figure 4A In the rotor hub 20, the root section 50 of the first blade is installed. Figure 4A In the rotor hub 20, the root section 50 of the first blade is mounted to the rotor hub 20, wherein the root section 50 of the first blade is oriented in a substantially horizontal direction.

[0055] In some embodiments, for example, in Figure 3 In block 120, method 100 may include installing a third blade root section 54 to the rotor hub 20 after installing the first blade root section 50 and before installing the second blade 72. Specifically, the third blade root section 54 may be installed to the rotor hub 20 without the third blade extension section 64 being connected to it. In another embodiment, the third blade root section 54 may be installed to the rotor hub 20 after the second blade 72 is installed. Specifically, the third blade 74, including the third blade root section 54 together with the third blade extension section 64 connected to the third blade root section 54, may be installed after the second blade 72 is installed.

[0056] exist Figure 4B In this process, after the first blade root section 50 is installed and before the second blade 72 is installed, the third blade root section 54 is installed onto the rotor hub 20. Specifically, before installing the third blade root section, the rotor, including the rotor hub 20 and the first blade root section 50, is rotated such that the third blade root section 54 can be connected to the rotor hub 20, while the third blade root section 54 is in a substantially horizontal orientation.

[0057] According to an embodiment, method 100 includes mounting a second blade 72 to a rotor hub 20 after mounting a first blade root section 50. The second blade 72 includes a second blade root section 52 and a second blade extension section 62. Specifically, before mounting the second blade 72 to the rotor hub 20, the second blade extension section 62 of the second blade 72 is connected to the second blade root section 52. The second blade extension section 62 of the second blade 72 may be connected to the second blade root section 52 according to the embodiments described herein, particularly by connecting a first connector member 78 of the second blade root section 52 to a second connector member 84 of the second blade extension section 62 (see, for example, see...). Figure 6A In one embodiment, before the second blade 72 is raised toward the rotor hub 20 to mount it to the rotor hub 20, the second blade extension section 62 may be connected to the second blade root section 52. For example, in Figure 3 In the middle, within frame 130, the second blade 72 is mounted to the rotor hub 20. Figure 4C In this configuration, the second blade 72 is mounted to the rotor hub 20. Specifically, the rotor, including the rotor hub 20, the first blade root section 50, and the third blade root section 54, rotates such that the second blade 72 can be connected to the rotor hub 20, wherein the longitudinal blade axis of the second blade 72 is oriented in a substantially horizontal direction. In an embodiment, the second blade root section 52, together with the second blade extension section 62, can be connected to the rotor hub 20 at an angle for mounting the blade root section 56 according to the embodiments described herein. Mounting the second blade root section 56 together with the second extension section 62 facilitates connection between the second blade root section 56 and the second extension section 62, reducing assembly time and / or reducing the number of rotor movements during assembly.

[0058] According to an embodiment, for example in Figure 3 Method 100, according to block 140, includes connecting a first blade extension segment 60 to a first blade root segment 50 after mounting a second blade 72. Connecting the first blade extension segment 60 to the first blade root segment 50 may include raising the first blade extension segment 60 to the first blade root segment 50. Connecting the first blade extension segment 60 to the first blade root segment 50 may include connecting the first blade extension segment 60 to the first blade root segment 50 after raising the first blade extension segment 60. For example, in Figure 4D In the first blade extension section 60, the first blade root section 50 is connected. Before connection, the rotor including the first blade root section 50 is rotated such that the first blade root section 50 points downward, specifically in a substantially vertically downward direction.

[0059] In an embodiment, method 100 may include connecting a third blade extension segment 64 to a third blade root segment 54 after installing the second blade 72. In some embodiments, the third blade extension segment 64 may be connected after connecting a first blade extension segment 60 to a first blade root segment 50. For example, in Figure 3 In the middle, within frame 150, the third blade extension segment 64 is connected. Figure 4E In this embodiment, the third blade extension section 64 is connected to the third blade root section 54, and the third blade root section 54 is oriented in a substantially vertically downward direction. In another embodiment, the third blade extension section 64 may be connected to the third blade root section 54 before the first blade extension section 60 is connected to the first blade root section 50.

[0060] In one embodiment, the blade 22 is fully installed after connecting the first blade extension segment 60 and the third blade extension segment 64, particularly if the first blade extension segment 60 and the third blade extension segment 64 are terminal segments. In another embodiment, the method of installing the blade may continue to connect additional blade extension segments to the blade extension segments connected to the blade root segment.

[0061] In some embodiments, a first blade extension segment 60 is connected to a first blade root segment 50, wherein the first blade root segment 50 is oriented downward at an angle of at least 50 degrees relative to a horizontal plane, and / or a third blade extension segment 64 is connected to a third blade root segment 54, wherein the third blade root segment 54 is oriented downward at an angle of at least 50 degrees relative to a horizontal plane. Specifically, this angle may be at least 70 degrees or at least 80 degrees, for example, approximately 90 degrees. Figure 4D and Figure 4E Specifically, if the root of blade root segment 56 points upward, then blade root segment 56 can be understood as oriented downward. The upward and downward directions can be understood relative to the direction of gravity. The upward and downward directions can point parallel to a vertical axis parallel to the direction of gravity, or they can be angled relative to the vertical direction, particularly at an angle less than 90 degrees. In another embodiment, during connection, the angle between the first or third blade root segment and the horizontal plane can be less than 50 degrees. In still some other embodiments, the first blade root segment 50 and / or the third blade root segment can be oriented in a direction that is at least substantially horizontal. In some embodiments, the first blade root segment 50 and / or the third blade root segment can be oriented upward.

[0062] According to an embodiment, installing the first blade root section 50 includes using a first crane to lift the first blade root section 50 onto the rotor hub 20. Specifically, the first blade root section 50, the third blade root section 54, and the second blade 72 can be lifted by the first crane to install onto the rotor hub 20. For example, according to the embodiments described herein, the first crane may be configured to install the blade root section 56 or the blade 22 onto the rotor hub while the blade root section 56 or the blade 22 is oriented in a substantially horizontal direction or oriented at an angle relative to the horizontal plane, for example, less than 45 degrees, particularly less than 30 degrees.

[0063] In an embodiment, connecting the first blade extension section 60 may include using a second crane, different from the first crane, to lift the first blade extension section 60 to the first blade root section 50. The second crane may be used to lift the third blade extension section 64 to connect it to the third blade root section 54. In an embodiment, the second crane may be smaller than the first crane, particularly in height. The first crane may have a higher mass lifting capacity than the second crane. For example, the second crane may be a vehicle-mounted crane. Specifically, the blade extension section 66 may be connected to the blade root section 56, while the blade root section 56 is oriented in a downward direction, particularly in a substantially vertical downward direction, such as, for example, in... Figure 4D and Figure 4E As illustrated in the diagram, the blade extension section 66 can be connected to the blade root section 56 at a lower height relative to the support surface 14 than the height at which the blade root section 56 is mounted to the rotor hub 20. Using a second crane (especially a second crane smaller than the first crane) can reduce the crane cost and / or crane time used for installing the blade, particularly the crane cost and / or crane time of the first crane.

[0064] In some embodiments, a crane (particularly a second crane or another crane) may be used to lift assembly personnel to the blade root section 56 mounted to the rotor hub to connect the blade extension section 66 to the blade root section 56. For example, the crane may be a vehicle-mounted crane. In embodiments, the crane may be used to lift assembly personnel to connect a first blade extension section 60 to the first blade root section 50, and / or to connect a third blade extension section 64 to the third blade root section 54. After being lifted to the blade root section 56, the assembly personnel may connect the blade extension section 66 to the blade root section 56, for example, by connecting a first joint member 78 of the blade root section 56 to a second joint member 84 of the blade extension section 66. Specifically, the first joint member 78 and the second joint member 84 may be connected according to the embodiments described herein (e.g., as...). Figure 6A (As shown in the image).

[0065] According to an embodiment, the extension static moment of the blade extension section 66 of blade 22 is at least 5%, particularly at least 10%, of the blade static moment of blade 22, and / or a maximum of 50%, particularly a maximum of 25%, of the blade static moment of blade 22. For example, the extension static moment can be in the range of 5% to 50% of the blade static moment, particularly in the range of 10% to 25%. The blade static moment and the extension static moment of blade 22 can be calculated or measured, particularly for blade 22 mounted to rotor hub 20, blade 22 having a blade longitudinal axis oriented in the horizontal direction.

[0066] The installation of the blade 22 according to the embodiments described herein can particularly reduce the torque acting on the main shaft 34 of the wind turbine 10 during the installation of the blade 22. Figure 5 A graph 200 illustrates the resultant torque 201 acting on the spindle 34 throughout the entire installation process 203. Specifically, graph 200 includes a first curve 205 (dashed line) of torque during installation according to the embodiment described herein. Graph 200 also includes a second curve 207 (solid line) of torque during conventional installation, where the blade is installed as a complete blade. The second curve 207 follows the installation progress of the first curve 205, where, in conventional installation, the complete blade is installed instead of the blade root section. The torque of either the first curve 205 or the second curve 207 can be calculated or measured, for example, in Newton-meters (Nm).

[0067] Referring to the first curve 205 of the installation according to the embodiment, at installation progress 203, at point 210, the rotor hub 20 has been installed. The rotor lock engages with the blade mounting position of the rotor hub 20 in its orientation for mounting the first blade root segment 50 (first curve 205) or the entire blade (second curve 207) to the blade mounting position. In the embodiment, the rotor lock of the wind turbine 10 may be configured to lock the rotor in a rotating position. The rotor lock may, for example, include a locking disc fixed to the main shaft 34 and rotatable with the main shaft, and a locking device for locking the locking disc in the rotating position. Specifically, the locking device may be fixed within the nacelle. The locking disc may include a plurality of holes spaced circumferentially around the main shaft rotation axis of the main shaft 34. The locking device may include a locking pin capable of engaging with one of the holes to lock the main shaft and rotor in the rotating position.

[0068] At position 212, the root section 50 of the first blade (first curve 205) or the complete blade (second curve 207) has been mounted to the rotor hub 20. For example, as Figure 4AAs shown, at 212, a high torque (e.g., a high positive torque) can act on the main shaft 34, and for example on the rotor lock. Compared to the conventional installation of the complete blade (second curve 207), the installation at this stage according to the embodiment (first curve 205) can reduce the torque by, for example, more than 10%.

[0069] At 214, the rotor lock is released. After the rotor lock is released, the high torque can be at least partially offset by the drive tool or rotor brake. The gearbox may be subjected to high torque, especially if the drive tool is configured to drive a high-speed shaft. At 216, the rotor has rotated to the next rotational position for mounting the third blade root section 54 (first curve 205) or for mounting another complete blade (second curve 207). At 218, the rotor lock is engaged. At 220, the third blade root section 54 (first curve 205, see also...) Figure 4B Either another complete blade (second curve 207) has been installed onto the rotor hub 20.

[0070] At 222, the rotor lock is released. At 224, the rotor has rotated to the next rotational position for mounting the second blade 72 (first curve 205) or for mounting another complete blade (second curve 207). Specifically, at 224, another high absolute value of torque is reached, particularly a high negative torque. At 226, the rotor lock is engaged. At 230, the second blade (first curve 205, see also...) Figure 4C Alternatively, another complete blade (second curve 207) has been installed onto rotor hub 20. At 230, three complete blades have been installed in the regular installation procedure, and the regular installation procedure can be completed.

[0071] At 232, the rotor lock is released. At 234 (first curve 205), the rotor has rotated to the next rotational position for connecting the first blade extension section 60 to the first blade root section 50. At 236, the rotor lock is engaged. At 240, the first blade extension section 60 has been connected to the first blade root section 50 (see also...). Figure 4D ).

[0072] At position 242, the rotor lock is released. At position 244, the rotor has rotated to the next rotational position for connecting the third blade extension section 64 to the third blade root section 54. Figure 5 In the example (see also) Figure 4D The rotor rotates so that the third blade extension section points substantially vertically downward, with the torque reaching approximately zero at 244. At 246, the rotor lock is engaged. At 250, the third blade extension section 60 is connected to the third blade root section 54. Figure 5As illustrated in the figures, the embodiments described herein offer the advantage of reduced torque acting on the spindle, gearbox, rotor lock, rotor brake, drive tool, or other components. In particular, the maximum absolute value of the torque (positive and / or negative torque) acting in one or both rotational directions of the rotor can be reduced, for example, by more than 10%.

[0073] According to some embodiments, at least one blade extension section 66 of the blades 22 is connected to the blade root section 56 of the blade 22 by a pitch angle offset relative to the pitch angle alignment line of the blade root section 56 and the blade extension section 66 during normal operation of the wind turbine 10. Specifically, the blade extension section 66 may be connected such that the extension section chord at the joint location between the blade root section 56 and the blade extension section 66 is offset by a pitch angle offset relative to the blade root section chord at the joint location. The blade extension section chord may extend between the leading edge and the trailing edge of the blade extension section 66. The root section chord may extend between the leading edge and the trailing edge of the blade root section 56.

[0074] In embodiments, the pitch angle offset may be at least 30 degrees, particularly at least 45 degrees. In some embodiments, the pitch angle offset is at least 90 degrees, particularly at least 135 degrees, and / or a maximum of 270 degrees, particularly a maximum of 225 degrees. For example, the pitch angle offset may be at least substantially 180 degrees. Connecting the blade extension sections 66 of blade 22 with the pitch angle offset may, for example, reduce the aerodynamic lift or aerodynamic torque of blade 22. A weather window for mounting blade 22 may be added. In embodiments, the method of mounting blade 22 may include disconnecting the blade extension sections 66 from the blade root section 56, particularly after each of the blade root sections 56 is mounted to the rotor hub 20 and after each of the blade extension sections 66 is connected to the blade root section 56. The method may include reconnecting the blade extension sections 66 to the blade root section 56, wherein the blade extension sections 66 and the blade root section 56 are aligned according to a pitch angle alignment line for normal operation. Specifically, disconnection and reconnection can be performed before the wind turbine 10 begins normal operation. Disconnection and reconnection can be performed for each blade 22 mounted to the rotor hub 20 with a pitch angle offset, for example, for all three blades 22.

[0075] In some embodiments, the method may include mounting a counterweight to the blade extension section 66. The method may include removing the counterweight from the blade extension section 66. In some embodiments, the counterweight may be static. In other embodiments, the counterweight may be controllable. For example, a counterweight mounted to the blade extension section 66 of blade 22 (which is mounted to rotor hub 20) may be controllable by pitching the blade 22. In particular, the counterweight may be rotationally asymmetrical relative to the pitch axis 28 of the blade 22. Pitching the blade 22 and the counterweight may change the counterweight torque, particularly the counterweight torque acting on the main shaft 34.

[0076] Another aspect of the invention relates to a hook-and-connector device 88. The hook-and-connector device 88 can be used in method 100 for mounting a blade 22 to a rotor hub 20 according to the embodiments described herein. The hook-and-connector device 88 can be used in other methods, particularly in methods in which a blade root section 56 is mounted to the rotor hub 20 and in which a blade extension section 66 is connected to the blade root section 56 after the blade root section 56 has been mounted to the rotor hub 20.

[0077] According to embodiments of the present disclosure, the blade 22 includes a blade root section 56 and a blade extension section 66, the blade extension section 66 being configured to connect to the blade root section 56. The blade extension section 66 may connect to an extended end section 77 of the blade root section 56. The extended end section 77 may be a section of the blade root section 56 located at the opposite end of the root of the blade root section 56 relative to the longitudinal axis of the blade root section.

[0078] In one embodiment, the blade root section 56 (particularly the extended end section 77) includes a first connector component 78 configured for connection to a second connector component 84 of the blade extension section 66. The first connector component 78 and the second connector component 84 can be connected between the blade root section 56 and the blade extension section 66 as a joint, particularly as a releasable joint. For example, the first connector component 78 and the second connector component 84 can be connected to form a flange joint, a bolted joint, a pin joint, or a combination thereof. Figure 6A An exemplary illustration shows a blade extension section 66 connected via a pin joint to a blade root section 56. The blade root section 56 includes a first joint member 78 at an extension end section 77. Figure 6AIn this assembly, the first connector component 78 includes a concave structural member 80 configured to receive a convex structural member 85 of the second connector component 84 of the blade extension section 66. The concave structural member 80 may include a first pin hole 82. The convex structural member 85 may include a second pin hole 86. When the convex structural member 85 is inserted into the concave structural member 80, the blade root section 56 and the blade extension section 66 are mechanically interlocked by inserting a connecting pin 76, for example, in the tangential direction into the first pin hole 82 and the second pin hole 86. Specifically, the connecting pin 76 may be inserted through a pin inlet 81 of the blade root section 56.

[0079] In embodiments, a method (particularly method 100 according to the embodiments described herein) may include mounting a hook-and-connector 88 to an extended end section 77 of a blade root section 56. For example, one or more hook-and-connectors 88 may be mounted to a first blade root section 50 and / or a third blade root section 54. In some embodiments, mounting the hook-and-connector 88 to the extended end section 77 includes connecting a coupling joint member 90 of the hook-and-connector 88 to a first joint member 78 of the extended end section 77. Specifically, the first joint member 78 and the coupling joint member 90 may be connected to form a flange joint, a bolt joint, a pin joint, or a combination thereof. For example, Figure 6B The diagram shows the installation process. Figure 6A An exemplary embodiment of the hook connection device 88 for the blade root section 56 shown is illustrated. The connection joint component 90 may include a connection joint convex structural member 91 capable of being inserted into a concave structural member 80 of the blade root section 56. The connection joint convex structural member 91 may include a connection joint pin hole 92. By inserting a connecting pin 76 into the first pin hole 82 and the connection joint pin hole 92, the hook connection device 88 can be mechanically interlocked with the blade root section 56.

[0080] In some embodiments, the hook connection device 88 is installed on the blade root section 56 before it is mounted to the rotor hub 20, particularly before it is lifted to the rotor hub 20. For example, the hook connection device 88 may be installed on the blade root section 56 when it is positioned on the support surface 14.

[0081] According to an embodiment, the method may include hooking a hook 96 of a lifting device 98 to a hook connection device 88. The lifting device 98 may include a pulling device such as a crane or winch. The winch may be positioned on a support surface 14, such as on a truck on the support surface 14. The lifting device 98 may include a hook 96. The hook 96 may be configured to hook to the hook connection device 88. The hook 96 may include, for example, a crane hook. In embodiments, the hook 96 may include an eye, a rope loop, or a wire loop. In some embodiments, the lifting device 98 may include a connection device 97 connected to the hook 96. The connection device 97 may be wound up by the pulling device to retract the connection device 97, and may be unwound from the pulling device to extend the connection device 97. The pulling device may be configured to pull the connection device 97. “Pulling” may be specifically understood as applying a force to the connection device 97, such as applying a pulling force when winding up the connection device 97, or applying a braking force when unwinding the connection device 97. The connection device 97 may include, for example, a rope, wire, chain, or a combination thereof. In some embodiments, hook 96 may engage with hook connection device 88 after the blade root section 56 has been mounted to rotor hub 20. In another embodiment, hook 96 may engage with hook connection device 88 before the blade root section 56 has been lifted to rotor hub 20.

[0082] In one embodiment, the method includes rotating the blade root section 56 relative to the rotor axis of the wind turbine 10 after mounting the blade root section 56 to the rotor hub 20, wherein the blade root section 56 is rotated using a lifting device 98. In the embodiment described herein, at least one blade root section 56 of the first blade root section 50 and the third blade root section 54 may be rotated using the lifting device 98. The blade root section 56 may be rotated from a first angular position to a second angular position. The first angular position and the second angular position can be understood as angular positions relative to the rotor axis of the rotor. The blade root section 56 may be rotated by using the lifting device 98 to pull the hook connection device 88.

[0083] In some embodiments, the lifting device 98 includes a connecting device 97 connected to the hook 96, and the rotating blade root section 56 includes a device using the lifting device 98 to pull the connecting device 97 downwards. Specifically, the connecting device 97 can be pulled downwards toward the support surface 14. The pulling mechanism of the lifting device 97 (particularly the entire pulling mechanism) can be positioned below the rotor, for example, on the support surface 14. Figure 7A The blade root section, particularly the third blade root section 54, is shown, having a hook-and-connector 88 attached to it. The hook-and-connector 88 is hooked to a connecting device 97 via a hook 96. The connecting device 97 is being pulled downwards using a lifting device 98. Specifically, the rotor has been rotated by pulling the third blade root section, such that the first blade root section 50 is positioned for connecting to the first blade extension section 60. Figure 7AIn this configuration, the lifting device 98 includes a winch mounted on a truck and positioned on a support surface 14. The lifting device 98 includes a connecting device 97 and a hook 96.

[0084] In one embodiment, the root section 56 of the rotating blade includes a connecting device 97 that is pulled upwards using a lifting device 98. Specifically, the connecting device 97 can be pulled upwards using a crane as the pulling device. For example, Figure 7B The rotor shown includes a blade root section (particularly the third blade root section 54) that rotates by pulling the lifting device 98 upwards via a connecting device 97. Figure 7B In the middle, the connecting device 97 is pulled by a crane, which acts as a pulling device.

[0085] In one embodiment, an installation method may specifically include using a first lifting device to pull a first connecting device of the first lifting device in an upward direction to rotate the rotor from a first angular position to a second angular position. The method may include using a second lifting device to pull a second connecting device of the second lifting device in a downward direction to rotate the rotor from a third angular position to a fourth angular position.

[0086] For example, according to the embodiments described herein, using a hook coupling device 88 mounted to the root section 50 of the first blade, the rotor can be rotated between the root section 50 of the first blade and the root section 54 of the third blade. Specifically, the rotor can be rotated from... Figure 4A The angular position shown is rotated to Figure 4B The rotor can be rotated by pulling the connecting device upwards or while pulling the connecting device upwards, particularly by applying a braking force to the connecting device while lowering the first blade root section 50. By pulling the connecting device upwards, the rotor can be mounted on the third blade root section 54 and the second blade 72. Figures 4B to 4C The rotor is rotated between the second blade 72 and the connecting device hooked onto the hook connecting device mounted to the root section 54 of the third blade. By pulling the connecting device hooked onto the root section 54 of the third blade in a downward direction, the rotor can rotate between the mounting of the second blade 72 and the connecting section 60 of the first blade. Figures 4C to 4D The rotor can rotate between the connecting device that pulls the hook to the root section 54 of the third blade in the downward direction. Figures 4D to 4EThe rotor is rotated between these positions. In embodiments, the rotor can be locked in each of the angular positions using a rotor lock for mounting the blade root section 56 or blade 22 to the rotor hub, or for connecting the blade extension section 66. In embodiments, the rotor can be rotated to and locked in the angular position without using a drive tool located in the nacelle to drive the main shaft or high-speed shaft, or the rotor can be rotated using a weaker drive tool. In some embodiments, extreme torsional loads on the gearbox can be reduced, particularly if the drive tool is used to drive the high-speed shaft.

[0087] In some embodiments, the method may include pre-tensioning the blade root section 56 in a first direction using a first connecting device coupled to a hook connecting device 88 and in a second direction using a second connecting device coupled to the hook connecting device 88, the first direction being different from the second direction. Specifically, the blade root section 56 may be pre-tensioned in the first direction by applying a force to the first connecting device. The blade root section 56 may be pre-tensioned in the second direction by applying a reaction force to the second connecting device by another pulling device. The pulling device and the other pulling device may include, for example, two winches (e.g., two winches positioned on a support surface) or a winch and a crane. For example, the blade root section may be stabilized by pre-tensioning, for example, during the installation of the blade root section to the rotor hub.

[0088] According to some embodiments, the hook coupling device 88 includes a remotely controllable locking device 94 configured to remotely controllably lock the hook 96 to the hook coupling device 88 and / or to remotely controllably release the hook 96 from the hook coupling device 88. In embodiments, the remotely controllable locking device 94 may include a locking device actuator 95 for locking the hook 96 to the hook coupling device 88. In particular, the locking device actuator 95 may be configured to actuate a gripper device 99 to lock the hook 96 to the hook coupling device 88 and / or release the hook 96 from the hook coupling device 88. For example, Figure 6B A hook connection device 88 is shown, including a locking device actuator 95 for actuating the clamping device 99.

[0089] In some embodiments, the hook coupling device 88 may include a remote control device. The remote control device may include a receiver device for receiving remote control signals. The remote control device may include a controller device configured to control the locking device actuator 95. The controller device may be communicatively connected to the receiver device. The controller device may be configured to control the locking device actuator 95 to lock the hook 96 in response to receiving a remote locking signal via the receiver device. The controller device may be configured to control the locking device actuator 95 to release the hook 96 in response to receiving a remote release signal via the receiver device. In some embodiments, the hook coupling device 88 may include an energy storage device, such as a battery, for powering the locking device actuator 95 and / or the remote control device. Remote control of the hook coupling device 88 may enable, for example, the efficient use of a crane to lift blades or blade sections and rotate the rotor.

[0090] The embodiments of this disclosure offer advantages such as reducing extreme torsional moments on the wind turbine's gearbox or other components (e.g., gearbox mounts, main shaft, retraction disc, rotor lock disc, high-speed shaft lock, and / or base plate) during blade installation. The gearbox and / or other components can be designed for lower extreme torsional moments. Extreme loads on the drive tools used to rotate the rotor during blade installation can be reduced. In particular, the cost of the gearbox, other components, and / or drive tools can be reduced. The embodiments may allow blade installation under higher wind conditions, particularly extending the weather window where the wind turbine can be assembled. Installation under higher wind conditions can particularly reduce assembly costs, such as crane costs or assembly personnel costs.

[0091] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system and performing any incorporated methods. The patentability of the invention is defined by the claims and may include other examples that would occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A method (100) for mounting blades (22) to a rotor hub (20) of a wind turbine (10), the wind turbine (10) comprising a tower (12), a nacelle (16) mounted on the tower (12), the rotor hub (20) coupled to the nacelle (16), and blades (22), each blade (22) comprising a blade root section (56) and a blade extension section (66), the method (100) comprising: - Lifting the first blade root section (50) of the first blade (70) to the rotor hub (20) and mounting the first blade root section (50) to the rotor hub (20), the first blade (70) having a first blade extension section (60); - After the first blade root section (50) is installed, the second blade (72) is lifted and installed into the rotor hub (20), the second blade (72) including the second blade root section (52) and the second blade extension section (62); and - After the second blade (72) is installed, the first blade extension section (60) is connected to the first blade root section (50).

2. The method (100) according to claim 1 further includes: - After the first blade root section (50) is installed and before the second blade (72) is installed, the third blade root section (54) is installed to the rotor hub (20).

3. The method (100) according to claim 2, further comprising: - After the second blade (72) is installed, the third blade extension section (64) is connected to the root section (54) of the third blade.

4. The method (100) according to any one of claims 1 to 3, wherein, The first blade extension section (60) is connected to the first blade root section (50), while the first blade root section (50) is oriented downward at an angle of at least 50 degrees relative to the horizontal plane; and / or The third blade extension section (64) is connected to the third blade root section (54), and the third blade root section (54) is oriented downward at an angle of at least 50 degrees relative to the horizontal plane.

5. The method (100) according to any one of claims 1 to 3, wherein, Installing the first blade root section (50) includes using a first crane to lift the first blade root section (50) onto the rotor hub (20); and wherein connecting the first blade extension section (60) includes using a second crane to lift the first blade extension section (60) onto the first blade root section (50), the second crane being different from the first crane.

6. The method (100) according to any one of claims 1 to 3, wherein, The extension static moment of the blade extension section (66) of the blade (22) is at least 5% of the blade static moment of the blade (22) and / or the maximum 50% of the blade static moment of the blade (22).

7. The method (100) according to any one of claims 1 to 3, wherein, At least one of the blades (22) has a blade extension section (66) connected to the blade root section (56) of the blade (22) by a pitch angle offset relative to the pitch angle alignment line of the blade root section (56) and the blade extension section (66) during normal operation of the wind turbine (10).

8. The method (100) according to claim 7, wherein, The pitch angle offset is at least 90 degrees and / or at most 270 degrees.

9. The method (100) according to any one of claims 1 to 3, further comprising: - Install the hook connection device (88) to the extended end section (77) of the blade root section (56); and - Hook the hook (96) of the lifting device (98) onto the hook connection device (88).

10. The method (100) according to claim 9, further comprising: - After the blade root section (56) is installed onto the rotor hub (20), the blade root section (56) is rotated relative to the rotor axis of the wind turbine (10), wherein the blade root section (56) is rotated using the lifting device (98).

11. The method (100) according to claim 9, wherein, The extended end section (77) includes a first connector component (78) configured for connection to a second connector component (84) of the blade extension section (66), and wherein mounting the hook coupling device (88) to the extended end section (77) includes connecting a coupling connector component (90) of the hook coupling device (88) to the first connector component (78) of the extended end section (77).

12. The method (100) according to claim 9, wherein, The hook connection device (88) includes a remotely controllable locking device (94) configured to remotely lock the hook (96) to the hook connection device (88) and / or to remotely release the hook (96) from the hook connection device (88).

13. The method (100) according to claim 9, wherein, The hook connection device (88) is installed on the blade root section (56) before the blade root section (56) is installed on the rotor hub (20).

14. The method (100) according to claim 9, wherein, The lifting device (98) includes a connecting device (97) connected to the hook (96), and wherein rotating the root section (56) of the blade includes using the lifting device (98) to pull the connecting device (97) in the downward direction.

15. The method (100) according to claim 9, further comprising: - The blade root section (56) is pre-tensioned in a first direction using a first connecting device connected to the hook connecting device (88) and in a second direction using a second connecting device connected to the hook connecting device (88), the first direction being different from the second direction.

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