Method of servicing or installing wind turbine component using crane

Abstract

A method (100) of servicing or installing components of a wind turbine (10) using a crane (50), the wind turbine (10) comprising a nacelle (16) and a rotor hub (20) coupled to the nacelle (16) and rotatable about a rotor axis, the method (100) comprising: rotating the rotor hub (20) about the rotor axis to a first rotational position; lifting the crane (50) to the rotor hub (20) while the rotor hub (20) is positioned at the first rotational position; a mounting portion (21) that mounts the crane (50) to the rotor hub (20) when the rotor hub (20) is positioned at the first rotational position; and rotating the rotor hub (20) together with the crane (50) from the first rotational position to the second rotational position.

Description

Technical Field

[0001] The present disclosure relates generally to wind turbines, and more particularly to a method of repairing or installing components of a wind turbine using a crane, and to a crane for a wind turbine. Background Art

[0002] Wind power is considered one of the cleanest and most environmentally friendly energy sources currently available, and wind turbines have received increasing attention in this regard. A modern wind turbine typically includes a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The rotor blades capture kinetic energy from the wind using the known airfoil principle and transfer the kinetic energy through rotational energy to turn a shaft that couples the rotor blades to a gearbox, or if a gearbox is not used, the shaft couples the rotor blades directly to a generator. The generator then converts the mechanical energy into electrical energy that can be deployed to a utility grid.

[0003] During installation, removal or maintenance of wind turbine components, cranes are typically used to move the components, in particular for lifting the components from the ground to the hub or nacelle, or for lowering the components from the hub or nacelle to the ground. The use of large ground-based cranes can be very expensive and typically involves time-consuming transportation to the wind turbine site, and on-site assembly and disassembly of the crane. Alternatively, an uptower service crane can be used, which can be partially lifted to the nacelle, wherein the service crane is assembled on or in the nacelle.

[0004] However, using known maintenance cranes that can be raised to the nacelle may involve time-consuming processes, such as lifting several components up to the nacelle and lowering them down from the nacelle, as well as manual assembly and disassembly on the tower. Known maintenance cranes may also reduce the amount of space available in the nacelle for performing maintenance operations. Furthermore, a crane mounted in or on the nacelle may make access to some areas of the nacelle more difficult, such as access from the nacelle to a hatch in the tower that may be used as an escape route from the nacelle.

[0005] Accordingly, the present disclosure is directed to a crane and a method of installing a crane on a wind turbine that may reduce crane assembly time on site, reduce crane transportation effort, increase available space on the tower during maintenance or installation, provide increased safety, and / or provide cost-effective installation and / or maintenance of one or more components of a wind turbine. Summary of the invention

[0006] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0007] In one aspect, the present disclosure is directed to a method for repairing or installing a wind turbine component using a crane. The wind turbine includes a nacelle and a rotor hub. The rotor hub is coupled to the nacelle and is rotatable about a rotor axis. The method includes rotating the rotor hub about the rotor axis to a first rotational position. The method includes lifting the crane to the rotor hub when the rotor hub is positioned at the first rotational position. The method also includes mounting the crane to a mounting portion of the rotor hub when the rotor hub is positioned at the first rotational position. The method includes rotating the rotor hub together with the crane from the first rotational position to a second rotational position. It should be understood that the method may also include any additional steps and / or features as described herein.

[0008] In another aspect, the present disclosure is directed to a crane for a wind turbine. The crane includes a crane base configured to enable the crane to be mounted to a rotor hub of a wind turbine. The crane also includes a crane arm connected to the crane base. The crane base includes a connecting portion configured to enable the crane base to be fastened to the rotor hub when the crane is oriented with the connecting portion facing in an upward direction. It should be understood that the crane may also include any of the features as described herein, and / or may be configured for any of the operations of the methods described herein.

[0009] These and other features, aspects and advantages of the present invention will be further supported and described with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention.

[0010] Technical Solution 1. A method (100) for repairing or installing a component of a wind turbine (10) using a crane (50), wherein the wind turbine (10) comprises a nacelle (16) and a rotor hub (20) coupled to the nacelle (16) and rotatable about a rotor axis, the method (100) comprising:

[0011] Rotating the rotor hub (20) about the rotor axis to a first rotational position;

[0012] When the rotor hub (20) is positioned at the first rotational position, lifting the crane (50) to the rotor hub (20);

[0013] When the rotor hub (20) is positioned at the first rotational position, mounting the crane (50) to a mounting portion (21) of the rotor hub (20); and

[0014] The rotor hub (20) is rotated together with the crane (50) from the first rotational position to a second rotational position.

[0015] Technical Solution 2. The method (100) according to Technical Solution 1, wherein, in the first rotational position, the mounting portion (21) points in a downward direction.

[0016] Technical Solution 3. The method (100) according to Technical Solution 1 or 2, wherein, in the second rotational position, the mounting portion (21) of the rotor hub (20) is directed in an upward direction.

[0017] Technical Solution 4. A method (100) according to any one of the preceding technical solutions, wherein lifting the crane (50) to the rotor hub (20) comprises lifting the crane (50) using a connection device (82) arranged through the rotor hub (20).

[0018] Technical Solution 5. A method (100) according to any one of the preceding technical solutions, wherein mounting the crane (50) to the rotor hub (20) comprises fastening the crane (50) to the mounting part (21), wherein the fastening operation for fastening the crane (50) to the mounting part (21) is performed inside the rotor hub (20).

[0019] Technical Solution 6. A method (100) according to any one of the aforementioned technical solutions, wherein the mounting portion (21) is at least partially located on the outer surface of the rotor hub (20), between two blade flanges of the rotor hub (20).

[0020] Technical Solution 7. A method (100) according to any one of the aforementioned technical solutions, wherein the rotor hub (20) is rotated from the first rotational position to the second rotational position using a driving tool installed in the nacelle (16), and the driving tool is configured to rotate a main shaft (34) of the wind turbine (10), and the main shaft (34) is connected to the rotor hub (20).

[0021] Technical solution 8. The method (100) according to any one of the above technical solutions, further comprising:

[0022] After rotating the rotor hub (20) together with the crane (50) from the first rotational position to the second rotational position, at least a portion of a roof (70) of the nacelle (16) is lifted using the crane (50).

[0023] Technical solution 9. The method (100) according to any one of the preceding technical solutions, wherein the crane (50) comprises a crane base (52), the crane base (52) being configured to enable the crane (50) to be mounted to the rotor hub (20), the crane (50) further comprising at least one load bearing arm (56) connectable to the crane base (52) and the nacelle (16), the method (100) further comprising:

[0024] After rotating the rotor hub (20) together with the crane (50) from the first rotational position to the second rotational position, the at least one load bearing arm (56) of the crane (50) is connected to the nacelle (16).

[0025] Technical Solution 10. The method (100) according to Technical Solution 9, wherein the at least one load-bearing arm (56) is mounted to a floor (46) of the nacelle (16).

[0026] Technical Solution 11. The method (200) according to any one of the above technical solutions, further comprising:

[0027] The component of the wind turbine (10) is lifted using the crane (50).

[0028] Technical Solution 12. The method (200) according to Technical Solution 11, wherein the component of the wind turbine (10) is a component of a drive train of the wind turbine (10).

[0029] Technical Solution 13. The method (200) according to Technical Solution 11, wherein the component of the wind turbine (10) is a rotor blade (22) or a rotor blade segment of the wind turbine (10).

[0030] Technical solution 14. A crane (50) for a wind turbine (10), the crane (50) comprising:

[0031] a crane base (52) configured for mounting the crane (50) to a rotor hub (20) of the wind turbine (10); and

[0032] a crane arm (60) connected to the crane base (52);

[0033] The crane base (52) includes a connection portion (54) configured to secure the crane base (52) to the rotor hub (20) when the crane (50) is oriented with the connection portion (54) facing in an upward direction.

[0034] Technical Solution 15. A crane (50) according to Technical Solution 14, wherein the crane base (52) includes an attachment point for a connecting device (82), wherein the attachment point is arranged so that when the crane (50) is lifted using the connecting device (82), the crane (50) is suspended so that the connecting part (54) faces the upward direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] A complete and enabling disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0036] Figure 1 A perspective view of a wind turbine is shown;

[0037] Figure 2 illustrates a simplified interior view of a nacelle of a wind turbine, in particular illustrating the nacelle during normal operation;

[0038] Figure 3 A flow chart illustrating a method of repairing or installing a component of a wind turbine using a crane according to an embodiment of the present disclosure;

[0039] Figure 4 A schematic diagram showing a crane being lifted to the rotor hub of a wind turbine;

[0040] Figure 5 a schematic diagram showing a crane mounted to a mounting portion of a rotor hub;

[0041] Figure 6 shows a schematic diagram of a wind turbine in which a rotor hub rotates with a crane mounted on the rotor hub;

[0042] Figure 7 A schematic diagram showing a crane mounted on the rotor hub lifting the canopy section off the nacelle;

[0043] Figure 8 shows a schematic cross-sectional view of a crane with a load-bearing arm connected to the floor of a nacelle;

[0044] Fig. 9 shows a schematic top view of a crane mounted on a rotor hub and having a load bearing arm connected to the bedplate of the nacelle;

[0045] Fig.10 A flow chart illustrating a method of repairing or installing a component of a wind turbine according to an embodiment of the present disclosure;

[0046] Fig.11 a schematic diagram showing a crane during maintenance of a gearbox; and

[0047] Fig.12 Schematic diagram showing a crane during installation of a rotor blade. DETAILED DESCRIPTION

[0048] Reference will now be made in detail to embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. Each example is provided as an explanation of the present disclosure rather than as a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present disclosure without departing from the scope or spirit of the present disclosure. For example, a feature illustrated or described as part of one embodiment may be used together with another embodiment to produce yet another embodiment. Therefore, it is intended that the present disclosure covers such modifications and variations and their equivalents as fall within the scope of the appended claims.

[0049] Now referring to the accompanying drawings, Figure 1 A perspective view of a wind turbine 10 according to the present disclosure is illustrated. As shown, the wind turbine 10 generally includes a tower 12 extending from a supporting surface 14 (eg, the ground), a nacelle 16 mounted on the tower 12 , and a rotor 18 coupled to the nacelle 16 .

[0050] like Figure 1 As shown in , the rotor 18 includes a rotatable rotor hub 20 and at least one blade 22 coupled to the rotor hub 20 and extending outwardly from the rotor hub 20. For example, in the illustrated embodiment, the rotor 18 includes three blades 22. However, in alternative embodiments, the rotor 18 may include more or less than three blades 22. Each blade 22 may be spaced about the rotor hub 20 to facilitate rotating the rotor 18 so that kinetic energy can be converted from the wind into usable mechanical energy and subsequently into electrical energy. For example, the rotor hub 20 may be rotatably coupled to a generator 24 ( Figure 2 ), to allow the generation of electrical energy.

[0051] 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 external to the wind turbine 10. Furthermore, the controller 26 may be communicatively coupled to any number of components of the wind turbine 10 to facilitate control of the components. As such, the controller 26 may include a computer or other suitable processing unit. Thus, in several embodiments, the controller 26 may include suitable computer-readable instructions that, when implemented, configure the controller 26 to perform a variety of different functions, such as receiving, transmitting, and / or executing wind turbine control signals.

[0052] Reference now Figure 2 , which illustrates Figure 1 1 is a simplified internal view of the nacelle 16 of the wind turbine 10 shown in FIG. 1 , particularly illustrating its drive train components. More specifically, as shown, the generator 24 can be coupled to the rotor 18 for generating electrical power from the rotational energy generated by the rotor 18. The rotor 18 can be coupled to a main shaft 34, which can rotate via main bearings (not shown). The main shaft 34 can, in turn, be rotatably coupled to a gearbox output shaft 36 of the generator 24 through a gearbox 30. The gearbox 30 may include a gearbox housing 38, which is connected to a bottom plate 46 via one or more torque arms 48. More specifically, in certain embodiments, the bottom plate 46 may be a forged component in which the main bearings (not shown) are seated and through which the main shaft 34 extends. As generally understood, the main shaft 34 provides a low-speed, high-torque input to the gearbox 30 in response to the rotation of the rotor blades 22 and the rotor hub 20. Thus, the gearbox 30 converts a low speed, high torque input to a high speed, low torque output to drive the gearbox output shaft 36 and, therefore, the generator 24 .

[0053] 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, wind turbine 10 may include one or more yaw drive mechanisms 42 communicatively coupled to controller 26, wherein each yaw drive mechanism 42 is configured to change the angle of nacelle 16 relative to the wind (e.g., by engaging a yaw bearing 44 of wind turbine 10).

[0054] Typically, components of modern wind turbines may be very heavy. For example, the gearbox of some modern wind turbines may have a mass of approximately 45 metric tons. For installation, removal, replacement and / or repair, it may be necessary to lift the wind turbine components to or lower them from the nacelle or rotor hub, or it may be necessary to reposition them on the tower. In embodiments of the present disclosure, the components of the wind turbine to be moved using the crane may include major components of the wind turbine, in particular components of the nacelle, such as a transformer and / or one or more drive train components, such as a gearbox or a generator. Additionally or alternatively, the components of the wind turbine to be lifted by the crane according to an embodiment may include rotor blades or rotor blade segments of rotor blades.

[0055] The crane according to the embodiments described herein is configured to be lifted and mounted to a rotor hub. In particular, the crane can be lifted in an assembled state. After the crane is mounted to the rotor hub, the rotor hub is rotated to a different orientation, wherein the crane can be used to lift components of the wind turbine for maintenance or installation operations. Advantageously, the crane can be installed on the wind turbine in a short period of time, in particular without a long assembly time as with known ground-based cranes or known maintenance cranes assembled on the nacelle. In some embodiments, mounting the crane on the rotor hub can provide more space for personnel and equipment in the nacelle. Access from the nacelle to the hatch of the tower can be improved, thereby improving the safety of operations on the tower in particular due to the improved accessibility of the escape route. According to some embodiments, the crane, in particular the crane in an already assembled state, can be transported on a truck to the wind turbine site. Such transportation can facilitate logistics and / or reduce or avoid on-site assembly operations.

[0056] According to an embodiment of the present disclosure, a crane 50 is provided, which is configured to be mounted to the rotor hub 20 of the wind turbine 10. In particular, the crane 50 is a tower crane. In particular, the crane 50 may be configured to lift one or more components of the wind turbine 10 when the crane is mounted to the rotor hub 20 on the tower. Additionally or alternatively, the crane 50 may be used to lift equipment for servicing one or more components of the wind turbine 10 and / or equipment for installing one or more components of the wind turbine 10. According to an embodiment of the present disclosure, the crane 50 is a maintenance crane or an installation crane, particularly for servicing and / or installing one or more components of a wind turbine.

[0057] In an embodiment, the crane 50 includes a crane base 52 and a crane arm 60. In particular, the crane arm 60 is connected to the crane base 52. According to an embodiment, the crane base 52 is configured for mounting the crane 50 to the rotor hub 20 of the wind turbine 10. In particular, the crane base 52 may include a connection portion 54 configured for fastening the crane base 52 to the rotor hub 20, more specifically, for fastening the crane base 52 to the mounting portion 21 of the rotor hub 20. The connection portion 54 may be disposed on a first side of the crane base 52. The crane arm 60 of the crane 50 may be connected to a second side of the crane base 52, the second side being in particular opposite to the first side of the crane base 52.

[0058] The crane arm 60 may be rotatably mounted on the crane base 52. In particular, the crane 50 may comprise a crane arm rotation device 58 for rotating the crane arm 60 relative to the crane base 52 about a first crane axis. For example, the first crane axis may be directed at least substantially perpendicular to a first side and / or a second side of the crane base 52. The crane arm rotation device 58 may comprise a motor for rotating the crane arm 60. In some embodiments, the crane 50 may comprise a crane arm pivoting device for pivoting the crane arm 60 or a crane arm section about a second crane axis, in particular about a second crane axis perpendicular to the first crane axis. In particular, the crane arm pivoting device may comprise an actuator, in particular a pneumatic or hydraulic actuator, for pivoting the crane arm 60 or a crane arm section. In some embodiments, the crane arm 60 may be a single rigid arm. In further embodiments, the crane arm 60 may comprise a segmented arm. In some embodiments, which may be combined with other embodiments, the crane arm 60 may comprise an extendable arm or an extendable arm section, which may in particular extend the arm length of the crane arm 60. For example, the extendable arm or the extendable arm section may comprise a telescopic cylinder, in particular a pneumatic or hydraulic telescopic cylinder.

[0059] Figure 3 A method 100 for repairing or installing a component of a wind turbine 10 using a crane 50 according to an embodiment of the present disclosure is illustrated. The method 100 may include rotating the rotor hub 20 about the rotor axis of the rotor 18 to a first rotational position (block 110). In particular, the rotor hub 20 may be rotated such that a mounting portion 21 of the rotor hub 20 points in a downward direction. In this document, upward and downward are understood relative to the vertical direction, specifically relative to gravity. A downward direction is particularly understood as a direction having a downward direction component. An upward direction is particularly understood as a direction having an upward direction component. Thus, generally, the upward direction and the downward direction may deviate from a vertical upward direction and a vertical downward direction, respectively. For example, in order to point the mounting portion 21 in a downward direction, the rotor hub 20 may be rotated about the rotor axis of the rotor 18 such that the mounting portion 21 is positioned in a lower half of the rotor hub 20. In some embodiments, the mounting portion 21 may be particularly positioned at the lowest point of the rotor hub 20.

[0060] In an embodiment, the rotational position of the rotor hub 20, in particular the first rotational position and the second rotational position referred to herein, may be defined by the angular position of the mounting portion 21 around the rotor axis, in particular by the angular position of the center of the mounting portion 21 around the rotor axis. According to some embodiments, in the first rotational position, the angular difference between the center of the mounting portion 21 and the vertical downward direction may be less than 60 degrees, in particular less than 30 degrees or less than 20 degrees. In particular, the center of the mounting portion 21 may be oriented at least substantially in the vertical downward direction. If the wind turbine has three blades 22 mounted to the rotor hub 20, the rotor blades 22 arranged on the rotor hub 20 on opposite sides of the mounting portion 21 may be oriented, for example, to the 12 o'clock position, and the other two rotor blades 22 may be oriented to the 4 o'clock position and the 8 o'clock position, respectively. In particular, the mounting portion 21 may be positioned at the 6 o'clock position and may be accessible from below the rotor hub 20.

[0061] In an embodiment, the mounting portion 21 is at least partially located on the outer surface of the rotor hub 20, in particular between two blade flanges of the rotor hub 20, more particularly in the circumferential direction between the two blade flanges. In some embodiments, the rotor hub 20 may include a casting hub and a shell around the casting hub. The outer surface of the rotor hub may particularly refer to the outer surface of the casting hub. The method 100 may include removing at least a portion of the shell, in particular in order to expose the mounting portion before mounting the crane 50 to the mounting portion. In other embodiments, the rotor hub 20 may not have a shell around the casting portion of the rotor hub 20.

[0062] The mounting portion 21 of the rotor hub 20 may be configured to connect with the connecting portion 54 of the crane base 52 of the crane 50. In some embodiments, the mounting portion 21 may include at least one hole, in particular a plurality of holes, in the rotor hub 20. For example, the mounting portion 21 may include at least two groups of holes, in particular at least three groups of holes, which are spaced apart from each other in the outer surface of the rotor hub 20. For example, the holes may be through holes extending from the outer surface of the rotor hub 20 through the rotor hub wall of the rotor hub 20 to the interior of the rotor hub 20.

[0063] According to an embodiment, the method 100 includes lifting the crane 50 to the rotor hub 20 when the rotor hub 20 is positioned at the first rotational position (block 120). In particular, before lifting the crane 50, the crane 50 may be positioned below the rotor 18 of the wind turbine 10. The crane 50, in particular the crane base 52 of the crane 50, may be connected to a connection device 82, such as a lifting line connected to a winch 80, in particular to a rope, a cable or a chain. In some embodiments, lifting the crane 50 to the rotor hub 20 includes lifting the crane 50 using a connection device 82 arranged through the rotor hub 20. In particular, the connection device 82 may be arranged through an opening in a rotor hub wall of the rotor hub 20. The opening for the connection device 82 may, for example, be arranged in the region of a mounting portion 21 of the rotor hub 20. In some embodiments, the connection device 82 may be guided by a pulley 84 between the winch 80 and the crane 50. For example, the winch 80 may be fixed on a tower, for example in the nacelle 16 or in the rotor hub 20. In other embodiments, the winch 80 may be secured at another location, such as on the ground near the wind turbine 10 , with the connection device 82 directed up to the nacelle 16 or rotor hub 20 and back down to the crane 50 .

[0064] According to some embodiments, the crane 50 may be lifted with the crane 50 in an assembled state, in particular with the crane base 52 connected to the crane arm 60. The assembled state may particularly refer to a configuration of the crane base 52 and the crane arm 60 that is suitable for normal operation of the crane 50. Lifting the crane 50 in the assembled state may avoid or reduce assembly time on the tower.

[0065] In an embodiment, the crane base 52 includes an attachment point for the connection device 82, wherein the attachment point is arranged such that when the crane 50 is lifted using the connection device 82, the crane 50 is suspended with the connection portion 54 facing in an upward direction. In particular, the attachment point can be arranged on the crane base 52 such that a first side of the crane base 52 faces in an upward direction. A second side of the crane base 52, on which the crane arm 60 is attached to the crane base 52, can face in a downward direction. In particular, during normal operation of the crane 50, the crane 50 can be lifted in an orientation that is substantially flipped relative to the orientation of the crane 50.

[0066] According to an embodiment, the crane 50 is lifted to the rotor hub 20 until the crane 50 comes into contact with the rotor hub 20 , in particular until the connecting portion 54 of the crane 50 engages the mounting portion 21 of the rotor hub 20 .

[0067] Figure 4A cross-sectional view of a wind turbine 10 and a crane 50 being lifted from a truck 86 positioned on a support surface 14 (the ground) to a rotor hub 20 is shown. In some embodiments, the crane 50 (particularly the crane 50 already in an assembled state) may be transported to the wind turbine 10 on the truck 86. Figure 4 As shown in FIG. 1 , the connection device 82 is attached to an attachment point of the crane base 52 of the crane 50. The crane 50 is lifted by a winch 80 positioned in the nacelle 16, which winds up the connection device 82.

[0068] According to an embodiment of the present disclosure, the method 100 includes mounting the crane 50 to the mounting portion 21 of the rotor hub 20 (block 130), when the rotor hub 20 is positioned at the first rotational position, in particular after the crane 50 is lifted to the rotor hub 20. In particular, mounting the crane 50 to the rotor hub 20 may include fastening the crane 50, in particular the connecting portion 54 of the crane 50, to the mounting portion 21 of the rotor hub 20. For example, Figure 5 A crane 50 is shown mounted to the rotor hub 20 of the wind turbine 10 .

[0069] According to an embodiment, the connecting portion 54 is configured for fastening the crane base 52 to the rotor hub 20 when the crane 50 is oriented with the connecting portion 54 facing in an upward direction. In some embodiments, at least one fastening operation, in particular all fastening operations, for fastening the crane 50 to the mounting portion 21 are performed inside the rotor hub 20. For example, the connecting portion 54 of the crane base 52 may include a flange with threaded bolt holes. The bolts may be inserted through through holes of the rotor hub wall of the mounting portion 21 and into the threaded bolt holes of the flange to fasten the crane 50 to the rotor hub 20. Fastening the crane to the rotor hub using bolts may in particular be performed from inside the rotor hub 20. In another example, the connecting portion 54 of the crane base 52 may include a threaded rod protruding from a first side of the crane base 52. In particular, the threaded rod may be oriented in an upward direction when the crane 50 is lifted. The rod may be inserted through a corresponding through hole in the rotor hub wall of the mounting portion 21 of the rotor hub 20. The crane 50 can then be fastened to the rotor hub 20 by tightening the nuts on the threaded rods, particularly from the interior of the rotor hub 20. It should be appreciated that other connection mechanisms may be used to fasten the crane base 52 to the rotor hub 20. Installing the crane 50 from the interior of the hub may avoid the need for a climbing technician and / or increase safety during the installation process. In further embodiments, one or more fastening operations for fastening the crane 50 to the mounting portion 21 may be performed from the exterior of the rotor hub 20.

[0070] In some embodiments, the crane base 52 comprises at least two connection portions 54, such as flanges for fastening the crane base 52 to the rotor hub 20, in particular at least three connection portions 54. The at least three connection portions may be arranged non-collinearly. The mounting portion 21 may have a corresponding arrangement of connection points, for example groups of holes arranged in a pattern corresponding to the connection portions 54 of the crane base 52. In an embodiment, the connection portions 54 may be spaced apart from each other, for example at least one meter. The plurality of connection portions 54 may be particularly configured for supporting the crane 50 on the rotor hub 20 during rotation of the rotor hub 20 with the crane 50. The crane 50 according to some embodiments may have a mass greater than 5 metric tons, in particular greater than 7 metric tons or greater than 10 metric tons. In an embodiment, the crane 50 is mounted to the mounting portion 21 of the rotor hub 20 such that the rotor hub 20 can be rotated from a first rotational position to a second rotational position together with the crane 50.

[0071] According to an embodiment, the method 100 includes rotating the rotor hub 20 together with the crane 50 from a first rotational position to a second rotational position (block 140), in particular after mounting the crane 50 to the mounting portion 21 of the rotor hub 20. The second rotational position is different from the first rotational position. For example, Figure 6 The figure shows the rotation of the rotor axis from the first position ( Figure 5 ) is rotated to a second rotational position (e.g., a second rotational position in which the mounting portion 21 faces in a vertically upward direction, such as Figure 7 ) and the rotor hub 20 and the crane 50.

[0072] In some embodiments of the present disclosure, in the second rotational position, the mounting portion 21 of the rotor hub 20 points in an upward direction. In particular, the mounting portion 21 is positioned in the upper half of the rotor hub 20. More specifically, in the second rotational position, the angular difference between the center of the mounting portion 21 and the vertical upward direction may be less than 60 degrees, in particular less than 30 degrees or less than 20 degrees. In some embodiments, the center of the mounting portion 21 may be oriented in at least substantially a vertical upward direction.

[0073] The rotor hub 20 may be rotated from the first rotational position to the second rotational position using a drive tool mounted in the nacelle 16. The drive tool may be configured to rotate the main shaft 34 of the wind turbine 10, which is coupled to the rotor hub 20. In some embodiments, to rotate the main shaft 34, the drive tool may be coupled to a high-speed shaft (gearbox output shaft 36) of the wind turbine 10, which is coupled to the main shaft 34 and the rotor hub 20 via the gearbox 30 of the wind turbine 10. The drive tool may be, for example, a drive tool used to rotate the unbalanced rotor 18 of the wind turbine 10 during the installation of a single blade. Such a drive tool may sometimes be referred to as an unbalanced rotor rotation gear drive. For example, the drive tool may be mounted on the back side of the gearbox. The drive tool may mesh with teeth on a brake disk of the high-speed shaft to rotate the high-speed shaft, the main shaft 34, and the rotor hub 20. The drive tool may provide a torque for rotating the rotor hub 20 together with the crane 50 from the first rotational position to the second rotational position. The drive tool may be a dedicated device, in particular not a generator.

[0074] According to some embodiments, method 100 may include, after rotating rotor hub 20 with crane 50 from the first rotational position to the second rotational position, lifting at least a portion of roof 70 of nacelle 16 using crane 50 (block 150). Lifting roof 70 or a portion of the roof may provide crane 50 with access to components of wind turbine 10 disposed within nacelle 16. For example, Figure 7 The crane 50 is shown mounted on the rotor hub 20 and rotated to a second rotational position in which the mounting portion 21 and the crane 50 are oriented in a vertical upward direction. The crane arm 60 comprising a first crane arm section 62 and a second crane arm section 64 has been rotated toward the nacelle 16 using the crane arm rotation device 58. A first roof section 72 of the roof 70 is attached to the crane hook 66 of the crane 50. The crane 50 is used to lift the first roof section 72 from the nacelle 16. Subsequently, the first roof section 72 can be lowered to the ground. Figure 7 In the embodiment shown in FIG. 1 , the second roof part 74 remains on the nacelle 16 . After removing the first roof part 72 , the crane 50 can access the interior of the wind turbine, in particular for lifting wind turbine components of the nacelle 16 .

[0075] In some embodiments, the crane 50 further includes at least one load-bearing arm 56 connectable to the crane base 52 and the nacelle 16. The method 100 may include connecting the at least one load-bearing arm 56 of the crane 50 to the nacelle 16 (block 160). In particular, after rotating the rotor hub 20 with the crane 50 from the first rotational position to the second rotational position, and more particularly after lifting the canopy 70 or a canopy portion from the nacelle 16, the at least one load-bearing arm 56 of the crane 50 may be connected to the nacelle 16. The load-bearing arm 56 may in particular support a load lifted by the crane 50 and / or stabilize the crane 50 relative to the nacelle 16.

[0076] According to some embodiments, each of the at least one load-bearing arm 56 includes a first end connected to the crane base 52 or configured to be connected to the crane base 52, and a second end configured for connection to the nacelle 16. The second end may, for example, include a flange portion for connection to the nacelle 16. In some embodiments, the at least one load-bearing arm 56 may be mounted to the base plate 46 of the nacelle 16. In particular, the flange portion of the second end of the at least one load-bearing arm 56 may be fastened to one or more attachment points of the base plate 46. If the rotor hub 20 is rotated so that the crane 50 is positioned at the top of the rotor hub 20, the at least one load-bearing arm 56 may be particularly mounted to the base plate 46. For example, Figure 8 A crane 50 is shown having a load bearing arm 56 having a first end connected to a crane base 52 of the crane 50 and a second end connected to the floor 46 of the nacelle 16 .

[0077] In some embodiments, before the crane 50 is lifted to the rotor hub 20, at least one load-bearing arm 56 may be connected to the crane base 52. For example, the at least one load-bearing arm 56 may be connected to the crane base 52 via an actuator, in particular a hydraulic actuator. The actuator, in particular comprising a hydraulic folding mechanism, may be configured to fold the second end of the at least one load-bearing arm from an extended position back toward the crane base into a retracted position and from a retracted position away from the crane base into an extended position. Before rotating the rotor hub to the second rotational position, and in particular before removing the top cover 70 or a top cover portion, the at least one load-bearing arm 56 may be in the retracted position. Then, the actuator may extend or fold down the second end of the at least one load-bearing arm 56 toward the nacelle, in particular so that the second end may be mounted to the base plate 46. In further embodiments, the at least one load-bearing arm 56 may comprise one or more separate components that may be connected to the base plate 46 and the crane base 52 on the tower.

[0078] According to an embodiment, the at least one load bearing arm 56 may include at least two load bearing arms 56, in particular exactly two load bearing arms. In an embodiment, at least one or exactly one load bearing arm 56 may be mounted to the base plate 46 on each side of the main shaft 34. The at least one load bearing arm 56 according to the embodiments described herein may advantageously be used as a lever in order to provide lateral stabilization for the crane 50, support reaction loads and / or increase the lifting capacity of the crane 50, in particular by transferring loads from the crane 50 to the base plate 46. In particular, the loads on the rotor and / or the main bearings may be reduced.

[0079] Fig. 9 A top view of a crane 50 according to an exemplary embodiment is shown, which is mounted on a wind turbine, as explained in conjunction with an embodiment of the method 100. The crane 50 is mounted to a mounting portion 21 of a rotor hub 20, the mounting portion 21 being arranged between two rotor blades 22 of the wind turbine 10. A crane base 52 of the crane 50 is mounted to the mounting portion 21 via a plurality of flanges of a connecting portion 54 and bolts 55. The crane 50 includes a crane arm rotation device 58 ( Fig. 9 5 (not shown) for rotating a crane arm 60 of the crane 50 about a vertical first crane axis. The crane arm 60 is a segmented crane arm comprising a first crane arm section 62 and a second crane arm section 64. The second crane arm section 64 is actuatable to pivot relative to the first crane arm section 62 about a horizontal second crane axis. The crane 50 has been used to remove a portion of the top cover 70. The crane base 52 is connected to the floor 46 of the nacelle 16 via two load-bearing arms 56, one on each side of the drive train. The crane 50 can be used to lift wind turbine components of the nacelle 16, for example drive train components such as the gearbox 30.

[0080] According to an embodiment of the present disclosure, a method 200 of repairing or installing a component of a wind turbine 10 is provided, such as Fig.10 According to the embodiments described herein, for example, as combined with method 100 ( Figure 3 ), the method 200 includes placing the crane 50 on the wind turbine (block 210). It should be understood that in other embodiments, placing the crane 50 on the wind turbine may only involve some of the operations or steps described in conjunction with the method 100.

[0081] In an embodiment, the method 200 includes lifting a component of the wind turbine 10 using the crane 50 (block 220). In particular, the component of the wind turbine 10 may be a component of a drive train of the wind turbine 10, such as the gearbox 30 or the generator 24. For example, Fig.11A schematic cross-sectional view of a wind turbine 10 is illustrated with a crane 50 that has been mounted on a rotor hub 20 and rotated to a second rotational position. The crane 50 uses a crane hook 66 fixed to the gearbox 30 to lift the gearbox 30 of the wind turbine. In further embodiments, the crane 50 may lift further components of the nacelle, such as a transformer and / or equipment for repairing or installing components of the wind turbine 10. In an embodiment, lifting a component of the wind turbine 10 to repair the component may include lifting the component out of the nacelle 16. The component of the wind turbine 10 may be lowered to the ground, for example, for repair. The crane 50 may also lift a repaired component or a replacement component from the ground to the nacelle 16. In further embodiments, the crane 50 may lift a component of the wind turbine 10 to reposition the component in the nacelle 16 to provide access for repair operations in the nacelle 16.

[0082] According to some embodiments, the component of the wind turbine 10 lifted by the crane 50 may be a rotor blade 22 or a rotor blade segment of the wind turbine 10. In particular, the crane 50 may lift the rotor blade 22 or the rotor blade segment for installing or replacing one or more rotor blades 22 of the wind turbine 10. In some embodiments, before lifting the rotor blade 22 or the rotor blade segment, the rotor hub 20 may be rotated together with the crane 50 to a second rotational position different from the vertical upward direction. For example, the crane 50 may be centrally positioned between two blade flanges including a first blade flange to which the rotor blade 22 or the blade segment is to be installed. The crane 50 may be oriented at approximately 30 degrees from the vertical upward direction toward the first blade flange. Such a situation may occur, for example, in Fig.12 6 , wherein the crane 50 lifts a complete rotor blade 22 to be connected to a first blade flange 90. The first blade flange 90 is specifically positioned at the 3 o'clock position. The rotor blade 22 is lifted using a blade holder 88 secured to a crane hook 66 of the crane 50. In an embodiment, the crane 50 may lift a rotor blade 22 to install the rotor blade 22 at the rotor hub 20 for the first time, lift a repaired rotor blade 22 to reinstall the rotor blade 22, or lift a replacement rotor blade 22 to be installed at the rotor hub 20 during a rotor blade replacement.

[0083] According to embodiments of the present disclosure, which may be combined with other embodiments, the crane 50 may be configured to lift any component of the wind turbine 10 referred to herein, in particular when the crane 50 is mounted on the wind turbine 10. The crane 50 may be configured to lift a wind turbine component having a mass of at least 10 metric tons, in particular a mass of at least 15 metric tons or at least 20 metric tons. In some embodiments, the crane arm 60 may have a length of at least 3 meters, in particular a length of at least 5 meters or at least 7 meters. In this document, a component of a wind turbine may also be referred to as a wind turbine component.

[0084] In an embodiment of the present disclosure, the crane 50 may include a hoist line, a crane hook 66 on the hoist line, and / or a crane winch for the hoist line. It should be understood that the hoist line may be provided as a hoist rope, cable, chain, or other suitable connection device. In some embodiments, the winch of the crane 50 is fixed to one or more other components of the crane 50, such as to the crane base 52. In other embodiments, the winch may be separated from the crane 50. In particular, the hoist line of the crane 50 may be arranged to the crane 50 or guided to the crane 50 by a pulley, and in particular to the crane arm 60 of the crane 50. For example, the winch may be positioned on the ground, while the crane 50 is operated on the tower, and the hoist line of the crane 50 extends between the winch and the crane arm 60. Leaving the winch on the ground can reduce the weight to be lifted onto the tower.

[0085] According to some embodiments, the orientation of the crane base 52 relative to the outer surface of the rotor hub 20 may be adjustable. Adjusting the orientation may be performed by an actuator, in particular a hydraulic actuator. For example, the height of one or more connecting portions 54 between the first side of the crane base 52 and the outer surface of the rotor hub 20 may be adjusted so that the crane base 52 is tilted relative to the outer surface of the rotor hub 20. In particular, the actuator may be used to tilt the crane base 52 toward a horizontal orientation. For example, Fig.12 As shown in , for example, if the crane 50 is to be used in a second rotational position that deviates from the vertical upward direction, it may be advantageous to adjust the orientation of the crane base 52. The crane base 52 tilted toward the horizontal orientation may provide improved support for the crane 50 during lifting operations.

[0086] Embodiments of the present disclosure may provide advantages such as reducing the hoisting time for lifting a crane onto a tower. In some embodiments, the crane may be installed on a wind turbine in a very short time, such as a few hours. In particular, a crane according to an embodiment may eliminate the need for time-consuming assembly after transportation to a wind turbine site. For example, a crane according to some embodiments may be transported by a single truck and lifted to a rotor hub without time-consuming assembly steps on the ground. The crane may also be lifted and installed when the crane is already in an assembled state, thereby reducing the number of lifting operations and / or assembly steps on the tower. The use of the crane described herein may provide more space on the tower, particularly in the nacelle, for maintenance or installation operations and / or escape routes for personnel. Embodiments of the present disclosure may reduce the time for maintenance and / or installation of wind turbine components, reduce crane costs, personnel costs, and / or improve the safety of operations on the tower.

[0087] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any device or system and performing any combined method. The patentable scope of the invention is defined by the claims and may include other examples that 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 do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A method (100) of repairing or installing a component of a wind turbine (10) using a crane (50), the wind turbine (10) comprising a nacelle (16) and a rotor hub (20) coupled to the nacelle (16) and rotatable about a rotor axis, the method (100) comprising: Rotating the rotor hub (20) about the rotor axis to a first rotational position; When the rotor hub (20) is positioned at the first rotational position, lifting the crane (50) to the rotor hub (20); When the rotor hub (20) is positioned at the first rotational position, mounting the crane (50) to a mounting portion (21) of the rotor hub (20); and The rotor hub (20) is rotated together with the crane (50) from the first rotational position to a second rotational position.

2. The method (100) according to claim 1, wherein: In the first rotational position, the mounting portion (21) is directed in a downward direction.

3. The method (100) according to claim 1 or 2, wherein: In the second rotational position, the mounting portion (21) of the rotor hub (20) is directed in an upward direction.

4. The method (100) according to any one of the preceding claims, wherein: Lifting the crane (50) to the rotor hub (20) includes lifting the crane (50) using a connection device (82) disposed through the rotor hub (20).

5. The method (100) according to any one of the preceding claims, wherein: Mounting the crane (50) to the rotor hub (20) includes fastening the crane (50) to the mounting portion (21), wherein a fastening operation for fastening the crane (50) to the mounting portion (21) is performed inside the rotor hub (20).

6. The method (100) according to any one of the preceding claims, wherein: The mounting portion (21) is at least partially located on the outer surface of the rotor hub (20), between two blade flanges of the rotor hub (20).

7. The method (100) according to any one of the preceding claims, wherein: The rotor hub (20) is rotated from the first rotational position to the second rotational position using a drive tool mounted in the nacelle (16), the drive tool being configured for rotating a main shaft (34) of the wind turbine (10), the main shaft (34) being coupled to the rotor hub (20).

8. The method (100) according to any one of the preceding claims, further comprising: After rotating the rotor hub (20) together with the crane (50) from the first rotational position to the second rotational position, at least a portion of a roof (70) of the nacelle (16) is lifted using the crane (50).

9. The method (100) according to any one of the preceding claims, wherein: The crane (50) includes a crane base (52) configured for mounting the crane (50) to the rotor hub (20), the crane (50) further comprising at least one load bearing arm (56) connectable to the crane base (52) and the nacelle (16), the method (100) further comprising: After rotating the rotor hub (20) together with the crane (50) from the first rotational position to the second rotational position, the at least one load bearing arm (56) of the crane (50) is connected to the nacelle (16).

10. The method (100) according to claim 9, wherein: The at least one load bearing arm (56) is mounted to a floor (46) of the nacelle (16).

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