Method for installing cable-supported rotor wind turbine

Abstract

A method of mounting a cable system (30) comprising cable assemblies (32a-c) on a wind turbine (10) having a tower (12), a rotor (22) and a central hub (24). A plurality of blades (26a-c) are coupled to the hub (24). The cable assembly (32a-c) includes a plurality of cables (40a-c, 42a-c, 44a-c). The crane (102) has a hoist rope (104, 106) and is attached to one of the cables (44a-c). The crane (102) lifts the cable assembly (32a-c) to the hub (24). The cable (44a-c) is then coupled to the hub (24). A hoist rope (104, 106) is attached to the other one of the cables (40a-c, 42a-c), moved to one of the blades (26a-c), and the cable (40a-c, 42a-c) is coupled to one of the plurality of blades (26a-c). Moving the cable (40a-c, 42a-c) may include pulling an end of the second cable (40a-c, 42a-c) to the one of the plurality of blades (26a-c). Pulling the end of the second cable (40a-c, 42a-c) may include moving the first crane (102) toward the one of the plurality of blades (26a-c).

Description

Technical Field

[0001] The present invention generally relates to wind turbines, and more particularly to a method of installing a wind turbine on which a plurality of wind turbine blades are supported by cables. Background Art

[0002] Wind turbines are used to generate electrical energy using renewable resources without burning fossil fuels. A wind turbine converts the kinetic energy of wind into mechanical energy and then converts the mechanical energy into electrical energy. A common type of wind turbine is a single-rotor upwind horizontal axis wind turbine (HAWT). Exemplary single-rotor HAWTs include a tower, a nacelle located at the apex of the tower, and a single rotor having a central hub and one or more blades (e.g., three blades) mounted to the hub and extending radially therefrom. The rotor is supported by the nacelle and positioned at the front of the nacelle such that the rotor faces the wind upstream of its supporting tower. The rotor may be directly or indirectly coupled to a generator (not shown) housed inside the nacelle and is configured to convert the mechanical rotation of the rotor into electrical energy.

[0003] Wind turbine manufacturers continuously strive to design and manufacture wind turbines with improved power production. The design of a wind turbine plays an important role in the power output generated from the wind. For example, the energy obtained from the wind is proportional to the swept area of the wind turbine blades. For a single-rotor HAWT, the swept area can be increased by using longer wind turbine blades. The longer the blades, the larger the area traced by the blade tips. This translates into extracting more energy from the wind. However, the length, maximum chord length, and root diameter of the wind turbine blades for a particular wind turbine are limited by several design factors.

[0004] As an exemplary limitation, the blade weight and root diameter increase with blade length. Each of these physical characteristics presents significant design challenges. On the one hand, reliably supporting the increasingly heavy wind turbine blades at their attachment points at the rotor becomes a limiting factor. When the wind turbine operates, during the rotation of the rotor and during the yaw movement of the rotor, the increased loads at the root amplify the fatigue at that location. The transportation of the blades from the manufacturing site to the field for installation is a known challenge, and increasing the blade length, root diameter, and weight makes the transportation even more challenging.

[0005] One design solution that allows for increased blade length is to support the wind turbine blade with a cable during wind turbine operation. A cable-supported blade can be relatively longer than a blade without cable support. A wind turbine that utilizes a rotor supported by cables can be referred to as a "cable-supported rotor" or a "cable-stayed rotor". Specifically, the cable mesh extends to adjacent blades and extends between adjacent blades. With the aid of the cables, the blades can be proportionally longer while addressing the above design issues. In this way, a cable-supported rotor can be utilized to increase the swept area of the blades to generate more energy from the wind.

[0006] Accordingly, wind turbine manufacturers and operators seek improved wind turbines and, in particular, improved energy production while overcoming current design limitations, including solutions for stabilizing the wind turbine rotor during energy production and installing and attaching the cables at minimum cost. Summary of the Invention

[0007] To facilitate these goals, and in a first aspect of the invention, a method of installing a wind turbine is disclosed. The wind turbine is preferably a single-rotor HAWT. In one embodiment, there is a method of installing a cable system on the wind turbine. The cable system can include a plurality of cable assemblies, but typically one cable assembly per blade. By way of example, the cable assembly includes a first cable and a second cable, the first cable can be a centerline cable, and the second cable can be an end cable. The method includes providing a crane having at least one hoist rope, attaching the cable assembly to the at least one hoist rope. The crane uses the hoist rope to lift the cable assembly to the hub. The first cable of the cable assembly is coupled to the hub. After disconnecting the hoist rope from the cable assembly, the method includes attaching the hoist rope to the second cable and using the hoist rope to move the second cable to one of the plurality of blades. The method further includes coupling the second cable to the one of the plurality of blades.

[0008] In one embodiment, the cable assembly includes a third cable, which can be an end cable. The method further includes attaching a pulley to an adjacent one of the plurality of blades, operably coupling a lifting cable to the pulley, attaching the lifting cable to the third cable, and pulling the lifting cable to pull the third cable towards the pulley. In one embodiment, the lifting cable is operably coupled to a winch, and pulling the lifting cable includes pulling the lifting cable onto the winch. In one embodiment, pulling the lifting cable includes limiting the load on the lifting cable to below a predetermined level. For example, a load limiter is located between the lifting cable and the third cable, and limiting the load includes limiting the load on the load limiter to less than 300 kg.

[0009] In one embodiment, the cable assembly includes a connector, and one end of each of the first cable, the second cable, and optionally the third cable is coupled to the connector, and attaching at least one lifting rope to the cable assembly includes attaching at least one lifting rope to the connector. In one embodiment, attaching a lifting rope to the cable assembly includes stitching a sling around the connector and attaching the lifting rope to the sling.

[0010] In one embodiment, moving the second cable includes moving at least a portion of the first crane. By way of example, the first crane includes a boom and a moving crane (trolley) extending from the upper end of the boom. Moving at least a portion of the first crane includes changing the angle of the boom and / or the moving crane. As an additional / alternative example, moving the second cable includes translating the first crane from an initial position toward a second position different from the first position during coupling the first cable to the hub.

[0011] In one embodiment, moving the second cable includes limiting the load on at least one lifting rope below a predetermined level.

[0012] In one embodiment, providing the first crane includes providing a first lifting rope and a second lifting rope. In one embodiment, the first lifting rope and the second lifting rope are each individually operably coupled to the first crane. In one embodiment, during lifting the cable assembly, the first lifting rope and the second lifting rope are horizontally spaced apart by 2 m to 5 m. In one embodiment, the first lifting rope is operable from the first crane, and the second lifting rope is operable from a second device different from the first crane. Providing the second lifting rope may include providing a second device different from the first crane. In one embodiment, providing the first crane includes providing a first lifting rope, a second lifting rope, and a second device, the second lifting rope being operable from the second device. By way of example, the second device is one of a second crane, a cherry picker, and a fixed lift.

[0013] In one embodiment, providing the first crane includes providing a first lifting rope coupled to a platform, and attaching at least one lifting rope includes attaching a second lifting rope to the cable assembly. In one embodiment, coupling the first cable to the hub is achieved from the platform. In one embodiment, coupling the second cable to one of a plurality of blades is achieved from the platform.

[0014] Embodiments may include repeating lifting and moving other cables of the cable system until the cable system is installed on the rotor. The cable system is configured to support a wind turbine blade during operation. The support provided by the cable system enables the use of longer blades, such that the energy production of the wind turbine can be increased relative to a wind turbine having relatively short blades.

[0015] A particularly advantageous type of cable-stayed rotor is the variable pitch cable-stayed rotor, since pitch variation allows for simple and well-known control of the rotor speed. A specific type of variable pitch cable-stayed rotor is a rotor having blade connection cables between adjacent blades, wherein the tension force in the blade connection cables can be adjusted by tensioning a cable (also referred to as a central cable) of a tensioning system that is connected to the middle of the blade connection cable and the hub. This allows for adjustment of the tension force in the cables during pitch operation. Thus, the method of the present invention is particularly advantageous for installing a cable system for a variable pitch cable-stayed rotor.

[0016] The method described herein can also be used for repairing, replacing, or removing a cable assembly, rather than installing a cable system (or associated therewith). In these cases, the steps are typically performed in reverse order, and for example, instead of connecting a cable to a hub or blade, the cable is released from the hub or blade. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings incorporated in and forming a part of this specification illustrate one or more embodiments of the invention and, together with the general description of the invention given above and the detailed description given below, serve to explain the invention.

[0018] Figure 1 is a front view of a cable-supported rotor wind turbine according to an embodiment of the invention;

[0019] Figure 1A is coupled to Figure 1 an enlarged view of the cable system of the rotor shown;

[0020] Figure 1B is Figure 1A an enlarged view of the connector shown;

[0021] Figure 2 is a schematic front view of a wind turbine tower and rotor and shows a system for installing a Figure 1 cable system;

[0022] Figure 3 is a schematic front view of a wind turbine tower and rotor before installing a cable system according to an embodiment; Figure 2 ;

[0023] Figure 4 , Figure 4A , Figure 5 , Figure 6 and Figure 7 are schematic front views illustrating the installation of a Figure 1 cable system to a Figure 2 rotor shown;

[0024] Figure 7A and Figure 7B are a wire sheath according to an embodiment and a schematic view of the wire sheath during its use with a wire end, respectively;

[0025] Figure 8 illustrates the Figure 1 cable system being installed onto the Figure 2 illustrative front view of a step of a rotor shown;

[0026] Figure 8A is Figure 8 an enlarged view of an exemplary connection location on the wind turbine blade in

[0027] Figure 9 illustrates the Figure 1 cable system being installed onto the Figure 2 illustrative front view of a rotor shown. DETAILED DESCRIPTION

[0028] Referring to Figure 1 , the wind turbine 10 includes a tower 12 and an energy generation unit 14 (including a nacelle) disposed at the apex of the tower 12. The tower 12 may be coupled to a base 16 at its lower end. The base 16 may be a relatively large mass embedded in the ground (e.g., concrete, an anchor cage, etc.), and the forces on the wind turbine 10 may ultimately be transmitted through this relatively large mass. Although not shown, in alternative embodiments, the base 16 may include an offshore platform or the like used in offshore wind turbine applications. The tower 12 supports the weight of the energy generation unit 14 and operates to raise the energy generation unit 14 to a height above the ground plane or sea level where faster moving airflows with lower turbulence are typically found.

[0029] In this regard, the energy generating unit 14 converts wind energy into electrical energy. The energy generating unit 14 generally includes a housing or nacelle 20, a rotor 22 having a central hub 24 and wind turbine blades 26a, 26b, 26c (e.g., three blades) mounted to and radially extending from the central hub 24. The energy generating unit 14 includes a drivetrain having a generator (not shown) for converting mechanical energy into electrical energy (optionally via a gear arrangement). Most of the drivetrain may be located inside the nacelle 20 of the wind turbine 10. In addition to the generator, the nacelle 20 generally houses various components required to convert wind energy into electrical energy and various components required to operate, control, and optimize the performance of the wind turbine 10. The wind turbine blades 26a, 26b, 26c are configured to interact with the wind. The wind generates lift and causes the rotor 22 to rotate or revolve to generally define the swept area of the wind turbine blades 26a, 26b, 26c. The energy generating unit 14 generates electrical power from the wind passing through the swept area of the rotor 22. During operation of the wind turbine 10, the wind turbine blades 26a, 26b, 26c are supported by a cable system 30 that carries some of the static and dynamic loads. In essence, the cable system 30 causes the wind turbine blades 26a, 26b, 26c to support one another. For example, edge loads and flap loads (slapping loads) are shared among the wind turbine blades 26a, 26b, 26c via the cable system 30.

[0030] As shown in the figure, in Figure 1 the exemplary embodiment, the cable system 30 includes three cable assemblies 32a, 32b, 32c, one cable assembly 32a, 32b, 32c for each wind turbine blade 26a, 26b, 26c. In the exemplary embodiment, each cable assembly 32a, 32b, 32c is connected to the rotor 22 at three locations, one connection at the central hub 24 and one connection at each of two adjacent wind turbine blades 26a, 26b, 26c. That is, each of the cable assemblies 32a, 32b, 32c in the cable system 30 is coupled to adjacent wind turbine blades 26a, 26b, 26c and is coupled between the adjacent wind turbine blades 26a, 26b, 26c and to the central hub 24. As shown, this forms a Y-shaped cable configuration between the adjacent wind turbine blades 26a, 26b, 26c and the central hub 24.

[0031] More specifically, and by way of example only, as Figure 1AAs shown, the cable assembly 32a is coupled to the wind turbine blade 26a, the wind turbine blade 26b, and the central hub 24. Similarly, the cable assembly 32b is coupled to the wind turbine blade 26b, the wind turbine blade 26c, and the central hub 24, and the cable assembly 32c is coupled to the wind turbine blade 26c, the wind turbine blade 26a, and the central hub 24. For example, coupling the cable assemblies 32a, 32b, 32c to the hub 24 may include connecting the cable assemblies 32a, 32b, 32c to a cable tensioning system housed within the hub 24. An exemplary cable tensioning system may include one or more hydraulic cylinders to which the cable assemblies 32a, 32b, 32c are connected. In other words, the cable assemblies 32a, 32b, 32c may be directly or indirectly connected to the wind turbine blades 26a, 26b, 26c and directly or indirectly connected to the central hub 24. Although not shown, the connection between the cables of each assembly 32a, 32b, 32c and the rotor 22 may be through rope fittings commonly used in the industry. For example, referring to Figure 1B , a solid sleeve having an integrated bearing 34 may define one or more cable ends in each assembly 32a, 32b, 32c. The fittings mate with other fittings or sockets on the central hub 24 and / or on the wind turbine blades 26a, 26b, 26c to mechanically attach the assemblies 32a, 32b, 32c such that they are sufficient to carry a portion of the load on the rotor 22.

[0032] In addition, in this regard, although not shown in detail in the drawings, each of the wind turbine blades 26a, 26b, and 26c may include a cable-to-blade connection point to which the cable assemblies 32a, 32b, or 32c are coupled. These connections are described in detail in the co-owned PCT applications PCT / DK2021 / 050374 and PCT / DK2022 / 050051, which are incorporated herein by reference in their entirety. Although not shown, by way of example only, the cable-to-blade connection may be at a split location between an inner blade portion and an outer blade portion, the inner blade portion and the outer blade portion being connected to each other to form a wind turbine blade. Such a segmented blade design is generally known in the wind turbine industry and may facilitate the transportation of the blade. The connection point itself may be located externally of the wind turbine blade but at the split location. For example, the cable connection may extend outwardly from the blade and may be used to connect to the cable system 30. Also not shown in the figures, the central hub 24 may include a cable-to-hub structure (such as the cable tensioning system described above) to which the cable assemblies 32a, 32b, 32c are coupled, and the cable assemblies 32a, 32b, 32c are tensioned by the cable-to-hub structure before and during operation of the wind turbine 10. The cable-to-hub structure that can be used to couple to the cable assemblies 32a, 32b, 32c is also described in detail in the co-owned PCT applications PCT / DK2021 / 050374 and PCT / DK2022 / 050051. Embodiments of the present invention are not limited to the number of wind turbine blades. Specifically, although the wind turbine 10 is shown as having three wind turbine blades, embodiments of the present invention may include more than three wind turbine blades, where the cable assemblies are coupled between two adjacent blades and to each of the two adjacent blades and the central hub.

[0033] Advantageously, the cable system 30 according to embodiments of the present invention bears a portion of the load on the wind turbine blades 26a, 26b, 26c, particularly during operation of the wind turbine 10. For example, the cable system 30 bears at least a portion of the dynamic loads due to movement of the wind turbine blades 26a, 26b, 26c caused by wind and gravity. It is advantageous to offload these loads from the blades 26a, 26b, 26c to the cable system 30. As an exemplary advantage, the blades 26a, 26b, 26c can be redesigned to be longer without substantially increasing their diameter at each blade root at their connection to the central hub 24 compared to the diameter of a wind turbine blade without cable support. Accordingly, the swept area of the wind turbine blades 26a, 26b, 26c can be greater than the swept area of a wind turbine blade not supported by cables. Other advantages are possible.

[0034] Continuing to refer toFigure 1A In one embodiment, one or more of the cable assemblies 32a, 32b, 32c include two or more cables that are connected to each other and connected to the wind turbine blades 26a, 26b, 26c and the central hub 24. In the exemplary embodiment shown, each cable assembly 32a, 32b, 32c includes three separate cables corresponding to each part of the Y-shaped mounted cable assembly. For example, the cable assembly 32a includes a first cable 40a coupled to the wind turbine blade 26a at one end and a second cable 42a coupled to the wind turbine blade 26b at one end. The cable assembly 32a includes a third cable 44a coupled to the central hub 24. Each of the first cable 40a and the second cable 42a may be referred to herein as an end line or end cable, and the third cable 44a may be referred to as a center line or center cable. The end lines 40a and 42a and the center cable 44a are each coupled at the intersection point 50a. One or more of the end lines 40a, 42a and the center cable 44a may include a solid sleeve with an integrated bearing 34 as described above at one or both ends connected to the connection points on the wind turbine blades 26a, 26b and / or the central hub 24. The two end lines 40a and 42a may be manufactured as a unit, with each end of the unit forming an end line. The two end lines 40a and 42a and the center cable 44a may be manufactured as a unit, such as a T-shaped rope with three ends, where the end portions of the unit form the two end lines 40a, 42a and a center cable 44a respectively.

[0035] Similarly, the cable assembly 32b includes a first cable 40b coupled to the wind turbine blade 26b at one end, a second cable 42b coupled to the wind turbine blade 26c at one end, and a third cable 44b coupled to the central hub 24. Each of the first cable 40b and the second cable 42b may be referred to herein as an end line or end cable, and the third cable 44b may be referred to as a center line or center cable. Each of the lines 40b, 42b and 44b is coupled at the intersection point 50b. One or more of the end lines 40b, 42b and the center cable 44b may include a solid sleeve with an integrated bearing 34 as described above at one or both ends connected to the wind turbine blades 26b, 26c, the central hub 24, and / or at the intersection point 50b.

[0036] Moreover, the cable assembly 32c includes a first cable 40c coupled at one end to the wind turbine blade 26c, a second cable 42c coupled at one end to the wind turbine blade 26a, and a third cable 44c coupled to the central hub 24. Each of the first cable 40c and the second cable 42c may be referred to herein as an end line or end cable, and the third cable 44c may be referred to as a center line or center cable. Each of the lines 40c, 42c, and 44c is coupled at an intersection point 50c. One or more of the first cable 40c, the second cable 42c, and the third cable 44c may include a solid sleeve having an integrated bearing 34 as described above at one or both ends where they are connected to the wind turbine blades 26c, 26a, the central hub 24, and / or at the intersection point 50c.

[0037] Referring Figure 1B , by way of example, one or more of the intersection points 50a, 50b, 50c may include a connector 52 to which the first, second, and third cables of the respective cable assembly are coupled together. As Figure 1B shown, the connector 52 includes two opposing plates 54a, 54b joined together by three pins 56a, 56b, 56c. The pins 56a, 56b, 56c receive the respective ends of the end lines or the end of the center line, such as via a solid sleeve having an integrated bearing 34, to form the cable assembly. By way of example, one or more of the lines and cables of the cable system 30 may include a polymer material as a load-bearing member. The polymer material may be, for example, ultra-high molecular weight polyethylene (UHMWP). Exemplary UHMWP in fiber form is manufactured under the trade name . Due to the combination of high strength / weight ratio and good fatigue characteristics, ultra-high molecular weight polyethylene fibers are particularly advantageous. As an alternative, the polymer material may be based on polyester, polyamide, nylon, polypropylene, aramid, etc. As another alternative, the polymer material may be a composite material, such as a liquid crystal polymer, such as polybenzoxazole (PBO). However, the cable system 30 is not limited to polymer materials, as various types of steel cables may be used alone or in combination with polymer materials.

[0038] In Figure 1 and Figure 1AIn this case, each cable assembly 32a, 32b, 32c is tensioned in its attachment between the central hub 24 and the wind turbine blades 26a, 26b, 26c. Tensioning of the cable assemblies 32a, 32b, 32c can be achieved by means of an arrangement in the central hub 24. Exemplary arrangements are described in the co-owned PCT / DK2021 / 050374 and PCT / DK2022 / 050051 and can be achieved by using a hydraulic cylinder or the like, which is configured to pull one or more of the central cables 44a, 44b, 44c after the cable assemblies 32a, 32b, 32c have been installed, as will be described below. Pulling the central cables 44a, 44b, 44c in the direction towards the central hub 24 places the end lines 40a, 40b, 40c, 42a, 42b, 42c and the central cables 44a, 44b, 44c in a tensioned state. Once tensioned, the cable assemblies 32a, 32b, 32c share the load applied to the wind turbine blades 26a, 26b, 26c.

[0039] According to one embodiment of the invention, the cable system 30 is installed on the wind turbine 10 during or after the installation of the rotor 22. Referring Figures 2 - 9 to an exemplary installation where the cable system 30 is installed after the rotor installation is complete. In Figure 2 this case, the tower 12, the energy generating unit 14 including the nacelle 20 and the rotor 22 are assembled before the cable system 30 is installed. After the rotor 22 has been assembled, if required, the rotor 22 is rotated to the orientation shown, where an adjacent pair of blades 26a and 26b are in the 8 o'clock and 4 o'clock positions respectively, although other orientations of the blades 26a - c can be used during the installation of the cable system 30. The platform 100 is positioned close to the central hub 24. In the exemplary installation, the platform 100 is a basket that is raised by a crane 102 via a main lifting rope 104 to enable personnel (e.g., construction workers) to manually access the central hub 24, the cable system 30 and the wind turbine blades 26a, 26b, 26c.

[0040] As Figure 2 and Figure 3 shown, the crane 102 includes a boom 105, and at the uppermost end of the boom 105 a mobile crane 107 (also known as a jib) extends from the boom 105. An auxiliary lifting rope 106 can be operated from the uppermost end of the mobile crane 107 and is equipped with a hook. The auxiliary lifting rope 106 can be operated separately from the main lifting rope 104. The auxiliary lifting rope 106 is close to the platform 100. As an example, the auxiliary lifting rope 106 can be horizontally spaced from the main lifting rope 104 by 2 m to 5 m. The auxiliary lifting rope 106 can be accessed from the platform 100, such as by using a pole hook. Referring Figure 3, the personnel attach the auxiliary lifting rope 106 to the attachment point on the cable assembly 32a. As an example, and although not shown, the auxiliary lifting rope 106 can be attached to the central cable 44a via a wire sheath, such as Figure 7A and Figure 7B shown. An alternative connection between the auxiliary lifting rope 106 and the cable assembly 32a can include attaching the lifting rope 106 to the connection plate 52 via a ring bolt or a swivel ring bolt fixed to the plate 52, and attaching the lifting rope 106 to a sling stitched around the connection plate 52, as Figure 4 shown. In the exemplary embodiment shown in Figure 3 , the cable assembly 32a including the end wires 40a and 42a and the central cable 44a (each of which is coupled to the connector 52) is shown wound on the ground near the tower 12. As Figure 3 shown, when the cable assembly 32a is on the ground, the auxiliary lifting rope 106 is attached to the cable assembly 32a via a sling and a hook. Only as an example, the auxiliary lifting rope 106 is indirectly attached to the connector 52 of the cable assembly 32a ( Figure 1B ). Thus, in Figure 4 , the central cable 44a hangs from the connector 52.

[0041] Referring to Figure 4 and Figure 4A , the auxiliary lifting rope 106 is raised to lift the attached cable assembly 32a towards the hub 24. In this regard, the platform 100 is not used to lift the cable assembly 32a. Although not shown, the auxiliary lifting rope 106 can be a cable on another crane. That is, two separate cranes can be utilized instead of the single crane 102 shown. Additionally, other devices / systems separate from the crane 102 can be utilized to lift the cable assembly 32a towards the hub 24. For example, other combinations can include a crane and a vehicle-mounted aerial work platform or a crane and a fixed elevator. Once the cable assembly 32a is near the attachment point of the cable assembly 32a to the central hub 24, the personnel on the platform 100 connect the central cable 44a to the central hub 24 (e.g., a hydraulic cylinder). In this way, the auxiliary lifting rope 106 and the crane 102 carry the weight of the cable assembly 32a while the personnel on the platform 100 connect the cable assembly 32a to the hub 24. The personnel can more easily manipulate the end of the central cable 44a and connect it to the central hub 24. The auxiliary lifting rope 106 is then disconnected from the cable assembly 32a, and the cable assembly 32a hangs from the central hub 24 via the central cable 44a.

[0042] Referring to Figure 5, personnel on platform 100 attach the auxiliary lifting rope 106 to the cable assembly 32a, particularly near the end of the end line 42a opposite the end connected to the connector 52. The crane 102 moves the platform 100 and the end line 42a towards the wind turbine blade 26b via its attachment to the auxiliary lifting rope 106. Moving the platform 100 and the end line 42a can include moving the crane 102 by repositioning the crane 102, deflecting the boom 105, changing the angle of the boom 105 (as shown by comparing Figure 4 and Figure 5 ), or a combination thereof. Although not shown, repositioning the crane 102 can include translating the crane 102 from one position along the ground and away from the tower 12 to a second position with or without changing the orientation of the boom 105 and the mobile crane 107. In other words, the crane 102 moves along the ground as a whole rather than just the boom 105 and / or the mobile crane 107. Either way, the movement of the crane 102 pulls the end of the end line 42a towards the wind turbine blade 26b. To avoid high lateral loads on the auxiliary lifting rope 106, a load limiter (not shown) can be placed between the auxiliary lifting rope 106 and the end line 42a. The load limiter can be a supplement to the load sensor that the crane 102 can be equipped with. When the platform 100 is close to the wind turbine blade 26b, the personnel connect the end line 42a to the wind turbine blade 26b and then separate the auxiliary lifting rope 106 from the end line 42a. In Figure 6 , the end line 42a is shown connected to the wind turbine blade 26b.

[0043] Referring to Figure 6 and Figure 7 , in one embodiment, a pulley 110 can be attached to the wind turbine blade 26a. For this purpose, the auxiliary lifting rope 106 can be used to lift the pulley 110 to a position where the personnel on the platform 100 can attach the pulley 110 to the wind turbine blade 26a. The winch 112 is located on the ground near the wind turbine tower 12. As shown, the lifting cable 114 is drawn from the winch 112 and fed through the pulley 110. The personnel on the platform 100 then attach the lifting cable 114 to the end line 40a using the line sheath 116, making the end of the end line 40a more accessible for connection to the wind turbine blade 26a near the pulley 110. As shown in Figure 7A and Figure 7B , the line sheath 116 can have a mesh blanket portion 120 configured to wrap around the end line 40a and one or more eyelets 122 configured to be connected to the lifting cable 114. Referring to Figure 7B, the blanket portion 120 can be stitched together around the line 40a. In one embodiment, the wire sheath 116 is coupled near the end of the end wire 40a, but not at the end of the end wire 40a. This is shown only by way of example in Figure 7 and Figure 7B as shown.

[0044] Referring to Figure 7 , Figure 7A and Figure 7B , the winch 112 is activated to pull the lifting cable 114 into the winch 112 and pull the end wire 40a towards the wind turbine blade 26a. Advantageously, the winch 112 and the lifting cable 114 carry the weight of the end wire 40a when the end wire 40a is pulled towards the wind turbine blade 26a. When the winch 112 pulls the end wire 40a into place, the auxiliary lifting rope 106 can be moved to a deviated position. Thus, in an exemplary embodiment, the auxiliary lifting rope 106 is only used to pull the initial end wire 42a to the wind turbine blade 26b. The tension force in the lifting cable 114 can be monitored using a load sensor during the pulling. The load on the cable 114 can be measured and limited during the pulling. For example, if the lateral load on the lifting cable 114 exceeds a predetermined level (e.g., in the range of 100 kg to 300 kg), the load limiter can stop further movement to limit or stop a further increase in the tension force on the cable assembly 32a and / or the cable 114. The tension force in the lifting cable 114 can be monitored during the pulling. For example, an integrated load sensor or a separate load sensor can be on the lifting cable 114 and the cable assembly 32a or between the two. With this arrangement, if the tension force in the cable 114 or on the winch 112 exceeds a predetermined value, the pulling can be stopped to avoid damaging one of those components or the blade 26a. The pulley 110, the winch 112, and the cable 114 are used to attach the second end wire 40a to the adjacent wind turbine blade 26a. In contrast, it is contemplated that pulling the end wire 40a towards the wind turbine blade 26a using the platform 100 will impose a significant level of load from the static weight of the end wire 40a on the platform 100 and thus tilt the platform 100. Using the winch 112 and the lifting cable 114 to pull the end wire 40a significantly reduces or avoids the horizontal load imposed on the platform 100 and that may tilt the platform 100.

[0045] Alternatively, and although not shown, the auxiliary lifting rope 106 can be in a manner similar to Figure 5is attached to the end line 40a in the same manner as the shown end line 42a. The movement of the crane 102 towards the wind turbine blade 26a moves the end line 40a near the wind turbine blade 26a. A person on the platform 100 can then connect the end line 40a to the wind turbine blade 26a. In this configuration, the lateral load on the auxiliary lifting rope 106 can be greater than Figure 5 the lateral load in the shown configuration. As another alternative, each of the end lines 40a and 42a and the center line 44a can be separate and are individually lifted and connected to the wind turbine blades 26a, 26b, and the hub 24 respectively. Once each (each of the end lines 40a and 42a and the center line 44a) is connected to the rotor 22, the lines 40a, 42a, and 44a can be connected together at the connector 52.

[0046] Reference Figure 8 and Figure 8A , with the end of the end line 40a near the wind turbine blade 26a and with the winch 112 holding the end line 40a in place, a person on the platform 100 connects the end line 40a to the wind turbine blade 26a. Again, the winch 112 bears most of the weight of the cable assembly 32a not supported by the hub 24 while the person connects the end of the end line 40a to the wind turbine blade 26a. In an exemplary embodiment, a solid sleeve with an integrated bearing 124 defines the end of the shown end line 40a. In Figure 8A , the bearing 124 is inserted into a socket 126 on the wind turbine blade 26a to connect the end line 40a (i.e., the cable assembly 32a) to the wind turbine blade 26a.

[0047] As Figure 9 shown, the cable assembly 32a is fixed between the wind turbine blades 26a and 26b and fixed to the central hub 24. Although not shown in the figures, after connecting the cable assembly 32a to the rotor 22, as Figures 2 - 9 schematically shown in, the rotor 22 rotates 120° to position either pair of the wind turbine blades 26b and 26c or the wind turbine blades 26c and 26a at the 8 o'clock and 4 o'clock positions respectively. Rotating the rotor 22 through a smaller or larger portion of the entire rotation can facilitate the installation process, for example, by changing the relative positions of the cables or blades, such that gravity facilitates the installation or for safety reasons. One of the cable assemblies 32b and 32c is in the same manner as described above with reference to Figures 2 - 9is coupled to the respective adjacent wind turbine blades 26a, 26b, 26c in the same manner as described for the cable assembly 32a to the wind turbine blades 26a and 26b. After one of the cable assemblies 32b and 32c is installed according to this process, the rotor 22 is rotated 120°, and the remaining cable assembly 32b or 32c is then coupled to the respective wind turbine blades 26a, 26b, 26c in the same manner. Thus, each cable assembly 32a, 32b, 32c is coupled to a respective pair of adjacent wind turbine blades 26a, 26b, 26c and to the central hub 24.

[0048] Specifically, during the installation of the cable assemblies 32b and 32c (which follows the procedure described above for Figures 2 - 9 the cable assembly 32a in ), the cable assembly 32b or 32c is coupled to the auxiliary lifting rope 106 on the crane 102, the cable assemblies 32b, 32c are lifted towards the central hub 24 using the auxiliary lifting rope 106, and the central cables 44b, 44c of the cable assemblies 32b, 32c are coupled to the hub 24.

[0049] Once the cable assemblies 32b, 32c are coupled to the hub 24, the auxiliary lifting rope 106 is detached and then coupled to one of the end lines 42b, 42c, and the end line 42b or 42c is pulled to the blade 26c or 26a by moving the crane 102, and the end lines 42b, 42c are coupled to the blade 26c or 26a by personnel on the platform 100. The remaining end lines 40b, 40c are coupled using the winch 112 and the lifting cable 114. That is, the pulleys 110 are mounted to the wind turbine blades 26b, 26c, and the winch 112 and the lifting cable 114 pull the end lines 40b, 40c towards the wind turbine blades 26b, 26c when attached to the end lines 40b, 40c so that the end lines 40b, 40c can be coupled to the blades 26b, 26c.

[0050] As an example of the cable assembly 32b, once the centerline 44b is coupled to the hub 24, the end lines 40b and 42b are then coupled to adjacent wind turbine blades 26b and 26c, respectively. In this regard, the auxiliary lifting rope 106 is attached to the end line 40b or 42b, and the end lines 40b, 42b are pulled towards the wind turbine blades 26b or 26c. Once in place, the end line 40b or 42b is coupled to the blade 26b or 26c. For the remaining end line 40b or 42b, the auxiliary lifting rope 106 can be used to raise the pulley 110 for attachment to the wind turbine blades 26b, 26c. Once the pulley 110 is attached and the lifting cable 114 is operatively coupled to the winch 112 and the end line 40b or 42b, the end line 40b or 42b is pulled towards the wind turbine blades 26b, 26c and coupled to the wind turbine blades 26b, 26c.

[0051] After rotating the rotor 22 by 120° to position the adjacent blades 26c and 26a at the 8 o'clock and 4 o'clock positions, the same process is repeated for the remaining adjacent pair of wind turbine blades 26c and 26a and the remaining cable assembly 32c.

[0052] Embodiments of the present invention are not limited to any order in which one of the end lines of the end line pairs 40a, 42a; 40b, 42b; and 40c, 42c is positioned together with the auxiliary lifting rope 106 and the combination of the pulley 110, the winch 112, and the rope 114. However, in an exemplary embodiment, the auxiliary lifting rope 106 is initially used to couple one of the end lines of the pair to the wind turbine blades 26a, 26b, 26c before the combination of the pulley 110, the winch 112, and the cable 114 is used to couple the other end line of the end line pair.

[0053] After coupling, the tension force in each of the assemblies 32a, 32b, 32c is adjusted by operation of a tensioning system as described in one or both of PCT applications PCT / DK2021 / 050374 and PCT / DK2022 / 050051.

[0054] Embodiments of the present invention are exemplified by a single-rotor HAWT, but can similarly be used for a multi-rotor HAWT, where the method can be used to install a cable system for each rotor using the same steps and order as described above, thereby achieving the same advantages.

[0055] While the invention has been illustrated by the description of various preferred embodiments and while these embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such details. Further advantages and modifications will readily occur to those skilled in the art. Accordingly, the various features of the invention may be used singly or in any combination, depending upon the needs and preferences of the user.

Claims

1. A method of installing a cable system (30) including cable assemblies (32a-c) on a wind turbine (10) including a tower (12) and a rotor (22), the rotor (22) having a central hub (24) with a plurality of blades (26a-c) coupled to the central hub (24), the cable assemblies (32a-c) including first cables (44a-c) and second cables (40a-c, 42a-c), the method comprising: Providing a first crane (102) having at least one lifting rope (104, 106) operably coupled thereto; Attaching the at least one lifting rope (104, 106) to the cable assembly (32a-c); Lifting the cable assembly (32a-c) to the hub (24) using the at least one lifting rope (104, 106); Coupling the first cables (44a-c) to the hub (24); After disconnecting the at least one lifting rope (104, 106) from the cable assembly (32a-c), attaching the at least one lifting rope (104, 106) to the second cables (40a-c, 42a-c); Moving the second cables (40a-c, 42a-c) to one of the plurality of blades (26a-c) using the at least one lifting rope (104, 106); And Coupling the second cables (40a-c, 42a-c) to the one of the plurality of blades (26a-c).

2. The method according to claim 1, wherein, The cable assembly (32a-c) includes third cables (40a-c, 42a-c), and the method further comprises: Attaching a pulley (110) to an adjacent one of the plurality of blades (26a-c); Operably coupling a lifting cable (114) to the pulley (110); Attaching the lifting cable (114) to the third cables (40a-c, 42a-c); and Pulling the lifting cable (114) to pull the third cables (40a-c, 42a-c) towards the pulley (110).

3. The method according to claim 2, wherein The lifting cable (114) is operably coupled to a winch (112), and wherein pulling the lifting cable (114) includes pulling the lifting cable (114) onto the winch (112).

4. The method according to claim 2 or claim 3, wherein Pulling the lifting cable (114) includes limiting the load on the lifting cable (114) below a predetermined level.

5. The method according to claim 4, wherein A load limiter is located between the lifting cable (114) and the third cables (40a-c, 42a-c), and wherein limiting the load includes limiting the load on the load limiter to less than 300 kg.

6. The method according to any one of the preceding claims, wherein, The cable assembly (32a-c) includes a connector (52), and one end of each of the first cables (44a-c) and the second cables (40a-c, 42a-c) is coupled to the connector (52), and wherein attaching the at least one lifting rope (104, 106) to the cable assembly (32a-c) includes attaching the at least one lifting rope (104, 106) to the connector (52).

7. The method according to claim 6, wherein, Attaching the at least one lifting rope (104, 106) to the cable assembly (32a-c) includes stitching a sling around the connector (52) and attaching the at least one lifting rope (104, 106) to the sling.

8. The method according to any one of the preceding claims, wherein, Moving the second cables (40a-c, 42a-c) includes moving at least a portion of the first crane (102).

9. The method according to claim 8, wherein The first crane (102) includes a boom (105) and a mobile crane (107) extending from an upper end of the boom (105), and wherein moving at least a portion of the first crane (102) includes changing an angle of the boom (105) and / or the mobile crane (107).

10. The method according to claim 8 or claim 9, wherein Moving the second cables (40a-c, 42a-c) includes translating the first crane (102) from an initial position toward a second position different from the first position during coupling the first cables (44a-c) to the hub (24).

11. The method according to any one of the preceding claims, wherein, Moving the second cables (40a-c, 42a-c) includes limiting a load on the at least one lifting rope (104, 106) to below a predetermined level.

12. The method according to any one of the preceding claims, wherein, Providing the first crane (102) includes providing a first lifting rope (104) and a second lifting rope (106).

13. The method according to claim 12, wherein, The first lifting rope (104) and the second lifting rope (106) are each individually and operably coupled to the first crane (102).

14. The method according to claim 12 or claim 13, wherein During lifting the cable assembly (32a-c), the first lifting rope (104) and the second lifting rope (106) are horizontally spaced 2 m to 5 m apart.

15. The method according to claim 12, wherein, The first lifting rope (104) is operable from the first crane (102), and the second lifting rope (106) is operable from a second device different from the first crane (102).

16. The method according to claim 15, wherein, The second device is one of a second crane, an aerial work platform mounted on a vehicle, and a fixed elevator.

17. The method according to one of claims 12 - 16, wherein, Providing the first crane (102) includes providing the first lifting rope (104) coupled to the platform (100), and wherein attaching the at least one lifting rope (104, 106) includes attaching the second lifting rope (106) to the cable assembly (32a-c).

18. The method according to claim 17, wherein, Coupling the first cables (44a-c) to the hub (24) is achieved from the platform (100).

19. The method according to claim 17 or claim 18, wherein Coupling the second cables (40a-c, 42a-c) to one of the plurality of blades (26a-c) is achieved from the platform (100).

Images