Self-climbing hoisting system and hoisting method thereof

Abstract

The invention relates to the technical field of fan operation and maintenance, and provides a self-climbing hoisting system and a hoisting method thereof.The self-climbing crane in the system is stored in a container in the initial state, and a lifting hook module is arranged at the end of the self-climbing crane; the two main hoisting mechanisms are arranged in the container side by side, a main steel wire rope is led out from one main hoisting mechanism, the main steel wire rope is wound on the self-climbing crane and connected with the lifting hook module, and the tail end of the main steel wire rope returns to be connected with the other main hoisting mechanism; the auxiliary hoisting mechanism is arranged in the container, an auxiliary steel wire rope is led out of the auxiliary hoisting mechanism, and the auxiliary steel wire rope stretches out of the container, extends towards the wind driven generator cabin, winds around the wind driven generator cabin, is connected with the self-climbing crane and is used for driving the self-climbing crane to achieve self-climbing or descending. According to the invention, the high-efficiency lifting of heavy accessories can be realized by using the high-power auxiliary hoisting mechanism on the ground, and the installation burden and the safety risk of high-altitude operation personnel can be reduced.

Description

Technical Field

[0001] This invention relates to the field of wind turbine operation and maintenance technology, and in particular to a self-climbing hoisting system and its hoisting method. Background Technology

[0002] Wind power is a clean and renewable energy source. To improve power generation efficiency and reduce the cost per kilowatt-hour, wind turbines are developing towards higher power and larger sizes, with continuously increasing single-unit capacity and hub height. This presents new challenges for operation, maintenance, and replacement of major components (such as gearboxes, generators, and blades) throughout their entire lifecycle. While traditional crawler cranes can complete the lifting tasks, their costs for site entry, assembly, and relocation are high, and their operation cycle is long. Their application is particularly limited in wind farms with complex terrain such as mountains and offshore areas.

[0003] To address the aforementioned problems, those skilled in the art have developed single-winch self-lifting cranes. After climbing to the designated position, these cranes require the installation of an additional independent electric hoist outside the crane cabin or on the crane itself for lifting parts. However, in practice, the following technical drawbacks have been observed when using these single-winch self-lifting cranes with electric hoists: First, electric hoists used for hoisting are typically large and heavy. Manually installing or dismantling them at heights exceeding 100 meters is not only difficult and labor-intensive, but also poses a potential safety threat to workers. Second, the power supply from the top of the electric hoist nacelle is limited; some nacelles lack available power, requiring power to be drawn from the ground or batteries to be moved to the roof. Running cables from the ground to the roof is inefficient due to their length, making them prone to breakage, while batteries are too heavy to move and have limited power supply for continuous hoisting. Furthermore, as wind turbine towers grow to 200 meters or even higher, the main wire rope length and lifting height of conventional electric hoists are no longer sufficient, limiting their application. Summary of the Invention

[0004] This invention provides a self-climbing hoisting system and its hoisting method to solve the above-mentioned technical defects in the prior art. It can not only use a high-power auxiliary winch mechanism located on the ground to achieve efficient lifting of heavy attachments, but also reduce the installation burden and safety risks for high-altitude workers.

[0005] A first aspect of the present invention provides a self-climbing hoisting system, comprising: container; The self-climbing crane is initially housed inside the container, and the end of the self-climbing crane is equipped with a hook module; Two main winches are arranged side by side inside the container. One of the main winches has a main wire rope leading out. The main wire rope is wound around the self-climbing crane and connected to the hook module. Its end returns to connect with the other main winch. A secondary winch mechanism is installed inside the container. The secondary winch mechanism has a secondary wire rope extending out of the container and extending toward the nacelle of the wind turbine. The secondary wire rope passes around the nacelle of the wind turbine and connects to the self-climbing crane to drive the self-climbing crane to achieve self-climbing or descent.

[0006] The self-climbing hoisting system provided by this invention, by adding an auxiliary winch mechanism, allows the auxiliary wire rope led out by the auxiliary winch mechanism to cooperate with components on the nacelle (such as crane supports) to form a lifting system. This system is used to pull the self-climbing crane from the ground container to the predetermined working position in the nacelle, or to safely lower it from the nacelle to the ground. It eliminates the need to rent and transport expensive large ground cranes, reducing wind turbine operation and maintenance costs; at the same time, it solves the problems of low lifting capacity, limited lifting height, and limited power supply from the nacelle in existing technologies using electric hoists.

[0007] By retaining the heavy power unit (auxiliary winch mechanism) inside the ground-based container, and only installing a non-powered structural component (cabin top crane) as the force transmission fulcrum on the cabin roof, the auxiliary lifting equipment on the cabin roof does not need to integrate a heavy electric hoist, thus reducing its own weight. This setup allows for the efficient lifting of heavy attachments using the high-powered auxiliary winch mechanism located on the ground, while also reducing the installation burden and safety risks for personnel working at height.

[0008] Because the power source of the self-climbing lifting system is located inside the container on the ground, it can be equipped with a more powerful motor and longer, thicker main and auxiliary wire ropes. This allows it to meet the operational needs of towers even taller than meters, and to lift heavier attachments at once, thus reducing the number of lifting trips and improving operational efficiency. It also solves the problems of limited lifting height and small lifting capacity inherent in traditional electric hoists.

[0009] Furthermore, the auxiliary winch mechanism is not only the power source for driving the self-climbing crane to climb, but also a fully functional auxiliary lifting system. It is responsible for completing the installation of all necessary accessories before the self-climbing crane begins its main operation, making the entire system more compact.

[0010] A second aspect of the present invention provides a lifting method for a self-climbing lifting system, comprising the following steps: The nacelle top crane is disassembled into multiple parts weighing no more than 25 kg each, which are then manually transported and installed onto the nacelle of the wind turbine, and a guide device is installed on the nacelle top crane. The auxiliary winch mechanism drives the auxiliary wire rope to lift the crane support to the nacelle of the wind turbine and complete the installation. When it is confirmed that the auxiliary wire rope is connected to the self-climbing crane, the auxiliary winch mechanism is controlled to tighten the auxiliary wire rope, driving the self-climbing crane to climb upward along the tower. During the climbing process of the self-climbing crane, the two main winch mechanisms are simultaneously controlled to release ropes outward until the self-climbing crane is docked and fixed with the crane support on the nacelle of the wind turbine.

[0011] The hoisting method provided by this invention breaks down the most dangerous high-altitude heavy object installation work, establishes the initial support point through lightweight and manual installation, and places all power operations on the ground, maximizing the safety of high-altitude workers. It eliminates the reliance on large lifting machinery and its demanding operating conditions, making wind turbine operation and maintenance possible in complex terrains such as mountains, tidal flats, and the sea.

[0012] The steps are closely integrated, especially the synchronous rope release design of the main wire rope, which eliminates the secondary preparation time required in traditional solutions and improves overall operation and maintenance efficiency. Relying entirely on its own components, it requires no additional third-party lifting equipment, forming a closed-loop operation process from deployment and operation to recovery, demonstrating strong independence and practicality. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0014] Figure 1 This is a hoisting schematic diagram of the self-climbing hoisting system provided in an embodiment of the present invention.

[0015] Figure 2 This is a schematic diagram of the structure of the self-climbing crane located in the container provided in an embodiment of the present invention.

[0016] Figure 3 This is a side view of the self-climbing crane provided in an embodiment of the present invention, located in a container.

[0017] Figure 4 This is a partial schematic diagram of the lifting process of the self-climbing crane provided in an embodiment of the present invention.

[0018] Figure 5 This is a schematic diagram of the crane support for the self-climbing hoisting system provided in an embodiment of the present invention.

[0019] Figure 6 This is a schematic diagram showing the completed installation of the crane support in the self-climbing hoisting system provided in this embodiment of the invention.

[0020] Figure 7 This is a schematic diagram showing the installation of a self-climbing crane in the self-climbing hoisting system provided in this embodiment of the invention.

[0021] Figure 8 This is a front view of the container provided in an embodiment of the present invention.

[0022] Figure 9 This is a top view of the container provided in an embodiment of the present invention.

[0023] Figure 10 This is a top view of the rope guide mechanism provided in an embodiment of the present invention.

[0024] Figure 11 This is a top view of the compensation mechanism provided in an embodiment of the present invention.

[0025] Figure 12 This is a structural schematic diagram of a container provided in an embodiment of the present invention.

[0026] Figure 13 yes Figure 12 Enlarged view of part A in the middle.

[0027] Figure 14 yes Figure 12 Enlarged view of section B in the middle.

[0028] Figure 15 This is a schematic diagram of the installation position of the outlet guiding mechanism provided in an embodiment of the present invention.

[0029] Figure 16 This is a schematic diagram of the structure of the outlet pulley assembly provided in an embodiment of the present invention.

[0030] Figure 17 This is a front view of the outlet pulley assembly provided in an embodiment of the present invention.

[0031] Figure 18 yes Figure 17 Axonometric sectional view along line AA.

[0032] Figure 19 This is a top view of the outlet pulley assembly provided in an embodiment of the present invention.

[0033] Figure 20 yes Figure 19 Axonometric sectional view along line BB.

[0034] Figure 21 This is a schematic diagram of the pressure wheel mechanism and damping wheel mechanism provided in the embodiments of the present invention.

[0035] Figure 22 This is a front view of the pressure wheel mechanism and damping wheel mechanism provided in the embodiments of the present invention.

[0036] Figure 23 This is a partial structural schematic diagram of a container provided in an embodiment of the present invention.

[0037] Figure 24 yes Figure 23 The container shown is a side view.

[0038] Figure 25 This is a schematic diagram of the outlet guiding mechanism provided in an embodiment of the present invention.

[0039] Figure 26 yes Figure 25 The side view of the outlet guide mechanism shown.

[0040] Figure 27 This is a partial structural diagram (including guide rails) of a container provided in an embodiment of the present invention.

[0041] Figure label: 100 Wind turbine generator; 110 Nacelle; 200 Nacelle top crane; 210 Fixed pulley; 220 Lifting device; 300 Self-climbing crane; 310 Hook module; 400 Crane support; 410 Pulley module; 10. Container; 11. First end; 12. Second end; 13. First guide rail; 14. Second guide rail; 20. Main hoisting mechanism; 21. Main drum; 22. Main drive unit; 23. Main wire rope; 30. Rope guiding mechanism; 31. Rope guide rail bracket; 32. Rope guide pulley; 33. Rope guide drive unit; 331. Drive motor; 332. Drive sprocket; 333. Driven sprocket; 334. Transmission chain; 40. Compensation mechanism; 41. Compensation slide rail bracket; 42. Compensation pulley; 43. Compensation drive unit; 44. First fixed pulley; 45. Second fixed pulley; 50. Tensioning mechanism; 51. Tensioning slide rail bracket; 52. Counterweight mechanism; 53. Tensioning pulley; 54. First support pulley; 55. Second support pulley; 60. Outlet guiding mechanism; 61. Pulley bracket; 62. Main outlet pulley; 63. Main anti-derailment pulley; 70. Guide pulley; 80. Outlet pulley assembly; 81. Mounting bracket; 811. First mounting part; 812. Second mounting part; 813. Pivot part; 82. Steering pulley; 83. Secondary outlet pulley; 84. Pressure roller mechanism; 841. Support base; 842. Slider; 843. Pressure plate; 844. Pressure roller component; 8441. Pressure roller shaft; 8442. Pressure roller body; 845. Pressure roller elastic element; 846. Pressure roller adjusting element; 85. Damping roller mechanism; 851. Support plate; 852. Damping roller component; 8521. Damping shaft; 8522. Damping roller body; 853. Guide element; 854. Pressing plate; 855. Damping elastic element; 856. Friction plate; 857. Damping adjusting element; 86. Secondary anti-derailment pulley; 90. Secondary hoisting mechanism; 91. Secondary drum; 92. Secondary drive unit; 93. Secondary wire rope. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0043] See Figures 1 to 4 The present invention provides a self-climbing hoisting system for the operation and maintenance of a wind turbine 100. The entire self-climbing hoisting system is integrated into a standard container 10 and uses the tower of the wind turbine 100 as support to enable the self-climbing crane 300 to climb itself, thereby eliminating the dependence on large ground cranes.

[0044] The main power unit (main winch mechanism 20) and control unit of the self-climbing hoisting system are integrated into a standard container 10, while the lightweight crane body is installed on top of the nacelle 110 of the wind turbine 100 for operation via self-climbing. This solves the problems of traditional large cranes, such as high requirements for roads and foundations, and limited operating space and power supply from the nacelle.

[0045] The self-climbing lifting system includes a container 10, a self-climbing crane 300, two main winch mechanisms 20 and an auxiliary winch mechanism 90.

[0046] Container 10 is preferably a standard-sized container (such as a 20-foot or 40-foot high cube container). Container 10 serves not only as the transport carrier for the entire self-climbing lifting system but also as the operating platform and counterweight base during operation. All core components of the self-climbing lifting system, such as the self-climbing crane 300 in its initial stowed state, the main winch mechanism 20, the auxiliary winch mechanism 90, and possibly the control system, hydraulic station, generator, etc., are integrated inside the container 10. During transportation, container 10 can easily reach the wind farm via road, rail, or sea. During operation, container 10 provides a stable and windproof working environment for all components. For example, this embodiment of the invention uses a standard 40-foot container 10, which facilitates transportation to the wind farm via road, rail, or waterway.

[0047] Container 10 is not only a transportation and storage unit, but also a ground power station. The power supply (electric or hydraulic) for all main hoisting mechanisms 20, as well as the control system, are located within container 10, allowing operators to work from the ground and reducing the power requirements on the engine room 110. Furthermore, container 10 is equipped with a guidance system to provide precise guidance and support when the self-climbing crane 300 enters and exits container 10, ensuring a smooth process.

[0048] The self-climbing crane 300 is the main equipment for performing lifting tasks. In its initial state, the self-climbing crane 300 is housed within the container 10 and is driven by the auxiliary winch mechanism 90 to climb and descend along the tower. The end of the self-climbing crane 300 is equipped with a hook module 310 for lifting wind turbine components, such as generators, gearboxes, transformers, and other components within the nacelle 110, as well as external components like the hub and blades.

[0049] The self-climbing crane 300 mainly includes a boom, a slewing bearing, and a base (none of which are labeled in the figure). The base is fixedly installed inside the nacelle 110, the slewing bearing is installed on the base, the boom is installed on the slewing bearing, and the hook module 310 is located at the end of the boom.

[0050] The two main hoisting mechanisms 20 are preferably arranged side by side at the first end 11 of the container 10, while the auxiliary hoisting mechanism 90 is arranged at the second end 12 of the container 10. This arrangement is conducive to optimizing the space utilization and weight balance inside the container 10.

[0051] Each of the two main winch mechanisms 20 includes two independent main drums 21 and their own independent main drive units 22 and brakes. A complete main wire rope 23 is wound around the main drums 21 of both main winch mechanisms 20. One end of the main wire rope 23 is led out from one of the main winch mechanisms 20. After passing through a series of guiding, compensating, and tensioning mechanisms inside the container 10, the main wire rope 23 exits the container 10, winds upwards around pulleys mounted on the boom and base of the self-climbing crane 300, and connects with the hook module 310. The other end of the main wire rope 23 then returns and is finally connected to the main drum 21 of the other main winch mechanism 20.

[0052] The auxiliary winch mechanism 90 includes an auxiliary drum 91 and an auxiliary drive unit 92, as well as a brake mounted on the auxiliary drive unit 92. An auxiliary wire rope 93 extends from the auxiliary drum 91 of the auxiliary winch mechanism 90, extending out of the container 10 and towards the nacelle 110 of the wind turbine 100. It then winds around the nacelle 110 and connects to the self-climbing crane 300, driving the self-climbing crane 300 to achieve self-climbing or descent. In other words, the auxiliary winch mechanism 90 is the power source for driving the self-climbing crane 300 to climb or descend. When the auxiliary winch mechanism 90 winds the auxiliary wire rope 93, it can pull the self-climbing crane 300 upwards along the guide auxiliary wire rope 93 to the position of the nacelle 110; the descent process is the opposite.

[0053] Essentially, during the self-climbing process of the self-climbing crane 300, the auxiliary wire rope 93 led out by the auxiliary winch mechanism 90, in cooperation with the structural components (such as the crane support 400 described below) installed on the nacelle 110, forms a lifting system, and in cooperation with the spreader 220 described below, is used to pull the self-climbing crane 300 from the ground container 10 to the predetermined working position of the nacelle 110, or to safely lower it from the nacelle 110 to the ground.

[0054] When the auxiliary winch mechanism 90 tightens the auxiliary wire rope 93, it is equivalent to applying an upward pulling force at the nacelle 110 position, lifting the self-climbing crane 300 vertically upward along the tower. Similarly, when the auxiliary winch mechanism 90 slowly releases the auxiliary wire rope 93, the self-climbing crane 300 descends controllably under its own weight. By utilizing the height and structure of the wind turbine generator 100 itself as the fulcrum for climbing, the crane's self-climbing is achieved.

[0055] See Figures 5 to 7 Based on the above structure, the workflow of the self-climbing hoisting system provided in this embodiment of the invention is described as follows: First, container 10 is transported to the designated location below the wind turbine tower. Workers then board the nacelle 110 and manually install the lightweight nacelle top crane 200.

[0056] Operate the auxiliary winch mechanism 90 inside container 10, and use the auxiliary wire rope 93 to lift the crane support 400 of the self-climbing crane 300 from the ground to the engine room 110, and complete the installation.

[0057] Connect the auxiliary wire rope 93 to the self-climbing crane 300 housed inside the container 10. Start the auxiliary winch mechanism 90 to pull the self-climbing crane 300 smoothly up to the location of the engine room 110 along the guide direction of the auxiliary wire rope 93, and then secure the self-climbing crane 300 to the installed crane support 400. During this process, the two main winch mechanisms 20 simultaneously release the main wire rope 23 outwards.

[0058] Once the self-climbing crane 300 is in place, it begins to perform lifting tasks such as component replacement. At this time, the two main winch mechanisms 20 work together to control the lifting and lowering of the hook module 310 to carry out lifting operations for large components (such as gearboxes, generators, etc.).

[0059] After the operation is completed, the self-climbing crane 300 is first safely lowered from the engine room 110 and retrieved into the container 10 via the auxiliary winch mechanism 90. Then, the crane support 400 is disassembled and lifted off. Finally, the entire self-climbing lifting system is stored in the container 10 for easy transfer to the next work site.

[0060] It is understood that the self-climbing hoisting system provided in this embodiment of the invention, by adding an auxiliary winch mechanism 90, allows the auxiliary wire rope 93 led out by the auxiliary winch mechanism 90 to cooperate with components on the nacelle 110 (such as the crane support 400) to form a lifting system for pulling the self-climbing crane 300 from the ground container 10 to the predetermined working position of the nacelle 110, or for safely lowering it from the nacelle 110 to the ground. This eliminates the need to rent and transport expensive large ground cranes, reducing wind turbine operation and maintenance costs; it also solves the problems of low lifting capacity and limited lifting height of electric hoists in the prior art.

[0061] By retaining the heavy power unit (auxiliary winch mechanism 90) within the ground-based container 10, and only requiring a single unpowered structural component (cabin top crane 200) as the force transmission fulcrum on the roof of the cabin 110, the auxiliary lifting equipment on the roof of the cabin 110 does not need to integrate a heavy electric hoist, thus reducing its own weight. This configuration allows for the efficient lifting of heavy attachments using the high-powered auxiliary winch mechanism 90 located on the ground, while also reducing the installation burden and safety risks for personnel working at height.

[0062] Because the power source of the self-climbing lifting system is located inside the container 10 on the ground, it can be equipped with a more powerful motor and longer, thicker main wire ropes 23 and auxiliary wire ropes 93. This allows it to meet the operational needs of towers 200 meters or even higher, and to lift heavier attachments at once, thereby reducing the number of lifting batches and improving operational efficiency. It solves the problems of limited lifting height and small lifting capacity inherent in traditional electric hoists.

[0063] Furthermore, the auxiliary winch mechanism 90 is not only the power source for driving the self-climbing crane 300 to climb, but also a fully functional auxiliary lifting system responsible for completing the installation of all necessary accessories before the self-climbing crane 300 begins its main operation, making the entire system more compact.

[0064] Continue reading Figures 1 to 7 In some embodiments of the present invention, the self-climbing hoisting system further includes a nacelle crane 200 and a crane support 400. The nacelle crane 200 is used to be installed on the nacelle 110 of the wind turbine generator 100, and a fixed pulley 210 is provided at the end of the nacelle crane 200. The crane support 400 is used to support the self-climbing crane 300.

[0065] Among them, the auxiliary wire rope 93 is connected to the lifting device 220 after passing through the fixed pulley 210. The lifting device 220 is used to lift the crane support 400 so that the crane support 400 can be pre-installed on the nacelle 110 of the wind turbine generator 100.

[0066] Essentially, in order to enable the self-climbing crane 300 to be stably installed and operated on top of the nacelle 110 of the wind turbine 100, the self-climbing hoisting system introduces two key auxiliary components: the nacelle top crane 200 and the crane support 400.

[0067] The nacelle-top crane 200 is a lightweight, modular auxiliary lifting device. Its function is not to directly lift heavy objects, but rather to serve as a high-altitude anchor point on top of the nacelle 110 for the entire self-climbing lifting system, providing a force-directing fulcrum for the subsequent lifting of components. The nacelle-top crane 200 is designed to be installed manually on the nacelle 110 of the wind turbine 100. All its components can be disassembled into parts weighing no more than 25 kg, allowing workers to manually move it to the top of the nacelle 110 and assemble it without the need for any large lifting equipment, reducing the difficulty of initial installation and reliance on external equipment.

[0068] The key part of the overhead crane 200 is the fixed pulley 210 at the end. The fixed pulley 210 is the steering mechanism of the auxiliary wire rope 93. When the auxiliary wire rope 93 extends upward from the ground, it will pass around the pulley module 410, thereby converting the upward tension into a downward lifting force.

[0069] The crane support 400 is a load-bearing base used for installation on the nacelle 110 of the wind turbine 100, serving as a docking platform and working foundation for the subsequent self-climbing crane 300. The crane support 400 can withstand the weight of the self-climbing crane 300 itself, as well as all dynamic and static loads generated during lifting operations. The crane support 400 is a high-strength steel structural component and can be designed as a single unit or as multiple modules for easy separate lifting.

[0070] Continue reading Figures 5 to 7 Based on the above structure, the workflow of the self-climbing hoisting system provided in this embodiment of the invention is described as follows: First, the high-altitude anchor points are installed. The workers first climb onto the nacelle 110 of the wind turbine 100 and manually assemble and fix the lightweight nacelle top crane 200 in the predetermined position on the nacelle 110.

[0071] Then, one end of the auxiliary wire rope 93 from the auxiliary hoisting mechanism 90 inside the ground container 10 is pulled to the top of the cabin 110 and passes around the fixed pulley 210 at the end of the overhead crane 200. After passing around the fixed pulley 210, the end of the auxiliary wire rope 93 extends downward and is connected to a dedicated spreader 220.

[0072] Ground personnel connect the spreader 220 to the crane support 400 to be lifted. They then operate the auxiliary winch mechanism 90 inside the ground container 10 to wind the auxiliary wire rope 93. At this point, the auxiliary wire rope 93, via the fixed pulley 210 at a higher position, vertically lifts the crane support 400 to the height of the nacelle 110.

[0073] The workers on the engine room 110 assisted in positioning the crane support 400 and installed it on the structure of the engine room 110. At this point, the crane support 400 was pre-installed, preparing for the subsequent climbing and docking of the self-climbing crane 300.

[0074] This invention retains the heavy power unit (auxiliary winch mechanism 90) within the ground-based container 10, while only a lightweight, unpowered structural component (top crane 200) is installed at height as the force transmission fulcrum. This configuration allows for efficient lifting of heavy attachments using the high-powered auxiliary winch mechanism 90 located on the ground, accommodating the lifting needs of taller towers and enabling the transport of heavier attachments, thereby reducing the number of lifting batches and improving operational efficiency. It solves the problems of limited lifting height and small lifting weight inherent in traditional electric hoist solutions. It also reduces the installation burden and safety risks for personnel working at height, avoiding the difficulties and dangers of installing heavy electric hoists at height. Workers only need to install the structural component; power and control are all handled on the ground, improving the safety and convenience of high-altitude operations.

[0075] See Figures 8 to 11 In some embodiments of the present invention, the self-climbing hoisting system further includes two rope guide mechanisms 30 and two compensation mechanisms 40.

[0076] For example, two main winch mechanisms 20 arranged side by side are designated as the first main winch mechanism 20a and the second main winch mechanism 20b. Each main winch mechanism 20 has an independent power unit, that is, each main winch mechanism 20 includes a drum 21 for winding the wire rope 23 and a drive unit 22 for driving the drum 21 to rotate, such as a motor or a reducer. One of the drums 21 (such as the drum 21 of the first main winch mechanism 20a) leads out the wire rope 23a, which returns after winding around the container 10 to form the wire rope 23b. The end of the wire rope 23b is connected to the other drum 21 (such as the drum 21 of the second main winch mechanism 20b).

[0077] Two rope guiding mechanisms 30 correspond to the first main hoisting mechanism 20a and the second main hoisting mechanism 20b, respectively. Each rope guiding mechanism 30 includes a rope guide rail bracket 31, a rope guide pulley 32, and a rope guiding drive mechanism 33. The rope guide rail bracket 31 is typically fixedly mounted on the structural components of the container 10 parallel to the axis of the drum 21. The rope guide pulley 32 is mounted on a slider or trolley that can slide on the rope guide rail bracket 31, allowing the rope guide pulley 32 to slide against the rope guide rail bracket 31. The rope guide pulley 32a of one rope guiding mechanism 30 is used to guide the wire rope 23a. The rope guide pulley 32b of the other rope guiding mechanism 30 is used to guide the wire rope 23b.

[0078] The guide rope drive mechanism 33 is installed on the container 10. The guide rope drive mechanism 33 can be a motor-driven screw, rack and pinion or chain drive mechanism, etc., to provide power for the movement of the guide rope pulley 32, so as to drive the guide rope pulley 32 to move along the guide rope slide rail bracket 31, thereby dynamically adjusting the entry angle of the wire rope 23 into each main winch mechanism 20.

[0079] Two compensation mechanisms 40 are respectively set for the two guide rope mechanisms 30. Each compensation mechanism 40 is linked with the corresponding guide rope mechanism 30, and synchronous control can be achieved through PLC or dedicated controller to ensure the consistency and reliability of the entire self-climbing hoisting system. For example, the same controller can control the two drive mechanisms to move synchronously according to the algorithm to compensate for the change in the effective length of the wire rope 23 caused by the movement of the guide rope mechanism 30.

[0080] Unlike traditional single-winch hoisting systems, the wire rope 23 of the self-climbing lifting system of this invention forms a closed loop. A single wire rope 23 serves as the force transmission medium for the entire self-climbing lifting system. The wire rope 23a originates from the drum 21 of the first main hoisting mechanism 20a, passes through the rope guiding mechanism 30 and the compensation mechanism 40, and its path extends to the outside of the container 10 to connect to and drive loads (such as spreaders, trolleys, etc.). Subsequently, it forms a wire rope 23b, the end of which returns to the container 10 and connects to the drum 21 of the second main hoisting mechanism 20b.

[0081] By coordinating the forward and reverse rotation of the two main hoisting mechanisms 20, complex actions such as lifting, lowering, and translating the load can be achieved. For example, by having the first main hoisting mechanism 20a retract the rope and the second main hoisting mechanism 20b release the rope, the load can be driven to move in a certain direction. Alternatively, the first main hoisting mechanism 20a and the second main hoisting mechanism 20b can be controlled to simultaneously retract and release the rope.

[0082] When the main hoisting mechanism 20 operates and the wire rope 23 winds around the drum 21, a controller (such as a PLC, not shown) calculates the axial position of the wire rope 23 in real time based on the rotational speed and pitch of the drum 21. The controller then instructs the guide rope drive mechanism 33 to drive the guide rope pulley 32 to move synchronously along the guide rope slide rail bracket 31. This ensures that the guide rope pulley 32 is always approximately aligned with the winding point of the wire rope 23 on the drum 21, thereby ensuring that the entry angle of the wire rope 23 into the drum 21 is always kept at an ideal value (e.g., less than 0.5°), thus avoiding rope tangling, skipping, and abnormal wear.

[0083] While the movement of the guide pulley 32 solves the problem of the rope entry angle, it will cause a change in the total path length of the wire rope 23. For example, when the guide pulley 32 moves from a position near the middle of the drum 21 to both ends, geometrically, the path of the wire rope 23 will become longer.

[0084] To counteract this change, this embodiment of the invention includes a compensation mechanism 40 that is linked to the rope guide mechanism 30. The movement of the compensation mechanism 40 is synchronous with and related to the movement of the rope guide mechanism 30. When the movement of the rope guide pulley 32 causes the rope path to need to increase by ΔL, the compensation mechanism 40 will automatically extend a steel wire rope 23 of length ΔL through its own structural changes; conversely, when the rope path needs to be shortened, the compensation mechanism 40 will automatically take in a steel wire rope 23 of the corresponding length.

[0085] It is understood that the self-climbing hoisting system provided in this embodiment of the invention, by arranging two main winch mechanisms 20 side by side inside the container 10, and corresponding to the two main winch mechanisms 20, respectively arranging two rope guide mechanisms 30 and two compensation mechanisms 40, each compensation mechanism 40 is linked with the corresponding rope guide mechanism 30 to compensate for the change in the effective length of the wire rope 23 caused by the movement of the rope guide mechanism 30, realizes the real-time compensation of the effective length of the wire rope 23 while dynamically adjusting the rope entry angle, and avoids the self-climbing hoisting system from wear and unstable operation due to excessive rope entry angle.

[0086] Specifically, the movable rope guide mechanism 30 ensures that the rope entry angle is always within the ideal range, effectively preventing rope tangling and groove jumping, reducing wear between the wire rope 23 and the rope groove of the drum 21, extending the service life of the wire rope 23, and ensuring operational safety. The compensation mechanism 40 is linked with the rope guide mechanism 30, which in real time offsets the rope length changes caused by adjusting the rope entry angle, ensuring that the wire rope 23 is always in a stable pre-tension state, avoiding impact loads caused by rope slack or excessive tightness, and ensuring smooth operation under load.

[0087] Furthermore, the entire self-climbing lifting system is integrated within a standard container 10, saving on-site installation and commissioning time and providing excellent physical protection for the system, facilitating transportation and rapid deployment to different working conditions. Additionally, each drum 21 is individually equipped with a drive unit 22. If one drive unit 22 fails, the other can slowly lift or lower the component, ensuring that the self-climbing lifting system will not be completely paralyzed in the event of a single drive unit 22 failure, allowing for basic safety procedures and preventing the accident from escalating.

[0088] Continue reading Figure 9 and Figure 11 In some embodiments of the present invention, each compensation mechanism 40 includes a compensation slide rail bracket 41, a compensation pulley 42, and a compensation drive mechanism 43.

[0089] The compensating slide rail bracket 41 is typically one or a group of parallel linear guide rails (such as heavy-duty ball bearing guides, roller guides, or simple I-beam rails), and is mounted on the internal frame or floor of the container 10. The mounting direction of the compensating slide rail bracket 41 is usually parallel to the corresponding guide rope slide rail bracket 31 to simplify control and motion relationships.

[0090] The compensating pulley 42 is one or a group of pulleys, mounted on a slider or trolley that moves smoothly on the aforementioned compensating slide rail bracket 41, and can move along the compensating slide rail bracket 41. The routing path of the wire rope 23 is designed to pass around this compensating pulley 42, that is, the wire rope 23 enters from one direction, passes around the compensating pulley 42, and then exits from another direction.

[0091] The compensation drive mechanism 43 is specifically designed to drive the compensation pulley 42 (and its associated slider / trolley) to move precisely along the compensation slide rail bracket 41. The compensation drive mechanism 43 can be implemented using various mature linear drive methods, such as: motor and lead screw drive: a servo motor or stepper motor drives a long lead screw via a coupling, with a nut fixed to the slider to engage with the lead screw. Motor and rack and pinion drive: a motor drives a gear that meshes with a rack fixed to the frame of the container 10, thereby moving the entire slider. Motor and chain / synchronous belt drive: a motor drives a sprocket or synchronous belt pulley, which pulls the slider via a closed-loop chain or synchronous belt.

[0092] The compensating pulley 42 moves in the opposite direction to the corresponding guide pulley 32. Furthermore, its movement distance has a precise functional relationship with the movement distance of the guide mechanism 30 (this relationship can be derived through geometric calculations and incorporated into the controller algorithm). Through this coordinated reverse motion, one mechanism lengthens the rope path, while the other shortens it by an equal amount, ultimately ensuring that the total effective length of the entire wire rope 23 remains constant and the tension is stable.

[0093] Because the guide pulley 32 in the guide rope mechanism 30 moves along its guide rail to follow the winding point of the wire rope 23 on the drum 21, the effective total path length of the wire rope 23 increases as the guide pulley 32 moves from the midpoint of the guide rope guide rail bracket 31 (where the path of the wire rope 23 is shortest) to any endpoint. This increment (ΔL) is a non-linear function of the displacement of the guide pulley 32. The controller can calculate the rope length increment ΔL caused by the movement of the guide pulley 32 in real time.

[0094] To counteract this increment, the controller immediately sends a command to the compensation drive mechanism 43, driving the compensation pulley 42 to move. The wire rope 23 forms a rope storage loop by winding around the compensation pulley 42. Assuming that for every distance x the compensation pulley 42 moves, the length of the wire rope 23 in the rope storage loop changes by 2x (one in, one out). The controller will instruct the compensation pulley 42 to move an appropriate distance so that the length of the wire rope 23 it handles is exactly equal to ΔL, thus keeping the total length of the wire rope 23 constant.

[0095] It is understood that, unlike passive compensation methods such as springs and counterweights, this embodiment of the invention employs an independent compensation drive mechanism 43 for active compensation. Through precise control of a servo motor and PLC, the compensation displacement can reach sub-millimeter levels, effectively offsetting rope length changes and ensuring constant tension in the wire rope 23. Furthermore, since the compensation action is actively driven, it can be completely synchronized with the guide rope movement, adapting to rapid rope length changes under high-speed winding conditions and ensuring the dynamic stability of the hoisting system.

[0096] Continue reading Figure 9 and Figure 11 In some embodiments of the present invention, each compensation mechanism 40 further includes a first fixed pulley 44 and a second fixed pulley 45.

[0097] The first fixed pulley 44 is fixedly mounted on an internal structural component of the container 10 (e.g., a beam or base). Located on one side of the path of the movable compensating pulley 42, the first fixed pulley 44 acts as an inlet guide for the wire rope 23 as it enters the compensation loop. After being drawn from the previous component of the self-climbing lifting system (e.g., the guide pulley 32 of the rope guiding mechanism 30), the wire rope 23 first passes around the first fixed pulley 44 before being guided to the movable compensating pulley 42.

[0098] The second fixed pulley 45, similar to the first fixed pulley 44, is also fixedly installed inside the container 10. The second fixed pulley 45 is positioned opposite the first fixed pulley 44, on the other side of the movement path of the movable compensating pulley 42. The second fixed pulley 45 acts as the exit guide pulley for the wire rope 23 as it leaves the compensation circuit.

[0099] The axis of the second fixed pulley 45 is parallel to the axis of the compensating pulley 42, and the axis of the second fixed pulley 45 is perpendicular to the axis of the first fixed pulley 44. That is, the first fixed pulley 44 and the second fixed pulley 45 can not only serve as guides, but also as direction changers.

[0100] After passing the movable compensating pulley 42, the wire rope 23 will then pass through the second fixed pulley 45 before being led to the next component of the self-climbing hoisting system (e.g., tensioning mechanism 50 or another main winch mechanism 20).

[0101] Essentially, this embodiment is a more optimized description of the aforementioned compensation mechanism 40. By adding two key fixed pulleys—the first fixed pulley 44 and the second fixed pulley 45—and a compensation pulley 42, a total of three pulleys are formed. One of these pulleys is movable, and the other two are fixed, together constituting the rope storage compensation circuit. The specific path of the wire rope 23 is: the first fixed pulley 44, the movable compensation pulley 42, and the second fixed pulley 45. In this layout, the movable compensation pulley 42 moves back and forth between the first fixed pulley 44 and the second fixed pulley 45 on its compensation rail bracket 41, which not only clarifies the specific path of the wire rope 23 in the compensation circuit but also improves the compensation efficiency and the stability of the hoisting system.

[0102] Since the positions of the first fixed pulley 44 and the second fixed pulley 45 are constant, two fixed reference points are provided for the wire rope 23 to enter and exit the compensation circuit. No matter where the compensation pulley 42 moves, the angle at which the wire rope 23 enters and leaves the circuit is relatively stable, avoiding additional instability caused by drastic angle changes.

[0103] Furthermore, since the wire rope 23 forms a "U" or "V" shaped fold at the compensating pulley 42, when the compensating pulley 42 moves a linear distance X along its slide rail, it is stored in the loop formed by the first fixed pulley 44, the second fixed pulley 45, and the compensating pulley 42. The change in the total length of the wire rope 23 is approximately 2X.

[0104] Suppose that the movement of the rope guiding mechanism 30 causes the total path of the wire rope 23 to be shortened by ΔL. Upon receiving this signal, the central controller will instruct the compensation drive mechanism 43 to drive the compensation pulley 42 to move. To take in a length of ΔL of wire rope 23, the compensation pulley 42 only needs to move a distance of approximately ΔL / 2.

[0105] In other words, the movement of the compensating pulley 42 simultaneously changes the lengths of the two sections of wire rope 23: from the first fixed pulley 44 to the compensating pulley 42 and from the compensating pulley 42 to the second fixed pulley 45. Therefore, the effect of the compensating pulley 42 on the total length of the wire rope 23 is twice its own displacement. The same amount of wire rope 23 length compensation can be achieved with half the stroke of the compensating pulley 42. Under the premise of satisfying the same compensation range, the required slide rail length of the compensation mechanism 40 can be halved, or the compensation capacity can be doubled with the same slide rail length, making the entire self-climbing hoisting system more compact.

[0106] Continue reading Figure 10 In some embodiments of the present invention, the specific implementation methods of the power source and transmission method of the rope guide mechanism 30 are described in detail. The rope guide drive mechanism 33 includes a chain drive assembly and a drive motor 331.

[0107] The drive motor 331 can be a servo motor or a variable frequency motor with an encoder. It is the power source for the entire guide rope movement, and its rotation angle and speed determine the position and speed of the guide rope pulley 32. The drive motor 331 is fixedly mounted on the structural components of the container 10.

[0108] The chain drive assembly is a reliable transmission system, mainly composed of a drive sprocket 332, multiple driven sprockets 333, a drive chain 334, and connecting components. The drive sprocket 332 is fixed to the output shaft of the drive motor 331 and rotates with the motor. The multiple driven sprockets 333 are mounted on the structural components of the container 10. The drive chain 334 is a closed-loop roller chain that meshes with the drive sprocket 332 and the driven sprockets 333, forming a tensioned loop.

[0109] A connector is provided on the slider (or trolley) where the guide rope pulley 32 is located. This connector fixes the slider to a point on the transmission chain 334, for example, to a link of the chain. The drive motor 331 drives the transmission chain 334 to rotate cyclically via the drive sprocket 332. Since a part of the transmission chain 334 is fixed to the slider of the guide rope pulley 32, the cyclic movement of the transmission chain 334 will cause the slider to move linearly back and forth along the guide rope slide rail bracket 31.

[0110] In this embodiment, the drive mechanism utilizes a closed-loop transmission chain 334 to convert rotational motion into controlled linear motion. The central controller (PLC) monitors the rotational state of the drum 21 in real time and calculates the ideal axial position of the wire rope 23 at the next moment based on a preset algorithm (drum 21 diameter, pitch, etc.). The controller converts this position information into a rotation command for the drive motor 331 (e.g., requiring N revolutions forward or M revolutions reverse). Upon receiving the command, the drive motor 331 rotates by the specified angle, and the motor output shaft drives the drive sprocket 332 to rotate. The drive sprocket 332, through meshing, drives the transmission chain 334 to begin cyclic motion.

[0111] Since the slider of the guide rope pulley 32 is fixed on the transmission chain 334, the slider is dragged by the transmission chain 334 to move linearly along the guide rope slide rail bracket 31.

[0112] When the motor rotates in the forward direction, the transmission chain 334 circulates in one direction, driving the guide rope pulley 32 to move from one end of the guide rope slide rail bracket 31 to the other. When the motor rotates in the reverse direction, the transmission chain 334 circulates in the opposite direction, driving the guide rope pulley 32 to return from the far end to the near end. By controlling the forward and reverse rotation of the motor and the number of rotations, the guide rope pulley 32 can be positioned and moved back and forth at any position within the entire slide rail stroke.

[0113] For example, as the drum 21 begins winding the rope, the wire rope 23 winds around from left to right, one turn at a time. The controller instructs the guide rope drive motor 331 to slowly rotate clockwise at a matching speed, and the transmission chain 334 drives the guide rope pulley 32 to move synchronously from left to right, always following the winding point of the wire rope 23. When the wire rope 23 is fully wound on the drum 21 and it is time to start winding the second layer from right to left, the controller instructs the motor to reverse, driving the guide rope pulley 32 to return from right to left.

[0114] In this embodiment of the invention, a chain drive is used as the guide rope drive mechanism 33. Unlike friction drives such as belt drives, there is no relative slippage during the transmission process, ensuring a precise transmission ratio. Each rotation of the motor is accurately converted into a linear displacement of the guide rope pulley 32, ensuring positioning and synchronization accuracy.

[0115] Compared to synchronous belts, the chain drive 334 can transmit greater force, has a stronger load-bearing capacity, and is more impact-resistant within the same dimensions, making it suitable for heavy-duty, harsh-condition self-climbing lifting systems. At the same time, the overall structure of the chain drive is relatively compact, facilitating its installation within the limited space of the container 10.

[0116] See Figures 12 to 14 In some embodiments of the present invention, the self-climbing hoisting system further includes two tensioning mechanisms 50, which are respectively provided for two main winch mechanisms 20. Each tensioning mechanism 50 is in contact with the corresponding wire rope 23 and applies a preset tension to the corresponding wire rope 23 to keep the corresponding wire rope 23 in a continuously tensioned state.

[0117] It is understood that this embodiment adds a tensioning mechanism 50. Based on the above embodiment which already has a rope guide mechanism 30 and a compensation mechanism 40, the tensioning mechanism 50 is introduced to solve the problem of instantaneous slack that may occur in the dynamic operation of the self-climbing hoisting system, and to provide a constant preload for the entire wire rope 23 circuit, so as to ensure the stability of the self-climbing hoisting system.

[0118] Specifically, each tensioning mechanism 50 includes a tensioning slide rail bracket 51, a counterweight mechanism 52, and a tensioning pulley 53. The tensioning slide rail bracket 51 is typically a single linear guide rail or a set of linear guide rails vertically mounted on the internal columns or side walls of the container 10.

[0119] The counterweight mechanism 52 is a heavy block of considerable mass, which can be a solid cast iron block or a box into which the counterweight can be filled. The counterweight mechanism 52 is mounted on a slider or guide sleeve that slides freely on the aforementioned tensioning slide rail bracket 51, and the only power source for the counterweight mechanism 52 is its own weight.

[0120] The tension pulley 53 is mounted on the movable counterweight mechanism 52 and moves up and down together with the counterweight mechanism 52. The path of the wire rope 23 needs to pass through this tension pulley 53, that is, the tension pulley 53 and the wire rope 23 always remain in contact.

[0121] The tensioning mechanism 50 automatically maintains the preset tension of the wire rope 23 using its own gravitational potential energy; this is a passive and adaptive constant force application process. The total mass (M) of the counterweight mechanism 52 is preset. Under the action of gravity (g is the acceleration due to gravity), it generates a constant, vertically downward gravitational force (F=Mg). This gravitational force acts continuously on the U-shaped wire rope 23 loop through the tensioning pulley 53, attempting to stretch the loop downwards.

[0122] The downward pulling force of the counterweight mechanism 52 is decomposed into tension applied to both ends of the wire rope 23. Therefore, by selecting the mass of the counterweight mechanism 52, a preset tension of constant magnitude can be applied to the entire wire rope 23. For example, if friction and pulley weight are ignored, the tension applied to the wire rope 23 is approximately equal to half the weight of the counterweight.

[0123] During the operation of the self-climbing hoisting system, especially during start-up, shutdown, reversal, or load changes, even with the compensation mechanism 40, a momentary slack may still occur on one side of the wire rope 23. Once any slack occurs, the counterweight mechanism 52, under gravity, will immediately drive the tension pulley 53 downwards, absorbing the excess, slack wire rope 23 and re-tightening it. Conversely, if the self-climbing hoisting system causes the wire rope 23 to become over-tensioned for some reason, the increased tension will overcome the weight of the counterweight, slightly lifting the tension pulley 53 and the counterweight upwards, thereby releasing a small amount of rope length and providing a buffering effect.

[0124] Throughout the operation, the counterweight mechanism 52 acts like a buoy, floating slightly up and down on the vertical guide rail, but the tension it applies to the wire rope 23 remains constant (equal to the force generated by its own weight), thus ensuring that the wire rope 23 remains under tension.

[0125] Unlike elastic elements such as springs whose tension varies with stroke, the tension provided by gravity in this embodiment of the invention is constant and does not change with the position of the counterweight. This ensures that the wire rope 23 maintains a stable and reliable minimum tension regardless of the state of the self-climbing hoisting system, thereby preventing serious malfunctions such as rope slippage, tangling, or entangling caused by slack in the wire rope 23 and improving the operational safety of the system. In addition, the vertically floating counterweight mechanism 52 acts as a mechanical damper, effectively absorbing the slight vibrations and impacts generated by the wire rope 23 during high-speed operation, making the operation of the entire hoisting system smoother.

[0126] Continue reading Figures 12 to 14 In some embodiments of the present invention, based on the tensioning mechanism 50 described above, this embodiment further adds a first support pulley 54 and a second support pulley 55 to each tensioning mechanism 50.

[0127] The first support pulley 54 is fixedly mounted on the internal structural component of the container 10, located on one side of the movement path of the vertically movable tension pulley 53. The first support pulley 54 acts as an inlet guide pulley for the wire rope 23 as it enters the tensioning circuit. After the wire rope 23 is led out from the previous component of the system (such as the compensation mechanism 40), it first passes around the first support pulley 54 before being guided to the movable tension pulley 53.

[0128] Similar to the first support pulley 54, the second support pulley 55 is also fixedly installed inside the container 10. The second support pulley 55 is positioned opposite the first support pulley 54, on the other side of the movement path of the movable tension pulley 53, and at approximately the same height as the first support pulley 54. The second support pulley 55 acts as an exit guide pulley for the wire rope 23 as it leaves the tensioning circuit. After passing over the movable tension pulley 53, the wire rope 23 passes through the second support pulley 55 before being guided to the next component of the system.

[0129] In this embodiment, by adding two fixed first support pulleys 54 and second support pulleys 55, the entire tensioning circuit forms an inverted "U" or "V" shaped rope winding circuit. When the wire rope 23 enters and leaves the tensioning pulley 53, the direction of the wire rope 23 is forcibly constrained to be approximately vertical.

[0130] When the distance between the two fixed support pulleys is close, the two sections of wire rope 23 wound around the tension pulley 53 are almost vertically upward. In this case, the weight F of the counterweight mechanism 52 located on the tension pulley 53 will be converted into tension on the two sections of wire rope 23 almost completely and without loss.

[0131] Without these two fixed support pulleys, the wire rope 23 enters and exits the tensioning circuit from the rest of the lifting system at a near-horizontal angle. This generates a non-negligible horizontal component force on the movable tension pulley 53. This horizontal force acts on the tensioning rail bracket 51, generating additional lateral loads and friction.

[0132] Therefore, this embodiment of the invention adds two fixed support pulleys to align the path of the wire rope 23 vertically. Thus, regardless of where the wire rope 23 enters or exits the hoisting system, the force transmitted to the tensioning mechanism 50 is first absorbed and converted by these two fixed support pulleys. The vertical tension is transmitted to the movable tensioning pulley 53, ensuring that the counterweight mechanism 52 is almost unaffected by any lateral forces when sliding on the rail.

[0133] When the wire rope 23 becomes slack, the counterweight mechanism 52, along with the tension pulley 53, falls smoothly under pure gravity, absorbing the excess rope length. Because there is no horizontal force interfering, its falling and rising movements are smoother and its response speed is faster.

[0134] Continue reading Figure 12 and Figure 14In some embodiments of the present invention, the self-climbing lifting system further includes two exit guide mechanisms 60, namely exit guide mechanism 60a and exit guide mechanism 60b, wherein exit guide mechanism 60a is used to guide the wire rope 23a out of the container 10, and exit guide mechanism 60b is used to guide the wire rope 23b out of the container 10.

[0135] In application scenarios where the self-climbing lifting system is integrated inside the container 10, but the load served by the self-climbing lifting system is located outside the container 10, an exit guide mechanism 60 is set at a reserved opening in the container wall of the container 10 to reliably guide the wire rope 23 from inside the container 10 to the outside.

[0136] The export guide mechanism 60 includes a pulley bracket 61, a main export pulley 62, and two main anti-derailment pulleys 63.

[0137] The pulley bracket 61 is a rigid structural component that serves as the mounting base for the export guide mechanism 60. It is welded or secured to the structural frame of the container 10 with high-strength bolts to withstand the enormous load transmitted by the wire rope 23 during operation.

[0138] The main outlet pulley 62 is the main pulley in the outlet guide mechanism 60, mounted on the pulley bracket 61. It is primarily used for steering and load transfer when the wire rope 23 is led out of the container 10. For example, when the wire rope 23 runs horizontally inside the container 10, but needs to be vertically downwards to connect to the load after exiting the container, the axis of the main outlet pulley 62 is typically set horizontally to smoothly change the path of the wire rope 23 by 90 degrees. Its dimensions and strength are designed based on the system's maximum load.

[0139] Two main anti-derailment pulleys 63 are symmetrically mounted on the pulley bracket 61, located on either side of the main outlet pulley 62, forming a clamping or channel structure. The rotation axis of the main anti-derailment pulleys 63 is perpendicular to the rotation axis of the main outlet pulley 62. For example, if the main outlet pulley 62 is a horizontal axis, then the two main anti-derailment pulleys 63 must be vertical axes.

[0140] The wire rope 23 is drawn from inside the container 10, first passing through the rope groove of the main outlet pulley 62, then through the narrow channel formed between the two main anti-derailment pulleys 63, and finally being led out of the container 10. The rope groove of the main outlet pulley 62 provides constraint on the wire rope 23 in a plane perpendicular to its axis, ensuring the smooth turning of the wire rope 23 in the main direction of motion.

[0141] In actual working conditions, the swaying of external loads, rotation during hoisting, lateral wind force, or high-speed vibration of the wire rope 23 itself can all cause the wire rope 23 to swing or deflect laterally. This lateral force can easily cause the wire rope 23 to jump out of the rope groove of the main outlet pulley 62.

[0142] To address this, this embodiment of the invention provides two main anti-derailment pulleys 63 located on either side of the main outlet pulley 62. The gap between the two main anti-derailment pulleys 63 is only slightly larger than the diameter of the wire rope 23. When the wire rope 23 attempts to swing to the left, it will contact the left main anti-derailment pulley 63; when the wire rope 23 attempts to swing to the right, it will contact the right main anti-derailment pulley 63.

[0143] Since the main anti-derailment pulley 63 can rotate, when the wire rope 23 comes into contact with the main anti-derailment pulley 63, it will rotate along the lateral trend of the wire rope 23, using rolling friction instead of sliding friction to push the wire rope 23 back to the center rope groove position of the main outlet pulley 62, instead of rigidly blocking or wearing down the wire rope 23.

[0144] It should be noted that, for reference Figure 15 Two exit guide mechanisms 60 are located between the geometric center A and the center of gravity G of the container 10. That is, the two key points from which the main wire rope 23 leads out of the container 10 are arranged in the middle area along the length of the container 10, and are typically aligned with or very close to the position between the center of gravity G and the geometric center A of the container 10. This maximizes the stability of the container 10 as a ground base. When the self-climbing crane 300 performs lifting operations on top of the cabin 110, the main wire rope 23 will bear enormous tensile force, which is applied to the container 10 through the exit guide mechanisms 60.

[0145] Applying an upward lifting force near the center of gravity or geometric center of an object is the most effective way to avoid overturning moments. If the exit point is located at one end of container 10, the huge lifting force can easily cause the other end of container 10 to tilt, leading to instability of the entire self-climbing lifting system. However, this embodiment of the invention concentrates the force point of the main wire rope 23 (i.e., the exit guide mechanism 60) towards the central area of ​​container 10, ensuring that the upward force is applied to the most stable position during heavy-duty lifting. This enhances the anti-overturning capability of container 10 as a ground work platform, ensuring its overall stability and safety under various working conditions (especially on uneven ground or on ships with slight swaying).

[0146] In some embodiments of the present invention, the self-climbing lifting system further includes multiple guide pulleys 70. These guide pulleys 70 are standard pulleys, and the number depends on the complexity of the rope winding path. All guide pulleys 70 are fixedly installed inside the container 10, at various strategic locations within the container 10, such as the container frame, top plate, bottom plate, or a dedicated support. Unlike the compensating pulley 42 or tensioning pulley 53, the positions of the guide pulleys 70 are constant.

[0147] Within the long, narrow space of a container 10 filled with equipment, the path of the wire rope 23 cannot be a straight line. Multiple guide pulleys 70 serve as turning points for the wire rope 23, ensuring that the wire rope 23 enters functional pulley groups such as guide pulleys 32, compensating pulleys 42, and tensioning pulleys 53 at the correct angle and position. This is fundamental to ensuring the coordinated operation of the entire system.

[0148] By incorporating guide pulleys 70, it becomes possible to arrange a steel wire rope 23 loop, which can be tens or even hundreds of meters long, within the extremely limited space of a container 10, thereby improving the flexibility of the system layout and space utilization. Using smooth, rotatable guide pulleys 70 to change the direction of the steel wire rope 23 results in rolling friction far less than the sliding friction generated by the steel wire rope 23 directly scraping against the fixed structure. This reduces the overall system resistance, saves driving energy, and minimizes wear on the steel wire rope 23.

[0149] See Figure 16 In some embodiments of the present invention, the self-climbing hoisting system further includes an outlet pulley assembly 80, which includes a mounting frame 81, a steering pulley 82, an auxiliary outlet pulley 83, a pressure wheel mechanism 84, and a damping wheel mechanism 85.

[0150] The entire outlet pulley assembly 80 is based on the mounting frame 81, which is the load-bearing structure for all components on the outlet pulley assembly 80. The structure of the mounting frame 81 should have sufficient strength and rigidity to withstand various loads during operation. The mounting frame 81 is pre-set with connection points or spaces for mounting the steering pulley 82, the auxiliary outlet pulley 83, the pressure roller mechanism 84, and the damping roller mechanism 85.

[0151] A steering pulley 82 is mounted at one end of the mounting bracket 81 to guide the auxiliary wire rope 93 to turn and enter the outlet pulley assembly 80. The auxiliary outlet pulley 83 is mounted at the other end of the mounting bracket 81 to guide the auxiliary wire rope 93 to extend outward and exit the outlet pulley assembly 80.

[0152] The pressure roller mechanism 84 is mounted on the mounting frame 81 and located on the path of the auxiliary wire rope 93 between the steering pulley 82 and the auxiliary outlet pulley 83. The damping wheel mechanism 85 is mounted on the mounting frame 81 and located below the pressure roller mechanism 84, and is configured to cooperate with the pressure roller mechanism 84.

[0153] The pressure wheel mechanism 84 is configured to apply pressure to the auxiliary wire rope 93 to press the auxiliary wire rope 93 onto the damping wheel mechanism 85; the damping wheel mechanism 85 is configured to provide damping force to its own rotation to apply tension to the auxiliary wire rope 93 when it is slack.

[0154] When the outlet pulley assembly 80 is used in a hoisting system, the specific guiding path of the auxiliary wire rope 93 is as follows: The auxiliary wire rope 93 first enters the steering pulley 82, which changes the direction of the auxiliary wire rope 93, allowing it to smoothly enter the subsequent pressure roller mechanism 84 and damping roller mechanism 85. After passing through the pressure roller mechanism 84 and damping roller mechanism 85, the auxiliary wire rope 93 is finally guided away from the outlet pulley assembly 80 by the auxiliary outlet pulley 83. The auxiliary outlet pulley ensures that the auxiliary wire rope 93 extends outward at the correct angle (e.g., towards the top of the tower crane 200).

[0155] Two core mechanisms working in concert are set between the steering pulley 82 and the secondary outlet pulley 83: a pressure wheel mechanism 84 and a damping wheel mechanism 85. The pressure wheel mechanism 84 is located directly above the damping wheel mechanism 85, and its function is to apply downward force, that is, to provide an adaptive downward pressure, pressing the secondary wire rope 93 onto the damping wheel mechanism 85 below. The damping wheel mechanism 85 is located below the path of the secondary wire rope 93, directly supporting the secondary wire rope 93, and the damping wheel mechanism 85 is used to provide damping force.

[0156] It is understood that the export pulley assembly 80 provided in this embodiment of the invention, by cooperating with the pressure wheel mechanism 84 and the damping wheel mechanism 85 on the path of the auxiliary wire rope 93 between the steering pulley 82 and the auxiliary export pulley 83, achieves continuous tension of the auxiliary wire rope 93, ensuring that when using the overhead crane 200, no matter how the auxiliary wire rope 93 swings, the part located inside the container 10 can always maintain a moderate tension, thereby avoiding failures such as derailment, rope jamming or rope tangling caused by the slack of the auxiliary wire rope 93, so as to ensure the safety and reliability of the hoisting operation.

[0157] When the auxiliary wire rope 93 sways due to wind or inertia, the elastic element 845 (compression spring) on ​​the pressure roller mechanism 84 moves the pressure roller downward through elastic force, pressing the auxiliary wire rope 93 onto the damping wheel; this prevents the auxiliary wire rope 93 from becoming tangled or slipping off the groove due to swaying. The damping wheel mechanism 85 uses the damping elastic element 855 (compression spring) to generate friction between the friction plate 856 and the damping wheel, preventing the damping wheel from rotating freely and ensuring that the auxiliary wire rope 93 is always taut between the steering pulley 82 and the auxiliary hoisting mechanism 90. It also allows the auxiliary hoisting mechanism 90 to apply appropriate back pressure to the auxiliary wire rope 93 under no-load conditions, making the auxiliary wire rope 93 more neatly arranged on the drum of the auxiliary hoisting mechanism 90 and reducing interlayer compression and wear.

[0158] The entire tensioning process is automatically completed relying entirely on the elastic force of each elastic element and the friction between components, requiring no electrical or hydraulic systems. This ensures high reliability and stable operation even in harsh environments. It eliminates operational interruptions caused by rope management issues, reduces the risks of working at heights, and improves the maintenance efficiency and safety of the Wind Turbine 100.

[0159] See Figures 17 to 22 In some embodiments of the present invention, the pressure roller mechanism 84 includes two support seats 841, two sliders 842, a pressure roller component 844, a pressure plate 843, and at least two pressure roller elastic elements 845.

[0160] The two support seats 841 are the basic load-bearing structures of the entire pressure roller mechanism 84, providing a stable mounting reference. The two support seats 841 are installed spaced apart and opposite each other on both sides of the mounting frame 81; that is, the two support seats 841 are arranged symmetrically or parallelly, maintaining a certain distance from each other. This symmetrical distributed layout is key to ensuring the stable operation of subsequent components. In a typical embodiment, each support seat 841 is machined with a guide structure, such as a guide groove, guide rail, or protrusion, to guide the up-and-down movement of the slider 842.

[0161] Two sliders 842 are respectively mounted on two support seats 841 and can move up and down relative to the corresponding support seats 841. That is, each slider 842 is mounted on a support seat 841 and forms a sliding engagement with the support seat 841. In other words, the slider 842 can move freely only in the vertical direction (usually the vertical direction) within the guide structure of the support seat 841, while movement in other directions (such as forward and backward, left and right) is restricted, ensuring the accuracy of the movement of the pressure roller component 844.

[0162] The pressure plate 843 is fixedly mounted on the top of the support base 841. The pressure plate 843 connects the upper ends of each support base 841 into a whole, forming a sturdy "door" or "bridge" shaped frame. The position of the pressure plate 843 is fixed, serving as a fixed reaction surface and providing a stable top support point for the pressure roller elastic element 845.

[0163] The pressure roller component 844 is located between and connected to the two sliders 842. The pressure roller component 844 is the core component that directly performs the clamping function. The pressure roller component 844 applies pressure to the auxiliary wire rope 93 through rolling contact. In some embodiments, the pressure roller component 844 includes a central rotating shaft and at least one roller mounted on the shaft. Both ends of the rotating shaft are fixed to the two sliders 842. Therefore, when the sliders 842 move up and down, the entire pressure roller component 844 moves up and down synchronously.

[0164] At least two pressure roller elastic elements 845 are located between the slider 842 and the pressure plate 843, and respectively abut against the corresponding slider 842 and pressure plate 843. The pressure roller elastic elements 845 provide elastic force to move the slider 842 and pressure roller components 844 toward the damping wheel mechanism 85. That is, the pressure roller elastic elements are the power source for providing the clamping force. They store and release elastic potential energy, thereby enabling the pressure roller components 844 to continuously apply downward pressure. In specific embodiments, the most common form of pressure roller elastic element 845 is a helical compression spring. Of course, other forms of elastic elements can also be used, such as rubber blocks, disc spring assemblies, etc.

[0165] It is understood that the pressure roller mechanism 84 provided in this embodiment of the invention utilizes elastic potential energy to convert into continuous mechanical pressure, and achieves adaptive adjustment of pressure through a sliding guide mechanism. Through the cooperation of the elastic element 845 and the slider 842, the pressure roller component 844 can float up and down, automatically adapting to the auxiliary steel wire rope 93, ensuring the continuity and stability of the contact pressure.

[0166] The entire pressure roller mechanism 84 is composed of a limited number of standard or easily machinable parts, with a clear structure that is easy to assemble and disassemble. When the rollers or elastic elements 845 of the pressure roller component 844 wear or fail due to long-term use, they can be easily replaced, reducing maintenance costs and difficulties.

[0167] In practice, the initial pre-compression of the elastic element can be changed by replacing the pressure roller elastic element 845 with different stiffness coefficients (k values) or by setting an adjusting screw on the pressure plate 843, thereby conveniently adjusting the initial pressure applied by the pressure roller component 844 to adapt to different process requirements.

[0168] See Figures 17 to 22 In some embodiments of the present invention, the pressure roller mechanism 84 further includes a pressure roller adjusting member 846, which is disposed on the pressure plate 843 and threadedly connected to the pressure plate 843. The pressure roller adjusting member 846 is used to adjust the preload of the pressure roller elastic member 845.

[0169] Essentially, this embodiment adds an additional function: a pressure roller adjusting component 846 for pressure adjustment. The pressure roller adjusting component 846 is typically a long bolt or threaded rod. This pressure roller adjusting component 846 passes through the pressure plate 843, with its rod or end abutting against the pressure roller elastic element 845. Precise adjustment of the spring preload is achieved using threaded transmission. The head of the pressure roller adjusting component 846 (bolt) is located on the outside of the pressure plate 843, and the operator can use a tool (such as a wrench) to rotate it for pressure adjustment.

[0170] According to Hooke's Law (F=k·x), the greater the compression of a spring, the greater the elastic force (i.e., preload). Therefore, by simply rotating the pressure roller adjusting component 846, the operator can easily increase or decrease the initial pressure of the auxiliary wire rope 93. This makes the downward pressure of the pressure roller mechanism 84 no longer a fixed value, but adjustable according to the actual working conditions. For example, an optimal preload can be set based on different conditions such as the diameter of the auxiliary wire rope 93, its weight, wind speed, and operational requirements. For lighter loads or lower wind speeds, the preload can be lowered to reduce unnecessary energy consumption and wear; for heavy loads or strong winds, the preload can be increased to ensure absolute compression of the wire rope and prevent malfunctions.

[0171] Continue reading Figures 17 to 22 In some embodiments of the present invention, the pressure roller component 844 includes a pressure roller shaft 8441 and a pressure roller body 8442. The pressure roller shaft 8441 is located between two sliders 842 and is fixedly connected to each slider 842. The pressure roller body 8442 is mounted on the pressure roller shaft 8441 by bearings.

[0172] Specifically, a shoulder (i.e., a step on the shaft with a larger diameter) can be machined on the pressure roller shaft 8441. A bearing is installed in the center hole of the pressure roller body 8442 (the main body of the wheel). The pressure roller body 8442 with the bearing is fitted onto the pressure roller shaft 8441 and pushed axially until its inner ring end face abuts against the shoulder. On the other side of the pressure roller body 8442, a retaining ring groove is opened on the pressure roller shaft 8441. An elastic retaining ring (or retaining ring) is inserted into the groove, thereby limiting the pressure roller body 8442 in the other axial direction and preventing the pressure roller body 8442 from coming out.

[0173] By incorporating a bearing within the pressure roller body 8442, the pressure roller body 8442 can rotate freely with minimal frictional resistance as the auxiliary wire rope 93 passes through. This reduces the relative sliding friction between the auxiliary wire rope 93 and the pressure roller surface, effectively reducing wear on both the auxiliary wire rope 93 and the pressure roller body 8442 itself, and extending their service life. The combined use of a shoulder and an elastic retaining ring fixes the pressure roller body 8442 in an axial position, eliminating axial movement and ensuring smooth operation and a constant contact state with the auxiliary wire rope 93 during work.

[0174] Continue reading Figures 17 to 22 In some embodiments of the present invention, the damping wheel mechanism 85 includes two support plates 851, a damping wheel component 852, at least two guide members 853, a pressing plate 854, at least one damping elastic member 855, and at least one friction plate 856.

[0175] Two support plates 851 are arranged parallel to each other at a preset spacing and are fixed together on both sides of the mounting bracket 81. This symmetrical rigid mounting method provides a stable and reliable support foundation for the entire mechanism and a solid mounting base for the internal components.

[0176] The damping wheel component 852 is located between and connected to the two support plates 851 respectively. The damping wheel component 852 is the core component that directly contacts the auxiliary wire rope 93 and produces the damping effect. It should be understood that the damping wheel component 852 is rotatably mounted on the two support plates 851 via its central pivot (e.g., damping wheel shaft).

[0177] At least two guide members 853 are parallel to the axis of the damping wheel component 852 and are fixedly connected to two support plates 851 respectively. The guide member 853 can be a guide rod or a guide rail. The function of the guide member 853 is to provide a precise, single-degree-of-freedom motion trajectory for the clamping plate 854.

[0178] The pressure plate 854 is located on at least one side of the damping wheel component 852 and slides in engagement with the guide member 853. In a preferred embodiment, the pressure plate 854 is symmetrically arranged on both sides to achieve more uniform force distribution. The pressure plate 854 is a key moving component for transmitting pressure, and it forms a sliding engagement with the guide member 853 through through holes or sliders provided thereon. This ensures that the pressure plate 854 can only translate along the direction of the guide member 853 without deflection or wobbling, thus guaranteeing stable pressure application.

[0179] At least one damping elastic element 855 is located between the support plate 851 and the pressure plate 854, and abuts against both the support plate 851 and the pressure plate 854 respectively. The damping elastic element 855 is the source of pressure and can be a coil spring, a disc spring, a rubber elastic block, etc. The damping elastic element 855 is disposed between the support plate 851 and the movable pressure plate 854, and abuts against the end faces of both.

[0180] At least one friction plate 856 is disposed on the side of the clamping plate 854 facing the damping wheel component 852. The friction plate 856 is the direct interface for generating frictional force. The friction plate 856 is fixed (e.g., by adhesive or screws) to the inner surface of the clamping plate 854 facing the damping wheel component 852. The friction plate 856 is typically made of a composite material with high wear resistance and a high coefficient of friction.

[0181] The damping elastic element 855 is used to apply pressure to the friction plate 856, so that the friction plate 856 presses against the damping wheel component 852 to generate frictional damping force, and converts elastic potential energy into continuous and controllable frictional damping force.

[0182] After initial assembly or adjustment by the damping adjuster 857 described below, the damping elastic element 855 is compressed, storing elastic potential energy. This elastic force continuously pushes the pressure plate 854, which, guided by the guide 853, moves steadily toward the damping wheel component 852 and transmits pressure to the friction plate 856 fixed thereon.

[0183] Under pressure, friction plate 856 is pressed against the side of damping wheel component 852. According to the friction force formula F_f = μ... F_n (where μ is the coefficient of friction and F_n is the normal force) generates a frictional force on the side of the damping wheel component 852 that is opposite to its rotation direction. This frictional force acts on the radius of the wheel body, thereby forming a frictional damping torque that resists or delays its rotation.

[0184] When the auxiliary wire rope 93 passes over the damping wheel assembly 852, its movement tends to cause the wheel to rotate. However, due to the aforementioned frictional damping torque, the damping wheel assembly 852 cannot rotate freely, but instead generates a continuous resistance to the movement of the auxiliary wire rope 93. It is this resistance that keeps the auxiliary wire rope 93 taut from the damping wheel mechanism 85 to the auxiliary winch mechanism 90, preventing it from slackening even under no-load or low-load conditions.

[0185] It is understood that the damping wheel mechanism 85 provided in this embodiment of the invention can apply a constant and preset damping force to the auxiliary wire rope 93, effectively solving the problem of slack and tangled rope in the auxiliary winch mechanism 90 during unloaded rope winding or lowering, ensuring that the auxiliary wire rope 93 is always orderly wound on the drum, and improving the safety and reliability of equipment operation.

[0186] Because the auxiliary wire rope 93 is always under tension, it avoids the shaking, whipping, and abnormal friction with other parts of the equipment that would occur in a slack state. This effectively reduces the wear and fatigue damage of the auxiliary wire rope 93 itself and extends its service life.

[0187] Continue reading Figures 17 to 22 In some embodiments of the present invention, the damping wheel mechanism 85 further includes a damping adjustment member 857, which is disposed on the support plate 851 and threadedly connected to the support plate 851. The damping adjustment member 857 is used to adjust the elastic force of the damping elastic member 855 to change the magnitude of the frictional damping force applied to the damping wheel component 852.

[0188] Essentially, based on the structure of the above embodiment, this embodiment of the invention adds an adjustment function. That is, a damping adjustment component 857 is added to the support plate 851. The damping adjustment component 857 is usually an adjustment bolt or a lead screw. The damping adjustment component 857 can change the compression of the damping elastic component 855 by changing its screw-in depth, which can conveniently adjust the magnitude of the friction damping force to adapt to different specifications of wire ropes or different working conditions.

[0189] Based on the characteristics of springs, the greater the compression, the greater the elastic force generated. By rotating the damping adjustment component 857, the initial compression length of the damping elastic component 855 can be directly changed, thereby determining the normal pressure of the friction plate 856 on the damping wheel component 852, and directly adjusting the magnitude of the final frictional damping force. This makes the damping force no longer a fixed value, but can be precisely set by on-site personnel according to actual needs. The damping force can be adjusted to an optimal value based on the specifications of the auxiliary wire rope 93, ambient wind force, load conditions, etc., effectively tensioning the rope without causing excessive wear during normal operation.

[0190] See Figures 17 to 22 In some embodiments of the present invention, the damping wheel component 852 includes a damping shaft 8521 and a damping wheel body 8522. The damping shaft 8521 is located between two support plates 851 and is fixedly connected to the two support plates 851 respectively. The damping wheel body 8522 is mounted on the damping shaft 8521 by bearings.

[0191] As can be seen, the damping wheel component 852 in this embodiment is similar to the pressure wheel component 844 mentioned above. A damping shaft 8521 is fixed between two support plates 851, and the damping shaft 8521 is stationary. The damping wheel body 8522 (the main body of the wheel) is mounted on this fixed damping shaft 8521 through bearings.

[0192] To achieve precise axial positioning, the damping shaft 8521 has a shoulder, and one end of the damping wheel body 8522 (via its bearing inner ring) rests against this shoulder. At the other end, an elastic retaining ring engages with a groove in the damping shaft 8521 to axially limit the damping wheel body 8522 and prevent it from falling off. This ensures that the damping wheel body 8522 can rotate freely around the fixed damping shaft 8521 with extremely low frictional resistance. By reducing friction during the rotation of the damping wheel body 8522 through bearings, the rotational resistance of the entire damping wheel assembly 852 almost entirely comes from the frictional damping force generated by the friction plate 856. This ensures that the magnitude of the damping force is pure and controllable, and is not disturbed by the uncertain frictional force of the damping shaft 8521 itself, thus making the adjustment function effective and reliable.

[0193] The usage process of the outlet pulley assembly 80 provided in this embodiment of the invention is as follows: The auxiliary wire rope 93 is led out from the auxiliary winch mechanism 90, passes around the steering pulley 82, then passes between the pressure wheel component 844 and the damping wheel component 852, and finally extends outward through the auxiliary outlet pulley 83.

[0194] When the auxiliary wire rope 93 is under tension (such as when lifting heavy objects or winding the rope), it will push upward against the pressure roller assembly 844, compressing the pressure roller elastic element 845. The pressure roller assembly 844 and the damping roller assembly 852 rotate normally as the auxiliary wire rope 93 moves. At this time, the damping force of the damping roller mechanism 85 will generate slight resistance, but it is much smaller than the working tension of the auxiliary winch mechanism 90, so it does not affect normal operation.

[0195] If the auxiliary wire rope 93 becomes slack due to wind sway, inertia, or other reasons, the force pushing upward against the pressure roller component 844 will decrease or disappear. The elastic potential energy stored in the pressure roller elastic element 845 will be released immediately, driving the pressure roller component 844 to move downward and press the auxiliary wire rope 93 tightly against the damping roller component 852 below. In the damping roller mechanism 85, the preload of the damping elastic element 855 (e.g., adjusted by a spring or bolt) continuously applies pressure to the friction plate 856 on the side of the damping roller component 852.

[0196] When the damping wheel assembly 852 attempts to rotate, it must overcome the static friction force applied by the friction plate 856. This force that prevents the damping wheel assembly 852 from rotating freely is the damping force. The magnitude of the damping force is designed to be neither too large to cause excessive wear on the auxiliary wire rope 93 during normal winching, nor too small to provide effective tension when the auxiliary wire rope 93 is slack. The damping force acts like a brake, preventing the damping wheel assembly 852 from rotating freely, thereby also preventing the auxiliary wire rope 93 from sliding freely, ensuring that the section of the auxiliary wire rope 93 between the outlet pulley assembly 80 and the auxiliary winching mechanism 90 is always under minimum tension and cannot be completely slack.

[0197] This configuration allows the pressure roller assembly 844 to automatically move up and down following the minute displacements of the auxiliary wire rope 93, ensuring that the auxiliary wire rope 93 is reliably pressed against the damping roller assembly 852 at all times. The symmetrically arranged two pairs of elastic rollers 845 ensure uniform pressure application and prevent the pressure roller assembly 844 from tilting.

[0198] See Figures 16 to 17 In some embodiments of the present invention, the mounting bracket 81 includes a first mounting portion 811 and a second mounting portion 812 connected to each other, the first mounting portion 811 and the second mounting portion 812 being perpendicular to each other; a steering pulley 82 is disposed at the end of the first mounting portion 811, a secondary outlet pulley 83 is disposed at the end of the second mounting portion 812, and a damping wheel mechanism 85 and a pressure wheel mechanism 84 are both disposed in the first mounting portion 811.

[0199] Essentially, the mounting bracket 81 is designed as an "L"-shaped structure of a first mounting section 811 and a second mounting section 812 that are perpendicular to each other. It utilizes three-dimensional space to rationally distribute multiple functional components such as the steering pulley 82, the secondary outlet pulley 83, the pressure roller mechanism 84, and the damping roller mechanism 85 in different positions, making the structure of the entire outlet pulley assembly 80 more compact, occupying less space, improving space utilization, and facilitating deployment in limited installation space.

[0200] In some embodiments of the present invention, the outlet pulley assembly 80 further includes a support frame, and the bottom of the mounting frame 81 is provided with a pivot portion 813. The interior of the pivot portion 813 is provided with a hollow cavity, and the auxiliary steel wire rope 93 passes through the hollow cavity and is wound around the steering pulley 82.

[0201] This configuration ensures that the path of the auxiliary wire rope 93 passes through the rotation center of the mounting frame 81. Therefore, when the outlet pulley assembly 80 needs to rotate according to the direction of the auxiliary wire rope 93, the path of this section of the auxiliary wire rope 93 passing through the pivot portion 813 remains unchanged. Regardless of the angle of the auxiliary wire rope 93, its tension remains relatively stable, improving the stability and reliability of the outlet pulley assembly 80's operation, while also reducing abnormal wear and extending its service life. Because the mounting frame 81 can rotate freely around the pivot portion 813, the entire outlet pulley assembly 80 can adaptively adjust its posture to align with the pull-out or winding direction of the outlet pulley assembly 80.

[0202] See Figures 23 to 26 It should be noted that both the pulley bracket 61 and the mounting frame 81 are rotatably connected to their respective support frames via corresponding pivots; the pivots have hollow cavities inside, and the main wire rope 23 is laid through the rotation center of the pulley bracket 61 to drive the pulley bracket 61 to swing; the auxiliary wire rope 93 is laid through the rotation center of the mounting frame 81 to drive the mounting frame 81 to swing.

[0203] In actual wind power operation and maintenance sites, the ground is often not perfectly level, or when the system is deployed on an operation and maintenance vessel, it may sway with the waves. Simultaneously, during the ascent or descent of the self-climbing crane, its relative position and angle with container 10 are also dynamically changing. These factors can all cause the exit angle of the various wire ropes leading from container 10 to deviate. Without effective guidance and restraint, this deviation can cause the individual wire ropes to rub against the pulley sidewalls or the exit edge of container 10, accelerating wear and reducing service life.

[0204] To this end, by threading each wire rope through the hollow cavity of the corresponding pivot, the entry point of the corresponding wire rope coincides with the swing center point of the support. When the container 10 tilts due to uneven ground or sways with the ship due to being loaded on the ship, the entire support frame together with its pulley system will passively swing around the pivot to align the actual tension direction of each wire rope in real time.

[0205] It should also be noted that the secondary outlet pulley 83 is also equipped with two secondary anti-derailment pulleys 86, so that the secondary wire rope 93 is surrounded on three sides, forming a semi-enclosed guide channel. The secondary outlet pulley 83 restricts the vertical movement of the secondary wire rope 93, while the secondary anti-derailment pulleys 86 on both sides restrict the lateral swing of the secondary wire rope 93. When the secondary wire rope 93 is laterally deviated due to external disturbances (such as the shaking of container 10) and attempts to "jump" out of the rope groove of the secondary outlet pulley 83, it will immediately contact one of the secondary anti-derailment pulleys 86. Since the secondary anti-derailment pulley 86 can rotate freely, it will roll in accordance with the lateral force of the secondary wire rope 93, rather than rigidly blocking it, thus gently confining the secondary wire rope 93 within the correct path, effectively preventing the secondary wire rope 93 from derailing and improving the operational safety of the system.

[0206] See Figure 27 In some embodiments of the present invention, the container 10 is positioned near both ends by two first guide rails 13 and two second guide rails 14, respectively. The first guide rails 13 and the second guide rails 14 are used to guide the self-climbing crane 300 to leave or return to the container 10.

[0207] Accordingly, rollers that can engage with guide rails are provided at the front end (e.g., the end of the boom) and rear end (e.g., the base) of the self-climbing crane 300. When the self-climbing crane 300 begins to climb (leaves the container 10), its front roller slides along the first guide rail 13, and its rear roller slides along the second guide rail 14. This allows the entire self-climbing crane 300 to be smoothly pushed out of the container 10 under the constraint of a long-distance, multi-point supported rail system. The return process is exactly the opposite; the crane is precisely returned to its initial position inside the container 10 under the guidance of the guide rails.

[0208] In addition, the container 10 has a first end 11 and a second end 12 arranged opposite to each other; two main hoisting mechanisms 20 are located at the first end 11 of the container 10, and a secondary hoisting mechanism 90 is located at the second end 12 of the container 10; the two main hoisting mechanisms 20 are provided with multiple secondary guide pulleys 70 and secondary outlet guide mechanisms 60, and the secondary wire rope 93 passes through the multiple secondary guide pulleys 70 and secondary outlet guide mechanisms 60 and extends to the outside of the container 10.

[0209] The main hoisting mechanism 20 is typically the heaviest component in the entire ground system. By concentrating it at one end and placing the relatively lighter auxiliary hoisting mechanism 90 and other auxiliary equipment at the other end, the main mass can be effectively distributed across the two far ends of the container 10. This avoids excessive weight concentration at one point, resulting in better weight balance for the container 10 during transport, hoisting, and placement on potentially uneven ground. It also reduces the likelihood of the container being unbalanced at the rear and improves overall stability.

[0210] The auxiliary wire rope 93 extends to the outside of the container 10: After the auxiliary wire rope 93 is led out from the auxiliary winch mechanism 90 located at the second end 12, it does not exit directly from the second end 12. Instead, it runs along the inside of the container 10 to the top of the main winch mechanism 20 located at the first end 11, passes around the outlet pulley assembly 80 installed thereon, and finally extends upward from the first end 11 of the container 10.

[0211] When the auxiliary winch mechanism 90 drives the auxiliary wire rope 93 to pull the self-climbing crane 300, weighing tens of tons, upward from the ground, the auxiliary wire rope 93 will generate a huge, vertically upward reaction force on the exit pulley assembly 80 inside the container 10. This force is applied to the first end 11 of the container 10, which can easily cause that end to be lifted upward, creating a significant safety risk of the container 10 overturning.

[0212] In this invention, the outlet pulley assembly 80 of the auxiliary wire rope 93 and multiple auxiliary guide pulleys (not labeled in the figure) are mounted on the main winch mechanism 20. The multiple auxiliary guide pulleys guide the auxiliary wire rope 93 as it is laid out around the main winch mechanism 20. The main winch mechanism 20 is used as a counterweight to counteract the enormous overturning moment generated when the self-climbing crane 300 climbs. With this configuration, the upward lifting force of the auxiliary wire rope 93 is directly applied to the main winch mechanism 20. The main winch mechanism 20 itself typically weighs several tons or tens of tons, which effectively balances this upward lifting force.

[0213] Instead of adding additional counterweights, the system reuses the functionality of its existing components (main hoist mechanism 20) to act as ballast against overturning moments. This ensures that container 10 remains firmly grounded during the most dangerous self-climbing condition, improving system stability. This design avoids the need for additional counterweights to achieve stability, resulting in a more compact and integrated ground system that effectively controls overall system weight and transportation costs.

[0214] The present invention also provides a lifting method for a self-climbing lifting system, comprising the following steps: Step S100: Disassemble the nacelle crane 200 into multiple parts weighing no more than 25 kg, manually transport and install them onto the nacelle 110 of the wind turbine generator 100, and install a guide device on the nacelle crane 200.

[0215] Understandably, this step marks the beginning of the entire hoisting process. Workers, without the aid of any machinery, simply use the tower elevator or ladder to transport the pre-disassembled modular components of the overhead crane 200 to the top of the nacelle 110. Ensuring that each disassembled component does not exceed 25 kg complies with most industrial safety regulations regarding the safe weight limit for a single person, this step is purely manual. After installation, the fixed pulley 210, serving as the core steering component, is installed at the end of the boom of the overhead crane 200.

[0216] The purpose of this step is to establish a high-altitude anchor point, creating a turning fulcrum capable of withstanding 93% tension in the auxiliary wire rope at a height of several hundred meters with minimal risk and cost. This lays the foundation for all subsequent vertical hoisting operations utilizing ground power. It reduces the difficulty and risk of initial installation and solves the problem of installing heavy electric hoists at high altitudes in existing technologies, thus improving safety.

[0217] Step S200: Control the auxiliary winch mechanism 90 to drive the auxiliary wire rope 93 to move, lift the crane support 400 to the wind turbine 100 nacelle 110 and complete the installation.

[0218] Understandably, the workers inside the ground container 10 activate the auxiliary winch mechanism 90. The auxiliary wire rope 93 extends from the container 10, upwards to the engine room 110, around the fixed pulley 210 installed in step one, and downwards to the ground. Ground personnel connect the lifting device 220 at the end of the auxiliary wire rope 93 to the crane support 400 to be lifted. Subsequently, the auxiliary winch mechanism 90 retracts the rope, smoothly lifting the crane support 400 to the predetermined position in the engine room 110. Workers in the engine room 110 assist in positioning and complete the secure installation.

[0219] The purpose of this step is to utilize the powerful auxiliary winch mechanism 90 within the ground container 10 as a power source, and to change the direction of force through a high-altitude anchor point, precisely lift the heavy crane support 400 from the ground to the engine room 110. This achieves efficient and safe lifting of heavy attachments. Compared to electric hoists with load limits, the auxiliary winch mechanism 90 can provide greater lifting force and a higher height, enabling the lifting of the crane support 400 in one go, thus improving operational efficiency.

[0220] Step S300: When it is confirmed that the auxiliary wire rope 93 is connected to the self-climbing crane 300, control the auxiliary winch mechanism 90 to tighten the auxiliary wire rope 93 and drive the self-climbing crane 300 to climb upward along the tower.

[0221] Understandably, after the crane support 400 is installed, the auxiliary wire rope 93 is rearranged. Its path is as follows: it extends upwards from container 10 to the engine room 110, passes through the pulley module 410 on the installed crane support 400, extends downwards, and connects to a specific lifting point on the self-climbing crane 300 housed inside container 10. After confirming the connection is correct, the auxiliary winch mechanism 90 is activated again to wind up the rope. At this time, the auxiliary wire rope 93 acts as a traction rope and guide rope, pulling the self-climbing crane 300 out of container 10 and driving it to climb vertically upwards along the outer wall of the tower.

[0222] This step again utilizes the auxiliary winch mechanism 90 as power to transport the main working body of the hoisting system (self-climbing crane 300) to the working position. No large crane work site or foundation treatment is required; only the installation location of the container 10 is needed, thus broadening the applicability of wind turbine operation and maintenance.

[0223] Step S400: During the climbing process of the self-climbing crane 300, the two main winch mechanisms 20 are controlled to release ropes outward until the self-climbing crane 300 is docked and fixed with the crane support 400 on the nacelle 110 of the wind turbine generator 100.

[0224] Understandably, this step is crucial for the collaborative operation of multiple systems. In step three, while the auxiliary winch mechanism 90 drives the self-climbing crane 300 upwards, the control system inside the ground container 10 must simultaneously control the two main winch mechanisms 20 to release the main wire rope 23 outwards at the same speed. The main wire rope 23 has been pre-wound onto the boom and hook module 310 of the self-climbing crane 300. This synchronized rope release process continues until the self-climbing crane 300 has reached its position and completed mechanical docking and locking with the crane support 400 on the nacelle 110.

[0225] Since one end of the main wire rope 23 is connected to the main winch mechanism 20 on the ground, and the other end is wound around the self-climbing crane 300, if the main winch mechanism 20 does not release the rope, the main wire rope 23 will pull on the self-climbing crane 300, preventing it from climbing; if the rope is released too quickly, the main wire rope 23 will slack and become tangled, causing danger. Therefore, the rope must be released synchronously. This ensures a smooth and safe climbing process and achieves seamless operation. Synchronous rope release avoids interference from the main wire rope 23 in the climbing process, ensuring a stable climb. More importantly, once the self-climbing crane 300 is docked and fixed, the main wire rope 23 is already on the correct working path, eliminating the need for secondary winding and allowing for immediate use in lifting operations, thus shortening preparation time.

[0226] The hoisting method provided by this invention breaks down the most dangerous high-altitude heavy object installation work, establishes the initial support point through lightweight and manual installation, and places all power operations on the ground, maximizing the safety of high-altitude workers. It eliminates the reliance on large lifting machinery and its demanding operating conditions, making wind turbine operation and maintenance possible in complex terrains such as mountains, tidal flats, and the sea.

[0227] Each step is seamlessly integrated, especially the synchronous rope release design of the main wire rope 23, which eliminates the secondary preparation time required in traditional solutions and improves overall operation and maintenance efficiency. Relying entirely on its own components, it requires no additional third-party lifting equipment, forming a closed-loop operation process from deployment and operation to recovery, demonstrating strong independence and practicality.

[0228] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A self-climbing hoisting system, characterized in that, include: container; The self-climbing crane is initially housed inside the container, and the end of the self-climbing crane is equipped with a hook module; Two main winches are arranged side by side at one end of the container. One of the main winches has a main wire rope leading out. The main wire rope is wound around the self-climbing crane and connected to the hook module. Its end returns to connect with the other main winch. A secondary winch mechanism is installed inside the container. The secondary winch mechanism has a secondary wire rope extending out of the container, passing through the nacelle of the wind turbine, and connecting to the self-climbing crane to drive the self-climbing crane to achieve self-climbing or descent.

2. The self-climbing hoisting system according to claim 1, characterized in that, Also includes: A nacelle-top crane is installed on the nacelle of the wind turbine, and a fixed pulley is provided at the end of the nacelle-top crane; The auxiliary wire rope is connected to the lifting device after passing through the fixed pulley. The lifting device is used to lift the crane support, so that the crane support is pre-installed on the nacelle of the wind turbine to support the self-climbing crane after it has completed its self-climbing.

3. The self-climbing hoisting system according to claim 1, characterized in that, Also includes: Two rope guide mechanisms are respectively provided for the two main hoisting mechanisms, and each rope guide mechanism includes: A guide rope slide rail bracket is installed on the container; A guide rope pulley is provided on the guide rope slide rail bracket and can move along the guide rope slide rail bracket; A guide rope drive unit, installed in the container, is used to drive the guide rope pulley to move along the guide rope slide rail bracket, so as to dynamically adjust the entry angle of the main wire rope into each of the main winches. Two compensation mechanisms are provided on the container, corresponding to the two guide rope mechanisms respectively. Each compensation mechanism is linked to the corresponding guide rope mechanism to compensate for the change in the effective length of the main wire rope caused by the movement of the guide rope mechanism.

4. The self-climbing hoisting system according to claim 3, characterized in that, Each of the aforementioned compensation mechanisms includes: Compensating slide rail bracket, installed on the container; A compensating pulley is mounted on the compensating slide rail bracket and can move along the compensating slide rail bracket; A compensation drive unit is used to drive the compensation pulley to move along the compensation slide rail bracket; The main wire rope passes through the guide pulley and the compensation pulley, and the direction of movement of the compensation pulley is opposite to that of the corresponding guide pulley.

5. The self-climbing hoisting system according to claim 3, characterized in that, Also includes: Two tensioning mechanisms are respectively provided for the two main hoisting mechanisms, and each tensioning mechanism includes: Tensioned slide rail brackets are installed on the container; A counterweight mechanism is provided on the tensioning slide rail bracket and can move along the tensioning slide rail bracket; The tension pulley is mounted on the counterweight mechanism and abuts against the main wire rope; The main wire rope is led out from the main hoisting mechanism and passes sequentially through the corresponding guide pulley, the compensation pulley of the compensation mechanism, and the tension pulley. The counterweight mechanism drives the tension pulley to move along the tension rail bracket under its own weight, thereby applying tension to the main wire rope.

6. The self-climbing hoisting system according to claim 3, characterized in that, It also includes two export guiding mechanisms located between the geometric center and the center of gravity of the container; each of the export guiding mechanisms includes: The pulley bracket is installed on the container; The main outlet pulley, located on the pulley bracket, is used to lead the main steel wire rope out of the container; Two main anti-derailment pulleys are symmetrically arranged on the pulley bracket and located on both sides of the main outlet pulley. The axis of the main anti-derailment pulley is perpendicular to the axis of the main outlet pulley.

7. The self-climbing hoisting system according to claim 6, characterized in that, It also includes an outlet pulley assembly, the outlet pulley assembly comprising: Mounting rack; A steering pulley, located at one end of the mounting bracket, is used to guide the auxiliary wire rope into the outlet pulley assembly; A secondary outlet pulley, located at the other end of the mounting frame, is used to guide the secondary wire rope away from the outlet pulley assembly; The pressure roller mechanism is mounted on the mounting frame and located on the secondary wire rope path between the steering pulley and the secondary outlet pulley; A damping wheel mechanism is mounted on the mounting frame and is configured to cooperate with the pressure wheel mechanism; The pressure wheel mechanism is configured to apply pressure to the auxiliary wire rope to press the auxiliary wire rope onto the damping wheel mechanism; the damping wheel mechanism is configured to provide damping force to its own rotation to apply tension to the auxiliary wire rope when it is slack.

8. The self-climbing hoisting system according to claim 7, characterized in that, Both the pulley bracket and the mounting frame are rotatably connected to their respective support frames via corresponding pivots. The pivot has a hollow cavity inside. The main steel wire rope is laid through the rotation center of the pulley bracket to drive the pulley bracket to swing. The secondary steel wire rope is laid out along the rotation center of the mounting frame to drive the mounting frame to swing.

9. The self-climbing hoisting system according to any one of claims 1 to 8, characterized in that, The container is positioned near both ends by two first guide rails and two second guide rails, both of which are used to guide the self-climbing crane away from or back to the container. Both main hoisting mechanisms are equipped with multiple auxiliary guide pulleys.

10. A lifting method based on the self-climbing lifting system according to any one of claims 1 to 9, characterized in that, Includes the following steps: The nacelle top crane is disassembled into multiple parts weighing no more than 25 kg each, which are then manually transported and installed onto the nacelle of the wind turbine, and a guide device is installed on the nacelle top crane. The auxiliary winch mechanism drives the auxiliary wire rope to lift the crane support to the nacelle of the wind turbine and complete the installation. When it is confirmed that the auxiliary wire rope is connected to the self-climbing crane, the auxiliary winch mechanism is controlled to tighten the auxiliary wire rope, driving the self-climbing crane to climb upward along the tower. During the climbing process of the self-climbing crane, the two main winch mechanisms are simultaneously controlled to release ropes outward until the self-climbing crane is docked and fixed with the crane support on the nacelle of the wind turbine.

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