Wind turbine alignment tool

Abstract

A tool (600) for aligning tubular structures (200, 300) of a wind turbine includes: a plurality of suspension members (601) configured to pivotally attach to an end region of a first tubular structure (300) to extend axially outward from that end region, each suspension member including a guide portion (605) adapted to engage an inner wall (203) of a second tubular structure (200); at least one cable (615) connecting the suspension members (601) together; and a tensioning mechanism arranged to adjust the tension of the at least one cable (615). When the first tubular structure (300) moves axially toward the second tubular structure (200), the tensioning mechanism is operable to adjust the tension to pivot the guide portion (605) to engage with the inner wall (203) of the second tubular structure (200), thereby guiding the first tubular structure (300) to axially align with the second tubular structure (200).

Description

Technical Field

[0001] The present invention relates to a tool for aligning a tubular structure of a wind turbine (e.g., an offshore or onshore wind turbine). Background Technology

[0002] A typical wind turbine consists of a tubular tower, a nacelle located on the tower and housing a generator connected to a drive hub via a shaft, and rotor blades attached to the drive hub. During on-site installation of the wind turbine, the tower is typically assembled using bolted flange-to-flange connections, and the nacelle is attached to the top of the tower. For proper connection, the flanges need to be centered so that they are face-to-face, and further rotated to align the bolt holes of the flanges.

[0003] The tower can consist of multiple sections, one placed on top of another to construct the tower. Each of these sections is a large and heavy structure. The same is true for the nacelle. Therefore, large cranes or other lifting equipment must be used to lift the tower sections and the nacelle. These operations are made more difficult because they are often carried out under non-ideal conditions, such as at sea or in uneven terrain.

[0004] In particular, the structure is susceptible to wind loads during its installation. In the case of offshore wind turbines, the tower is also subjected to forces from water waves. Therefore, when the nacelle is lowered toward the tower by a crane for attachment, the nacelle and tower can move laterally relative to each other. Similarly, the upper and lower sections of the tower can move laterally relative to each other during tower construction. These lateral movements make it difficult to align the structural center, thus hindering the achievement of the required flange-to-flange connections between them. The present invention aims to alleviate this problem at least to some extent. Summary of the Invention

[0005] According to one aspect of the invention, a tool for aligning a tubular structure of a wind turbine is provided, the tool comprising: a plurality of suspension members configured to pivotally attach to an end region of a first tubular structure to extend axially outward from the end region, each suspension member including a guide portion adapted to engage an inner wall of a second tubular structure; at least one cable connecting the suspension members together; and a tensioning mechanism arranged to adjust the tension of the at least one cable, wherein, when the first tubular structure moves axially toward the second tubular structure, the tensioning mechanism is operable to adjust the tension to pivot the guide portion to engage the inner wall of the second tubular structure, thereby guiding the first tubular structure to axially align with the second tubular structure.

[0006] As used in this article, "cable" refers to a slender, flexible component capable of withstanding tension (i.e., maintaining a state of tension). Examples include, but are not limited to, cables, wire ropes, cords, chains, etc.

[0007] The tension of the cable can be controlled by a tensioning mechanism to pivotally deploy the guide portion of the suspension member to engage with the inner wall of the second tubular structure. Thus, the first tubular structure is guided to be axially aligned or centered with the second tubular structure. The guide portion applies an outward radial force to the inner wall, the magnitude of which depends on the tension in the cable. Therefore, the tension in the cable can be controlled to suppress lateral oscillations or vibrations of the first and second tubular structures caused by crosswinds. As a result of damping, vibrations from any contact between the first and second tubular structures are reduced or eliminated.

[0008] Therefore, as the first tubular structure moves axially toward the second tubular structure, the alignment tool gradually guides the first tubular structure to axially align with the second tubular structure, while providing damping for oscillations or vibrations of the first and second tubular structures caused by crosswinds.

[0009] Each of the plurality of hoisting components may include a support portion, the support portion including a first pivoting feature for pivotally attaching.

[0010] The support member may include a cable attachment feature for attaching the at least one cable to the suspension member, the cable attachment feature and the guide portion being located on opposite sides of the first pivot feature, such that the tensioning mechanism can be operated to adjust the tension so that the guide portion pivots to engage with the inner wall of the second tubular structure.

[0011] Each of the plurality of suspension components may include an interface member for attachment to the end region of the first tubular structure, the interface member including a second pivot feature connected to the first pivot feature for the pivotally attachable configuration.

[0012] The pivoting feature may include a through hole formed in the support portion of the hoisting member; and the second pivoting feature may include a U-shaped clamp, the U-shaped clamp including a U-shaped clamping pin received by the through hole.

[0013] The interface component may include an elastic element arranged adjacent to the support portion of the suspension component. The elastic element is capable of elastically deforming due to the adjustment of the tension to allow the guide portion to pivot into engagement with the inner wall of the second tubular structure; and is capable of elastically restoring to resist the tension, thereby biasing the guide portion away from the inner wall of the second tubular structure.

[0014] The tool may include multiple support members, each configured to support a corresponding one of the suspension members against the inner wall of the first tubular structure, thereby limiting the range of pivoting movement of the guide portion away from the inner wall of the second tubular structure.

[0015] Each of the plurality of support members may be integrally formed with and extend from the support portion of a corresponding suspension member of the suspension members, and the end portion of each support member is adapted to engage the inner wall of the first tubular structure.

[0016] Each of the plurality of support components may include an extension of the interface component, the extension including a through-hole for receiving a fastener; and the tool may further include a plate adapted to engage each of the extension and the inner wall of the first tubular structure for positioning between the extension and the inner wall, the plate including a threaded hole for receiving a threaded portion of the fastener for securing the plate to the extension, thereby causing the head of the fastener to abut the support portion of the hanger component. Preferably, the fastener is adjustable to change the distance between the head and the inner wall of the first tubular structure.

[0017] The plate may include an elastic material for engagement with the inner wall of the first tubular structure.

[0018] The tensioning mechanism may include: an actuator comprising a movable part connected to and arranged to move the at least one cable to adjust the tension; and a controller arranged to control the movable part of the actuator.

[0019] The actuator may include a hydraulic cylinder, and the movable part may include the piston of the hydraulic cylinder.

[0020] The actuator may include an electromechanical linear actuator, and the movable part may include the screw shaft of the electromechanical linear actuator.

[0021] The tensioning mechanism may include: a spring having a first end and a second end connected to corresponding portions of the at least one cable; a clamp arranged to selectively compress and relax the spring; and a controller arranged to control the clamp.

[0022] According to another aspect of the invention, a wind turbine generator is provided, which is at least partially mounted and includes the tools described above herein.

[0023] According to another aspect of the invention, a method for installing a wind turbine generator is provided, the method comprising: pivotally attaching a plurality of sling members of an alignment tool to an end region of a first tubular structure of the wind turbine generator to extend axially outward from the end region, each sling member including a guide portion adapted to engage an inner wall of a second tubular structure of the wind turbine generator, the sling members being connected together by at least one cable of the tool; and axially moving the first tubular structure toward the second tubular structure and operating a tensioning mechanism of the tool to adjust the tension of the at least one cable, thereby pivoting the guide portion to engage the inner wall of the second tubular structure to guide the first tubular structure substantially axially aligned with the second tubular structure.

[0024] According to another aspect of the invention, the use of the tools as described above herein in the methods described above herein is provided. Attached Figure Description

[0025] Embodiments will now be described by way of example with reference to the accompanying drawings, in which:

[0026] Figure 1 The wind turbine, including the nacelle mounted on the tower, is shown.

[0027] Figure 2 The upper part of the tower is shown separately;

[0028] Figure 3 A side view of a portion of a tool according to a first example of the invention is shown, the tool being attached to the lower part of the cabin;

[0029] Figure 4 A top view shows the part of the tool that is attached to the tool's cable;

[0030] Figure 5 The cut top view shows the part of the tool and the cable;

[0031] Figure 6 A top view shows multiple parts of the tool, along with a tensioning mechanism for controlling the tension of the cables, these parts being spaced apart circumferentially around the lower part of the cabin and connected together by cables; and

[0032] Figure 7 and Figure 8 The device used to support the tool portion on the cabin is shown. Detailed Implementation

[0033] Reference Figure 1 and Figure 2An exemplary offshore wind turbine 100 includes a tower 200 (with a mass of approximately 200-500 tons), a nacelle 300 (approximately 300-500 tons), a rotor hub 400, and multiple rotor blades 500a-500c.

[0034] Tower 200 comprises a tubular (e.g., cylindrical) structure having a longitudinal or vertical axis Zt. The lower end (not shown) of tower 200 is anchored to the seabed. Nacelle 300 is mounted to tower 200. Although... Figure 1 Not shown, but a tubular (e.g., cylindrical) structure 301 of the nacelle 300 having a longitudinal or vertical axis Zn extends downward from the lower surface of the nacelle 300. The base of the tubular structure 301 of the nacelle 300 includes a flange portion 303, which is bolted to a complementary flange portion 201 at the upper end of the tower 200 (see...). Figure 2 The nacelle 300 also includes a housing 301 that houses a generator (not shown). A rotor hub 400 extends from the nacelle 300 and is connected to the generator via a horizontally arranged shaft (not shown) having an axis Xs substantially perpendicular to the longitudinal axis Zt of the tower 200. Rotor blades 500a-500c are attached to the rotor hub 400. In operation of the wind turbine 100, wind forces acting on the rotor blades 500a-500c cause them to rotate about the horizontal axis Xs, thereby driving the generator via the shaft to produce electrical energy.

[0035] The installation of the nacelle 300 on the tower 200 is performed with the aid of an alignment tool, which will now be described.

[0036] See Figures 3 to 6 The exemplary alignment tool 600 includes a plurality of hanger components 601 ( Figures 3 to 5 Only one is shown in the image), each pylon member is connected to the flange portion 303 of the tubular structure 301 of the nacelle 300. Figures 3 to 5 (Only a portion of it is shown in the image). In this example, tool 600 includes seven hanger components 601 (see [image]). Figure 6 These elements are regularly spaced apart from each other around the circumference of the flange portion 303 and radially spaced from the longitudinal axis Zn of the tubular structure 301. Therefore, when arranged on the flange portion 303 in this way, the tool 600 has a vertical or longitudinal axis Za that coincides with the longitudinal axis Zn of the tubular structure 301, i.e., along the longitudinal axis Zn of the tubular structure 301.

[0037] In this example, each suspension member 601 comprises steel. In this example, each suspension member 601 includes a bend defining a support portion 603 and a guide portion 605 of the suspension member 601. Figure 3As shown, when the hoisting member 601 is connected to the flange portion 303 of the tubular structure 301 of the nacelle 300, the support portion 603 extends vertically so as to be substantially parallel to the longitudinal axis Zn of the tubular structure 301 of the nacelle 300, while the guide portion 605 extends radially inward so as to be inclined relative to the longitudinal axis Zn.

[0038] Support portion 603 includes a through hole 607 for receiving a U-shaped clamping pin 609. Support portion 603 also includes an extended lug 611 having a through hole 613. Cable 615 of tool 600 is received in the through hole 613. In this example, cable 615 comprises steel. Guide portion 605 includes a curved outer surface 617 configured to interact with the curved inner flange wall 203 of tower 200 (see...). Figure 2 Consistent.

[0039] In this example, tool 600 also includes an interface member 619 for attaching the hoisting member 601 to the flange portion 303 of the tubular structure 301 of the cabin 300. In this example, the interface member 619 comprises steel. The interface member 619 includes a flange portion 621 having an outer surface configured to engage the flange portion 303 of the tubular structure 301 of the cabin 300. The flange portion 621 is secured to the flange portion 303 by at least one fastener, in this example, an expansion fastener, particularly an expansion bolt 623. The interface member 619 also includes a U-shaped clamp engagement portion 625 extending radially inward from the flange portion 621 and receiving a support portion 603 of the hoisting member 601. The hoisting member 601 is supported by a U-shaped clamp pin 609 extending laterally through the U-shaped clamp engagement portion 625.

[0040] Therefore, the sling member 601 is pivotally attached to the flange portion 303 of the tubular structure 301 of the cabin 300 and extends axially outward from the flange portion 303. That is, the sling member 601 is suspended or dangling downward from the U-shaped clamp 609 and is pivotally and rotationally related to the flange portion 303. The U-shaped clamp 609 extends in a direction substantially perpendicular to the longitudinal axis Zn of the tubular structure 301 of the cabin 300, and the sling member 601 is rotatable about the U-shaped clamp 609 in a plane intersecting the longitudinal axis Zn.

[0041] In this example, the interface member 619 also includes an elastic element 627, more specifically a rubber block, which is mounted to the inner surface of the flange portion 621 so as to be located between the flange portion 621 and the outer surface of the support portion 603 of the hanger member 601.

[0042] In this example, tool 600 also includes a support member 629 for supporting the hoisting member 601 against the inner wall 305 of the tubular structure 301 of the nacelle 300. In this example, the support member 629 comprises steel. In this example, the support member 629 is integrally formed with the hoisting member 601. The support member 629 extends outward from the support portion 603 of the hoisting member 601 and includes a curved outer surface 631 configured to conform to the curved inner wall 305 of the tubular structure 301 of the nacelle 300 (see [link to documentation]). Figure 2 and Figure 4 In this example, the curved outer surface 631 includes an elastic material, such as rubber, to protect the curved inner wall 305 from impact damage.

[0043] See details Figure 6 The cable 615 is arranged in a circular manner, and the circle formed by the cable 615 is substantially concentric with the circular flange portion 303 of the tubular structure 301 of the nacelle 300. The tool 600 also includes a tensioning mechanism arranged to control the tension of the cable 615, which will be described later. The tensioning mechanism includes an actuator located between the two ends of the cable 615, in this example a hydraulic cylinder 641. The hydraulic cylinder 641 contains hydraulic fluid, such as oil, and includes a movable, horizontally arranged piston 633 having a head in contact with the fluid and a rod extending from a first end of the hydraulic cylinder 641. A controller 635 is connected to the hydraulic cylinder 641 and configured to control the hydraulic fluid in the hydraulic cylinder 641 to move the piston 633. Control of the hydraulic fluid and the piston 633 can be achieved in various ways, such as a manual pump pressurizing the fluid and an accumulator acting as a “spring.” Alternatively, the accumulator can be replaced by a return spring in the hydraulic cylinder 641.

[0044] The first end of cable 615 is attached to the rod of piston 633 so that it can move together with piston 633. The second end of cable 615 is connected to the opposite end of the body of hydraulic cylinder 641 so as to be fixed thereto. That is, the second end of cable 615 is anchored to the opposite end of hydraulic cylinder 641.

[0045] like Figure 6 As shown, the head of piston 633 is located in the middle position within hydraulic cylinder 641. In this position, the tensioning mechanism is in a neutral state, where cable 615 is taut and not slack, but does not bear high tensile loads. In this neutral state, the hoisting member 601 is... Figure 3 The position shown indicates the location of the sling assembly 601 after the flange portion 303 of the tubular structure 301 attached to the nacelle 300, but before the sling assembly 601 is activated, so that the tubular structure 301 is axially aligned with the tower 200, thereby enabling flange-to-flange connections.

[0046] In this pre-start position, the support portion 603 of the hoisting member 601 is adjacent to the elastic element 627 of the interface member 619, but no compressive load sufficient to cause deformation of the elastic element 627 is applied to it.

[0047] Also in this pre-start position, the curved outer surface 631 of the support member 629 is adjacent to the inner wall 305 of the tubular structure 301 of the cabin 300.

[0048] Furthermore, in this pre-start position, the guide portion 605 of the hoisting component 601 is located radially inside the flange portion 303 of the tubular structure 301 of the nacelle 300. Additionally, no part or portion of the alignment tool 600 extends laterally into the tubular structure 301. That is, the entire alignment tool 600 is contained within a circle projected radially downward from the outer side of the tubular structure 301.

[0049] Furthermore, in this pre-start position, the guide portions 605 of the multiple hoisting components 601 together define a circle with a diameter smaller than the inner diameter of the upper part of the tower 200.

[0050] The use of the alignment tool 600 when installing the nacelle 300 onto the tower 200 will now be described.

[0051] See you again Figures 2 to 6 At the start of the alignment procedure, the alignment tool 600 is attached to the flange portion 303 of the tubular structure 301 of the cabin 300, and the hoisting component 601 is in the pre-start position, as described above.

[0052] For example, a crane is used to position the nacelle 300 above the tower 200, so that the tower 200 and the tubular structure 301 of the nacelle 300 are roughly vertically aligned. The nacelle 300 is then lowered toward the tower 200. Due to the interference forces exerted on the nacelle 300 by crosswinds, the nacelle 300 can move horizontally (i.e., left and right) and vertically (i.e., downwards). As a result, the longitudinal axis Zn of the tubular structure 301 of the nacelle 300 is laterally displaced relative to the longitudinal axis Zt of the tower 200. Depending on the intensity of the crosswinds, the lateral displacement can be as high as approximately 2 meters.

[0053] When the nacelle 300 is lowered, the curved outer surface 617 of one or more inwardly tilted guide portions 605 of the multiple pylon components 601 (see...) Figure 3 The inner edge of the flange portion 201 at the upper end of the tower 200 (see...) Figure 2 Contact. As the nacelle 300 moves further downward, the inwardly inclined guide portion 605 will be guided downward on its inner edge under the weight of the nacelle 300, causing the longitudinal axis Zn of the tubular structure 301 of the nacelle 300 to move laterally toward the longitudinal axis Zt of the tower 200.

[0054] It should be understood that when any guide portion 605 moves laterally to contact the inner edge of the flange portion 201 at the upper end of the tower 200, the inner edge will exert a reaction force on the guide portion 605 (in Figure 3 (In the sense of rightward). It should also be understood that the reaction force will not cause the hoisting component 601 to pivot about the U-shaped clamp 609 (i.e., in the sense of rightward). Figure 3 (In a sense, it is counterclockwise). This rotation of the gantry member 601 will be resisted by the tension Ft in the support member 629 and the cable 615, the curved outer surface 631 of the support member 629 abutting the curved inner wall 305 of the tubular structure 301 of the nacelle 300, and the tension Ft in the cable 615 acting radially inward. Therefore, the gantry member 601 is essentially rigid in terms of rotation and will not be deflected by the reaction force of the inner edge of the flange portion 201 at the upper end of the tower 200.

[0055] Therefore, the inclined guide portion 605 of the hoisting member 601 serves to generally guide the nacelle 300 toward axial alignment with the tower 200, even when the nacelle 300 is still subject to lateral movement due to crosswinds. Thus, the lateral displacement of the nacelle 300 is limited by the presence of the alignment tool 600. That is, lateral movement of the nacelle 300 is prevented by the contact between the guide portion 605 and the inner edge of the flange portion 201.

[0056] As the nacelle 300 is lowered further, the hoisting component 601 is activated to axially align the nacelle 300 with the tower 200, as described below.

[0057] Refer again Figure 6 The controller 635 is actuated to displace the hydraulic fluid in the hydraulic cylinder 641, thereby moving the piston 633 further into the hydraulic cylinder 641, thus reducing the length of the rod extending outside the body of the hydraulic cylinder 641. Since the first end of the cable 615 is attached to the rod, the cable 615 is pulled by the piston 633 and slides through the through-hole 613 of the extension lug 611 of the hanger member 601. As a result, the distance between the first and second ends of the cable 615 decreases, and the tension in the cable 615 increases.

[0058] Now refer to it again Figure 3 The tension Ft in cable 615 (acting radially inward, in) Figure 3 (In a sense, to the right, as indicated by the arrow) pull the extended lug 611 of each hanger member 601. The force Ft is transmitted via the outer surface of the support portion 603 of the hanger member 601 to the elastic element 627 of the interface member 625, and is sufficient to cause elastic deformation of the elastic element 627 (specifically, in...) Figure 3 In a sense, the lower part of the elastic element 627 causes the hanger member 601 to rotate around the U-shaped clamp 609 (in Figure 3(In a clockwise sense, as indicated by the arrow). As a result, the curved outer surface 617 of the guide portion 605 advances toward and engages with the curved inner flange wall 203 of the tower 200. Simultaneously, the curved outer surface 631 of the support member 629 disengages from the inner wall 305 of the tubular structure 301 of the nacelle 300, and the support portion 603 of the hoisting member 601 moves radially inward (in the sense of clockwise). Figure 3 (In the sense of moving to the right). Therefore, the diameter of the circle formed by the cable 615 passing through the extended lug 611 of the sling member 601 decreases.

[0059] When engaged in this manner with the curved inner flange wall 203, the hoisting member 601 is in the activated position. It should be understood that when multiple hoisting members 601 are in the activated position, the curved outer surface 617 together defines a circle with a diameter substantially equal to the inner diameter of the upper part of the tower 200.

[0060] Therefore, in the start position, the curved outer surface 617 of the guide portion 605 applies an outward radial force to the curved inner flange wall 203 of the tower 200, thereby centering the tubular structure 301 of the nacelle 300 on the tower 200, such that the longitudinal axis Zn of the tubular structure 301 is at least approximately axially aligned with the longitudinal axis Zt of the tower 200.

[0061] The movement of piston 633 within hydraulic cylinder 641 can be controlled so that the increase in tension Ft in cable 615 is gradual, rather than essentially instantaneous. In this way, the curved outer surface 617 of guide section 605 advances towards and engages with the curved inner flange wall 203 of tower 200 in a progressive manner, thereby avoiding the risk of vibration shocks that could cause damage.

[0062] As the nacelle 300 is lowered further toward the tower 200 in the final stage of the alignment process, the curved outer surface 617 of the guide portion 605 slides downward along the curved inner flange wall 203 of the tower 200. At this point, the tension in the cable 615 can be controlled such that the outward radial force exerted by the curved outer surface 617 is large enough to keep the tubular structure 301 axially aligned with the tower 200, but not large enough to prevent the curved outer surface 617 from sliding smoothly downward along the curved inner flange wall 203 of the tower 200, i.e., under the weight of the nacelle 300.

[0063] If the travel of the curved outer surface 617 on the curved inner flange wall 203 is not smooth, the friction between the two surfaces can be reduced by decreasing the tension Ft in the cable 615. To achieve this, the actuation controller 635 moves the hydraulic fluid in the hydraulic cylinder 641, causing the piston 633 to move back in the opposite direction, i.e., increasing the length of the rod extending outside the body of the hydraulic cylinder 641. Therefore, the distance between the first and second ends of the cable 615 increases, causing the cable 615 to slack slightly. (Refer again) Figure 3 The magnitude of the tension Ft is thus reduced. Therefore, the elastic element 627, having undergone elastic deformation, is able to recover to some extent, i.e., due to the energy stored in the elastic element 627 through its earlier compression, thereby exerting a reaction force on the outer surface of the support portion 603 of the suspension member 601 (in... Figure 3 (In the sense of acting radially inward to the right). As a result, the hanger component 601 rotates slightly back about the U-shaped clamp 609 (in the sense of acting radially inward to the right). Figure 3 (In the sense of counterclockwise rotation), thereby reducing the pressure exerted on the curved inner flange wall 203 by the curved outer surface 617. Therefore, the restoring elastic element 627 functions to bias the guide portion 605 away from the curved inner flange wall 203, at least to the extent permitted by the tension level in the cable 615. The elastic element 627 also functions as a shock absorber.

[0064] Therefore, the tension Ft in cable 615 can be controlled to allow the nacelle 300 to travel smoothly downwards. Furthermore, the tension in cable 615 can be controlled to maintain the axial alignment of the tubular structure 301 with the tower 200, while the nacelle 300 still experiences small lateral movements due to crosswinds. Additionally, the tension in cable 615 can be controlled to suppress lateral movements of the nacelle 300 due to crosswinds.

[0065] Finally, the flange portion 303 of the tubular structure 301 of the nacelle 300 engages with the flange portion 201 at the upper end of the tower 200. Thus, the nacelle 300 is positioned on top of the tower 200. In this resting position, the curved outer surface 617 of the guide portion 605 remains in contact with the curved inner flange wall 203 of the tower 200, ensuring that the tubular structure 301 of the nacelle 300 and the tower 200 are substantially perfectly axially aligned.

[0066] Therefore, as the nacelle 300 is lowered toward the tower 200, the alignment tool 600 gradually guides the tubular structure 301 of the nacelle 300 to be axially aligned with the tower 200, while providing damping for oscillations or vibrations of the nacelle 300 and tower 200 structures caused by crosswinds.

[0067] When the nacelle 300 is placed on the tower 200, it can be swayed if necessary, i.e., rotated about the longitudinal axis Zn of the nacelle 300 and the longitudinal axis Zt of the tower 200, so as to align the bolt holes of the flange portion 303 of the tubular structure 301 of the nacelle 300 with the bolt holes of the flange portion 201 at the upper end of the tower 200. At this point, the flange portion 303 of the tubular structure 301 can be described as the sway interface between the nacelle 300 and the tower 200. Once these bolt holes are aligned, bolts can be installed in these bolt holes to securely attach the nacelle 300 to the tower 200.

[0068] The alignment tool 600 is then preferably removed to improve personnel access to the structure and allow for reuse of the alignment tool 600 with another wind turbine. To remove the alignment tool 600, the cable 615 can be slacked in the manner described above, allowing the hoisting member 601 to return to its pre-start position. The expansion bolt 623 can then be removed to allow the tool 600 to be removed from the flange portion 303 of the tubular structure 301.

[0069] While in the example above, the support member 629 is integrally formed with the hanger member 601, in another example, the support member is integrally formed with the interface member 619. This example... Figure 7 and Figure 8 As shown, the support member 629' includes an extension 643 of the interface member 619. A through hole 645 is formed in the extension 643. In this example, the support member 629' is made of steel.

[0070] The plate 639 of tool 600 includes a bent side 631' for engaging with the inner wall 305 of the first tubular structure 300. In this example, the bent side 631' includes an elastic material, such as rubber, to protect the bent inner wall 305 from impact damage. Opposite sides of plate 639 are adapted to conform to the outer surface of the extension 643 of interface member 619. Plate 639 includes threaded holes. Figure 7 and Figure 8 (Not shown in the image).

[0071] from Figure 7 As can be most clearly seen, plate 639 is located between the extension 643 of interface member 619 and the inner wall 305 of the first tubular structure 300. A fastener (bolt 637' in this example) is received by a through-hole in extension 643 and extends to plate 639. The threaded end of bolt 637' engages with a threaded hole in plate 639 to securely attach plate 639 to extension 643. The head end of bolt 637' is positioned adjacent to the support portion 603 of hanger member 601. Figure 7 (Not shown in the image). In this example, bolt 637' can be finely adjusted (in... Figure 7(in the sense of left / right) so as to bring the head of bolt 637' to the desired position for the adjacent.

[0072] Still referencing Figure 7 In the example, the outer surface of the flange portion 621 of the interface member 619 includes a chamfer 621a to provide a second final fine alignment and ellipticity correction of the flange before the flange assembly.

[0073] While the alignment tool in the example above includes seven hanger components, the tool can include any other suitable number of hanger components. For example, the tool can include three, four, five, six, eight, nine, ten, or more hanger components.

[0074] In the example above, the elastic element 627 of the interface member 619 comprises a rubber block. It will be understood that the elastic element 627 may take various other forms, such as one or more springs. All these other forms are within the scope of the claimed invention, provided they function to bias the guide portion 605 away from the curved inner flange wall 203, and preferably also function as a shock absorber, as described above.

[0075] While in the above example, the alignment tool 600 includes an interface member 619 for attaching the hoisting member 601 to the flange portion 303 of the tubular structure 301 of the cabin 300, in other examples, the tool 600 does not include the interface member 619. In these examples, the flange portion 303 of the tubular structure 301 of the cabin 300 itself may include some structural features for pivotally attaching the hoisting member 601. For example, the flange portion 303 may include an integral U-shaped clamping engagement extending from the edge of the flange portion 303 for receiving the hoisting member 601 on a U-shaped clamping pin 609. Therefore, it can be understood that the interface member 619 is not a necessary feature of the tool 600. Rather, it is only required that the hoisting member 601 be pivotally mounted to the flange portion 303 in some way, whether directly to the flange portion 303 itself or indirectly via some intermediate element.

[0076] While in the above example, the alignment tool 600 includes support members 629, 629', in other examples, the tool 600 does not include support members. As described above herein, support members 629, 629' help the hoisting member 601 resist rotation under the reaction force applied to the guide portion 605 by the inner edge of the flange portion 201 at the upper end of the tower 200. In other examples, the tool 600 does not include support members. In such examples, resistance to rotation of the hoisting member 601 under said reaction force can be provided by the tension Ft in the cable 615, which acts radially inward. Therefore, it should be understood that support members 629, 629' are not a necessary feature of the tool 600.

[0077] While in the above example, the alignment tool 600 includes a U-shaped clamp 621; 609 for providing a pivotable connection between the flange portion 303 of the tubular structure 301 of the sling member 601 and the nacelle 300, it should be understood that various other types of pivotable connections are conceivable. All these other types are within the scope of the claimed invention, provided they provide a pivotable connection.

[0078] In the example above, cable 615 is connected to an extension lug 611 of the suspension member 601, which is located on one side of a U-shaped clamp 609 (on which the suspension member 601 pivots), while a guide portion 605 of the suspension member 601 is located on the other side of the U-shaped clamp 609. Therefore, when the tension Ft of cable 615 increases to pull the extension lug 611 radially inward, the guide portion 605 advances radially outward toward the curved inner flange wall 203 of the tower 200.

[0079] In other examples, the gantry member 601 is constructed differently such that the guide portion 605 advances radially outward as the tension Ft of the cable 615 decreases. In one such example, an extension lug 611 for cable connection is provided on the guide portion 605 of the gantry member 601, and the tool 600 includes a biasing member, such as a compression spring located between the support portion 603 and the curved inner wall 305 of the tubular structure 301 of the nacelle 300, arranged to apply a force to bias the guide portion 605 toward the curved inner flange wall 203 of the tower 200. In this example, in the pre-start position, the cable 615 remains taut, i.e., by a tensioning mechanism, to keep the biased guide portion 605 away from the curved inner flange wall 203 of the tower 200. The hoisting member 601 is activated by slack cable 615 (i.e., reducing the tension Ft in the cable), causing the guide portion 605 to advance toward the curved inner flange wall 203 under the force of the biasing member.

[0080] It should be understood that the hoisting member 601 can be configured in various ways regarding its pivot position and cable connection. In some of these configurations, the guide portion 605 advances when the tension in the cable 615 increases, while in others, the guide portion 605 advances when the tension in the cable 615 decreases. All of these configurations are within the scope of the claimed invention, and adjusting the tension Ft in the cable 615 causes or allows the guide portion 605 to advance toward the curved inner flange wall 203 of the tower 200.

[0081] Although the tensioning mechanism in the example above includes a hydraulic cylinder, other examples of the tool include different kinds of actuators for adjusting the tension of a cable, some of which will now be described.

[0082] In one example, the tensioning mechanism includes an electromechanical linear actuator 641' located between the two ends of a cable 615. The electromechanical linear actuator 641' includes a movable, horizontally arranged screw shaft 633'. The screw shaft 633' includes a driven portion and a rod portion that engages with a drive gear located within the housing of the electromechanical linear actuator 641', ​​the rod portion extending beyond a first end of the electromechanical linear actuator 641'. A controller 635' is connected to the electromechanical linear actuator 641' and configured to control the drive gear to displace the screw shaft 633'. The screw shaft 633' of the electromechanical linear actuator 641' is thus similar to the piston 633 of the hydraulic actuator 631 described above.

[0083] The first end of cable 615 is connected to the rod portion of screw shaft 633' so that it can move together with screw shaft 633'. The second end of cable 615 is connected to the opposite end of the body of electromechanical linear actuator 641' so as to form a fixed relationship with it. That is, the second end of cable 615 is anchored to the opposite end of electromechanical linear actuator 641'.

[0084] At a certain position on the screw shaft 633', the tensioning mechanism is in the aforementioned neutral state, wherein the cable 615 is taut and not slack, but is not subjected to high tensile loads. Therefore, the hoisting components 601 are in their pre-start position, as described above herein.

[0085] During the alignment process, the actuator controller 635' rotates the drive gear, thereby causing the screw shaft 633' to move further into the electromechanical linear actuator 641', ​​in order to reduce the length of the rod extending outside the body of the electromechanical linear actuator 641'. Since the first end of the cable 615 is connected to the rod, the cable 615 is pulled by the screw shaft 633' and slides through the through-hole 613 of the extension lug 611 of the hanger member 601. As a result, the distance between the first and second ends of the cable 615 decreases, and the tension in the cable 615 increases. Therefore, the hanger member 601 is activated in the manner described above.

[0086] The movement of the screw shaft 633' in the electromechanical linear actuator 641' can be controlled so that the increase in tension Ft in the cable 615 is gradual, rather than essentially instantaneous. In this way, the curved outer surface 617 of the guide section 605 advances towards and engages with the curved inner flange wall 203 of the tower 200 in a progressive manner, thereby avoiding the risk of impacts that could cause vibration damage, as already mentioned above herein.

[0087] As described above, if the travel of the curved outer surface 617 on the curved inner flange wall 203 is not smooth, the friction between the two surfaces can be reduced by decreasing the tension Ft in the cable 615. To achieve this, the controller 635' is actuated to rotate the drive gear, thereby causing the screw shaft 633' to move back in the opposite direction, i.e., to increase the length of the rod extending outside the body of the electromechanical linear actuator 641'. Therefore, the distance between the first and second ends of the cable 615 increases, causing the cable 615 to slack slightly. As described above, the hanger member 601 thus rotates slightly back about the U-shaped clamp 609, thereby reducing the pressure exerted by the curved outer surface 617 on the curved inner flange wall 203.

[0088] In another example, the tensioning mechanism actuator includes a spring 641", preferably a helical spring, located between and connected to the ends of the cable. The spring can be controlled to move between different degrees of compression / expansion to change the distance between the ends of the cable. For example, a helical clamp 633" can engage the spring and be adjusted by a controller 635 to selectively compress and relax the spring, thereby controlling the cable tension so that the tool functions as described above herein. More simply, the helical clamp can be arranged to allow the spring to move from a compressed state to a relaxed state, or vice versa, thereby changing the cable tension to move the hoisting member from a pre-start position to a start position.

[0089] It should be understood that the actuators described above are merely some examples of actuators suitable for use in the tensioning mechanism according to the claimed invention. Other suitable actuators include, but are not limited to: mechanical actuators; electromechanical actuators; pneumatic actuators; and telescopic linear actuators. All of these are within the scope of the claimed invention, provided they function to regulate the tension in the cable.

[0090] In the examples described above, the tensioning mechanism actuator is arranged such that the ends of the cable are brought closer together to increase the tension in the cable. In other examples, the ends of the cable can be moved apart to increase the tension in the cable. In one such example, the first end of the cable is wound in the opposite direction around a pulley or the like, such that moving the first end away from the second end of the cable causes an increase in the cable tension. All these arrangements are within the scope of the claimed invention, provided they function to move at least a portion of the cable to adjust the tension in the cable.

[0091] In the above example, the alignment tool 600 includes a single cable 615 arranged in a circular manner to connect the hanger components 601 together. In other examples, the tool 600 includes multiple cables for directly or indirectly connecting the hanger components 601 together. In one such example, the multiple cables are arranged radially in the manner of bicycle spokes, with the outer ends of the cables connected to individual hangers and the inner ends connected to a common central loop. The central loop is arranged to move via a tensioning mechanism, such as rotation or up / down movement, to adjust the tension in the cables, thereby activating the hanger component 601. In another example, the hanger components are arranged in pairs, diametrically opposed to each other, with each of the hanger components in each pair connected by a cable to the other opposing hanger component in that pair. It should be understood that various other cable arrangements are conceivable, and all of these are within the scope of the claimed invention, provided they function to adjust the tension in one or more cables to activate the hanger component 601.

[0092] While the alignment tool has been described in the examples above regarding the axial alignment of tubular sections of the tubular tower and nacelle, it should be understood that the alignment tool is equally applicable to the axial alignment of other tubular structures of the wind turbine, such as tubular sections or portions of the wind turbine tower. The alignment tool is suitable for any internal flange connection, nacelle-to-tower, tower-to-tower, or tower-to-foundation connection. An example is the nacelle and RNA (rotor nacelle assembly, i.e., the nacelle and hub with blades). It should also be understood that the alignment tool is applicable to non-cylindrical tubular structures, such as the oval, elliptical, or rectangular tubular structures of the wind turbine.

[0093] It should be understood that the invention has been described with respect to preferred embodiments, and that the invention may be modified in many different ways without departing from the scope of the invention as defined by the appended claims.

Claims

1. A tool (600) for aligning tubular structures (200, 300) of a wind turbine (100), the tool comprising: Multiple hanger members (601) are configured to be pivotally attached to an end region of a first tubular structure (300) to extend axially outward from the end region, each hanger member (601) including a guide portion (605) adapted to engage the inner wall (203) of a second tubular structure (200). At least one cable (615) connects the hoisting components (601) together; as well as A tensioning mechanism, arranged to adjust the tension of the at least one cable (615), When the first tubular structure (300) moves axially toward the second tubular structure (200), the tensioning mechanism can be operated to adjust the tension so that the guide portion (605) pivots to engage with the inner wall (203) of the second tubular structure (200), thereby guiding the first tubular structure (300) and the second tubular structure (200) to be axially aligned.

2. The tool (600) according to claim 1, wherein, Each of the plurality of hoisting members (601) includes a support portion (603) that includes a first pivoting feature for pivotally attaching.

3. The tool (600) according to claim 2, wherein, The support portion (603) includes a cable attachment feature (611) for attaching the at least one cable (615) to the suspension member (601), the cable attachment feature (611) and the guide portion (605) being located on opposite sides of the first pivot feature, such that the tensioning mechanism can be operated to adjust the tension to pivot the guide portion (605) to engage with the inner wall (203) of the second tubular structure (200).

4. The tool (600) according to claim 2 or 3, wherein, Each of the plurality of hoisting components (601) includes an interface member (619) for attachment to the end region of the first tubular structure (300), the interface member (619) including a second pivot feature connected to the first pivot feature for the pivotally attachable configuration.

5. The tool (600) according to claim 4, wherein: The first pivoting feature includes a through hole (607) formed in the support portion (603) of the hoisting member (601); and The second pivoting feature includes a U-shaped clamp (625) which includes a U-shaped clamp pin (609) received by the through hole (607).

6. The tool (600) according to claim 4, wherein, The interface component (619) includes an elastic element (627) arranged adjacent to the support portion (603) of the suspension component (601), the elastic element (627) being: Due to the adjustment of the tension, it can elastically deform to allow the guide portion (605) to pivot into engagement with the inner wall (203) of the second tubular structure (200); and It can elastically recover to resist the tension, thereby biasing the guide portion (605) away from the inner wall (203) of the second tubular structure (200).

7. The tool (600) according to claim 2 or 3, the tool comprising a plurality of support members (629; 629'), each support member being configured to support a corresponding one of the suspension members (601) against the inner wall (305) of the first tubular structure (300), thereby limiting the range of pivoting movement of the guide portion (605) away from the inner wall (203) of the second tubular structure (200).

8. The tool (600) according to claim 7, wherein, Each of the plurality of support members (629) is integrally formed with and extends from the support portion (603) of the corresponding one of the hanging members (601), and the end portion of each support member (629) is adapted to engage the inner wall (305) of the first tubular structure (300).

9. The tool (600) according to claim 4, the tool comprising a plurality of support members (629; 629'), each support member being configured to support a corresponding one of the suspension members (601) against the inner wall (305) of the first tubular structure (300), thereby limiting the range of pivoting movement of the guide portion (605) away from the inner wall (203) of the second tubular structure (200).

10. The tool (600) according to claim 9, wherein: Each of the plurality of support members (629') includes an extension (643) of the interface member (619), the extension (643) including a through hole (645) for receiving a fastener (637'); and The tool (600) further includes a plate (639) adapted to engage each of the extension (643) and the inner wall (305) of the first tubular structure (300) for positioning between the extension (643) and the inner wall (305). The plate (639) includes a threaded hole for receiving a threaded portion of the fastener (637') for securing the plate (639) to the extension (643), thereby causing the head of the fastener (637') to abut the support portion (603) of the hanger member (601).

11. The tool (600) according to claim 10, wherein, The fastener (637') is adjustable to change the distance between the head and the inner wall (305) of the first tubular structure (300).

12. The tool (600) according to claim 10, wherein, Each of the plurality of support members (629) is integrally formed with and extends from the support portion (603) of a corresponding hanging member in the hanging member (601), the end portion of each support member (629) being adapted to engage the inner wall (305) of the first tubular structure (300), and the plate (639) comprising an elastic material for engagement with the inner wall (305) of the first tubular structure (300).

13. The tool (600) according to any one of claims 1 to 3, wherein, The tensioning mechanism includes: An actuator comprising a movable part connected to and arranged to move the at least one cable (615) to adjust the tension; and A controller (635; 635') is arranged to control the movable part of the actuator.

14. The tool (600) according to claim 13, wherein, The actuator includes a hydraulic cylinder (641), and the movable part includes a piston (633) of the hydraulic cylinder.

15. The tool (600) according to claim 13, wherein, The actuator includes an electromechanical linear actuator (641'), and the movable part includes the screw shaft (633') of the electromechanical linear actuator.

16. The tool (600) according to any one of claims 1 to 3, wherein, The tensioning mechanism includes: A spring (641") having a first end and a second end connected to corresponding portions of the at least one cable (615); A clamp (633") arranged to selectively compress and release the spring (641); and A controller (635") is arranged to control the clamp (633).

17. A wind turbine generator, which is at least partially mounted and includes the tool (600) according to any one of claims 1 to 16.

18. A method for installing a wind turbine generator, the method comprising: A plurality of slings (601) of the alignment tool (600) are pivotally attached to an end region of the first tubular structure (300) of the wind turbine generator to extend axially outward from that end region. Each sling (601) includes a guide portion (605) adapted to engage the inner wall (203) of the second tubular structure (200) of the wind turbine generator. The slings (601) are connected together by at least one cable (615) of the tool (600). The first tubular structure (300) is moved axially toward the second tubular structure (200) and the tensioning mechanism of the tool (600) is operated to adjust the tension of the at least one cable (615), thereby pivoting the guide portion (605) to engage with the inner wall (203) of the second tubular structure (200) so as to guide the first tubular structure (300) to be substantially axially aligned with the second tubular structure (200).

19. Use of the tool (600) according to any one of claims 1 to 16 in the method according to claim 18.

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