Wind turbine assembly system and method for assembling wind turbine

Abstract

The invention relates to a wind turbine assembly system (1) comprising a first part (2), a second part (3) connectable to the first part (2), first alignment means (4) attached to the first part (2) and second alignment means (5) attached to the second part (3). The first alignment device (4) comprises an engagement section (6) in a central region of the first part (2) and a holding section (7) for holding the engagement section (6), and the second alignment device (5) is configured to engage with the engagement section (6). The invention also relates to a method for assembling a wind turbine (20).

Description

Technical Field

[0001] The present invention relates to a wind turbine assembly system. The present invention also relates to a method for assembling a wind turbine. Background Art

[0002] It is known that rotor blades of modern wind turbines are made of composite materials, such as fiber reinforced plastics, etc. Such rotor blades usually include a main section with a tip and a root section, wherein the main section is usually flat and the root section has a substantially circular cross section. In addition, the main section has a rounded leading edge and a sharp trailing edge and is usually much longer than the root section.

[0003] The root section of the rotor blade is configured as a pitch bearing which is assembled to the hub of the wind turbine. With the help of the pitch bearing, the pitch angle of the rotor blade can be adjusted relative to the hub. The standard pitch bearing is configured as a rolling bearing. The hub is part of the nacelle which is mounted atop the tower of the wind turbine.

[0004] A challenging assembly step for wind turbines, especially large offshore wind turbines, in environments with sustained strong winds, waves and swells is the installation of the rotor blades to the pitch bearings at the hub. This process is also known as "blade landing". In an offshore environment, there is a relatively large relative motion between the hub and the rotor blades in the yoke. The rotor blades are usually held nearly stationary in the yoke, while the tower on which the hub is mounted swings in several directions depending on the wind, waves and swells.

[0005] Simulations have shown that from NG11 and above, the relative motion between the blade in the yoke and the pitch bearing of the hub may exceed the allowed relative motion, depending on the design of the components. Therefore, a key aspect of the blade landing procedure is to provide correct alignment of the components to avoid collisions, tilted mating, component breakage, etc.

[0006] Document EP 3492734 A1 discloses a wind turbine assembly system and a method for assembling a wind turbine. A blade landing system having a plurality of flexible spring elements is used, the spring elements being attached at the blade hub and protruding from the blade hub towards the rotor blade, the rotor blade being arranged to be assembled to the blade hub. By moving the rotor blade towards the blade hub, the spring elements engage the root portion of the rotor blade and thereby align the rotor blade with the blade hub. By this process, the spring elements are deformed.

[0007] Document WO 2021 / 013584 A1 discloses another method for connecting a rotor blade to a hub by means of a different blade landing system. According to the method, a rope of the blade landing system is attached to the rotor blade and inserted into a channel of the blade landing system of the hub. By pulling the rope, the rotor blade is pulled toward the hub and aligned with the hub. According to a special embodiment, the channel comprises a rigid centering element for engaging a counter-centering element of the rotor blade.

[0008] Known wind turbine assembly systems and methods have the disadvantage that the blade landing system must be carefully designed with respect to the flexibility and stiffness of its elements. Furthermore, since the blade landing system is in contact with a wall section of the rotor blade, the rotor blade needs to be provided with additional reinforcement structures to avoid damage during assembly. Especially for large rotor blades, the spring elements need to be large and the rotor blades need to be heavily reinforced, and thus the assembly system will be very expensive. Summary of the invention

[0009] Therefore, the object of the present invention is to eliminate or at least partially eliminate the above-mentioned disadvantages with respect to a wind turbine assembly system and a method for assembling a wind turbine. In particular, the object of the present invention is to create a wind turbine assembly system and an assembly method which avoids complex designs for different rotor blade sizes in a simple and inexpensive manner.

[0010] The above objects are achieved by the claims. Accordingly, the problem is solved by a wind turbine assembly system having the features of the independent claim 1 and by a method for assembling a wind turbine having the features of the subordinate claim 10. Further features and details of the invention emerge from the dependent claims, the description and the drawings. Features and details described in connection with the wind turbine assembly system according to the invention naturally also apply in connection with the method for assembling a wind turbine according to the invention and vice versa, so that, with respect to the disclosure of the various aspects of the invention, reference is made to each other or can always be made to each other.

[0011] According to a first aspect of the present invention, the object is achieved by a wind turbine assembly system. The wind turbine system comprises a first part, a second part that can be connected to the first part, a first alignment device attached to the first part and a second alignment device attached to the second part. According to the present invention, the first alignment device comprises a joining section in a central area of ​​the first part and a holding section for holding the joining section in the central area, wherein the second alignment device is configured to engage with the joining section.

[0012] In the context of the present invention, a wind turbine assembly system is considered to be a plurality of components for assembling to build a wind turbine. The components are larger parts of a wind turbine, such as rotor blades, hubs, nacelles, towers or tower sections, foundations, etc.

[0013] The first part and the second part are adjacent components of the wind turbine, which are configured to be connected to each other during an assembly procedure of the wind turbine. Preferably, the second part is configured to be installed first at the operating site of the wind turbine, and the first part is configured to be installed at the already installed second part. Alternatively, the first part is configured to be installed first at the operating site of the wind turbine, and the second part is configured to be installed at the already installed first part.

[0014] The first alignment device is attached to the first part. The attachment is such that during an assembly procedure, the orientation of the first part can be manipulated by applying a force at the first alignment device.

[0015] The second alignment device is attached to the second part. The attachment is such that during the assembly procedure, forces can be transferred from the second part to the first alignment device via the second alignment device.

[0016] Furthermore, according to the present invention, the first alignment device comprises an engagement section in a central area of ​​the first part. The central area is considered to be an area closer to the central axis of the first part. Preferably, the central area is within the physical limits of the first part. In other words, it is preferred that the engagement section does not protrude from the first part. Furthermore, it is preferred that the central part is spaced apart from the fixing means of the first part to avoid damage during the alignment procedure. The engagement section is configured to engage with the second alignment device during the meeting of the first part and the second part. Preferably, the first alignment device is positioned inside the first part.

[0017] In addition, the first alignment device includes a holding segment for holding the joining segment. According to the present invention, the holding segment and the joining segment can be constructed as one part or as separate parts. If constructed as separate parts, it is preferred that the joining segment is fixedly attached to the holding segment. Further preferably, the holding segment is fixedly attached to the first part. Preferably, the holding segment includes a predetermined elasticity for yielding due to a critical lateral force during the assembly procedure. This strength of the holding segment is sufficient to align the first part with the second part and has sufficient elasticity to avoid damage when excessive force occurs.

[0018] The second alignment means is configured to engage with an engagement section of the first alignment means. Preferably, the second alignment means has an elongated shape and is configured to extend into the first portion so as to engage the first alignment means. When the second alignment means engages with the first alignment means, relative movement of the first portion and the second portion is restricted, preferably in two dimensions. For this reason, preferably, the first alignment means and the second alignment means are configured to withstand lateral forces that may be generated by relative movement of the first portion and the second portion when the first alignment means engages with the second alignment means.

[0019] The wind turbine assembly system according to the invention has the advantage over conventional wind turbine assembly systems that the alignment of the first part and the second part during the joining procedure is improved in a simple and inexpensive manner. Since the joining section is arranged in a central area of ​​the first device, the joining section is further spaced apart from the fastening device for fastening the first part to the second part. This has the advantage that a collision of the alignment device with the fastening device, for example a blade bolt of a rotor blade, can be avoided. Due to the design of the first alignment device, forces above a predetermined threshold can be better compensated. In addition to this, the wind turbine assembly system can be configured such that it can be easily transported when the alignment device is already assembled or at least substantially assembled and the risk of damaging the alignment device is reduced.

[0020] According to a preferred further development of the invention, the wind turbine assembly system can provide that the holding section is constructed as a mesh structure. Within the limits of the invention, a mesh structure is a structure having one or more mesh building elements and gaps between adjacent mesh building elements. Preferably, the mesh building elements are arranged so as to establish nodes between two or more mesh building elements. Preferably, the mesh structure has an essentially two-dimensional extension. For example, the mesh structure can have the shape of a spider web, the shape of a star, preferably with four, six, eight or more prongs, etc. Preferably, reinforcing elements are embedded in the mesh structure to increase the stability of the mesh structure. This has the advantage that the first alignment device is provided in a simple and inexpensive manner. The mesh structure has the further advantage of better elastically absorbing force peaks.

[0021] According to the present invention, it is preferred that the mesh structure is formed by one or more wires, one or more strips or multiple rods. Therefore, the mesh structure can be formed by wires wound along the path constituting the mesh structure. The wires can be arranged to pass through the holes of the fixing device (such as bolt bushing) or retaining hooks for fixing the mesh structure to the first part. Alternatively, multiple wires can form the mesh structure, for example, each wire constitutes a straight line between two fixed points. Alternatively, the mesh structure can be constructed by rods, such as tubes, profile elements, rods, etc. The rods are preferably attached to the first part by the fixing device, or can be directly screwed into the first part or screwed into the fixing device of the first part. Preferably, the joining section is a separate part, which is embedded and held by the wire, or connected to the wire by an additional fixing element. This has the advantage that the absorption of the peak value of the force can be improved in a simple and inexpensive way. In addition, the mesh structure can be better removed after the assembly procedure. The removable first alignment device can be reused.

[0022] More preferably, the first alignment device is attached to the first part by means of a bolt bushing. In this case, the bolt bushing for attaching the first alignment device is preferably configured to protrude into the first part. The protruding part of the bolt bushing may have a threaded portion, a hook, a hole, etc. for attaching the first alignment device. Preferably, the first alignment device is attached to a plurality of adjacent bolt bushings, for example two or three adjacent bolt bushings. However, it can be provided that one or two ordinary bolt bushings are arranged between two bolt bushings for attaching the first alignment device. In this case, an ordinary bolt bushing is considered to be a bolt bushing that is not configured or used for attaching the first alignment device. Alternatively, an alternative retaining device can be used instead of the bolt bushing, which is positioned in the hole of the first part for the bolt bushing. The attachment points of the first alignment device to the first part are preferably distributed (preferably evenly distributed) on the circumference of the first part. This has the advantage that the attachment of the first alignment device to the first part is improved in a simple and inexpensive manner.

[0023] In a particularly preferred embodiment, adjacent bolt bushings are connected by a pressure distribution plate. Preferably, one bolt bushing holds the first alignment device and two or more adjacent bolt bushings do not hold the first alignment device. The pressure distribution plate is configured to distribute the pressure from the bolt bushings to the first part. This has the advantage that damage to the first part due to overload of forces (e.g. when the first alignment device and the second alignment device engage with each other) during the assembly procedure can be avoided in a simple and inexpensive manner.

[0024] Preferably, the first alignment device comprises a guide device with a lead-through, wherein the joining section is formed by the guide device. It is further preferred that the guide portion is spaced apart from a fixing device for fixing the first part to the second part so as to avoid collisions with the fixing device during the assembly procedure. Preferably. The guide portion passes through the joining section. Preferably, the joining section surrounds the guide portion. The guide device is preferably embedded in the retaining device, for example in a mesh structure of the retaining device. It is further preferred that the guide device is more rigid than the retaining device. Preferably, the guide device has a conical shape for improving the alignment. This has the advantage that the alignment of the first part with the second part can be further improved in a simple and inexpensive manner.

[0025] According to a preferred embodiment of the present invention, the second alignment device comprises one or more protruding members. The protruding member is configured to engage with the engagement section of the first alignment device. The protruding member can be a rod, a structural shape, a profile element, etc. Preferably, a plurality of protruding members are arranged obliquely and meet at the end of the second alignment device. Preferably, the protruding member is screwed into the second part. It is further preferred that the protruding members are connected to each other at the end, for example by screws, welding, caps, etc. This has the advantage that the alignment of the first part with the second part can be further improved in a simple and inexpensive way.

[0026] Particularly preferably, the second alignment means comprises a conical envelope surface for aligning the first alignment means with the second alignment means when the first and second parts meet. The envelope shape may be the shape of a cone, a pyramid, etc. This has the advantage that the alignment of the first part with the second part can be further improved in a simple and inexpensive manner.

[0027] According to the present invention, it is preferred that the first part is a rotor blade and the second part is a hub, or the first part is a nacelle and the second part is a tower of the wind turbine assembly system, or the first part and the second part are adjacent segment elements of the tower, or the first part is a tower and the second part is a base of the wind turbine assembly system. Alternatively, the reverse is also possible. The assembly of these parts can be very challenging. Therefore, the use of an alignment device to pair these parts can be beneficial to improve the alignment process during the assembly procedure.

[0028] According to a second aspect of the present invention, the object is achieved by a method for assembling a wind turbine. The method comprises:

[0029] - providing a wind turbine assembly system according to the first aspect of the invention,

[0030] - moving the first part and the second part towards each other so that the first alignment means engages with the second alignment means,

[0031] - aligning the first part with the second part by further moving the first part and the second part towards each other through the interaction of the first alignment means with the second alignment means, and

[0032] - connecting said first part to said second part.

[0033] The wind turbine assembly system may be provided in a pre-assembled state in case some components of the wind turbine are already installed at the operating site of the wind turbine.

[0034] Subsequently, the first part and the second part are moved towards each other. This is preferably done by moving the first / second part towards the already mounted second / first part. The movement is further implemented so that the first alignment means engages with the second alignment means. During this engagement, one or more degrees of freedom of relative movement of the first part and the second part are restricted. In other words, the relative deviation of the parts is restricted in at least one dimension, preferably in two dimensions. As a result, alignment is improved.

[0035] By further moving the first part and the second part towards each other, the parts are further aligned with each other. This is preferably still done by moving the first / second part towards the already installed second / first part.

[0036] When the alignment is complete or within a predetermined tolerance, the first part is connected to the second part, for example by bolts, screws, nuts, rivets or the like.

[0037] The method for assembling a wind turbine according to the invention has all the advantages that have been described for the wind turbine assembly system according to the first aspect of the invention. Accordingly, the method according to the invention has the advantage over conventional methods that the alignment of the first part and the second part during the joining procedure is improved in a simple and inexpensive manner. Since the joining section is arranged in a central area of ​​the first device, the joining section is further spaced apart from the fastening device for fastening the first part to the second part. This has the advantage that. A collision of the alignment device with the fastening device, such as a blade bolt of a rotor blade, can be avoided. Due to the design of the first alignment device, forces above a predetermined threshold can be better compensated. In addition to this, the provision of the wind turbine assembly system can be improved due to its construction, in the case where the alignment device has been assembled or at least substantially assembled and the risk of damaging the alignment device is reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Further advantages, features and details of the invention are explained in the following description, in which a working example of the invention is described in detail with reference to the accompanying drawings. Therefore, the features from the claims as well as the features mentioned in the description may be essential to the invention individually or in any combination. In the drawings:

[0039] Figure 1 A schematic perspective view showing a portion of a wind turbine assembly system according to a preferred embodiment of the present invention,

[0040] Figure 2 A schematic front view showing a first alignment device of a preferred first embodiment of the present invention,

[0041] Figure 3 A schematic front view showing a first alignment device of a preferred second embodiment of the present invention,

[0042] Figure 4 Shows Figure 3 Schematic perspective view of a portion of a first alignment device of a preferred second embodiment.

[0043] Figure 5 A schematic cross-sectional view of a first portion of a preferred embodiment of the present invention is shown.

[0044] Figure 6 A schematic cross-sectional view of a first portion of a preferred embodiment of the present invention is shown.

[0045] Figure 7 A schematic perspective view of a second portion of a preferred embodiment of the present invention is shown.

[0046] Figure 8 A schematic perspective view of a first portion of a preferred embodiment of the invention is shown.

[0047] Fig. 9 A schematic perspective view of a wind turbine assembly system according to a preferred embodiment of the present invention is shown.

[0048] Fig.10 A flow chart showing a preferred embodiment of the method according to the invention is shown.

[0049] exist Figure 1-10 In the drawings, elements having the same function and effect are denoted by the same reference numerals, respectively. DETAILED DESCRIPTION

[0050] exist Figure 1 In FIG. 1 , a part of a wind turbine assembly system 1 according to a preferred embodiment of the present invention is shown in a schematic perspective view. The wind turbine assembly system 1 comprises a first part 2 and a second part 3. In this figure, the first part 2 is spaced apart from the second part 3.

[0051] The first part 2 comprises a first alignment device 4. The first alignment device 4 comprises a wire 8 forming a star-shaped mesh structure with a holding section 7 and an engagement section 6 in a central area of ​​the first part 2. In the holding section 7, the wire 8 is attached to the first wall 22 of the first part 2 via a bolt bushing 9.

[0052] The second part 3 comprises a second alignment device 5. The second alignment device 5 comprises three protruding members 13, which are attached to the second wall 23 of the second part 3, forming a vertex. In the illustrated state, the protruding members 13 are aligned with the engagement section 6 and are about to extend into the engagement section 6. In the further procedure of moving the first part 2 and the second part 3 together, the first alignment device 4 and the second alignment device 5 will engage with each other and align the first part 2 with the second part 3.

[0053] Figure 2 In a schematic front view a preferred first embodiment of the present invention is shown of a first alignment device 4. The first alignment device 4 comprises a wire 8 which is guided through a bolt bushing 9, thereby forming a net-like structure with an engagement section 6 and a retaining section 7. In this embodiment, the engagement section 6 is octagonal in shape.

[0054] exist Figure 3 In the figure, a first alignment device 4 of a preferred second embodiment of the present invention is shown in a schematic front view. Figure 4 In the schematic perspective view shown Figure 3 The retaining section 7 is formed by a wire 8 and the engaging section 6 is provided by a guiding device 11 with a central guide 12. In order to increase the stability of the retaining section 7, reinforcing elements 21 are positioned between adjacent wires 8. In this embodiment, the engaging section 6 is circular in shape.

[0055] exist Figure 5 In the embodiment of the invention, a first part 2 of a preferred embodiment of the invention is shown in a schematic cross-sectional view. A bolt bushing 9 is arranged in a first wall 22 of the first part 2. A wire 8 is guided through a hole 24 of the bolt bushing 9.

[0056] Figure 6 2 shows a first part 2 of a preferred embodiment of the invention in a schematic cross section. In this figure, three adjacent bolt bushings 9 are shown, wherein the middle bolt bushing 9 comprises an additional hole 24 for fixing a not shown wire 8. A pressure distribution plate 10 is positioned between the nuts or head sections 25 of the bolt bushings 9 for distributing the pressure of the bolt bushings 9 to the first wall 22.

[0057] exist Figure 7, a second part 3 of a preferred embodiment of the present invention is shown in a schematic perspective view. The second part 3 comprises a second alignment device 5, which is attached to a second wall 23 of the second part 3. The second alignment device 5 comprises three protruding members 13 forming a vertex.

[0058] Figure 8 The first part 2 of a preferred embodiment of the invention is shown in a schematic perspective view. In this embodiment, the shape of the engagement section 6 is similar to Figure 2 The joining section 6 is different. In this embodiment, the shape of the joining section 6 is rectangular.

[0059] Fig. 9 A wind turbine assembly system 1 according to a preferred embodiment of the present invention is shown in a schematic perspective view. In the illustrated state, the wind turbine assembly system 1 is assembled to a wind turbine 20. The wind turbine assembly system 1 comprises a tower 17, which is composed of a plurality of segment elements 18. The tower 17 is arranged on a foundation 19. A nacelle 16 with a blade hub 15 is arranged on top of the tower 17. Three rotor blades 14 are mounted on the blade hub 15.

[0060] exist Fig.10 , a flow chart of a preferred embodiment of the method according to the invention is shown. In a first action 100, a wind turbine assembly system 1 according to the invention is provided. In a second action 200, the first part 2 and the second part 3 are roughly arranged and moved towards each other so that the first alignment device 4 of the first part 2 is engaged with the second alignment device 5 of the second part 3. In this state, due to the engagement of the first alignment device 4 with the second alignment device 5, the relative movement between the first part 2 and the second part 3 with respect to two degrees of freedom is restricted.

[0061] In a third action 300, the first part 2 and the second part 3 are moved towards each other in the assembly direction. Due to the interaction of the first alignment means 4 and the second alignment means 5, the first part 2 is aligned with the second part 3. The third action 300 is performed until the first part 2 and the second part 3 are in a mutual assembly position. The mutual assembly position is a position in which the first part 2 can be fixed to the second part 3. In a fourth action 400, the first part 2 is connected to the second part 3 by fixing means (e.g. bolts, screws, nuts, rivets, etc.).

Claims

1. A wind turbine assembly system (1) comprising a first part (2), a second part (3) connectable to the first part (2), a first alignment device (4) attached to the first part (2) and a second alignment device (5) attached to the second part (3), It is characterized in that The first alignment device (4) comprises a joining section (6) in a central area of ​​the first part (2) and a holding section (7) for holding the joining section (6), wherein the second alignment device (5) is configured to engage with the joining section (6).

2. The wind turbine assembly system (1) according to claim 1, It is characterized in that The holding section (7) is constructed as a mesh structure.

3. The wind turbine assembly system (1) according to claim 2, It is characterized in that The mesh structure is formed by one or more cords (8), one or more strips or a plurality of rods.

4. A wind turbine assembly system (1) according to any one of the preceding claims, It is characterized in that The first alignment device (4) is attached to the first part (2) by means of bolt bushings (9).

5. The wind turbine assembly system (1) according to claim 4, It is characterized in that Adjacent bolt bushings (9) are connected by a pressure distribution plate (10).

6. A wind turbine assembly system (1) according to any one of the preceding claims, It is characterized in that The first alignment device (4) comprises a guide device (11) having a guide portion (12), wherein the engagement section (6) is formed by the guide device (11).

7. A wind turbine assembly system (1) according to any one of the preceding claims, It is characterized in that The second alignment device (5) comprises one protruding member (13) or a plurality of protruding members (13).

8. A wind turbine assembly system (1) according to any one of the preceding claims, It is characterized in that The second alignment means (5) comprises a tapered envelope surface for aligning the first alignment means (4) with the second alignment means (5) when the first part (2) and the second part (3) meet.

9. A wind turbine assembly system (1) according to any one of the preceding claims, It is characterized in that The first part (2) is a rotor blade (14) and the second part (3) is a hub (15), or the first part (2) is a nacelle (16) and the second part (3) is a tower (17) of the wind turbine assembly system (1), or the first part (2) and the second part (3) are adjacent segment elements (18) of the tower (17), or the first part is a tower (17) and the second part is a foundation (19) of the wind turbine assembly system (1).

10. A method for assembling a wind turbine (20), comprising: - providing a wind turbine assembly system (1) according to any one of the preceding claims, - moving the first part (2) and the second part (3) towards each other so that the first alignment means (4) engages with the second alignment means (5), - aligning the first part (2) with the second part (3) by further moving the first part (2) and the second part (3) towards each other through the interaction of the first aligning means (4) and the second aligning means (5), and - Connecting said first part (2) to said second part (3).

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