An assembly tool and method for a wind turbine tower

Abstract

The present application relates to wind turbine tower assembly technology field, concretely is a kind of wind turbine tower's assembly tool and assembly method. Including two symmetrically arranged base frame, two base frames are equipped with two symmetrically arranged electric beam tightening frame, each base frame is equipped with assembly mechanism, assembly mechanism, including half-arc track frame fixed on the top of base frame and climbing platform fixed on the lower part of base frame, half-arc track frame is equipped with self-propelled platform, self-propelled platform is equipped with the detection frame that can linearly displace, detection frame is respectively fixedly installed with fiber laser welding head, electromagnetic hammer, elastic rod and detection calibration unit, the output end of electromagnetic hammer is equipped with knock head, the end of elastic rod is equipped with vibration signal acquisition element, the lower part of base frame is equipped with the auxiliary slide that can linearly displace. The beneficial effects of the present application are: through the integrated auxiliary slide and the arm structure, the problem of poor alignment accuracy and large coaxiality error when the tower is connected in the existing technology is solved.

Description

Technical Field

[0001] This invention relates to the field of wind turbine tower assembly technology, specifically to an assembly tooling and assembly method for wind turbine towers. Background Technology

[0002] Wind energy, as a clean and renewable energy source, is primarily utilized through wind power generation. The tower, as the core supporting component of a wind turbine, directly determines the construction cycle, installation cost, and subsequent operational stability of the wind turbine through its assembly efficiency and installation accuracy. In the existing technology, patent document CN118387743B discloses a hybrid tower assembly tooling and method. This method mainly focuses on the on-site lifting and flipping of tower sections after prefabrication and transportation. It provides a lifting device to achieve the flipping of the tower from horizontal to vertical. However, this type of solution mainly addresses the initial positioning problem of tower sections from transportation to lifting and then to vertical flipping. Its core lies in improving the lifting device structure to reduce the steps in the lifting and flipping process of tower sections and improve the flexibility of lifting individual sections. However, for the more complex core assembly processes of precise alignment, efficient connection, and quality inspection during the installation and docking stage, the existing technology still has significant shortcomings. Specific problems are as follows: Existing technologies primarily address ground-based rotation but do not address the challenge of precise high-altitude docking. Specifically, in existing technologies, when hoisting an upper tower segment onto a fixed lower segment, traditional methods rely on a combination of coarse adjustments using lifting equipment and fine adjustments using manual visual observation and pry bars to align the flange holes. This method not only makes it difficult to guarantee alignment accuracy and results in large coaxiality errors, directly affecting the overall verticality and structural stress of the tower, but also poses significant safety risks when performing close-range manual fine adjustments at heights of tens of meters. Furthermore, after the initial installation of the tower, existing technologies still require manual or auxiliary equipment to connect the flange bolts, and welding, inspection, and other processes are often carried out separately, requiring the use of different equipment and personnel. This leads to a fragmented assembly process, long auxiliary time, and overall inefficiency that needs improvement. Based on this, the present invention provides an assembly tooling and assembly method for wind turbine towers to solve the problems mentioned in the background art. Summary of the Invention

[0003] This invention addresses the technical problems existing in the prior art by providing an assembly fixture and method for wind turbine towers, thus solving the problems of existing assembly devices failing to guarantee alignment accuracy and separation of assembly processes.

[0004] The technical solution of the present invention to solve the above technical problems is as follows: an assembly fixture for a wind turbine tower, comprising two symmetrically arranged base frames, two symmetrically arranged electric clamping frames installed between the two base frames, and an assembly mechanism installed on each base frame; The assembly mechanism includes a semi-circular track frame fixed to the top of the base frame and a climbing platform fixed to the bottom of the base frame. A self-propelled platform is mounted on the semi-circular track frame, and a linearly movable inspection frame is installed on the self-propelled platform. A fiber laser welding head, an electromagnetic impactor, an elastic rod, and a testing and calibration unit are fixedly mounted on the inspection frame. An impact head is installed at the output end of the electromagnetic impactor, and a vibration signal acquisition element is installed at the end of the elastic rod. A linearly movable auxiliary slide is installed at the bottom of the base frame. Two symmetrically arranged clamping arms are hinged to the auxiliary slide, and each clamping arm is hinged to the auxiliary slide with an adjusting arm push rod. A floating frame is slidably connected to the top of the clamping arms. A floating spring is installed between the floating frame and the arm. The floating frame is equipped with an electrically rotatable floating clamping wheel. The middle of the auxiliary slide is slidably connected to the calibration frame and the positioning frame. Two clamping push rods are installed between the auxiliary slide and the calibration frame. A reverse synchronous transmission unit is provided between the calibration frame and the positioning frame to drive the calibration frame and the positioning frame to move synchronously and in opposite directions. Two positioning probes and two arc-shaped claws are installed at the front end of the calibration frame. An elastic clamping component is installed on the positioning frame. A brake arc plate is installed at the other end of the elastic clamping component. Two synchronously lifting traction frames are installed on the auxiliary slide. Each traction frame is rotatably connected to a traction clamping wheel.

[0005] Based on the above technical solution, the present invention can be further improved as follows.

[0006] Preferably, a linear feed transmission module is installed on the self-propelled platform, the linear feed transmission module is connected to the inspection frame, the inspection frame is slidably connected to the self-propelled platform, and two symmetrically arranged lifting lugs are installed on the base frame.

[0007] Preferably, two symmetrically arranged horizontal electric actuators are installed on the lower part of the base frame, and the movable ends of the two horizontal electric actuators are fixedly connected to the auxiliary slide. Two symmetrically arranged vertical electric actuators are installed on the auxiliary slide, and the movable ends of the two vertical electric actuators are fixedly connected to two traction frames respectively. The bottom surfaces of the two traction frames are fixedly connected to guide slides, and the two guide slides are slidably connected to the auxiliary slide.

[0008] Preferably, the assembly mechanism further includes a rotary motor fixedly mounted on the arm, a spline shaft fixedly mounted on the output shaft end of the rotary motor, and a keyhole slidably connected to the spline shaft is opened at the axial position of the floating clamping wheel, and the cross-section of the keyhole and the spline shaft are both regular hexagonal.

[0009] Preferably, the reverse synchronous transmission unit includes a synchronous gear rotatably connected to the auxiliary slide, and rack plates are installed on the bottom surface of the calibration frame and the top surface of the positioning frame. Both rack plates are connected to the synchronous gear, and the two rack plates are respectively arranged on the upper and lower sides of the synchronous gear. Two guide grooves are opened on the auxiliary slide, and the two guide grooves are slidably connected to the calibration frame and the positioning frame respectively.

[0010] Preferably, the detection and calibration unit includes a microcontroller fixed at the rear of the self-propelled platform and an industrial camera and a laser displacement detection sensor fixed at the front of the self-propelled platform. The data terminals of the vibration signal acquisition element, the positioning probe, the laser displacement detection sensor and the industrial camera are all connected to the microcontroller.

[0011] Preferably, a tower segment is clamped between the two assembly mechanisms, and the axes of the fiber laser welding head, electromagnetic knocker, elastic rod, spline shaft, laser displacement detection sensor, industrial camera and clamping push rod are all perpendicular to the axis of the tower segment, while the axis of the positioning probe is parallel to the axis of the tower segment.

[0012] Preferably, the elastic clamping assembly includes two T-shaped light rods fixedly mounted on the back of the brake arc plate. The axes of the two T-shaped light rods are perpendicular to the axis of the tower segment. The two T-shaped light rods are slidably connected to the auxiliary slide. A compression spring is sleeved on the T-shaped light rod at the position between the auxiliary slide and the brake arc plate.

[0013] Preferably, the braking arc plate has an arc-shaped structure, and a rubber block is installed on the side of the braking arc plate opposite to the tower section. Friction protrusions are evenly distributed on the surface of the rubber block, and the striking head is made of metal with a circular cross-section.

[0014] Preferably, an assembly method for a wind turbine tower assembly fixture includes the following steps: SS01, Tooling installation and positioning: Connect the two symmetrically arranged base frames into one piece by electric clamping frame, hold it tightly to the outer periphery of the fixed lower tower section, drive the base frame to move along the tower axis to the flange connection end by climbing platform, and align the positioning probe with the flange hole of the lower tower to complete the initial positioning of the tooling; SS02, Upper Tower Section Lifting and Eight-Point Positioning: Lift the upper tower section to the top of the lower tower section, maintaining the first distance difference. Drive the auxiliary slide to move towards the tower section through the horizontal electric push rod, so that the traction clamping wheel can be positioned at four points from the outside of the bottom of the tower section. At the same time, the boom push rod drives the clamping arm to clamp tightly, so that the floating clamping wheel can be positioned at four points from the outside of the middle and lower part of the tower section, completing the initial eight-point clamping. SS03 Automatic flange hole alignment: The positioning probe collects the position data of the flange holes of the upper tower section. The microcontroller controls the rotary motor to drive the floating clamping wheel to rotate, thereby rotating the upper tower section and making the flange holes of the upper and lower tower sections accurately aligned. SS04, Tower Traction Fitting: The traction frame is driven to move down synchronously by the vertical electric push rod, pulling the upper tower section closer to the lower tower section to the second distance difference. Then, the calibration frame is driven to retract by the clamping push rod, so that the arc-shaped claw and the braking arc plate are disengaged from the tower section. The traction frame continues to move down until the flange surfaces of the two tower sections are precisely fitted. The bolt connection is completed manually or with auxiliary equipment. SS05, Circumferential Welding: The self-propelled platform moves circumferentially along the 360° track formed by the semi-arc track frame, driving the fiber laser welding head to automatically weld the circumferential seam at the connection of the two tower flange sections; SS06 Weld Inspection and Connection Strength Assessment: After welding is completed, the self-propelled platform moves along the circumference again. The weld morphology, tower coaxiality and weld width are identified by laser displacement detection sensor and industrial camera. Then, the electromagnetic knocker drives the knocking head to knock on the tower. The vibration signal acquisition element captures the vibration feedback. The microcontroller processes the signal and compares it with the standard threshold, and automatically outputs the connection strength assessment result. SS07. Reset and Displacement: After passing the inspection, release the constraints on the tower and drive the tooling along the tower to the next assembly point via the climbing platform. Repeat the above steps to complete the assembly of the subsequent tower sections.

[0015] The beneficial effects of this invention are: This invention solves the problems of poor alignment accuracy and large coaxiality error during high-altitude tower docking in existing technologies by integrating auxiliary carriage and arm structure. It uses traction clamping wheels for four-point lower positioning from the bottom of the tower, and floating clamping wheels for four-point upper positioning from the outer side of the lower middle part of the tower, forming a coordinated eight-point positioning mechanism. This significantly improves the initial attitude stability of the upper tower section during hoisting. On this basis, positioning probes collect flange hole position data in real time, and a microcontroller controls a rotary motor to drive the floating clamping wheels to rotate precisely, achieving automatic high-precision alignment of the upper and lower flange holes. This method of mechanical clamping and electrical control linkage eliminates the traditional operation mode that relies on coarse adjustment by lifting equipment and fine adjustment by manual crowbars. It not only greatly improves coaxiality and alignment accuracy, but also eliminates the safety hazards of close-range manual operation at high altitudes.

[0016] 2) This invention highly integrates the three core processes of tower traction bonding, circumferential welding, and quality inspection onto the same tooling. Through the sequential action and intelligent control of each component, the assembly process is made continuous and automated. After the flange holes are aligned, the vertical electric push rod drives the traction frame to move the tower smoothly down for bonding. Before bonding, the calibration frame is automatically controlled to retract and avoid interference. After bonding, the self-propelled platform travels along a 360° track, driving the fiber laser welding head to complete automatic welding. After welding is completed, the same self-propelled platform starts again. Using laser displacement detection sensors, industrial cameras, and electromagnetic impactors, the weld morphology identification, coaxiality detection, and connection strength assessment are completed in one go. This design connects the originally separate processes, avoiding the waste of auxiliary time caused by equipment replacement or repeated positioning. The overall assembly efficiency is significantly better than that of the existing technology.

[0017] 3) This invention integrates data from positioning probes, industrial cameras, laser displacement sensors, and vibration signal acquisition elements using a microcontroller, and controls clamping, traction, welding, and hammering actions in a coordinated manner. This creates a complete intelligent closed-loop control system for tower assembly. Particularly in the connection strength assessment stage, a controllable hammering is applied to the tower using an electromagnetic hammer, and the vibration signal acquisition element captures the feedback. The microcontroller compares the processed signal with a built-in standard threshold, automatically and quantitatively outputting assessment results of "tight connection," "gap present," or "loose connection." This automated and intelligent non-destructive testing method replaces the traditional subjective judgment relying on human experience, making the test results more objective and accurate, and providing reliable data support for the long-term stable operation of the tower. This demonstrates the high level of integration and intelligence of the tooling. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of an assembly tooling for a wind turbine tower according to the present invention; Figure 2 This is a schematic diagram of the structure of the electric clamping frame and floating clamping wheel of the present invention; Figure 3 For the present invention Figure 2 A magnified schematic diagram of the partial structure at point A in the middle; Figure 4 This is a schematic diagram of the floating spring and semi-circular track frame of the present invention; Figure 5 This is a schematic diagram of the fiber laser welding head and electromagnetic impactor of the present invention; Figure 6 This is a schematic diagram of the linear feed transmission module of the present invention; Figure 7 This is a schematic diagram of the floating frame and guide slide of the present invention; Figure 8This is a schematic diagram of the positioning probe of the present invention; Figure 9 For the present invention Figure 8 A structural diagram from another angle.

[0019] The attached diagram lists the components represented by each number as follows: 1. Base frame; 2. Electric tensioning frame; 3. Auxiliary carriage; 4. Self-propelled platform; 5. Tower segment; 101. Lifting lug; 301. Boom clamp; 302. Boom adjusting push rod; 303. Floating frame; 304. Floating spring; 305. Floating clamping wheel; 306. Calibration frame; 307. Positioning frame; 308. Clamping push rod; 309. Positioning probe; 310. Arc-shaped chuck; 311. Elastic clamping assembly; 312. Braking arc plate; 313. Traction frame; 314. Traction clamping wheel; 315. Horizontal electric push rod; 316. Vertical electric actuator; 317. Guide slide plate; 318. Rotary motor; 319. Splined shaft; 320. Synchronous gear; 321. Rack plate; 322. Climbing platform; 401. Semi-arc track frame; 402. Fiber laser welding head; 403. Electromagnetic impactor; 404. Elastic rod; 405. Impact head; 406. Vibration signal acquisition element; 407. Inspection rack; 409. Linear feed transmission module; 410. Microcontroller; 411. Industrial camera; 412. Laser displacement detection sensor. Detailed Implementation

[0020] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0021] The present invention provides the following preferred embodiments. like Figure 1-9 As shown, an assembly fixture for a wind turbine tower includes two symmetrically arranged base frames 1, two symmetrically arranged lifting lugs 101 installed on the base frames 1, and two symmetrically arranged electric tensioning frames 2 installed between the two base frames 1. The electric tensioning frame 2 includes two symmetrically arranged double-headed push rods. The two double-headed push rods are fixedly connected as one unit by a connecting frame. Each double-headed push rod has a T-shaped threaded tension head fixedly installed at both ends. Limit nuts are threadedly installed on both T-shaped threaded tension heads. Two positioning tension holes are opened on the base frame 1. Both positioning tension holes are adapted to and connected to the T-shaped threaded tension heads. In the transportation mode, the two base frames 1 are separated from each other, which facilitates the flexible transportation of this tooling; In the working mode, the two base frames 1 are connected as one unit by the electric tensioning frame 2, and during installation, the distance between the two base frames 1 is adjusted according to the specifications of the tower section 5. Meanwhile, in the working mode, a power distribution control box and a laser welding machine can be externally mounted on the base frame 1. The fiber laser welding head 402 is connected to the external laser welding machine through a fiber optic transmission line. The output power of the laser welding machine is 5000-8000W, which is suitable for circumferential welding of tower flanges. The power distribution control box is used to supply power to the electrical components in this assembly tooling. When the power distribution control box is working, it is connected to the external power supply equipment and central control equipment through cables and data transmission cables, thereby providing real-time power supply and real-time central control for this tooling. Furthermore, the power distribution control box has a built-in remote control module. The external design of the power distribution control box and the configuration of the remote control module not only facilitate the maintenance and repair of power components, but also allow operators to perform wireless remote control from inside the tower or at the top, avoiding the safety risks of working on the outside of the tower at high altitudes. In addition, the real-time power supply and the connection method of the central control ensure the stability and controllability of the tooling operation process. This tooling is suitable for tower section 5 with a diameter of 3-8m, a wall thickness of 20-50mm, and a single section height of 5-10m; The lifting lug 101 structure of the base frame 1 is combined with the self-propelled function, which allows the tooling to flexibly choose the method of hoisting or self-propelled positioning according to the on-site installation conditions, adapting to the working conditions of different wind power installation sites. Each base frame 1 is equipped with an assembly mechanism, and a tower section 5 is sandwiched between two assembly mechanisms; The assembly mechanism includes a semi-circular track frame 401 fixed to the top of the base frame 1 and a climbing platform 322 fixed to the bottom of the base frame 1. A self-propelled platform 4 is installed on the semi-circular track frame 401. The arc of the semi-circular track frame 401 is 180°. After the two semi-circular track frames 401 are installed and aligned, a 360° guide walking platform is formed. The climbing platform 322 includes two power units. Each power unit includes a first power motor and a set of climbing wheels rotatably connected to the base frame 1. The output shaft of the first power motor is fixedly connected to a climbing wheel. The set of climbing wheels rotates synchronously via a chain belt. During operation, the climbing platform 322 can climb straight up along the axial direction of the tower section 5. The first power motor has a built-in electromagnetic power-off braking mechanism. After power failure, it can achieve lock-up braking within 0.2s to prevent the climbing platform 322 from sliding down. The self-propelled platform 4 includes four rotatably connected wheels and a second power motor fixedly mounted on the self-propelled platform 4. The output shaft end of the second power motor is fixedly connected to one of the wheels. The outer and inner surfaces of the semi-arc track frame 401 are provided with annular track grooves adapted to the wheels. During assembly, the self-propelled platform 4 can move 360° along the formed 360° guide walking platform; The self-propelled platform 4's traveling wheels are adapted to the annular track groove of the semi-arc track frame 401, making the circumferential movement of the self-propelled platform 4 more stable and avoiding deviation or shaking during operation, thus providing structural protection for the accuracy of subsequent welding and inspection. The 360° movement function of the self-propelled platform 4 enables the fiber laser welding head 402 and the inspection and calibration unit on the inspection rack 407 to perform operations without blind spots along the circumference of the tower segment 5, without having to repeatedly adjust the overall position of the tooling, which greatly improves the efficiency of circumferential welding and inspection of the tower. The self-propelled platform 4 is equipped with a linearly movable inspection frame 407. The inspection frame 407 is fixedly installed with a fiber laser welding head 402, an electromagnetic impactor 403, an elastic rod 404 and a detection and calibration unit. The output end of the electromagnetic impactor 403 is equipped with an impact head 405, and the end of the elastic rod 404 is equipped with a vibration signal acquisition element 406. The electromagnetic percussion device 403 is an electromagnetic high-frequency percussion device with an adjustable percussion frequency of 0-5Hz and a maximum percussion force of 150N. The elastic rod 404 is a hollow metal elastic telescopic rod. One end is fixed to the inspection frame 407, and the other end is clamped with the vibration signal acquisition element 406 through the shock-absorbing pad. It can adaptively fit the outer wall of the tower and transmit the vibration signal generated by the impact. At the same time, it has a buffering and vibration reduction function to prevent the vibration signal acquisition element 406 from being damaged due to hard contact. The detection and calibration unit includes a microcontroller 410 fixed at the tail of the self-propelled platform 4, an industrial camera 411 fixed at the front of the self-propelled platform 4, and a laser displacement detection sensor 412. The data terminals of the vibration signal acquisition element 406, the positioning probe 309, the laser displacement detection sensor 412, and the industrial camera 411 are all connected to the microcontroller 410. The 411 industrial camera is a 2-megapixel industrial area scan camera with a 12mm lens focal length, a shooting frame rate of 30fps, and automatic fill light function. The fill light source is a ring LED light source with adjustable brightness. The laser displacement detection sensor 412 is a laser triangular reflection sensor with a detection distance of 50-300mm, a detection accuracy of 0.01mm, and a sampling frequency of 1kHz. The striking head 405 is made of metal and has a circular cross-section. It is connected to the output end of the electromagnetic striker 403 by a threaded connection. After the two tower sections 5 are assembled into one unit through the flange connection surface and related connecting parts, the self-propelled platform 4 performs structural and connection strength tests on the two tower sections 5. During the test, the hammer head 405 repeatedly strikes the tower section 5 from the outside. In a preferred embodiment, a linear feed transmission module 409 is installed on the self-propelled platform 4. The linear feed transmission module 409 is connected to the inspection rack 407 in a transmission connection, and the inspection rack 407 is slidably connected to the self-propelled platform 4. The transmission direction of the linear feed drive module 409 is perpendicular to the axis of the tower section 5; In a preferred embodiment, the striking head 405 is made of tungsten-cobalt alloy. The striking stroke of the striking head 405 is limited to 1 mm, the striking force is limited to 100 N, the striking frequency is limited to 3 Hz, and the striking speed is limited to 0.2 m / s to ensure uniform striking without damaging the outer coating of the flange. At the same time, the number of sampling points along the 5 circumferences of the tower segment is limited to 18. The sampling points are evenly distributed along the 5 circumferences of the tower segment. The interval time during sampling is limited to 2 min. After each sampling point completes one strike, it moves to the next sampling point after a corresponding time interval. By limiting the sampling points to 18 evenly distributed points in the circumference and the sampling interval to 2 minutes, the vibration signal is collected more comprehensively and evenly, thus improving the accuracy of the detection results. Vibration signal acquisition element 406 is used to capture vibration feedback and is deployed on the outside. Vibration signal acquisition element 406 includes an accelerometer, a signal transmission cable or a wireless transmission module. The vibration signal acquisition element 406 is arranged on the outside to avoid interference with the internal structure of the tower. The accelerometer is attached to the outer circumference of tower segment 5. The accelerometer can accurately collect vibration acceleration signals in the range of 0.1-1000Hz. The accelerometer collects vibration acceleration signals in the range of 0.1-1000Hz, covering the core vibration frequency range of the tower connection parts, ensuring the accuracy of signal acquisition; The microcontroller 410 integrates a signal processing unit and a striking control unit. The signal processing unit is electrically connected to the accelerometer and the electromagnetic striking device 403. The signal processing unit has a built-in signal filtering and amplification module, which can filter out vibration interference signals from high-altitude wind vibration, tooling operation, or walking. The signal processing unit extracts the core vibration frequency signal and converts the analog signal into a digital signal; The striking control unit is used to precisely control the striking force, stroke, frequency and speed of the striking head 405, keeping it stably within the limited range. At the same time, it controls the striking device to move evenly along the five circumferences of the tower section at 18 preset sampling points and 2-minute intervals, synchronously collecting the feedback signal from the acceleration sensor corresponding to each sampling point, and transmitting the feedback signal to the control module for analysis and comparison. The control module has a built-in standard database with preset vibration frequency thresholds for three scenarios: "tight connection", "gap exists", and "loose connection". This standard database can be preset according to the tower material and wall thickness to adapt to multiple tower segments. The control module can compare the processed vibration signal with the standard threshold and automatically output the detection results; The lower part of the base frame 1 is equipped with an auxiliary slide 3 that can be linearly displaced. Two symmetrically arranged clamping arms 301 are hinged on the auxiliary slide 3. An adjusting arm push rod 302 is hinged between the two clamping arms 301 and the auxiliary slide 3. A floating frame 303 is slidably connected to the top of the clamping arms 301. A floating spring 304 is installed between the floating frame 303 and the clamping arms 301. A floating clamping wheel 305 that can be electrically rotated is provided on the floating frame 303. In a preferred embodiment, two symmetrically arranged horizontal electric actuators 315 are installed on the lower part of the base frame 1, and the movable ends of the two horizontal electric actuators 315 are fixedly connected to the auxiliary slide 3. The assembly mechanism also includes a rotary motor 318 fixedly mounted on the arm 301. A spline shaft 319 is fixedly mounted on the output shaft end of the rotary motor 318. A keyhole is provided at the axial position of the floating clamping wheel 305 to slide and connect with the spline shaft 319. The cross-sections of the keyhole and the spline shaft 319 are both regular hexagonal. The boom push rod 302 can drive the two clamping arms 301 to achieve opening and closing actions, which can adapt to the clamping requirements of tower sections 5 with different diameters and improve the versatility of the tooling. The floating spring 304 between the floating frame 303 and the clamping arm 301 gives the floating clamping wheel 305 the ability to float elastically. When clamping the tower section 5, it can adaptively adjust its position according to the surface curvature of the tower, so that the floating clamping wheel 305 fits tightly with the surface of the tower, improving the stability of clamping.

[0022] Simultaneously, as tower section 5 descends, floating clamping wheel 305 can descend accordingly; The rotary motor 318 drives the floating clamping wheel 305 to rotate via the splined shaft 319. The regular hexagonal splined shaft 319 is slidably connected to the keyhole, which not only realizes the stable transmission of rotational power, but also allows the splined shaft 319 to slide axially in the keyhole in conjunction with the elastic floating of the floating frame 303. This ensures that the floating clamping wheel 305 can still maintain the transmission of rotational power when it adaptively adjusts its position, providing stable power support for the rotational alignment of the subsequent tower section 5 and avoiding the interruption of power transmission from affecting the alignment accuracy. The auxiliary slide 3 is slidably connected to the calibration frame 306 and the positioning frame 307 in the middle, and two clamping push rods 308 are installed between the auxiliary slide 3 and the calibration frame 306. A reverse synchronous transmission unit is provided between the calibration frame 306 and the positioning frame 307 to drive the calibration frame 306 and the positioning frame 307 to move synchronously and in opposite directions. The reverse synchronous transmission unit includes a synchronous gear 320 rotatably connected to the auxiliary slide 3. The bottom surface of the calibration frame 306 and the top surface of the positioning frame 307 are both equipped with rack plates 321. Both rack plates 321 are connected to the synchronous gear 320 in a transmission manner, and the two rack plates 321 are respectively located on the upper and lower sides of the synchronous gear 320. Two guide grooves are opened on the auxiliary slide 3, and the two guide grooves are slidably connected to the calibration frame 306 and the positioning frame 307 respectively. Two positioning probes 309 and two arc-shaped claws 310 are installed at the front end of the calibration frame 306. An elastic clamping assembly 311 is installed on the positioning frame 307. A braking arc plate 312 is installed at the other end of the elastic clamping assembly 311. The braking arc plate 312 has an arc-shaped structure. A rubber block is installed on the side of the braking arc plate 312 opposite to the tower section 5. Friction bumps are evenly distributed on the surface of the rubber block. Two positioning probes 309 are arranged symmetrically. One positioning probe 309 is installed on the top surface of the calibration frame 306 with its detection end set vertically upward, and the other positioning probe 309 is installed on the bottom surface of the calibration frame 306 with its detection end set vertically downward. The alignment of the flange holes on both sides of the tower section 5 of the calibration frame 306 was finally achieved; The positioning probe 309 is an industrial vision inspection probe adapted to the alignment of tower flange holes. Its axis is parallel to the tower segment 5. The positioning probe 309 forms a linkage closed loop with the microcontroller 410 and the rotary motor 318, and has four major functions: initial positioning calibration of tooling, data acquisition of upper tower flange holes, real-time alignment monitoring, and position verification before traction. The positioning probe 309 integrates an industrial vision lens. Its working logic is as follows: pre-calibration eliminates errors and establishes a benchmark database. It then captures images of the flange hole through coaxial supplementary lighting. After preprocessing such as image filtering and edge extraction, the data is transmitted to the microcontroller 410. The microcontroller 410 compares the standard parameters to generate a rotation command, which drives the upper tower section 5 to rotate. The positioning probe 309 continuously feeds back data to achieve dynamic adjustment. After alignment is completed, it outputs a signal to connect to the subsequent processes. In addition, the positioning probe 309 is precisely linked with components such as the reverse synchronous transmission unit, the rotary motor 318, and the vertical electric actuator 316 to provide a benchmark for subsequent inspection processes. It is the core component for realizing automatic and accurate alignment of flange holes and replacing traditional manual methods. The elastic clamping assembly 311 includes two T-shaped light rods fixed on the back of the brake arc plate 312. The axes of the two T-shaped light rods are perpendicular to the axis of the tower section 5. The two T-shaped light rods are slidably connected to the auxiliary slide 3. A clamping spring is sleeved on the T-shaped light rod at the position between the auxiliary slide 3 and the brake arc plate 312. When this tooling moves to the flange connection end of the tower section 5, the two arc-shaped claws 310 clamp the tower section 5 with the inner ring of the tower section 5 to limit the relative height and relative position of the tower section 5 and this tooling in the working state. When the arc-shaped chuck 310 clamps the tower section 5 from the inner ring of the tower section 5, the braking arc plate 312 simultaneously clamps the tower section 5 from the outer side of the tower section 5, thus completing the precise positioning of this tooling in the alignment stage of the tower section 5. The T-shaped smooth rod of the elastic clamping assembly 311 cooperates with the clamping spring to give the brake arc plate 312 elastic clamping capability. When it comes into contact with the outside of the tower, it can achieve a tight fit through the elastic force of the clamping spring. At the same time, the rubber block of the brake arc plate 312 and the surface friction protrusions can increase the friction with the tower, improve the stability of braking positioning, and prevent relative displacement between the tooling and the tower during the operation. The dual positioning method of the arc-shaped chuck 310 clamping tightly from the inner ring of the tower and the braking arc plate 312 pressing tightly from the outer side of the tower enables the tooling to be accurately positioned during the alignment stage of the tower segment 5, which limits the relative height and position of the tooling and the tower, and provides a precise position reference for the subsequent splicing and alignment of the tower segment 5, greatly improving the coaxiality and alignment accuracy of the tower splicing. The auxiliary slide 3 is equipped with two synchronously lifting traction frames 313, and each traction frame 313 is rotatably connected to a traction clamp wheel 314.

[0023] The core of both the floating clamping wheel 305 and the traction clamping wheel 314 is made of high-strength alloy steel, and its outer layer is wrapped with polyurethane elastomer, and the surface of the polyurethane elastomer is evenly covered with knurled patterns. In a preferred embodiment, two symmetrically arranged vertical electric actuators 316 are installed on the auxiliary slide 3. The movable ends of the two vertical electric actuators 316 are fixedly connected to two traction frames 313 respectively. The bottom surfaces of the two traction frames 313 are fixedly connected to guide slide plates 317, and the two guide slide plates 317 are slidably connected to the auxiliary slide 3. Two vertical electric actuators 316 synchronously drive two traction frames 313 to lift and lower, which can precisely control the lifting height of the traction frames 313, realize precise lifting and traction of the tower segment 5, and provide precise displacement control for the splicing and fitting of the tower segment 5. The guide plate 317 on the bottom surface of the traction frame 313 is slidably connected to the auxiliary slide 3, which guides the lifting and lowering movement of the traction frame 313, prevents the traction frame 313 from deviating or tilting during the lifting and lowering process, and ensures the traction stability of the traction clamp wheel 314 on the tower section 5.

[0024] Meanwhile, the lifting design of the traction frame 313 allows the traction clamp wheel 314 to flexibly adjust its position according to the hoisting height of the tower section 5, adapting to different height requirements during the tower splicing process and improving the operational flexibility of the tooling. The axes of the fiber laser welding head 402, electromagnetic impactor 403, elastic rod 404, spline shaft 319, laser displacement detection sensor 412, industrial camera 411, and clamping push rod 308 are all perpendicular to the axis of the tower segment 5, while the axis of the positioning probe 309 is parallel to the axis of the tower segment 5.

[0025] Preferably, an assembly method for a wind turbine tower assembly fixture includes the following steps: SS01, Fixture installation and positioning: Connect the two symmetrically arranged base frames 1 into one unit through the electric clamping frame 2, and hold them tightly to the outer periphery of the fixed lower tower section 5. Drive the base frame 1 along the tower axis to the flange connection end through the climbing platform 322, and align it coaxially with the lower tower flange hole through the positioning probe 309 to complete the initial positioning of the fixture. SS02, Upper Tower Section Lifting and Eight-Point Positioning: Lift the upper tower section 5 to the top of the lower tower section, maintaining the first distance difference. Drive the auxiliary slide 3 towards the tower section through the horizontal electric push rod 315, so that the traction clamping wheel 314 can perform four-point centering and lower positioning from the outside of the bottom of the tower section. At the same time, the boom adjusting push rod 302 drives the clamping arm 301 to clamp tightly, so that the floating clamping wheel 305 can perform four-point centering and upper positioning from the outside of the middle and lower part of the tower section, completing the initial eight-point clamping. SS03, Automatic alignment of flange holes: The positioning probe 309 collects the position data of the flange holes of the upper tower section. The microcontroller 410 controls the rotary motor 318 to drive the floating clamping wheel 305 to rotate according to the data, thereby rotating the upper tower section and making the flange holes of the upper and lower tower sections accurately aligned. SS04, Tower Traction Fitting: The traction frame 313 is driven to move down synchronously by the vertical electric push rod 316, pulling the upper tower section closer to the lower tower section to the second distance difference. Then, the calibration frame 306 is driven to retract by the clamping push rod 308, so that the arc-shaped claw 310 and the braking arc plate 312 are disengaged from the tower section. The traction frame 313 continues to move down until the flange surfaces of the two tower sections are precisely fitted. The bolt connection is completed manually or with auxiliary equipment. SS05, Circumferential Welding: The self-propelled platform 4 moves circumferentially along the 360° track formed by the semi-arc track frame 401, driving the fiber laser welding head 402 to automatically weld the circumferential seam at the connection of the two tower flange sections. SS06 Weld Inspection and Connection Strength Assessment: After welding is completed, the self-propelled platform 4 moves circumferentially again. The laser displacement detection sensor 412 and industrial camera 411 identify the weld morphology, tower coaxiality and weld width. Then, the electromagnetic hammer 403 drives the hammer head 405 to hammer the tower. The vibration signal acquisition element 406 captures the vibration feedback. The microcontroller 410 processes the signal and compares it with the standard threshold, and automatically outputs the connection strength assessment result. SS07. Reset and Displacement: After passing the inspection, release the constraints on the tower and use the climbing platform 322 to drive the tooling to move along the tower to the next assembly point. Repeat the above steps to complete the assembly of the subsequent tower sections.

[0026] The specific steps for using this invention are as follows: In the preparation stage, the wind turbine tower assembly fixture of the present invention first fixes the bottom tower segment 5, connects two symmetrical base frames 1 into one unit through an electric clamping frame 2, and fixes the fixture on the bottom tower segment 5. When installing the base frames 1, the spacing of the base frames 1 is adjusted according to the specifications of the tower segment 5. Before operation, the base frames 1 are externally connected to the power distribution control box and laser welding machine and connected to the external power supply and central control equipment. When the fixture is initially installed, the positioning probe 309 axis is aligned with the flange hole of the tower segment 5 by manual positioning. Then the fixture is allowed to move along the tower axis to the flange connection end. The electric clamping frame 2 adjusts the spacing so that the climbing platform 322 clamps the tower segment 5 tightly and self-brakes. Furthermore, when this tooling moves to the flange connection end of the tower section 5, the two arc-shaped claws 310 clamp the tower section 5 from the inner ring of the tower section 5, thereby limiting the relative height and relative position of the tower section 5 and this tooling in the working state. When the arc-shaped chuck 310 clamps the tower section 5 from the inner ring of the tower section 5, the braking arc plate 312 simultaneously clamps the tower section 5 from the outer side of the tower section 5. Finally, the tooling is accurately positioned in the alignment stage of the tower section 5. Before work, the positioning probe 309 under the calibration frame 306 moves forward and is precisely coaxial with the flange hole. During the working phase, the boom 301 is first extended and the traction clamping wheel 314 is moved away. The external hoisting equipment hoists the next tower segment 5 until it maintains a first distance difference from the previous segment, which is set to 3m. The two auxiliary slides 3 are brought closer together so that the traction clamping wheel 314 is positioned lower and centered at four points from the bottom of the tower. The boom 301 is tightened so that the floating clamping wheel 305 is positioned upper and centered at four points from the middle and lower part of the tower. After completing the eight-point preliminary positioning, the positioning probe 309 collects the flange hole positions of the tower to be assembled and establishes the working parameters of the rotary motor 318. The rotary motor 318 works synchronously to realize the upper and lower tower flanges. With the holes precisely aligned, the traction frame 313 then moves down synchronously, pulling the two tower sections closer together to maintain a second distance difference, which is set at 0.35m. The positioning probe 309 and calibration frame 306 retract, causing the arc-shaped claw 310 and braking arc plate 312 to disengage from the tower. The traction frame 313 continues to move down to complete the precise alignment and fitting of the tower sections. Workers install screws and nuts on the inside of the tower sections to secure them. The traction clamping wheel 314 and floating clamping wheel 305 remain tightly clamped. The self-propelled platform 4 moves along the 360° guide walking platform, driving the fiber laser welding head 402 to complete the circumferential weld. During circumferential welding, the welding speed is 8 mm / s, the shielding gas is argon, and the gas flow rate is 15 L / min. After welding and solidification, the laser displacement detection sensor 412 and the industrial camera 411 move along the circumferential seam to complete the detection and identification of the weld morphology, tower coaxiality and seam width. Then, the electromagnetic hammer 403 drives the metal hammer head 405 to repeatedly strike the tower according to the limited parameters. The vibration signal acquisition element 406 captures the vibration feedback. The microcontroller 410 processes the signal and transmits it to the control module. The connection strength is intelligently detected by comparing it with the standard database threshold. If all the test items pass the final stage, the tooling is reset to release the clamping and positioning of the tower. When releasing, first control the traction clamping wheel 314 to release, then control the floating clamping wheel 305 to release. Then move to the next assembly point according to the operation requirements. If the test fails, make the corresponding adjustments and retest. Throughout the operation, the tooling can be hoisted into position via the lifting lug 101 on the base frame or by self-propelled positioning. Operators can also use the remote control module of the power distribution control box to wirelessly control the tooling from inside the tower or at the top.

[0027] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An assembly fixture for a wind turbine tower, comprising two symmetrically arranged base frames (1), and two symmetrically arranged electrically operated tensioning frames (2) installed between the two base frames (1), characterized in that, Each base frame (1) is equipped with an assembly mechanism; The assembly mechanism includes a semi-circular track frame (401) fixed to the top of the base frame (1) and a climbing platform (322) fixed to the bottom of the base frame (1). A self-propelled platform (4) is installed on the semi-circular track frame (401). A linearly movable inspection frame (407) is provided on the self-propelled platform (4). A fiber laser welding head (402), an electromagnetic knocker (403), an elastic rod (404), and a testing and calibration unit are fixedly installed on the inspection frame (407). 3) The output end is equipped with a striking head (405), the end of the elastic rod (404) is equipped with a vibration signal acquisition element (406), the lower part of the base frame (1) is equipped with an auxiliary slide (3) that can be linearly displaced, two symmetrically arranged arms (301) are hinged on the auxiliary slide (3), and an adjusting arm push rod (302) is hinged between the two arms (301) and the auxiliary slide (3). A floating frame (303) is slidably connected to the top of the arms (301). 3) A floating spring (304) is installed between the auxiliary slide (301) and the arm (301). A floating clamping wheel (305) that can be electrically rotated is provided on the floating frame (303). A calibration frame (306) and a positioning frame (307) are slidably connected in the middle of the auxiliary slide (3). Two clamping push rods (308) are installed between the auxiliary slide (3) and the calibration frame (306). A drive calibration frame (306) and a positioning frame (307) are provided between the calibration frame (306) and the positioning frame (307). The reverse synchronous transmission unit with reverse movement has two positioning probes (309) and two arc-shaped claws (310) installed at the front end of the calibration frame (306). An elastic clamping assembly (311) is installed on the positioning frame (307). A brake arc plate (312) is installed at the other end of the elastic clamping assembly (311). Two synchronously lifting traction frames (313) are installed on the auxiliary slide (3). Each traction frame (313) is rotatably connected to a traction clamping wheel (314).

2. The assembly fixture for a wind turbine tower according to claim 1, characterized in that, The self-propelled platform (4) is equipped with a linear feed transmission module (409), which is connected to the inspection frame (407) and the inspection frame (407) is slidably connected to the self-propelled platform (4). Two symmetrically arranged lifting lugs (101) are installed on the base frame (1).

3. The assembly tooling for a wind turbine tower according to claim 1, characterized in that, The lower part of the base frame (1) is equipped with two symmetrically arranged horizontal electric push rods (315). The movable ends of the two horizontal electric push rods (315) are fixedly connected to the auxiliary slide (3). The auxiliary slide (3) is equipped with two symmetrically arranged vertical electric push rods (316). The movable ends of the two vertical electric push rods (316) are fixedly connected to two traction frames (313) respectively. The bottom surfaces of the two traction frames (313) are fixedly connected with guide slides (317). The two guide slides (317) are slidably connected to the auxiliary slide (3).

4. The assembly fixture for a wind turbine tower according to claim 1, characterized in that, The assembly mechanism also includes a rotary motor (318) fixedly mounted on the arm (301). A spline shaft (319) is fixedly mounted on the output shaft end of the rotary motor (318). A key hole is provided at the axial position of the floating clamp wheel (305) to slide and connect with the spline shaft (319). The cross-section of the key hole and the spline shaft (319) are both regular hexagonal.

5. The assembly fixture for a wind turbine tower according to claim 4, characterized in that, The reverse synchronous transmission unit includes a synchronous gear (320) rotatably connected to the auxiliary slide (3). The bottom surface of the calibration frame (306) and the top surface of the positioning frame (307) are both equipped with rack plates (321). Both rack plates (321) are connected to the synchronous gear (320) in a transmission manner, and the two rack plates (321) are respectively located on the upper and lower sides of the synchronous gear (320). The auxiliary slide (3) has two guide grooves, which are slidably connected to the calibration frame (306) and the positioning frame (307) respectively.

6. The assembly tooling for a wind turbine tower according to claim 1, characterized in that, The detection and calibration unit includes a microcontroller (410) fixed at the tail of the self-propelled platform (4) and an industrial camera (411) and a laser displacement detection sensor (412) fixed at the front of the self-propelled platform (4). The data terminals of the vibration signal acquisition element (406), the positioning probe (309), the laser displacement detection sensor (412) and the industrial camera (411) are all connected to the microcontroller (410).

7. The assembly tooling for a wind turbine tower according to claim 6, characterized in that, A tower section (5) is clamped between two assembly mechanisms. The axes of the fiber laser welding head (402), electromagnetic knocker (403), elastic rod (404), spline shaft (319), laser displacement detection sensor (412), industrial camera (411) and clamping push rod (308) are all perpendicular to the axis of the tower section (5), and the axis of the positioning probe (309) is parallel to the axis of the tower section (5).

8. The assembly tooling for a wind turbine tower according to claim 1, characterized in that, The elastic clamping assembly (311) includes two T-shaped light rods fixed on the back of the brake arc plate (312). The axes of the two T-shaped light rods are perpendicular to the axis of the tower section (5). The two T-shaped light rods are slidably connected to the auxiliary slide (3). A clamping spring is sleeved on the T-shaped light rod at the position between the auxiliary slide (3) and the brake arc plate (312).

9. The assembly tooling for a wind turbine tower according to claim 1, characterized in that, The braking arc plate (312) has an arc-shaped structure. A rubber block is installed on the side of the braking arc plate (312) opposite to the tower section (5). Friction bumps are evenly distributed on the surface of the rubber block. The striking head (405) is made of metal and has a circular cross-section.

10. An assembly method for a wind turbine tower assembly fixture according to any one of claims 1-9, characterized in that, Includes the following steps: SS01, Tooling installation and positioning: Connect the two base frames (1) into one unit through the electric clamping frame (2), hold them tightly to the outer periphery of the fixed lower tower section (5), drive the base frame (1) along the tower axis to the flange connection end through the climbing platform (322), and align it coaxially with the lower tower flange hole through the positioning probe (309) to complete the initial positioning of the tooling; SS02, Upper Tower Section Lifting and Eight-Point Positioning: Lift the upper tower section (5) to the top of the lower tower, maintaining the first distance difference, and drive the auxiliary slide (3) to move towards the tower through the horizontal electric push rod (315), so that the traction clamping wheel (314) can be positioned at four points from the outside of the bottom of the tower. At the same time, the boom push rod (302) drives the clamping arm (301) to clamp tightly, so that the floating clamping wheel (305) can be positioned at four points from the outside of the lower middle part of the tower, completing the initial eight-point clamping. SS03, Automatic alignment of flange holes: The positioning probe (309) collects the position data of the flange holes of the upper tower section. The microcontroller (410) controls the rotary motor (318) to drive the floating clamp wheel (305) to rotate according to the data, thereby rotating the upper tower section and making the flange holes of the upper and lower tower sections accurately aligned. SS04, Tower Traction Fitting: The traction frame (313) is driven to move down synchronously by the vertical electric push rod (316), pulling the upper tower section closer to the lower tower section to the second distance difference. Then, the calibration frame (306) is driven to retract by the clamping push rod (308), so that the arc-shaped claw (310) and the braking arc plate (312) are disengaged from the tower section. The traction frame (313) continues to move down until the flange surfaces of the two tower sections are precisely fitted. The bolt connection is completed manually or by auxiliary equipment. SS05, Circumferential Welding: The self-propelled platform (4) moves circumferentially along the 360° track formed by the semi-arc track frame (401), driving the fiber laser welding head (402) to automatically weld the circumferential seam at the connection of the two tower flange sections; SS06, Weld inspection and connection strength assessment: After welding is completed, the self-propelled platform (4) moves along the circumference again. The weld morphology, tower coaxiality and weld width are identified by the laser displacement detection sensor (412) and industrial camera (411). Then, the electromagnetic knocker (403) drives the knocking head (405) to knock on the tower. The vibration signal acquisition element (406) captures the vibration feedback. The microcontroller (410) processes the signal and compares it with the standard threshold, and automatically outputs the connection strength assessment result. SS07, Reset and Displacement: After passing the inspection, release the constraint on the tower and drive the tooling along the tower to the next assembly point via the climbing platform (322). Repeat the above steps to complete the assembly of the subsequent towers.

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