A hoisting method for a small-platform wind turbine impeller in a complex mountainous wind farm

Abstract

The present application relates to the technical field of wind power engineering construction, and more particularly to a complex mountainous wind farm small platform wind turbine impeller hoisting method, comprising four core stages of hoisting platform digital optimization arrangement, herringbone tool support installation, impeller assembly and impeller hoisting whole-process precise control, and being suitable for 30m*30m small platform wind turbine impeller hoisting; the impeller comprises a hub and three blades, and the three blades are fixedly installed in a circumferentially equidistant array state on the outer wall of the hub; the herringbone tool support is used for assisting the impeller to assemble. Through the integrated design of "platform optimization + tool installation + process innovation + whole-process control", the present application realizes a substantial increase in space utilization, solves the core problem of small platform function partition and process cooperation, adapts to typical mountainous sites such as independent mountain tops and ridges, and avoids the earthwork excavation amount caused by large platform construction, avoids mountainous water and soil loss and vegetation damage, and realizes the coordinated development of engineering construction and ecological protection.

Description

Technical Field

[0001] This invention relates to the field of wind power engineering construction technology, and in particular to a method for hoisting the rotor of a small platform wind turbine in a complex mountain wind farm. Background Technology

[0002] Wind power engineering construction refers to the entire process of wind turbine generator construction from site selection and planning to grid connection and power generation. It is mainly divided into two categories: onshore wind power construction and offshore wind power construction. The core components include infrastructure construction, generator hoisting, electrical installation and system commissioning.

[0003] As wind power development extends into complex mountainous areas, the installation of turbine rotors on small platforms has become a core technical aspect of mountain wind power construction. Existing installation technologies largely follow the construction approach used for large platforms in plains areas, presenting numerous key problems when adapted to small mountain platforms. The core issue lies in the lack of customized design for the spatial, topographical, meteorological, and ecological characteristics of small mountain platforms, resulting in the following problems: 1. Traditional installation lacks a standardized layout plan for small platforms, leading to a chaotic layout of the main crane, auxiliary equipment, and material storage areas, resulting in severe cross-process interference. (30m×30m...) 1. The space utilization rate of small platforms is less than 60%, which cannot meet the needs of multi-process collaborative operation; 2. Mountain weather is changeable (gusts, low visibility, etc.), which can easily cause safety accidents such as blade overturning and falling objects from heights, and there is a lack of targeted full-process safety management mechanisms; 3. Traditional solutions rely on dual auxiliary cranes for impeller assembly, which results in high equipment rental and relocation costs, and the excavation of large platforms involves a large amount of earthwork, increasing the cost of ecological restoration; 4. The equipment relocation and process connection time is long, and the effective working window is short due to weather. The traditional process has a long construction period for the hoisting of a single wind turbine impeller, and the progress control is difficult when multiple wind turbines are being constructed, resulting in a high rework rate; 5. Traditional large platform hoisting requires the excavation of a working surface of more than 1,800 square meters, with a large amount of earthwork excavation, which can easily cause soil erosion and vegetation damage in mountainous areas, which is contrary to the requirements of ecological protection for mountain wind power.

[0004] To address the aforementioned issues, there is an urgent need for a method for hoisting wind turbine rotors on small platforms in complex mountainous wind farms that achieves efficient space utilization, precise safety control, cost-ecological synergy, and improved construction efficiency, filling the gap in existing technologies for customized hoisting of small mountainous platforms. Summary of the Invention

[0005] The purpose of this invention is to develop an integrated hoisting method for wind turbine impellers that is compatible with 30m×30m small platforms by adopting the core technology path of digital optimization of hoisting platform layout → R&D and application of A-frame tooling support → impeller assembly process innovation → precise control of the entire hoisting process, thereby achieving synergistic optimization of space, safety, cost, efficiency and ecology in hoisting small platforms in mountainous areas.

[0006] The technical solution of this invention is a method for hoisting wind turbine rotors on small platforms in complex mountain wind farms. It includes four core stages: digital optimization layout of the hoisting platform, installation of A-frame tooling brackets, rotor assembly, and precise control of the entire rotor hoisting process. It is applicable to the hoisting of wind turbine rotors on small platforms of 30m×30m. The impeller includes a hub and three blades, the three blades being fixedly mounted on the outer wall of the hub in a circumferentially equidistant array. A herringbone-shaped tooling bracket is used to assist in the assembly of the impeller.

[0007] Optionally, the digitally optimized layout of the hoisting platform is constructed at a 1:1 scale, creating a small platform of 30m×30m to simulate the layout of the main crane, auxiliary equipment, material storage area, and transportation channel. After multiple rounds of simulation and adjustments based on the site's terrain and geological conditions, the space utilization rate of the small platform is achieved to be ≥90%.

[0008] Optionally, the herringbone tooling bracket is made of Q235B steel, integrates an intelligent monitoring module, and has an overall anti-overturning weight of 90t. The herringbone tooling bracket includes a first pad, an elephant leg cylinder, an adjustable support base, elephant legs, and a second pad.

[0009] Optionally, the standardized installation process of the herringbone tooling bracket is as follows: level the site and determine the placement coordinates; place the first pad and two second pads according to the determined placement coordinates; connect the elephant leg cylinder and the adjustable support base with threads and adjust the height before hoisting them to the top of the first pad and fixing them; hoist the two elephant legs and connect them with the elephant leg cylinder and the corresponding second pads; and use connecting pins to complete the connection and assembly of the elephant legs with the elephant leg cylinder and the second pads; activate the intelligent monitoring module and verify the verticality and stress state.

[0010] Optionally, the impeller assembly process based on the herringbone tooling bracket is as follows: the hub is hoisted to the top of the adjustable support and fixed, and then the three blades are hoisted to the periphery of the hub in sequence, so that the three blades are symmetrically connected to the hub in a 120° equally divided state.

[0011] Optionally, the first two blades are installed along the direction of the two elephant legs, so that the elephant legs of the herringbone tooling bracket provide balanced support for the weight of the wheel hub, and the last blade is installed to fill in the gap along the axis of symmetry of the previous two blades.

[0012] Optionally, the blade's scale line reference is aligned with the reference mark on the outer ring of the pitch bearing inside the hub, and the blade is fastened to the hub using high-strength bolts through two steps of pre-tightening and final tightening to form a complete impeller.

[0013] Optionally, the precise control of the entire hoisting process includes: selecting a 550t crawler crane with a matching impeller installation height (90m) and total impeller weight (81.28t); the 550t crawler crane has a boom length of 96+7m under a slewing radius of 18m; the rocky mountain platform is leveled and compacted; soft soil foundations are replaced with boulders or 30mm thick steel plates and roadbed boxes are laid; hoisting is stopped immediately when the average wind speed exceeds 8m / s or severe weather occurs; the two blades below the main hoisting point of the impeller are fitted with φ18×150m safety ropes to control stability; the docking accuracy between the impeller and the nacelle is controlled within ±5mm; and data from each stage of the hoisting process is recorded and traced throughout.

[0014] Optionally, the A-frame tooling support is a detachable structure, which improves its relocation efficiency by 60% and replaces the traditional dual auxiliary crane, reducing the mechanical cost of hoisting a single wind turbine.

[0015] Optionally, the 30m×30m small platform reduces the floor space by 50% compared to the traditional large platform, the total investment of a single wind turbine platform decreases by 16.5%, and the installation period of a single wind turbine impeller is shortened by more than 14%.

[0016] In summary, this application includes at least one of the following beneficial technical effects: This invention achieves a significant increase in space utilization through an integrated design of "platform optimization + tooling installation + process innovation + full-process control". It solves the core problem of functional zoning and process coordination of small platforms, is suitable for typical mountain locations such as independent mountain tops and ridges, and avoids the amount of earthwork excavation caused by large platform construction, avoids soil erosion and vegetation damage in mountainous areas, and achieves coordinated development of engineering construction and ecological protection. Through full-process control, safety risks caused by mountain weather and terrain can be effectively avoided, achieving zero accidents in construction safety; the docking accuracy between the impeller and the nacelle can be controlled within ±5mm, which is far superior to the 10mm deviation standard of traditional processes, improving the subsequent operation stability of the unit and achieving dual protection of hoisting safety and accuracy. By using A-frame tooling supports to replace dual auxiliary cranes, the mechanical cost of wind turbine hoisting is reduced, the efficiency of site relocation is improved, the connection time between impeller assembly and hoisting is shortened, the pressure of schedule control is effectively alleviated, and the construction efficiency is improved and the construction cost is saved. By establishing a standardized process for the entire hoisting method, it can be directly replicated and applied to the hoisting and installation of turbine rotors on small platforms in similar complex mountain wind farms, thus forming a standardized operation. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the impeller and herringbone tooling support structure proposed in this invention.

[0018] Figure label: 1. First pad; 2. Elephant leg cylinder; 3. Adjustable support base; 4. Elephant leg; 5. Second pad; 6. Hub; 7. Blade. Detailed Implementation

[0019] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0020] The components of the embodiments of the invention described and shown in the accompanying drawings can typically be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0021] Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] Example 1, such as Figure 1 The method for hoisting wind turbine rotors on small platforms in complex mountain wind farms includes four core stages: digital optimization layout of the hoisting platform, installation of A-frame tooling brackets, rotor assembly, and precise control of the entire rotor hoisting process. It is applicable to the hoisting of wind turbine rotors on small platforms of 30m×30m. The impeller includes a hub 6 and three blades 7, which are fixedly mounted on the outer wall of the hub 6 in a circumferentially equidistant array. A-frame tooling bracket is used to assist in the assembly of the impeller.

[0025] The digital optimization layout of the hoisting platform is constructed at a 1:1 scale, with a 30m×30m small platform to simulate the layout of the main crane, auxiliary equipment, material storage area, and transportation channels. After multiple rounds of simulation and adjustments based on the site's terrain and geological conditions, the small platform achieves a space utilization rate of ≥90%. The 30m×30m small platform reduces the floor space by 50% compared to the traditional large platform, reduces the total investment of a single wind turbine platform by 16.5%, and shortens the hoisting period of a single wind turbine impeller by more than 14%, thereby achieving the effects of reducing costs and improving wind turbine installation efficiency. Among them, the space utilization rate of the 30m×30m small platform is improved through three-dimensional simulation optimization, which solves the core problem of functional zoning and process coordination of the small platform and is suitable for typical mountain positions such as independent mountain tops and ridges.

[0026] The A-frame tooling support is made of Q235B steel and integrates an intelligent monitoring module. The overall anti-overturning weight reaches 90t. The A-frame tooling support is a detachable and modular structure, which improves its transfer efficiency by 60% and replaces the traditional double auxiliary crane, reducing the mechanical cost of hoisting a single wind turbine. The A-frame tooling support includes a first pad 1, elephant leg cylinders 2, adjustable support seats 3, elephant legs 4, and a second pad 5. The standardized installation process of the A-frame tooling support is as follows: level the site and determine the placement coordinates. Place the first pad 1 and two second pads 5 according to the determined placement coordinates. Connect the elephant leg cylinders 2 and the adjustable support seats 3 with threads and adjust the height before hoisting them to the top of the first pad 1 and fixing them. Hoist the two elephant legs 4 and connect them with the elephant leg cylinders 2 and the corresponding second pads 5. Use connecting pins to complete the connection and assembly of the elephant legs 4 with the elephant leg cylinders 2 and the second pads 5. Turn on the intelligent monitoring module and check the verticality and stress status. Among them, by replacing the double auxiliary cranes with A-frame tooling supports, the mechanical cost of hoisting a single wind turbine is reduced and the area occupied is reduced, thereby reducing the amount of earthwork excavation, reducing construction costs, shortening construction time, and facilitating subsequent ecological restoration. Among them, the impeller hoisting is assisted by the A-frame tooling bracket, which shortens the connection time between the impeller assembly and hoisting processes, thereby effectively alleviating the pressure of progress control; Among them, by setting the A-frame tooling support as a detachable structure, the ease of relocation of the A-frame tooling support is improved, and the whole hoisting method forms a standardized process that can be directly replicated and applied to the hoisting construction of wind turbine rotors on small platforms in similar complex mountain wind farms. The impeller assembly process based on the herringbone tooling bracket is as follows: The hub 6 is hoisted to the top of the adjustable support 3 and fixed. Then, the three blades 7 are hoisted to the periphery of the hub 6 in sequence, so that the three blades 7 are symmetrically aligned with the hub 6 at 120° intervals. The first two blades 7 are installed along the direction of the two elephant legs 4, so that the elephant legs 4 of the herringbone tooling bracket can balance the weight of the hub 6. The last blade 7 is installed along the symmetrical axis of the previous two blades 7. During installation, the scale line reference of the blade 7 is aligned with the reference mark of the outer ring of the pitch bearing inside the hub 6. The blade 7 is fastened to the hub 6 by pre-tightening and final tightening with high-strength bolts to form a complete impeller.

[0027] Precise control throughout the entire hoisting process includes: selecting a 550t crawler crane with a matching impeller installation height (90m) and total impeller weight (81.28t); the 550t crawler crane has a boom length of 96+7m under a slewing radius of 18m; the rocky mountain platform is leveled and compacted; soft soil foundations are replaced with boulders or 30mm thick steel plates and roadbed boxes are laid; hoisting is immediately stopped when the average wind speed exceeds 8m / s or in severe weather; the two blades below the main impeller hoisting point are fitted with φ18×150m safety ropes to control stability; the docking accuracy between the impeller and the nacelle is controlled within ±5mm; and data from each stage of the hoisting process is recorded and traced throughout. Among them, the process control system can effectively avoid the safety risks brought by mountain weather and terrain, and achieve zero accidents in construction safety.

[0028] This invention, through its integrated design of "platform optimization + tooling installation + process innovation + full-process control," has significant advantages over existing mountain wind turbine impeller hoisting technologies. The detailed implementation process of this technology is as follows: 1. Digital optimization layout of hoisting platform A 30m×30m digital model of a small platform was constructed at a 1:1 scale to simulate the 18m turning radius of the 550t crawler crane, the auxiliary crane parking area, the tower, the nacelle, the blade stacking area, and the transportation channel. Safe operating distances were reserved, and the layout was adjusted according to the rocky terrain on site. The main crane was placed on the north side of the crane position, the nacelle and hub were stacked within the main crane's operating radius, and the blades were arranged in an orderly manner along the operating line. The equipment entry sequence was determined to be "tower → nacelle → hub → blades".

[0029] 2. Installation of A-frame tooling bracket Level the work area and place the first pad 1 (2600mm×2300mm×70mm) and the second pad 5 (1700mm×1700mm×70mm) according to the calculated coordinates. Fix the elephant leg cylinder 2 and the adjustable support base 3 with threaded connection and adjust the height before hoisting them above the first pad 1 and fixing them. Hoist the two elephant legs 4 and connect them to the elephant leg cylinder 2 and the corresponding second pad 5. Complete the connection and fixation of the elephant legs 4 to the elephant leg cylinder 2 and the second pad 5 through the connecting pin. Make the included angle between the two fixed elephant legs 4 120°. At this time, the installation of the herringbone work support is completed. Turn on the intelligent monitoring module to check the verticality and stress state of the herringbone work support. Check the operation line of the herringbone work support, the main crane, and the wheel hub stacking area to ensure that there are no abnormalities.

[0030] 3. Impeller assembly After removing the hub transport base, the main crane hoisted the hub onto the adjustable support seat 3 of the herringbone tooling bracket. Then, three blades (each weighing 14.5t) were hoisted in sequence and symmetrically aligned with the hub at 120° intervals. The first and second blades were installed along the direction of the tooling legs, and the third blade was installed to fill in the gap. The blade scale line reference was precisely aligned with the hub markings. After pre-tightening the bolts, the assembly accuracy was checked. After confirming that the assembly accuracy was normal, the blade bolts were finally tightened to form a complete impeller weighing 81.28t. The intelligent monitoring module was activated to ensure that the herringbone tooling bracket was under normal stress.

[0031] 4. Precise hoisting throughout the entire process Before hoisting, on-site wind speed and weather conditions were monitored and adjusted to ensure that the wind speed was less than 8 m / s and that the weather conditions met the construction requirements. Then, the parameters of the main crane were checked: boom length 96+7m, rated lifting capacity 130t, and foundation bearing capacity. The hoisting tool was hung at the main hoisting point of the impeller, and φ18×150m safety ropes were symmetrically fitted onto the two blades below. Four workers simultaneously controlled the wind ropes, and the main crane slowly lifted the impeller. After the impeller was lifted to an installation height of 90m, the alignment was slowly adjusted. The wind ropes were manually controlled to keep the impeller stable, achieving a precise docking between the impeller and the nacelle. The docking deviation had to meet the accuracy requirement of ±5mm. The pre-tightening and final tightening of the docking bolts were completed, and the wind turbine impeller hoisting was completed. Finally, the hoisting tool, wind ropes, and A-frame tooling support were removed. The equipment parameters, operation procedures, accuracy data, and weather data were recorded throughout the process.

[0032] The above specific embodiments are merely optional embodiments of the present invention. Based on the technical solutions of the present invention and the relevant teachings of the above embodiments, those skilled in the art can make various alternative improvements and combinations to the above specific embodiments.

Claims

1. A method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm, characterized in that, It includes four core stages: digital optimization of the hoisting platform, installation of A-frame tooling brackets, impeller assembly, and precise control of the entire impeller hoisting process. It is suitable for the hoisting of wind turbine impellers on a 30m×30m small platform. The impeller includes a hub (6) and three blades (7), the three blades (7) being fixedly mounted on the outer wall of the hub (6) in a circumferentially equidistant array. A herringbone-shaped tooling bracket is used to assist in the assembly of the impeller.

2. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 1, characterized in that, The digitally optimized layout of the hoisting platform is constructed at a 1:1 scale, with a small platform of 30m×30m to simulate the layout of the main crane, auxiliary equipment, material storage area and transportation channel. After multiple rounds of simulation and adjustments based on the on-site terrain and geological conditions, the space utilization rate of the small platform is ≥90%.

3. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 1, characterized in that, The herringbone tooling bracket is made of Q235B steel and integrates an intelligent monitoring module. The overall anti-overturning weight reaches 90t. The herringbone tooling bracket includes a first pad (1), an elephant leg cylinder (2), an adjustable support seat (3), an elephant leg (4), and a second pad (5).

4. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 3, characterized in that, The standardized installation process of the herringbone tooling bracket is as follows: level the site and determine the placement coordinates. Place the first pad (1) and two second pads (5) according to the determined placement coordinates. Connect the elephant leg cylinder (2) and the adjustable support base (3) with threads and adjust the height before hoisting them to the top of the first pad (1) and fixing them. Hoist the two elephant legs (4) to the elephant leg cylinder (2) and the corresponding second pads (5) and use connecting pins to complete the connection and assembly of the elephant legs (4) with the elephant leg cylinder (2) and the second pads (5). Turn on the intelligent monitoring module and check the verticality and stress status.

5. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 4, characterized in that, The impeller assembly process based on the herringbone tooling bracket is as follows: the hub (6) is hoisted to the top of the adjustable support (3) and fixed, and then the three blades (7) are hoisted to the periphery of the hub (6) in sequence, so that the three blades (7) are symmetrically connected to the hub (6) in a 120° equally divided state.

6. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 5, characterized in that, The first two blades (7) are installed along the direction of the two elephant legs (4) respectively, so that the elephant legs (4) of the herringbone tooling bracket can balance the weight of the hub (6), and the last blade (7) is installed to fill the gap along the symmetrical axis of the previous two blades (7).

7. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 5, characterized in that, Align the scale line reference of the blade (7) with the reference mark of the outer ring of the pitch bearing inside the hub (6), and use high-strength bolts to fasten the blade (7) to the hub (6) in two steps of pre-tightening and final tightening to form a complete impeller.

8. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 1, characterized in that, The precise control of the entire hoisting process includes: selecting a 550t crawler crane with a matching impeller installation height (90m) and total impeller weight (81.28t); the 550t crawler crane has a boom length of 96+7m under a slewing radius of 18m; the rocky mountain platform is leveled and compacted; soft soil foundations are replaced with boulders or 30mm thick steel plates and roadbed boxes are laid; hoisting is stopped immediately when the average wind speed exceeds 8m / s or in severe weather; the two blades below the main impeller hoisting point are fitted with φ18×150m safety ropes to control stability; the docking accuracy between the impeller and the nacelle is controlled within ±5mm; and data from each stage of the hoisting process is recorded and traced throughout.

9. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 3, characterized in that, The herringbone tooling support is a detachable and modular structure, which improves its relocation efficiency by 60% and replaces the traditional dual auxiliary cranes, reducing the mechanical cost of hoisting a single wind turbine.

10. The method for hoisting the impeller of a small platform wind turbine in a complex mountain wind farm according to claim 2, characterized in that, The 30m×30m small platform reduces the floor space by 50% compared to the traditional large platform, reduces the total investment of a single wind turbine platform by 16.5%, and shortens the installation period of a single wind turbine impeller by more than 14%.

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