Wind turbine blade assembly device for ease of installation and removal in vertical position

Abstract

Methods and systems for assembling wind turbine blades for a wind turbine may include performing a vertical displacement of a blade holder elevator during assembly or disassembly of the wind turbine. The vertical displacement may be performed through either a hard connection or a flexible connection.

Description

[0001] Cross-references to patent applications

[0002] This patent application claims priority under the PCT (Patent Cooperation Treaty) to U.S. Provisional Patent Application Serial No. 63 / 329,538, entitled “Wind Turbine Blade Assembly Device for Easy Installation and Removal in Vertical Position,” filed on April 11, 2022, and is incorporated herein by reference in its entirety. Technical Field

[0003] Embodiments relate to apparatus, methods, and systems for wind turbine installation. Embodiments further relate to wind turbine assembly apparatus and methods and systems for installing and removing wind turbine assembly apparatus in a vertical position. Background Art

[0004] Wind power is considered to be one of the cleanest and most environmentally friendly energy sources currently available, and wind turbines have received increasing attention in this regard. Wind turbines are used to convert the kinetic energy of wind into electrical energy. Modern wind turbines typically include 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 rotate the main shaft (the rotor blades are connected to the gearbox, or if the gearbox is not used, the rotor blades are directly connected to the generator). The generator then converts the mechanical energy into electrical energy, which can be deployed to the utility grid, stored, or used in other local ways. Wind turbines typically include a rotor (i.e., a wheel) of considerable size connected to a nacelle disposed on the top of the tower. The nacelle includes a generator for generating electricity from the rotational motion energy generated by the rotor.

[0005] A conventional crane-assisted installation method is depicted in the following Figures 1A to 1F. Figure 1A illustrates an image 10 depicting components of a crane-assisted installation operation including a tower, one or more hoist wires, a lifted blade, a yoke, a crane arm, slings, and a hub. Figure 1B depicts an image 20 of components of a crane-assisted installation operation including a vertically lifted blade, a Liftra Blade Skylark retainer, and one or more hoist wires. Figure 1C depicts an external crane-assisted installation operation including a complete hub with a blade assembly and one or more hoist wires being lifted. Additionally, Figure 1D illustrates an image 40 of components of an external crane-assisted installation operation including a complete hub with a blade assembly and one or more hoist wires attached. Likewise, Figure 1E shows an image 50 of components of a crane-assisted installation operation including a horizontally lifted blade and one or more hoist wires. Finally, FIG. 1F depicts an image 60 of the components of a crane-assisted installation operation located at a nacelle, including a completed hub with blade assembly and one or more winch wires attached.

[0006] Conventional techniques such as those shown in Images 10, 20, 30, 40, 50, 60 of Figures 1A to 1F use an installation method that involves removing the blades and associated components into position with a crane (or a group of cranes), either external to the wind turbine or mounted on the wind turbine, for example operated via a lifting arm or wire ropes / slings.

[0007] As wind turbines and associated components increase in height and weight, there is an increasing need for large heavy cranes (onshore) and heavy lift or wind turbine installation vessels (WTIVs) (offshore). Conventional installation techniques depicted in Figures 1A to 1F are not adequate to handle the large equipment and installation or repair capabilities required as wind turbine installations increase. This lack of resources will ultimately lead to bottlenecks and delays in many wind farm projects. Summary of the invention

[0008] The following summary is provided to facilitate understanding of some of the unique innovative features of the disclosed embodiments and is not intended to be a complete description. A comprehensive understanding of the various aspects of the embodiments disclosed herein can be obtained by taking the entire specification, claims, drawings, and abstract as a whole.

[0009] It is therefore an aspect of an embodiment to provide methods and systems for improved wind turbine installation.

[0010] Another aspect of an embodiment is to provide a wind turbine assembly apparatus for easy installation and removal in a vertical position.

[0011] Another aspect of the embodiments is to provide methods and systems for wind turbine installation and for removal of blades, related components, and other systems.

[0012] The aforementioned aspects and other objects and advantages can now be achieved as described herein.A method and system for assembling a wind turbine blade for a wind turbine may include performing a vertical displacement of a blade holder lift during assembly or disassembly of the wind turbine.

[0013] In an embodiment, a hard connection may be used to perform vertical displacement of the blade holder lift. The hard connection may be based on gyroscopic stability and may include a holder based on the ability of the wind turbine blade to freely rotate on two axes from the hub end while being raised or lowered.

[0014] In an embodiment, a flexible connection may be implemented to perform vertical displacement of a blade holder lift, wherein the holder allows the wind turbine blade to rotate freely and securely from the hub end on more than two axes while being raised or lowered.

[0015] In one embodiment, the flexible connection may include at least one of the following connected to an end of the wind turbine hub: a chain, a cable, or a polymer interface.

[0016] Embodiments may further relate to forming a rotor by connecting / disconnecting wind turbine blades to a wind turbine hub. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings further illustrate the present invention and, together with the detailed description of the present invention, are used to explain the principles of the present invention. Like reference numerals in the accompanying drawings refer to the same or functionally similar elements in each individual view, and these drawings are incorporated into and constitute a part of the specification.

[0018] 1A-1F illustrate corresponding diagrams depicting a conventional crane-assisted installation method and system;

[0019] Figure 2A illustrates a diagram depicting a gyro arm handle that may be implemented in accordance with an embodiment;

[0020] Figure 2B illustrates a side view of a wind turbine blade according to an embodiment;

[0021] Figure 3A illustrates a top view and a side view of a wind turbine blade assembly device according to an embodiment;

[0022] Figure 3B A side view (at a low level) of a wind turbine blade assembly apparatus engaging wind turbine blades according to an embodiment is illustrated.

[0023] Figure 3C illustrates a side view (at a mid-level) of a wind turbine blade assembly according to an embodiment;

[0024] Figure 3D illustrates a side view (at a mid-level) of a wind turbine blade assembly according to an embodiment;

[0025] Figure 4A illustrates a schematic diagram of a wind turbine blade assembly including a wind turbine blade assembly device engaged with the blade according to an embodiment;

[0026] Figure 4B illustrates a schematic diagram of a lift-based wind turbine blade assembly according to an embodiment; and

[0027] Figure 4C A schematic diagram of winch-based wind turbine blade assembly according to an embodiment is illustrated.

[0028] Like reference numbers used herein may refer to the same or similar parts or elements. DETAILED DESCRIPTION

[0029] The specific values ​​and configurations discussed in these non-limiting examples may vary and are cited merely for illustration of one or more embodiments and are not intended to limit the scope thereof.

[0030] The subject matter will now be described more fully below with reference to the accompanying drawings, which form a part of this document and illustrate specific example embodiments by way of illustration. However, the subject matter may be embodied in a variety of different forms, and therefore, the subject matter covered or claimed is intended to be interpreted as not being limited to any example embodiment set forth herein; the example embodiments are provided for illustrative purposes only. Likewise, it is intended to provide a reasonably broad scope for the subject matter claimed or covered. Among other things, for example, the subject matter may be embodied as a method, device, component, or system. Thus, the embodiments may, for example, take the form of hardware, software, firmware, or any combination thereof (except the software itself). Therefore, the following detailed description is not intended to be interpreted as limiting.

[0031] Throughout the specification and claims, terms may have subtle meanings that are suggested or implied by the context, beyond the explicitly stated meanings. Likewise, phrases such as "in one embodiment" or "in an example embodiment" and variations thereof as used herein do not necessarily refer to the same embodiment, and phrases "in another embodiment" or "in another example embodiment" and variations thereof as used herein may or may not necessarily refer to different embodiments. For example, the claimed subject matter is intended to include, in whole or in part, a combination of the example embodiments.

[0032] In general, terms may be understood at least in part from their use in context. For example, terms such as "and", "or" or "and / or" as used herein may include multiple meanings that may depend at least in part on the context in which such terms are used. Typically, "or" (if used in an associative list, such as A, B, or C) is intended to mean A, B, and C (used herein in an inclusive sense) as well as A, B, or C (used herein in an exclusive sense). In addition, the term "one or more" as used herein (depending at least in part on the context) may be used to describe any feature, structure, or characteristic in a singular sense, or may be used to describe a combination of features, structures, or characteristics in a plural sense. Similarly, terms such as "a", "an", or "the" may again be understood to convey singular use or to convey plural use, depending at least in part on the context.

[0033] Furthermore, the term "based on" can be understood as not necessarily intended to convey an exclusive set of factors, but rather can allow for the presence of additional factors that are not necessarily explicitly described, again depending at least in part on the context. Furthermore, the phrase "at least one" can be understood to convey the meaning of "one or more." For example, "at least one widget" can convey the concept of "one or more widgets."

[0034] As previously mentioned, currently used, conventional tower assembly techniques may use wind turbine tower assembly methods that involve lifting wind turbine components into place with cranes. New methods are being developed that attempt to adapt conventional crane techniques to the erection of wind turbine components. These new methods, such as climbing cranes, tower cranes, etc., either utilize the wind turbine tower as its supporting foundation or member, or erect a box, lattice, or similar structure to mount a cantilever or crane system.

[0035] As will become clear from the following more detailed discussion, the disclosed embodiment uses neither conventional nor adapted assembly techniques of the type previously discussed, but rather includes its own unique rail system to elevate the self-climbing platform to carry a load to a determined height, once which height can then be acted upon with horizontal translational motion to place the load in place. Key novel features of the embodiment include continuous vertical and horizontal motion / displacement; no limits on load and height capabilities; the load is always secured in place by controlled motion (no sway or pendulum issues); and the ability to be used both onshore and offshore.

[0036] Embodiments allow users to lift any weight to any height (whether onshore or offshore) without the need for large, high-reach, high-capacity cranes to install complete wind turbines and / or their components. Embodiments also allow smaller loads to be transported to installation or repair sites, minimizing environmental impact and reducing carbon emissions compared to conventional systems with large mobilizations, large loads, and severe environmental impact and carbon emissions.

[0037] Embodiments relate to innovative methods and systems for assembling wind turbine blades. The methods relate to implementation methods and systems for performing vertical displacement of a blade holder lift during assembly and disassembly.

[0038] Wind turbine blade holders can be based on two systems. First, gyroscopic stabilization based on similar systems allows for hard connections, such as Figure 2A As shown in the device 80 shown in FIG. That is, Figure 2A A diagram depicting a gyro arm handle 82 is shown, which may be used, for example, with a television camera, which may include self-leveling and thus align itself with the horizontal plane, and which may be required when one moves closer to the hub on a wind turbine so that once the two flanges mate, the bolts will mate properly (e.g., the sockets align). In this case, a self-leveling bowl-type support is required so that the blade (e.g., Figure 2B and blades 90 shown elsewhere herein) can be lifted vertically straight and not bent at any angle. The retainer can be based on a wind turbine blade such as Figure 2B The blade 90 shown has the ability to rotate freely and securely on two axes from its hub end while being raised or lowered.

[0039] Second, a flexible connection may be implemented with the wind turbine hub end, for example using chains, cables or polymer interfaces. FIG. 4A to FIG. 4C As shown, the retainer may allow a wind turbine blade to rotate freely and securely from its hub end on more than two axes while being raised and lowered.

[0040] Figure 3A 1 and 2 illustrate a top view and a side view of a wind turbine blade assembly device 92 according to an embodiment. Figure 3A , and a side view of the wind turbine blade assembly device 92 is shown on the left side. Figure 3A is shown on the right side. Figure 3A The circular arrow 93 shown in the side view of the wind turbine blade assembly device 92 in FIG. 8 indicates the rotatability of the component 95 .

[0041] Figure 3BIllustrated is a side view (at a low level) of a wind turbine blade assembly apparatus 92 engaging a blade 90 with a component 95 according to an embodiment. Figure 3C Illustrated is a side view (at a mid-level) of a wind turbine blade assembly device 92 engaging a blade 90 according to an embodiment. Figure 3D A side view (at a mid-level) of a wind turbine blade assembly device 92 engaging a blade 90 according to an embodiment is shown.

[0042] Figure 4A A schematic diagram of a wind turbine blade assembly 100 including a wind turbine blade assembly device 92 engaged with a blade 90 is illustrated according to an embodiment. Figure 4A Other features shown include another blade 103 and a mechanical brake 105. Also shown are blade 90, wind turbine blade assembly device 92, and hub 109 of blade 90. Note that wind turbine blade assembly device 92 is located at the Figure 4A , Figure 4B and Figure 4C Also shown is a nacelle 111 with respect to a generator 112 and a pivoting system 115. The nacelle 111 and the hub are located above the pivoting system 115 towards the top of the tower 104.

[0043] Figure 4B A schematic diagram of a lift-based wind turbine blade assembly 127 is illustrated according to an embodiment. Note that Figure 4B The parts shown are Figure 4A The parts shown are the same, but Figure 4B Includes use of lifting platform frame / track 121.

[0044] Figure 4C A schematic diagram of a winch-based wind turbine blade assembly 127 is illustrated in accordance with an embodiment. Figure 4C The parts shown in Figure 4A and Figure 4B The parts shown in are similar, but Figure 4C Includes the use of winch 106.

[0045] From the above it will be appreciated that the holder can support the blade from the strongest section of the wind blade assembly, which is located at the hub end of the blade, which allows a flexible connection at this end to ensure that no unnecessary forces are generated when handling during lifting.

[0046] In additional embodiments, a method for assembling all wind turbine blades may involve connecting / disconnecting the blades to / from the hub to form the rotor.

[0047] Conventional techniques discussed in the background section of this disclosure employ methods of installing and removing blades and related components into place using one or more cranes, either external to or mounted on the wind turbine, such as by lifting jibs or wire ropes / slings.

[0048] However, an embodiment does not use any of these methods, neither a conventional crane nor its adaptation, nor a sling attached to a wind turbine, but has its own rail system to lift the self-climbing platform and the blade holder to carry the load to a determined height, which once reached will allow connection to the hub / rotor and enable installation of the blades. Alternatively, the self-climbing platform can also be raised and lowered via a rope / winch combination or any other similar lifting system with ropes / pulleys.

[0049] The platform arrangement may also allow the installation of a blade repair platform (where maintenance personnel can work), which can be used to repair blades in situ.

[0050] In addition to providing a safer installation method, the blade retainer system of the embodiment can allow for correct and safe handling of the blade and its components during installation, repair or removal. The key novel features of the embodiment include continuous controlled vertical displacement, no restrictions on load and height capabilities, a safer assembly method compared to the conventional methods previously discussed, a load that is always fixed in place by controlled movement (no sway or pendulum issues), and the ability to be used in both onshore and offshore applications.

[0051] Embodiments are superior to prior methods such as those discussed previously herein because they allow a user to install or remove any blade and associated components, regardless of the weight and height required, either onshore or offshore, without the need for hanging loads or the need for large, high reach, high capacity cranes, jib cranes or associated support systems.

[0052] As wind turbines and associated components increase in height and weight, there is an increasing need for large heavy-duty cranes (onshore) and (offshore) heavy-lift or wind turbine installation vessels (WTIVs). There is not enough of this large equipment to provide installation or repair capabilities around the world, and this lack of resources will lead to bottlenecks and delays in many wind farm projects.

[0053] Additionally, the cost and time spent on placing high capacity lifting (crane) equipment on site is very expensive and extensive. There are better installation methods that can be installed and repaired in parallel, saving time and cost for the end user / owner.

[0054] Environmental damage and carbon emissions reduction are also concerns. Our systems are also designed to reduce the environmental footprint by using the smallest possible cranes and the smallest possible transport loads, and by minimizing the area used at the wind turbine site and on the access roads.

[0055] The operating weather window is also short, especially in northern regions where the weather is colder, and having the ability to extend the operating window will allow for more efficient operations and save time.

[0056] Furthermore, there are many areas of the world that do not have the resources or ability to obtain large, heavy equipment, but would like to install, maintain and repair large capacity wind turbines and blades, but will not be able to do so due to the lack of installation and repair resources. Through our invention, we aim to allow any country, company or person to install and repair any desired wind turbine blade using existing small capacity cranes and fewer, safer resources.

[0057] The disclosed embodiments can solve the above problems while providing safer, more efficient and economical blade operation. Possible applications of the embodiments can also include, for example, wind turbine OEMs for onshore and offshore use, wind turbine operations and maintenance, wind turbine blade service and repair, crane rental applications of any type, space or aerospace related industries, and any industry or activity that may require lifting, repairing and / or replacing wind turbine blades or similar components. Other applications include offshore construction and / or repair applications involving lifting and handling systems in their operations, and EPIC / EPCI (engineering, procurement, installation and commissioning) applications.

[0058] It should be understood that variations of the above disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. It should also be understood that various currently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, and the alternatives, modifications, variations or improvements are also intended to be covered by the appended claims.

Claims

1. A method for assembling a wind turbine blade for a wind turbine, comprising: The vertical displacement of the blade holder lift is performed during assembly or disassembly of the wind turbine. 2 . The method of claim 1 , further comprising using a hard connection to perform the vertical displacement of the blade holder elevator.

3. The method according to claim 2, wherein: The hard connection is based on gyroscopic stability.

4. The method according to claim 2, wherein: The hard connection includes a retainer operable based on the ability of the wind turbine blade to freely rotate on two axes from the hub end while being raised or lowered. 5 . The method of claim 1 , further comprising using a flexible connection to perform the vertical displacement of the blade holder elevator.

6. The method according to claim 5, wherein: The retainer allows the wind turbine blade to rotate freely and securely from the hub end on two or more axes while being raised or lowered.

7. The method according to claim 5, wherein: The flexible connection comprises at least one of the following connected to an end of the wind turbine hub: Chain, Cable, or Polymer interface.

8. The method of claim 7, further comprising forming a rotor by connecting or disconnecting wind turbine blades to the wind turbine hub.

9. A system for assembling a wind turbine blade for a wind turbine, comprising: A blade holder elevator is vertically displaced during assembly or disassembly of a wind turbine.

10. The system according to claim 9, wherein: A hard connection is used to perform the vertical displacement of the blade holder elevator.

11. The system according to claim 10, wherein: The hard connection is based on gyroscopic stability.

12. The system according to claim 10, wherein: The hard connection includes a retainer operable based on the ability of the wind turbine blade to rotate freely on two axes from the hub end while being raised or lowered.

13. The system according to claim 10, wherein: The vertical displacement of the blade holder elevator is performed using a flexible connection.

14. The system according to claim 10, wherein: The retainer allows the wind turbine blade to rotate freely and securely from the hub end on two or more axes while being raised or lowered.

15. The system according to claim 10, wherein: The flexible connection comprises at least one of the following connected to an end of the wind turbine hub: Chain, Cable, or Polymer interface.

16. The system of claim 17, wherein: A rotor is formed by connecting or disconnecting wind turbine blades to the wind turbine hub.

17. A system for assembling a wind turbine blade for a wind turbine, comprising: A blade holder is vertically displaced during assembly or disassembly of a wind turbine, wherein a hard connection or a flexible connection is used to perform the vertical displacement of the blade holder lift.

18. The system of claim 17, wherein: The hard connection is based on gyroscopic stability and includes a retainer operable based on the ability of the wind turbine blade to freely rotate on two axes from the hub end while being raised or lowered.

19. The system of claim 17, further comprising a retainer that allows the wind turbine blade to freely and securely rotate from the hub end on two or more axes while being raised or lowered.

20. The system of claim 19, wherein: The flexible connection comprises at least one of the following connected to an end of the wind turbine hub: a chain, a cable, or a polymer interface.

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