Large wind power equipment integral hoisting system and method based on truss structure

Abstract

The invention relates to an integral hoisting system and method for large wind power equipment based on a truss structure. The system comprises four integral truss structures vertically surrounding a tower footing, a connection adjusting device with rotation and movement adjusting functions, a slewing bearing mechanism with a high-precision marking line, a laser positioning system for collecting position deviation in real time, a horizontal adjusting instrument for monitoring the horizontal state in real time and a lifting device capable of being independently controlled. Through cooperative work of all the components, sequential synchronous lifting and high-precision installation of large-scale wind power equipment from a cabin, a hub, blades to a tower drum are achieved; according to the method, through the five steps of early-stage preparation, connection of the truss and the component, lifting and posture adjustment, high-altitude butt joint and unloading separation, the hoisting butt joint precision and the operation efficiency are remarkably improved, the high-altitude operation risk is effectively avoided, and the wind resistance and the adaptability of the system in the complex environment are enhanced.

Description

Technical Field

[0001] This invention relates to a large-scale wind power equipment hoisting system and method based on a truss structure, belonging to the field of large-scale wind power engineering hoisting technology. Specifically, it is applied to the overall hoisting operation of wind turbine units (including nacelle, hub, and ultra-long blade assembly) in onshore, plateau, and deep-sea wind farms, and is especially suitable for high-precision hoisting scenarios of large-scale wind power equipment with a single unit capacity of 8MW or more and a component weight of 200t or more. Background Technology

[0002] As the global wind power industry rapidly develops towards larger capacity and larger scale, large wind turbine units (such as 8MW onshore wind turbines with nacelles weighing up to 200t and rotor diameters exceeding 180m) have become the industry mainstream. The installation of such wind turbine units faces multiple severe challenges: First, the terrain is complex, with slopes in mountainous and plateau areas often requiring special handling (traditional hoisting equipment is difficult to adapt when the slope is ≤5°); second, the equipment load is large, placing extremely high demands on the load-bearing capacity and stability of the hoisting equipment; third, the high-altitude docking precision is stringent, requiring flange bolt hole alignment deviations to be controlled within ≤2mm, verticality deviations within ≤1 / 1000, and horizontality deviations within ≤1mm / m.

[0003] Currently, the mainstream approach in the industry is "segmented lifting + manual assisted docking": onshore operations rely on the cooperation of crawler cranes for main and auxiliary lifting, while offshore operations are carried out using semi-submersible platforms or floating cranes. However, this approach is significantly affected by environmental factors. Under conditions such as changes in wind speed and terrain undulations, lifting efficiency and safety are difficult to guarantee, and it can no longer meet the lifting requirements of large wind power equipment.

[0004] Existing hoisting equipment lacks an active stabilization structure. When hoisting the nacelle, windproof cables must be installed in wind speeds ≥6m / s, and the wind speed limit for impeller operations is even stricter (≤8m / s). Wind-induced swaying easily leads to component collision risks (the docking space between the nacelle and the tower is only 500mm), potentially causing equipment damage or safety accidents. Flange alignment relies on manual traction cables or drone assistance, with a single docking typically taking over 40 minutes. Furthermore, verticality and horizontality require repeated adjustments, extending the work cycle and increasing the intensity and risk of manual high-altitude work. Traditional lifting tools require frequent rigging changes for components of different weights (e.g., a 150t impeller and a 200t nacelle). The wire rope safety factor (6-8) and lifting point layout lack adaptive adjustment capabilities, resulting in low equipment reuse rates and long tool change times (over 1 hour per change). Manual docking operations are mostly at high altitudes (typically ≥30m), exposing operators to risks such as falls and being struck by objects; moreover, the lack of real-time sensor monitoring and early warning mechanisms makes it impossible to detect abnormal component postures in a timely manner, resulting in insufficient safety redundancy. Existing hoisting equipment relies heavily on manual experience for leveling, lacking precise level monitoring and automatic adjustment devices. This makes it easy for level deviations to exceed standards during high-altitude operations, affecting docking accuracy and equipment installation quality. Summary of the Invention

[0005] This invention overcomes the shortcomings of existing technologies and provides a large-scale wind turbine hoisting system and method based on a truss structure. It avoids the risks of high-altitude operations and improves operational safety; it improves docking accuracy and shortens installation time; it enhances the system's wind resistance and breaks through wind speed limitations, enabling normal installation and construction even when wind speeds exceed 8 m / s; and through the coordination of a leveling instrument and other devices, it achieves adaptive attitude adjustment during the hoisting process of large-scale wind turbines, meeting high-precision requirements such as flange bolt hole alignment, verticality, and horizontality.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a large-scale wind power equipment overall hoisting system based on a truss structure, comprising: The integral truss structure is formed by splicing multiple towers and / or trusses to form an integral load-bearing frame; four of the integral truss structures are vertically arranged around the outer perimeter of the tower base; A connecting adjustment device is located on the upper part of the overall truss structure and is connected and fixed to the top of the four overall truss structures. The lower side of the connecting adjustment device is directly connected to the hoisted component. The connecting adjustment device has rotational adjustment and movement adjustment functions. The slewing bearing mechanism is located on the ground foundation at the bottom of the overall truss structure. The bottom of the overall truss structure can be movably connected to the slewing bearing mechanism and manually fixed together with bolts. A connecting plate is fixed on the slewing support surface of the slewing bearing mechanism, and high-precision marking lines are marked on the connecting plate. The marking lines on the connecting plate assist in quickly completing the centering operation between the overall truss structure and the hoisted component.

[0007] A laser positioning system is installed at the top of the overall truss structure. Two sets of laser emitters are symmetrically arranged at the top of the overall truss structure to collect the position deviation data of the hoisted parts in real time, and assist the connection adjustment device to achieve fine-tuning of attitude. The leveling device is installed on the connecting plate of the tower base, with four sets arranged at the four corners of the connecting plate; it can monitor the horizontal status of the entire truss structure in real time. The lifting devices are installed at the four corners of the overall truss structure to synchronously lift the overall truss structure and the components being hoisted; and each lifting device can be controlled independently. The lifting device, through the coordinated operation of various components including the overall truss structure, connecting adjustment device, laser positioning system, slewing bearing mechanism, and leveling instrument, enables the sequential lifting and installation of large wind turbine equipment from the nacelle, hub, blades to the tower, thus changing the traditional installation sequence of wind turbine equipment.

[0008] Furthermore, the connecting adjustment device is equipped with an electromagnetic locking mechanism, which automatically locks after the hoisted component is adjusted to the correct position, with a locking force ≥500kN, to prevent component displacement during hoisting.

[0009] Furthermore, the leveling device has a signal transmission function, which can feed back the collected levelness data to the operator or control system in real time. When the levelness deviation exceeds the limit, it will promptly remind the operator to make adjustments to ensure that the equipment levelness meets the requirements during the hoisting process and avoid affecting the docking accuracy due to levelness deviation.

[0010] Furthermore, the rotation and movement adjustment functions of the connecting adjustment device are achieved through a built-in servo motor drive, and can adjust the posture of the hoisted part in real time according to laser positioning data and level adjustment instrument data to ensure accurate docking position.

[0011] Furthermore, the slewing bearing mechanism adopts a high-precision ball bearing with a slewing accuracy of ±0.05°, and can achieve 360° rotation adjustment.

[0012] Furthermore, the lifting device may consist of a hydraulic cylinder, a wire rope, and a tension sensor, or it may be a crawler crane. The tension sensor monitors the lifting force at each corner in real time to ensure uniform load distribution. It works in conjunction with a leveling device to adjust the lifting speed at each corner, ensuring the levelness of the truss and preventing deformation or damage to the truss due to uneven stress.

[0013] Furthermore, the laser positioning system emits a laser beam towards the target docking position of the hoisted component through a laser transmitter, and works in conjunction with a laser receiving target at the target position to collect positioning data, providing a positional reference for docking, ensuring that the flange bolt hole alignment deviation is ≤2mm, and working in conjunction with the leveling instrument to ensure docking accuracy.

[0014] Furthermore, the web members of the overall truss structure are arranged in a triangular structure, and the spacing between the web members is designed according to the load distribution, so as to reduce the self-weight while ensuring the load-bearing capacity.

[0015] This invention discloses a method for the overall hoisting of large-scale wind power equipment based on a truss structure, which is implemented according to the following steps: Step 1, Preliminary Preparation Stage: a. Site survey and equipment deployment; Based on the terrain and environmental parameters of the hoisting site, determine the deployment positions of the overall truss structure and cranes to ensure that the site's load-bearing capacity meets the requirements; b. Equipment inspection and parameter setting; Check the integrity of the overall truss structure, connection adjustment device, laser positioning system, and leveling instrument; adjust the leveling instrument to normal working condition; and clarify the parameters of the hoisted parts and the docking accuracy requirements. Step 2, Truss and Component Connection Stage: a. The entire truss is in place; The entire truss structure is hoisted above the hoisted component using a crane, and the initial centering is completed using the marking lines on the connecting plate of the slewing bearing mechanism. b. Initial horizontal adjustment; The truss level is monitored by a leveling instrument. If there is a deviation, the crane or lifting device is adjusted to make the truss level initially meet the requirements. c. Connection and fixation; Activate the connection adjustment device, adjust its position and attitude to accurately align it with the lifting point of the hoisted component, and after the connection is completed, activate the electromagnetic locking mechanism to ensure a secure connection. Step 3, Lifting and Posture Adjustment Phase: a. Simultaneous improvement; Activate the four-corner lifting device to achieve synchronous lifting of the entire truss and the hoisted components under real-time monitoring by tension sensors. The lifting speed is controlled between 0.5 and 1 m / min to avoid load fluctuations. b. Real-time horizontal monitoring and adjustment; During the lifting process, the leveling instrument continuously monitors the levelness of the truss. If any deviation occurs, the lifting speed of each corner lifting device is independently controlled to adjust the levelness of the truss and ensure that the levelness is always ≤1mm / m. c. Position deviation adjustment; The laser positioning system collects docking position deviation data, drives the connection adjustment device and slewing bearing mechanism to adjust the posture of the hoisted component in real time, and ensures the stability of the component during the lifting process and that the position deviation is within the allowable range. Step 4, High-altitude docking stage: a. Precise positioning; When the hoisted component is lifted to the target docking height, the laser positioning system accurately measures the deviation of the flange bolt hole position, and the leveling instrument reconfirms the levelness of the truss. b. Adaptive docking; Based on the laser positioning deviation data, the drive connection adjustment device is fine-tuned, and the lifting device is fine-tuned in conjunction with the data of the leveling instrument until the flange bolt hole alignment deviation is ≤2mm and the verticality and horizontality meet the standards. c. Temporary fixation; After the components are properly connected, the positioning pins are manually inserted to temporarily fix them in place and prevent them from shifting during the connection process. Step 5, Unloading and Separation Phase: a. Permanently fixed; After temporary fixing is completed, the flange bolts are tightened to ensure that the bolt preload meets the design requirements. b. Equipment separation; After the bolts are tightened, release the electromagnetic lock of the connecting adjustment device, start the lifting device and slowly lift the device to separate it from the hoisted part. c. Equipment recycling; The entire truss structure is lifted away from the work area, completing one lifting operation and preparing for the next lifting or equipment transfer.

[0016] The beneficial effects of this invention compared to the prior art are: This invention enables operators to complete operations at a height of approximately 6 meters, completely avoiding the risks of traditional high-altitude (≥30m) operations. The leveling device monitors the horizontal status in real time, avoiding safety hazards such as equipment tilting and falling due to horizontal deviations. The risk of safety accidents is reduced by more than 90%, and the safety of operations is significantly improved.

[0017] The overall truss structure of this invention has a large span and high rigidity, with small displacement deviation (≤3mm) when operating at a height of 200m. Combined with a leveling instrument (measurement accuracy ±0.01°) to accurately control the levelness, the flange connection accuracy can reach ≤1mm, effectively ensuring the quality of equipment installation and greatly improving hoisting accuracy.

[0018] The horizontal leveling device of this invention works in conjunction with the laser positioning system to reduce the time spent on manual leveling and adjustment, shortening the time for a single docking to less than 15 minutes, which is more than 60% more efficient than traditional manual docking (more than 40 minutes); the slewing bearing mechanism quickly finds the center, further shortening the operation cycle and significantly improving the operation efficiency.

[0019] This invention, through the stable bearing capacity of the overall truss and the precise horizontal control of the leveling device, enables the system to carry out normal installation and construction in wind speeds above 8m / s (maximum adaptable wind speed ≤12m / s). Compared with traditional equipment (wind speed ≤8m / s), the wind resistance level is improved by 1 to 2 levels, effectively reducing work interruptions caused by wind speed, and achieving a breakthrough in wind resistance.

[0020] The leveling device of this invention has wide temperature range and low pressure resistance, and can work stably in high-altitude (below 5000m) and low-temperature (-40℃) environments. When operating at sea, it can be used in conjunction with the platform adjustment device to reduce the impact of waves on levelness, meet the needs of deep-sea wind field operations, and has wide environmental adaptability.

[0021] In summary, this invention, through structural optimization and the application of a leveling device, enables operators to work at a low height (approximately 6m), avoiding the risks of high-altitude operations and improving operational safety. The use of a large-span truss structure reduces displacement deviation when working at a height of 200m, and combined with precise control of levelness by the leveling device, improves docking accuracy and shortens installation time. Simultaneously, it enhances the system's wind resistance, overcoming wind speed limitations and enabling normal installation work even at wind speeds exceeding 8m / s. Through the coordination of the leveling device with other devices, it achieves adaptive attitude adjustment during the hoisting of large wind turbine equipment, meeting high-precision requirements such as flange bolt hole alignment, verticality, and levelness. Attached Figure Description

[0022] The present invention will now be further described with reference to the accompanying drawings.

[0023] Figure 1 This is a schematic diagram showing the position of the overall truss structure and the tower base in this invention.

[0024] Figure 2 This is a schematic diagram of the assembly structure of the working surface of the top section of the tower crane in this invention.

[0025] Figure 3 This is a schematic diagram of the structure for installing the first tower section in this invention.

[0026] Figure 4 This is a schematic diagram of the structure for installing the main body of the engine room in this invention.

[0027] Figure 5 This is a schematic diagram of the structure in which the first blade is installed in this invention.

[0028] Figure 6 This is a schematic diagram of the structure in which the second blade is installed in this invention.

[0029] Figure 7 This is a schematic diagram of the overall truss structure and the lifting structure of the tower crane in this invention.

[0030] Figure 8 This is a structural schematic diagram added to the lower-level integral truss structure in this invention.

[0031] Figure 9 This is a schematic diagram of the structure for adding the lower tower section in this invention.

[0032] Figure 10 This is a schematic diagram of the structure for installing the third blade in this invention.

[0033] In the diagram: 1 is the overall truss structure, 2 is the connecting and adjusting device, 3 is the slewing bearing mechanism, and 4 is the lifting device. Detailed Implementation

[0034] Below is the order Figures 1-10The installation sequence is described, and the installation process of this invention is explained in detail.

[0035] Figure 1 The specific work process is as follows: 1. A geological survey report is required; the bearing capacity is insufficient, necessitating replacement and layered compaction; Fak = 200 kPa. 2. Begin site leveling, ensuring the overall slope of the tower crane does not exceed 1 / 1000; 3. Lay out the lines, using a total station for assistance, ensuring the two-dimensional error does not exceed 10mm, and adjust the position of the wind turbine foundation on the tower according to the turbine model; 4. The auxiliary crane begins to place a total of 4 sets of tower crane base plates (2 plates are assembled into 1 set) according to the layout points; 5. Place a total of 4 lifting device platforms at a 45-degree angle to the tower crane's direction; 6. Initially adjust the leveling screws on the tower crane base plate (it is recommended to adjust them to the middle of the stroke) to ensure that the height of each group of 3 is consistent and the height of all 4 groups is consistent; 7. Place the rotating base at the wind turbine foundation (marked with lines).

[0036] Figure 2 The specific work process is as follows: 1. This step involves assembling the working surface of the top section of the tower crane; 2. Assembly steps: Erect 4 tower truss corner columns separately - tighten the corner columns and base plate bolts - upper tie rods (workers are inside the work platform) - lower tie rods - scissor braces - finally tighten all bolts - remove the base plate connecting bolts; 3. Install the top flat structure and mechanism to enable forward, backward, left and right rotation after clamping; 4. Install the steel platform (for vertically lifting the blades). The platform is an integrated system, hoisted as a whole, and fixed with axle pins after folding. 5. Connect the oil lines, electrical lines, signal lines, etc. of the system box; 6. Activate control equipment such as laser systems and electronic levels; 7. After installation, adjust the height of the column leg supports according to the electronic level.

[0037] Figure 3 The specific work process is as follows: 1. Loosen the rubber clamps of the clamping device and select the appropriate position according to the tower diameter; 2. Adjust the front, back, left, and right positions according to the model. This step is crucial to ensure that the blades are installed outside the tower. Incorrect steps will prevent the blades from being installed in the final step, resulting in the failure of the entire hoisting process. 3. Use an auxiliary hoist to insert the first tower section into the clamp. The clamp height should be adjusted according to the turbine model and the actual height of the control cabinet on the wind turbine foundation, but it should not exceed 5 meters above the platform. 4. The column leg supports should be adjusted to be level before and after installation.

[0038] Figure 4 The specific work process is as follows: 1. This step involves installing the main nacelle and impeller body; 2. It is necessary to communicate with the main engine manufacturer about the location of the four supports, hoist the main body of the nacelle (including generator, reducer and other facilities inside the nacelle) as a whole, and then the construction personnel will complete the fastening and connection inside the nacelle and connect the electrical and hydraulic systems, etc. 3. Hoist the impeller body, and after the construction personnel have secured it inside the chamber, connect the oil and electrical circuits, etc. 4. The lifting capacity of the auxiliary hoist is determined by a combination of the maximum lifting weight, lifting height, and luffing radius; 5. The column leg supports should be adjusted to be level before and after installation. This step involves a lot of weight, so it should be observed in real time. 6. Check the clamping block regularly for any upward or downward slippage and prepare emergency measures.

[0039] Figure 5 and Figure 6 The specific work process is as follows: 1. This step involves installing two blades; 2. Rotate one end of the hub to a horizontal position, and use an auxiliary crane to lift it to the designated position using blade fixtures. The installers then tighten the impeller inside. 3. Rotate the tightened blade 120° clockwise. At this point, the other end is horizontal. Tighten the second blade using the same installation method as in step two. 4. The hub rotates 30° clockwise, at which point the two blades are in a V-shape facing upwards, and the impeller is locked. 5. Connect the steel strands of the lifting device to the holes in the first column foot plate, and operate simultaneously on all four sides to ensure consistent length and level of the frame.

[0040] Figure 7 , Figure 8 and Figure 9 The specific work process is as follows: 1. This step involves the overall lifting of the tower crane and its fan, specifically the lifting process of the tower crane and tower casing. 2. The TS400D-300 lifting type is selected, with a nominal lifting capacity of 4043KN / unit, and a total of 4 units; 3. Used with CPDY23-2D CNC lifting hydraulic pump station; maximum lifting speed: 5.5m / h, maximum lowering speed: 4.5m / h; 4. Equipment Features: The CNC hydraulic synchronous lifting technology has the following features: 4.1 The lifting jack anchor has reverse motion self-locking property, so even if the lifting jack malfunctions during the lifting process, the component will not fall off, making the lifting process very safe. Furthermore, the component can be reliably locked at any position during the lifting process for a long period of time. 4.2 It has strong scalability and the number of lifting tops can be configured according to the weight of the lifting components. Each hydraulic pump station and the corresponding lifting top are connected to the control system as an independent unit through the network. As long as there are reasonable load-bearing lifting points, the lifting height and lifting range are not limited. 4.3 The lifting system has millimeter-level fine-tuning capabilities, enabling precise vertical positioning in the air; 4.4 The equipment is small in size, light in weight, and has a large load-bearing capacity, making it particularly suitable for lifting large-tonnage components in confined spaces or indoors; 4.5 The equipment is highly automated, easy to operate, safe, reliable, and widely adaptable; 4.6 The product conforms to GB / T 31133-2014 Technical Specification for Hydraulic Lifting Equipment for Power Equipment; 5. Lift the first tower crane section to the predetermined height without loosening it, insert the second tower crane section, connect the secondary structure to form a stable state, lower the first section to the top of the second section, tighten the through bolts, loosen the lifting steel strand, and then lower the steel strand to the bottom connection hole of the second section. Continue lifting, while the auxiliary hoist lifts the tower section in and connects the tower bolts. 6. The auxiliary crane simultaneously fills in the tower crane sections and tower sections, repeats the tower assembly and tightening work until the predetermined height is reached; 7. This step requires close monitoring of the level and timely adjustments to prevent tipping. 8. Installation personnel must work within the work platform throughout the entire process to avoid falls from height.

[0041] Figure 10 The specific work process is as follows: 1. This step is the process for installing the last blade (vertical installation process). 2. The blade is initially placed flat on the ground, and the position of the rope around it is as shown in the figure. There are two suspension points on two sides. 3. The blades are erected by a top hoist and auxiliary crane; 4. Once the blades are lifted vertically, the blade tip should be 500mm from the bottom. This can be done manually or with guy ropes. 5. With both hoists operating synchronously and the guy ropes preventing blade collisions, the pitch control system is activated simultaneously to allow the blade bolts to smoothly enter the flange, thus completing the tightening process.

[0042] like Figures 1-10The installation sequence shown in this invention is based on a large-scale wind power equipment hoisting system using a leveling device. It uses a "large-span integral truss structure as the main load-bearing component, a leveling device as the core of horizontal control, and multiple devices working together as the key to adjustment" to construct a hoisting system that integrates load-bearing, horizontal monitoring, attitude adjustment, and safety control.

[0043] This invention includes the following structure: 1. Overall truss structure 1) Structural composition: It consists of four tower trusses spliced ​​together to form an integral load-bearing frame. By optimizing the arrangement of the web members (adopting a triangular stable structure, the spacing of the web members is designed according to the load distribution, so as to reduce the self-weight while ensuring the load-bearing capacity).

[0044] 2) Functional advantages: The truss has a large span (suitable for components with impeller diameters of 180m and above), and the displacement deviation is small (≤3mm) when operating at a height of 200m, effectively improving the stability and accuracy of hoisting; compared with traditional steel lifting beams, the self-weight is reduced by more than 30%, reducing the additional load on the crane and improving the adaptability of the equipment.

[0045] 2. Connect the adjustment device 1) Installation location: The upper part of the overall truss structure, directly connected to the hoisted component.

[0046] 2) Adjustment function: It has the ability to rotate (rotation angle range 0~360°, adjustment accuracy ±0.1°) and move (horizontal movement stroke 0~500mm, adjustment accuracy ±0.5mm). Driven by the built-in servo motor, it can adjust the posture of the hoisted part in real time according to the laser positioning data and the level adjustment instrument data to ensure accurate docking position.

[0047] 3) Fixing mechanism: Equipped with an electromagnetic locking mechanism, which automatically locks after the posture is adjusted to the correct position, with a locking force ≥500kN, to prevent component displacement during hoisting.

[0048] 3. Laser positioning system 1) Installation location: Two sets of laser emitters are symmetrically arranged on the top of the overall truss structure.

[0049] 2) Working principle: The laser emitter emits a laser beam toward the target docking position of the hoisted part (such as the flange face of the tower), and in conjunction with the laser receiving target at the target position, it collects position deviation data in real time (range measurement accuracy ±0.1mm) to provide a position reference for docking.

[0050] 3) Function: The auxiliary connection adjustment device enables fine-tuning of the posture, ensuring that the flange bolt hole alignment deviation is ≤2mm, and works with the leveling instrument to ensure docking accuracy.

[0051] 4. Slewing bearing mechanism 1) Installation location: bottom of the overall truss structure.

[0052] 2) Structural features: It adopts a high-precision ball bearing slewing bearing with a slewing accuracy of ±0.05° and a load-bearing capacity of ≥1000kN; the slewing bearing is fixed with a connecting plate, and the connecting plate is marked with a high-precision marking line (marking line accuracy ±0.1mm).

[0053] 3) Adjustment function: It can achieve 360° rotation adjustment, and with the marking lines on the connecting plate, it can quickly complete the centering operation of the overall truss structure and the hoisted parts. The centering time is ≤5 minutes, which greatly shortens the preparation time.

[0054] 5. Leveling instrument 1) Installation location: Four sets are arranged on the connecting plate of the tower base (located at the four corners of the connecting plate respectively).

[0055] 2) Technical parameters: Measurement accuracy ±0.01°, response time ≤0.1s, operating temperature range -40℃~80℃, suitable for harsh environments such as high altitude and low temperature.

[0056] 3) Function: Real-time monitoring of the overall truss structure's horizontal status, feeding back the horizontality data to the operator or control system in real time. When the horizontality deviation exceeds the limit (>1mm / m), timely reminders for adjustment are given to ensure that the equipment's horizontality meets the requirements during hoisting and to avoid affecting the docking accuracy due to horizontal deviation.

[0057] 6. Lifting device 1) Installation location: at the four corners of the overall truss structure, with each lifting device controlled independently.

[0058] 2) Structural composition: It consists of a hydraulic cylinder (maximum lifting force ≥500kN, stroke 0~3000mm), a wire rope (safety factor ≥8, using anti-torsion steel core wire rope), and a tension sensor (range 0~1000kN, accuracy ±0.5%). A crawler crane can also be used.

[0059] 3) Functions: To achieve synchronous lifting of the overall truss structure and the hoisted components, the tension sensor monitors the lifting force at each corner in real time to ensure uniform load distribution (lifting force deviation at each corner ≤ 5%), and adjusts the lifting speed at each corner with the leveling instrument to ensure the truss levelness and avoid deformation or damage to the truss due to uneven stress.

[0060] The hoisting method steps in this invention are as follows: 1. Preliminary preparation stage 1) Site survey and equipment deployment: Based on the topography and environmental parameters of the hoisting site (land, plateau or sea), determine the deployment positions of the overall truss structure and cranes to ensure that the site's bearing capacity meets the requirements (bearing capacity of land sites ≥250kPa). 2) Equipment inspection and parameter setting: Inspect the integrity of the overall truss structure, connection adjustment device, laser positioning system, leveling instrument and other components, adjust the leveling instrument to normal working condition, and clarify the parameters of the hoisted parts (weight, size, flange bolt hole position, etc.) and docking accuracy requirements (flange bolt hole alignment deviation ≤2mm, verticality ≤1 / 1000, horizontality ≤1mm / m).

[0061] 2. Truss and component connection stage 1) Overall truss positioning: The overall truss structure is hoisted to the top of the component to be hoisted (such as the engine room) using a crane, and the initial centering is completed using the marking lines on the connecting plate of the slewing bearing mechanism; 2) Initial horizontal adjustment: Monitor the levelness of the truss using a leveling instrument. If there is a deviation, adjust the crane or lifting device to make the levelness of the truss initially meet the requirements (≤1mm / m). 3) Connection and fixing: Activate the connection adjustment device to adjust its position and attitude so that it is precisely aligned with the lifting point of the hoisted part. After the connection is completed, activate the electromagnetic locking mechanism to ensure a firm connection.

[0062] 3. Lifting and Posture Adjustment Phase 1) Synchronous lifting: Activate the four corner lifting devices to achieve synchronous lifting of the entire truss and the hoisted components under real-time monitoring by tension sensors. The lifting speed is controlled at 0.5 to 1 m / min to avoid load fluctuations. 2) Real-time level monitoring and adjustment: During the lifting process, the leveling instrument continuously monitors the levelness of the truss. If a deviation occurs, the lifting speed of each corner lifting device is independently controlled to adjust the levelness of the truss and ensure that the levelness is always ≤1mm / m. 3) Position deviation adjustment: The laser positioning system collects docking position deviation data, drives the connecting adjustment device (rotation, movement) and the slewing bearing mechanism (rotation), and adjusts the posture of the hoisted part in real time to ensure the stability of the component during the lifting process and that the position deviation is within the allowable range.

[0063] 4. High-altitude docking stage 1) Precise positioning: When the hoisted component is lifted to the target docking height (such as the top of the tower), the laser positioning system accurately measures the deviation of the flange bolt hole position, and the leveling instrument reconfirms the levelness of the truss; 2) Adaptive docking: Based on the laser positioning deviation data, drive the connection adjustment device to make fine adjustments (rotation adjustment angle ≤5°, movement adjustment distance ≤100mm), and combine with the data of the leveling instrument to fine adjust the lifting device until the flange bolt hole alignment deviation is ≤2mm, and the verticality and horizontality meet the standards. 3) Temporary fixation: After docking, the positioning pins are inserted manually to temporarily fix the components and prevent them from shifting during docking.

[0064] 5. Unloading and Separation Phase 1) Permanent fixing: After temporary fixing is completed, the flange bolts are tightened to ensure that the bolt preload meets the design requirements; 2) Equipment separation: After the bolts are tightened, release the electromagnetic lock of the connecting adjustment device, start the lifting device to slowly lift the equipment, and separate the connecting adjustment device from the hoisted part; 3) Equipment recovery: The entire truss structure is lifted away from the work area, completing one lifting operation and preparing for the next lifting or equipment transfer.

[0065] The following is a detailed description of the hoisting of an onshore nacelle (8MW wind turbine, nacelle weight 200t) as an example.

[0066] 1. Equipment parameters: 1) Overall truss structure: 4 tower trusses, made of Q690 steel, with a self-weight of 50t and a bearing capacity of 300t; 2) Leveling instrument: Measurement accuracy ±0.01°, response time 0.1s; 3) Lifting device: The hydraulic cylinder has a maximum lifting force of 500kN and a stroke of 3000mm; the tension sensor has a range of 0~1000kN. 4) Laser positioning system: ranging accuracy ±0.1mm, laser receiving target installed on the tower flange surface; 5) Main lifting equipment: 300t crawler crane with a main boom length of 100m.

[0067] 2. Work process: 1) Site deployment: Select a flat site (bearing capacity ≥250kPa), position the crane and the overall truss structure, and adjust the leveling device to normal working condition; 2) Connection and fixing: The truss is hoisted to the top of the nacelle, and the centering is achieved using the marking lines on the slewing bearing connection plate (takes 3 minutes). The leveling instrument monitors the level deviation to be 0.3mm / m. After meeting the requirements, the connection and adjustment device is docked and electromagnetically locked. 3) Lifting and Adjustment: The lifting device lifts synchronously at a speed of 0.8 m / min. The leveling instrument monitors in real time. If the level deviation on one side increases to 1.2 mm / m, the speed of the corresponding lifting device is immediately adjusted, and the level is corrected to 0.5 mm / m within 5 seconds. 4) High-altitude docking: Lift to a height of 120m (top of the tower), wind speed 10m / s, laser positioning to detect flange hole deviation of 3mm, fine adjustment of the connection adjustment device (rotate 1.2°, move 2mm), leveling instrument to confirm levelness of 0.6mm / m, deviation ≤1mm after 5 minutes; 5) Fixed separation: Insert positioning pins, tighten bolts, release locking, truss separation and recovery, the whole process takes 45 minutes.

[0068] 3. Effect Verification: The docking accuracy (flange hole deviation 0.8mm), verticality (0.8 / 1000), and horizontality (0.6mm / m) all meet the requirements; compared with the traditional hoisting (which takes 90 minutes), the efficiency is increased by 50%, and there is no high-altitude operation, which significantly improves safety.

[0069] The following is a detailed description of the hoisting of a high-altitude impeller (10MW wind turbine, impeller weight 180t, altitude 3000m) as an example.

[0070] 1. Special adaptation: 1) The leveling instrument should be of high altitude type (resistant to low air pressure, can work normally below 5000m altitude). 2) The overall truss structure is reinforced with wind-resistant ribs to improve wind resistance stability (suitable for wind speeds ≤12m / s).

[0071] 2. Highlights of the assignment: 3) In a low-temperature environment (-15℃), the leveling instrument has a response time of 0.08s and a measurement accuracy of ±0.01°. 4) When the wind speed is 11m / s, the maximum deviation of the levelness during the lifting process is 0.9mm / m. By adjusting the speed of the lifting device, it can be quickly corrected to 0.4mm / m. The impeller swing amplitude is ≤10mm, and the docking process is smooth. 5) The total time for centering and docking was 18 minutes, which is 85% more efficient than traditional high-altitude hoisting (which takes 120 minutes).

[0072] The remaining configurations are the same as in Example 1.

[0073] This invention involves simultaneously lifting the overall truss structure and the corresponding hoisted components using a lifting device. After being lifted, the lower end of the overall truss structure is then fitted with the same overall truss structure. This process is repeated sequentially to complete the continuous assembly of the nacelle, blades, and tower. Finally, the bottom of the tower is fixed to the tower crane, thus completing the installation.

[0074] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A large-scale wind power equipment overall hoisting system based on a truss structure, characterized in that, include: The integral truss structure is formed by splicing multiple towers and / or trusses to create an integral load-bearing frame; The four integral truss structures are vertically arranged around the outer perimeter of the tower base; A connecting adjustment device is located on the upper part of the overall truss structure and is connected and fixed to the top of the four overall truss structures. The lower side of the connecting adjustment device is directly connected to the hoisted component. The connecting adjustment device has rotational adjustment and movement adjustment functions. The slewing bearing mechanism is located at the bottom of the overall truss structure. The bottom of the overall truss structure can be movably connected to the slewing bearing mechanism. A connecting plate is fixed on the slewing support surface of the slewing bearing mechanism. The connecting plate is marked with high-precision marking lines. The marking lines on the connecting plate help to quickly complete the centering operation between the overall truss structure and the hoisted component. A laser positioning system is installed at the top of the overall truss structure. Two sets of laser emitters are symmetrically arranged at the top of the overall truss structure to collect the position deviation data of the hoisted parts in real time, and assist the connection adjustment device to achieve fine-tuning of attitude. The leveling device is installed on the connecting plate of the tower base, with four sets arranged at the four corners of the connecting plate; it can monitor the horizontal status of the entire truss structure in real time. The lifting devices are installed at the four corners of the overall truss structure to synchronously lift the overall truss structure and the components being hoisted; and each lifting device can be controlled independently. The lifting device achieves the sequential lifting and installation of large wind power equipment from the nacelle, hub, blades to the tower through the coordinated operation of various components in the overall truss structure, connecting adjustment device, laser positioning system, slewing bearing mechanism, and leveling instrument.

2. The overall hoisting system for large wind power equipment based on a truss structure according to claim 1, characterized in that, The connecting adjustment device is equipped with an electromagnetic locking mechanism, which automatically locks after the hoisted component is adjusted to the correct position, with a locking force ≥500kN, to prevent component displacement during hoisting.

3. The overall hoisting system for large wind power equipment based on a truss structure according to claim 1, characterized in that, The leveling device has a signal transmission function, which can feed back the collected levelness data to the operator or control system in real time. When the levelness deviation exceeds the limit, it will promptly remind the operator to make adjustments to ensure that the equipment levelness meets the requirements during the hoisting process and avoid affecting the docking accuracy due to levelness deviation.

4. The overall hoisting system for large wind power equipment based on a truss structure according to claim 1, characterized in that, The rotation and movement adjustment functions of the connection adjustment device are achieved by a built-in servo motor, and the attitude of the hoisted part can be adjusted in real time according to the laser positioning data and the level adjustment instrument data to ensure accurate docking position.

5. The overall hoisting system for large wind power equipment based on a truss structure according to claim 1, characterized in that, The slewing bearing mechanism adopts a high-precision ball bearing with a slewing accuracy of ±0.05° and can achieve 360° rotation adjustment.

6. The overall hoisting system for large wind power equipment based on a truss structure according to claim 1, characterized in that, The lifting device may consist of a hydraulic cylinder, wire rope and tension sensor, or it may be a crawler crane. The tension sensor monitors the lifting force at each corner in real time to ensure uniform load distribution. It works in conjunction with a leveling device to adjust the lifting speed at each corner, ensuring the levelness of the truss and preventing deformation or damage to the truss due to uneven stress.

7. The overall hoisting system for large wind power equipment based on a truss structure according to claim 1, characterized in that, The laser positioning system emits a laser beam towards the target docking position of the hoisted component through a laser transmitter. In conjunction with a laser receiving target at the target position, it achieves positioning data acquisition, provides a positional reference for docking, ensures that the flange bolt hole alignment deviation is ≤2mm, and works with the leveling instrument to ensure docking accuracy.

8. The overall hoisting system for large wind power equipment based on a truss structure according to claim 1, characterized in that, The web members of the overall truss structure are arranged in a triangular pattern, and the spacing between the web members is designed according to the load distribution, so as to reduce the self-weight while ensuring the load-bearing capacity.

9. A method for the overall hoisting of large wind power equipment based on a truss structure, characterized in that, Implement the following steps: Step 1, Preliminary Preparation Stage: a. Site survey and equipment deployment; Based on the terrain and environmental parameters of the hoisting site, determine the deployment positions of the overall truss structure and cranes to ensure that the site's load-bearing capacity meets the requirements; b. Equipment inspection and parameter setting; Check the integrity of the overall truss structure, connection adjustment device, laser positioning system, and leveling instrument; adjust the leveling instrument to normal working condition; and clarify the parameters of the hoisted parts and the docking accuracy requirements. Step 2, Truss and Component Connection Stage: a. The entire truss is in place; The entire truss structure is hoisted above the hoisted component using a crane, and the initial centering is completed using the marking lines on the connecting plate of the slewing bearing mechanism. b. Initial horizontal adjustment; The truss level is monitored by a leveling instrument. If there is a deviation, the crane or lifting device is adjusted to make the truss level initially meet the requirements. c. Connection and fixation; Activate the connection adjustment device, adjust its position and attitude to accurately align it with the lifting point of the hoisted component, and after the connection is completed, activate the electromagnetic locking mechanism to ensure a secure connection. Step 3, Lifting and Posture Adjustment Phase: a. Simultaneous improvement; Activate the four-corner lifting device to achieve synchronous lifting of the entire truss and the hoisted components under real-time monitoring by tension sensors. The lifting speed is controlled between 0.5 and 1 m / min to avoid load fluctuations. b. Real-time horizontal monitoring and adjustment; During the lifting process, the leveling instrument continuously monitors the levelness of the truss. If any deviation occurs, the lifting speed of each corner lifting device is independently controlled to adjust the levelness of the truss and ensure that the levelness is always ≤1mm / m. c. Position deviation adjustment; The laser positioning system collects docking position deviation data, drives the connection adjustment device and slewing bearing mechanism to adjust the posture of the hoisted component in real time, and ensures the stability of the component during the lifting process and that the position deviation is within the allowable range. Step 4, High-altitude docking stage: a. Precise positioning; When the hoisted component is lifted to the target docking height, the laser positioning system accurately measures the deviation of the flange bolt hole position, and the leveling instrument reconfirms the levelness of the truss. b. Adaptive docking; Based on the laser positioning deviation data, the drive connection adjustment device is fine-tuned, and the lifting device is fine-tuned in conjunction with the data of the leveling instrument until the flange bolt hole alignment deviation is ≤2mm and the verticality and horizontality meet the standards. c. Temporary fixation; After the components are properly connected, the positioning pins are manually inserted to temporarily fix them in place and prevent them from shifting during the connection process. Step 5, Unloading and Separation Phase: a. Permanently fixed; After temporary fixing is completed, the flange bolts are tightened to ensure that the bolt preload meets the design requirements. b. Equipment separation; After the bolts are tightened, release the electromagnetic lock of the connecting adjustment device, start the lifting device and slowly lift the device to separate it from the hoisted part. c. Equipment recycling; The entire truss structure is lifted away from the work area, completing one lifting operation and preparing for the next lifting or equipment transfer.

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