Platform and method for assembling platform

Abstract

The invention relates to a platform (10) for temporary or permanent assembly on an existing tower structure (1) of a wind turbine, comprising a deck (20) for receiving a crane and a side arm (30) for fixing the platform (10) on the tower structure (1).

Description

Technical Field

[0001] The present invention relates to a platform for mounting on an existing tower structure of a wind turbine, the platform including a deck for receiving a crane and a side arm for securing the platform to the tower structure, and to a method for mounting the platform. Background Technology

[0002] The assembly and installation of rotor blades and turbines pose significant challenges when erecting wind turbines. For turbines with a current power rating of approximately 4 megawatts, it is necessary to maintain hundreds of tons at an altitude of over 90 meters (and even over 130 meters in low wind speed areas) and reliably keep them in place until a force-locked connection with the support structure is established.

[0003] In the future, the task will become even more challenging, as turbines will tend to develop to power outputs of 6 to 7 megawatts and these turbines must be installed at hub heights exceeding 200 meters.

[0004] This cannot be achieved using currently available crane systems, or can only be achieved with enormous time and financial costs. Furthermore, it becomes even more difficult due to the extremely limited number of such cranes and their severely restricted availability. This unavailability can lead to significant project delays and substantial additional costs due to waiting time, resulting in losses of feed-in tariff subsidies.

[0005] To address this, a design is proposed that involves erecting a platform for temporary mounting on the existing tower structure of a wind turbine to achieve greater height, particularly through the use of a conventional tower crane. The application of such a platform for temporary mounting on the existing tower structure of a wind turbine is exemplarily disclosed in publication CN114180469A. Summary of the Invention

[0006] Therefore, the object of the present invention is to provide a platform by which wind turbines, especially wind turbines with a large hub height, can be economically constructed.

[0007] This task is accomplished by a platform having the features of claim 1 and a method having the features of claim 10.

[0008] The first teaching of the present invention relates to a platform for mounting on an existing tower structure of a wind turbine, the platform including a deck for receiving a crane and side arms for securing the platform to the tower structure, the side arms being constructed of a modular steel structure and each side arm including at least four longitudinal profiles, wherein one longitudinal profile is arranged as a lower longitudinal profile in the lower part of the side arm, and three longitudinal profiles are arranged as a front longitudinal profile, a middle longitudinal profile, and a rear longitudinal profile in the upper part of the side arm.

[0009] The platform includes at least two side arms, or preferably exactly two side arms.

[0010] This invention enables an economical method for erecting wind turbines, especially those with a large hub height. Hub height should be understood as the height of the wind turbine's rotor hub above the terrain surface (erection site).

[0011] The wind turbine to be erected therefore includes a tower structure and a nacelle rotatably arranged on the tower structure. The nacelle houses, for example, generators and other mechanical and electrical components. The hub extends outwards, and the rotor blades are arranged on the hub.

[0012] The tower structure of a wind turbine may be a steel structure or a concrete structure, or may be composed of a steel structure or a concrete structure. It may also be a hybrid structure (combining steel and concrete) or composed of a hybrid structure.

[0013] The tower structure of a wind turbine preferably includes a lower truss structure, a transition section, and an upper cylinder, wherein the transition section connects the upper cylinder to the truss structure, exemplarily referenced in DE102012106772A1, DE102012112415A1, DE102019218687A1, DE102019218358A1, and DE102019219722A1. The truss structure has at least three corner posts, lateral supports, and / or diagonal supports, wherein the corner posts are at least partially inclined relative to each other in their extension direction at an angle relative to the vertical direction of the truss structure. The corner posts are inclined relative to each other such that the spacing between the corner posts in the lower or middle section of the truss structure can be greater than the spacing between them in the upper section of the truss structure.

[0014] What tower structures have in common is at least that they are built on one or more site foundations at their lower ends.

[0015] Longitudinal profiles can be composed of profiles with open or preferably closed cross sections.

[0016] The crane to be placed on the platform is preferably a tower crane, and more preferably a "self-climbing" tower crane, which is used to complete the construction of the wind turbine. Because the tower crane is located on the platform or deck and is close to the tower structure, the torque acting on the tower crane is reduced, and the wind turbine can be erected even at high wind speeds.

[0017] The steel structures of the modular side arms and the deck are sized accordingly to support not only the weight of the crane but also components such as the nacelle, gearbox, and rotor blades. The provided platform (which can be temporarily or permanently assembled), along with the crane mounted on it, represents an economical and reliable overall design for the erection of wind turbines of any hub height. Preferably, at least the lower part of the tower structure has been pre-divided to adequately account for loads from the wind, rotor blades, and turbine, and the dimensional determination particularly preferably also takes into account at least temporary assembly of the platform and integration with the tower crane.

[0018] Therefore, the aforementioned platform can be temporarily assembled and thus fixed to the wind turbine tower structure for a limited time, especially during the duration of wind turbine erection or completion. Alternatively, the aforementioned platform can also be permanently retained on the tower structure, particularly to provide the possibility of storing other parts, components, equipment, containers for spare parts, etc.

[0019] Further advantageous designs and improvements are derived from the following description. One or more features in the claims, specification, and drawings may be combined with one or more other features to form further embodiments of the invention. One or more features in the independent claims may also be combined with one or more other features.

[0020] Each longitudinal profile includes a spherical bearing at its end. These spherical bearings are preferably manufactured separately and welded to the longitudinal profile.

[0021] The three longitudinal profiles in the upper part of the side arm are connected to the upper ends of the lower longitudinal profiles at their lower ends by spherical bearings. Therefore, the three upper longitudinal profiles are constructed in a roughly fan shape.

[0022] Positional designations such as up, down, front, and back are primarily for the assembly state, i.e., when the platform is fixed to the tower structure, to provide clear orientation.

[0023] Two transverse profiles, designated as a front transverse profile and a rear transverse profile, are arranged in the upper part of the side arm. Each transverse profile may include a spherical bearing at its end. The front longitudinal profile is connected to the front end of the front transverse profile at its upper end via a spherical bearing. The middle longitudinal profile is connected to the rear end of the front transverse profile and the front end of the rear transverse profile at its upper end via a spherical bearing. The rear longitudinal profile is connected to the rear end of the rear transverse profile at its upper end.

[0024] Each side arm includes at least three supports configured to receive the deck. At least two of these supports include spherical bearings, wherein the first or front support is connected via spherical bearings to spherical bearings at the upper end of the front longitudinal profile and at the front end of the front transverse profile, and the middle or second support is connected via spherical bearings to spherical bearings at the upper end of the middle longitudinal profile, at the rear end of the front transverse profile, and at the front end of the rear transverse profile. The front and middle supports are preferably identical in design. The rear or third support may be attached to the rear end of the rear transverse profile, either via a bracket or welded at a bracket.

[0025] The side arms can be mounted to the existing tower structure via spherical bearings on the lower end of the lower longitudinal support and on the upper end of the rear longitudinal profile. Therefore, for each side arm, two fixed positions are sufficient to stably and reliably secure the platform for the time required for erecting or completing the wind turbine on the existing tower structure.

[0026] The deck is constructed of a modular steel structure, comprising at least three longitudinal profiles, at least two transverse profiles, and at least one end plate on and connected to these profiles. At least one reinforcing plate is partially arranged on the at least one end plate. If, for example, multiple reinforcing plates are present, such as four or more, these reinforcing plates can also serve as supports for receiving a crane to be erected.

[0027] According to the second teaching, the present invention relates to a method for mounting a platform onto an existing tower structure of a wind turbine, the platform including a deck for receiving a crane and a side arm for securing the platform to the tower structure, wherein the side arm of the platform is first secured to the tower structure, and then the deck of the platform is subsequently attached to or connected to the side arm.

[0028] This can involve temporary or permanent assembly.

[0029] The side boom is lifted using a crane and a rope drive system. This system includes a main rope that branches into at least three branch ropes at its lower end. These branch ropes have different lengths, and the side boom is connected to the ends of these branch ropes at three defined lifting positions. The lengths of the branch ropes are determined such that the side boom, in its suspended state before being fixed to the tower structure, occupies an orientation substantially corresponding to its fixed position. This has the advantage of enabling simple fixing without complex orientation in the suspended state.

[0030] The erection or assembly of certain sections of the tower structure, particularly the lower and optionally the middle sections, is accomplished by a crane, especially a standard (mobile) crane, preferably capable of lifting at a height of 100 meters or more with a lifting capacity of at least 50 tons. This crane also enables temporary or permanent assembly of the platform and, preferably, lifting of the platform by a tower crane.

[0031] During the erection of the lower and optionally middle part of the tower structure, fixing points (e.g., in the form of spherical bearings) are integrated to secure the platform or side arm in defined positions. These fixing points may be retained on the tower structure, for example, as welded structures.

[0032] Another logistical advantage is the ability to establish a complete wind farm using a single platform and a tower crane. After completion, at least the platform, or components such as the boom and deck, can be retained or stored within the wind farm. This allows the platform to be directly used for maintenance, such as replacing rotor blades, gearboxes, and / or turbines, as well as for upkeep, minimizing downtime and thus contributing to economic efficiency. Therefore, either temporary or permanent platform installations can be provided, with a separate platform available for each wind turbine.

[0033] Depending on the wind turbine's construction and hub height, the platform can be secured to the tower structure at a height between 70 and 210 meters, particularly between 80 and 200 meters, preferably between 90 and 180 meters, and most preferably between 100 and 150 meters. Here, "height" refers to the distance between the ground and the crane's reception area on the deck. This height significantly increases the tower crane's lifting height.

[0034] Therefore, it is also possible to specify the application of permanently assembling the platform according to the invention onto a tower structure, which preferably enables the containment or storage of other parts, components, equipment, containers for storing spare parts, etc. Attached Figure Description

[0035] The invention will now be described in more detail with reference to the accompanying drawings. Identical components are given the same reference numerals. Specifically:

[0036] Figure 1 A perspective view of the platform in a fixed state according to the first embodiment is shown;

[0037] Figure 2 A perspective view of the side arm in its suspended state is shown;

[0038] Figure 3 Show Figure 2 A schematic, enlarged, three-dimensional partial view of the connection points in the diagram;

[0039] Figure 4 A side view of the platform in a fixed state according to a second embodiment of the present invention is shown; and

[0040] Figure 5 The finite element analysis contour plot shows an exemplary deformation state from an isometric perspective. Detailed Implementation

[0041] Figure 1 A CAD perspective view of the platform (10) in a fixed state according to the first embodiment is shown. The tower structure (1) can be implemented as a truss structure in the lower part of a wind turbine (not shown) that is still to be erected or completed, exemplarily referred to in DE102019219722A1. The truss structure is constructed, for example, using a mobile crane (not shown). In addition to the truss structure, a transition section for connecting the upper cylinder of the tower structure (1) that is still to be erected can be lifted by means of a mobile crane (not shown), the transition section being assembled and fixed to the truss structure. Fixing points (2) (e.g., in the form of spherical bearings) for fixing the platform (10) in a defined position are integrated into the tower structure (1) or the truss structure.

[0042] The platform (10) for temporary or permanent mounting on the existing tower structure (1) of the wind turbine includes a deck (20) for receiving a crane, preferably a self-climbing tower crane, and side arms (30) for securing the platform (10) to the tower structure (1). The side arms (30) are constructed of modular steel structures, and each side arm (30) includes at least four longitudinal profiles (31-34), wherein one longitudinal profile is arranged as a lower longitudinal profile (34) in the lower part of the side arm (30), and three longitudinal profiles are arranged as a front longitudinal profile (33), a middle longitudinal profile (32), and a rear longitudinal profile (31) in the upper part of the side arm (30). Each longitudinal profile (31-34) includes a spherical bearing (31.11-34.21) at its end (31.1-34.1, 31.2-34.2). Three longitudinal profiles (31-33) in the upper part of the side arm (30) are connected to the upper end (34.2) of the lower longitudinal profile (34) via spherical bearings (31.11, 32.11, 33.11, 34.21) at their lower ends (31.1-33.1). For example, bolts or other known connecting devices are suitable for this connection.

[0043] Two transverse profiles, serving as a front transverse profile (35) and a rear transverse profile (36), are arranged in the upper part of the side arm (30). Each transverse profile may include a spherical bearing (35.11-36.11) at its end (35.1, 36.1, 35.2). The front longitudinal profile (33) is connected to the front end (35.1) of the front transverse profile (35) at its upper end (33.2) via spherical bearings (33.21, 35.11). The middle longitudinal profile (32) is connected to the rear end (35.2) of the front transverse profile (35) and the front end (36.1) of the rear transverse profile (35) and the rear transverse profile (36) via spherical bearings (32.21, 35.21, 36.11) at its upper end (32.2). The rear longitudinal profile (31) is connected at its upper end (31.2) to the rear end (36.2) of the rear transverse profile (36). Each side arm (30) includes at least three supports (37, 38) configured to receive the deck (20). Two of the supports (37) include spherical bearings (37.1), wherein the front support (37) is connected to spherical bearings (33.21, 35.11) via spherical bearings (37.1), and the middle support (37) is connected to spherical bearings (32.21, 35.21, 36.11) via spherical bearings (37.1).

[0044] The side arm (30) is rigidly constructed and therefore consists of multiple interconnected or welded steel components.

[0045] The deck (20) is also constructed of a modular steel structure, comprising at least three longitudinal profiles (21), at least two transverse profiles (22), and at least one end plate (23) on and connected to these profiles (21, 22). The end plate (23), in particular, can be composed of multiple individual end plates (23) due to its large area. At least one reinforcing plate (24) may be locally arranged on the at least one end plate (23), in this embodiment being six reinforcing plates (24).

[0046] Figure 2The side arm (30) is shown in a suspended state. The method for temporarily or permanently mounting the platform (10) onto the existing tower structure (1) of the wind turbine specifies that the side arm (30) of the platform (10) is first secured to the tower structure (1), and then the deck (20) of the platform (10) is connected to or attached to the side arm (30). Thus, the deck (20) and the side arm (30) are detachably connected to each other. Here, the side boom (30) is lifted using a rope drive (100) by means of a crane (not shown), particularly a mobile crane, such that the rope drive (100) includes a main rope (101) which is divided at its lower end into at least three branch ropes (102-104) with different branch rope lengths, and the side boom (30) is connected to the ends of the branch ropes (102-104) at three defined lifting positions (40), wherein the lengths of the branch ropes are determined such that the side boom (30) occupies an orientation substantially corresponding to the fixed position in its suspended state before being fixed to the tower structure (1). The platform (10) is fixed to the tower structure (1) at a height (H) of 70 to 210 meters.

[0047] According to the turbine manufacturer's technical requirements, the exemplary truss structure can have an equilateral triangle as its base with a side length between 20 and 30 meters. This implementation allows for the transfer of large bending moments to the ground. In a conventional tower crane, this (missing) lever arm can be balanced by a correspondingly large counterweight. The truss structure is sized such that it can withstand not only loads from wind, rotor blades, and the turbine, but also the platform (10) on which a conventional self-climbing tower crane is mounted.

[0048] After the platform (10) is assembled to the tower structure (1), the first component of the pre-assembled tower crane is lifted onto the platform (10) or the deck (20) of the platform (30) by means of a mobile crane (not shown), and preferably secured by means of a threaded connection. Subsequently, the further construction of the overall structure or the completion of the wind turbine is completed with the assistance of the tower crane fixed to the platform (10). As the height of the tower structure (1) increases, the height of the tower crane is gradually increased by the additional sections of the tower crane, so that the tower crane mast can be climbed by inserting other intermediate elements and thus always preferably able to operate at an optimized height, see also DE102019219722A1, see Figure 3 When needed, the platform (10) as a whole can be reinforced and / or secured by additional ropes (39), which can be installed on the deck (20) and the tower structure (1).

[0049] After the tower crane is assembled, other parts or the upper part of the wind turbine tower structure, including the nacelle and rotor blades, can be installed with the assistance of the tower crane, thus completing the wind turbine (not shown). A key advantage of this method is that the individual components and parts are easy to transport and require little assembly space. This design enables rapid and reliable erection of wind turbines with significantly improved time planning. With this technology, hub heights can exceed 200 meters. The self-climbing tower crane can achieve sufficient stability by adding a support arm to the existing tower structure (1), on which the self-climbing tower crane can be supported, see also DE102019219722A1.

[0050] After the final assembly or installation of the wind turbine, the tower crane and platform (10) (unless set up for permanent use) can be disassembled again in reverse order, and thus another wind turbine can be built and installed. Therefore, another logistical advantage is that a complete wind farm can be built using a single crane and, for example, a single platform (10). After manufacturing is complete, the crane and platform (10) can be retained or stored in the wind farm. Thus, the system can be directly used for maintenance, such as replacing rotor blades, gearboxes, and / or turbines, as well as for servicing, which minimizes downtime and thus significantly contributes to economic efficiency.

[0051] Alternatively, a platform (10) can be provided for permanent installation of each wind turbine.

[0052] The tower structure of the wind turbine (not shown) is preferably designed for onshore wind farms.

[0053] According to the second embodiment, the platform (10) described above can also be applied or used in steel or concrete tower structures (1) with a circular or polygonal cross-section, see [link to relevant documentation]. Figure 4 .

[0054] Figure 5 The deformation and its variation process of the platform (10) simulated with the finite element solver MSCN astran are shown, wherein the maximum deformation on the deck (20) occurs in the region located on the side away from the tower structure (1).

[0055] All the described features can be combined with each other, provided it is technically feasible.

Claims

1. A platform (10) for mounting on an existing tower structure (1) of a wind turbine, comprising a deck (20) for receiving a crane and a side arm (30) for securing the platform (10) to the tower structure (1), characterized in that, The side arm (30) is constructed of a modular steel structure and each side arm (30) includes at least four longitudinal profiles (31-34), wherein one longitudinal profile is arranged in the lower part of the side arm (30) as a lower longitudinal profile (34), and three longitudinal profiles are arranged in the upper part of the side arm (30) as a front longitudinal profile (33), a middle longitudinal profile (32) and a rear longitudinal profile (31).

2. The platform according to claim 1, wherein, Each of the longitudinal profiles (31-34) includes a spherical bearing (31.11-34.21) at its ends (31.1-34.1, 31.2-34.2).

3. The platform according to any one of the preceding claims, wherein, The three longitudinal profiles (31-33) in the upper part of the side arm (30) are connected to the upper end (34.2) of the lower longitudinal profile (34) via the spherical bearings (31.11, 32.11, 33.11, 34.21) at their lower ends (31.1-33.1).

4. The platform according to any one of the preceding claims, wherein, Two transverse profiles, serving as a front transverse profile (35) and a rear transverse profile (36), are arranged in the upper part of the side arm (30). Each of the transverse profiles may include a spherical bearing (35.11-36.11) at its end (35.1, 36.1, 35.2). The front longitudinal profile (33) is connected at its upper end (33.2) to the front end (35.11) of the front transverse profile (35) via the spherical bearing (33.21, 35.11). The middle longitudinal profile (32) is connected together at its upper end (32.2) to the rear end (35.2) of the front transverse profile (35) and the front end (36.1) of the rear transverse profile (36) via the spherical bearings (32.21, 35.21, 36.11), and the rear longitudinal profile (31) is connected together at its upper end (31.2) to the rear end (36.2) of the rear transverse profile (36).

5. The platform according to any one of the preceding claims, wherein, Each side arm (30) includes at least three supports (37, 38) configured to receive the deck (20).

6. The platform according to claim 5, wherein, The two support members (37) include spherical bearings (37.1), with the front support member (37) connected to the spherical bearings (33.21, 35.11) via the spherical bearings (37.1) and the middle support member (37) connected to the spherical bearings (32.21, 35.21, 36.11) via the spherical bearings (37.1).

7. The platform according to any one of the preceding claims, wherein, The side arm (30) can be mounted to the existing tower structure (1) via a spherical bearing (34.11) on the lower end of the lower longitudinal support (34) and a spherical bearing (31.21) on the upper end of the rear longitudinal profile (31).

8. The platform according to any one of the preceding claims, wherein, The deck (20) is constructed of a modular steel structure, including at least three longitudinal profiles (21), at least two transverse profiles (22), and at least one end plate (23) on and connected to the profiles (21, 22).

9. The platform according to claim 8, wherein, At least one reinforcing plate (24) is partially arranged on the at least one sealing plate (23).

10. A method for mounting a platform (10) onto an existing tower structure (1) of a wind turbine, the platform comprising a deck (20) for receiving a crane and a side arm (30) for securing the platform (10) to the tower structure (1), the platform being particularly the platform (10) according to any one of the preceding claims, characterized in that, First, the side arm (30) of the platform (10) is fixed to the tower structure (1), and then the deck (20) of the platform (10) is connected to or connected to the side arm (30).

11. The method according to claim 10, wherein, The side arm (30) is lifted by means of a crane using a rope drive (100), such that the rope drive (100) includes a main rope (101) which is divided at its lower end into at least three branch ropes (102-104) with different branch rope lengths, and the side arm (30) is connected to the ends of the branch ropes (102-104) at three defined lifting positions (40), the lengths of the branch ropes being determined such that the side arm (30) occupies an orientation substantially corresponding to the fixed position in its suspended state before being fixed to the tower structure (1).

12. The method according to claim 10 or 11, wherein, The platform (10) is fixed to the tower structure (1) at a height (H) between 70 and 210 meters.

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