An auxiliary mechanical exoskeleton device for wind turbine tower climbing

Abstract

The utility model discloses an auxiliary mechanical exoskeleton device for the climbing of fan tower drum, through the targeted structure design and function integration, realize the efficient help and safety guarantee of the climbing process. Auxiliary mechanical exoskeleton device includes safety guarantee module, main drive module, upper limb power module and lower limb power module, and safety guarantee module contains safety rope, safety buckle and harness system, and safety rope one end is connected in harness system fixed, and the other end passes through detachable safety buckle and is fixed with the climbing structure of fan tower drum, and main drive module contains main control unit, battery pack and back support, and main control unit and battery pack are fixed on harness system through back support, and upper limb power module symmetry sets up in the double arms of wearer, contains big arm connecting rod, small arm connecting rod, upper limb drive assembly and upper limb binding spare, and lower limb power module symmetry sets up in the double legs of wearer, contains big leg connecting rod, small leg connecting rod, lower limb drive assembly and lower limb binding spare.

Description

Technical Field

[0001] This utility model belongs to the field of wind power equipment maintenance technology, specifically relating to an auxiliary mechanical exoskeleton device for climbing wind turbine towers. Background Technology

[0002] As a crucial component of clean energy, wind power generation is experiencing a steady increase in installed capacity. Wind turbine towers, the core supporting structure of wind turbine generators, typically exceed 80 meters in height, with some offshore wind turbine towers reaching as high as 120 meters. Currently, wind turbine maintenance personnel primarily conduct equipment inspections and maintenance using vertical ladders inside the tower or external suspended ladders. A single climb can take 20-30 minutes and requires carrying heavy equipment such as tool bags and testing instruments, resulting in significant physical exertion. Prolonged climbing can lead to occupational injuries such as lumbar strain and knee joint wear among wind turbine maintenance personnel. Furthermore, the risk of falls due to exhaustion during climbs remains a significant safety hazard in the industry.

[0003] Among existing auxiliary equipment, traditional safety ropes only provide fall protection and cannot reduce the physical exertion of climbing; while backpack-style assistive devices can distribute some of the load, they do not solve the problem of muscle load during limb movement. Existing mechanical exoskeleton technology has the following significant limitations: 1) Most exoskeletons are designed for walking on flat ground or carrying heavy loads. Their multi-link structure of the lower limbs and foot cushioning components are suitable for striding on horizontal surfaces, but cannot match the vertical movement pattern of "stepping-gripping" when climbing towers; 2) The foot support structure of some mechanical exoskeletons is prone to interference with the ladder steps during climbing; 3) Mechanical exoskeletons without upper limb assistive mechanisms cannot assist the repetitive movements of hand gripping ladders, resulting in prominent upper limb muscle fatigue; 4) Existing industrial exoskeletons focus on load distribution and lack locking devices adapted to the tower ladder structure, making it impossible to brake quickly in the event of a sudden fall; 5) Traditional exoskeletons mostly adopt a rigid frame design, which is time-consuming to put on and has limited flexibility when turning and avoiding obstacles in the narrow tower. At the same time, the lack of lightweight design for working at heights actually increases the physical burden.

[0004] Therefore, for the special scenario of climbing wind turbine towers, there is an urgent need for a mechanical exoskeleton device that combines lightweight design, targeted assistance, and safety assurance to address the shortcomings of existing technologies in vertical movement adaptation, limb coordination assistance, and high-altitude safety protection, thereby reducing the labor intensity and occupational risks of maintenance personnel. Utility Model Content

[0005] To overcome the shortcomings of existing technologies, the present invention aims to provide a technical solution for an auxiliary mechanical exoskeleton device for climbing wind turbine towers. Through targeted structural design and functional integration, it achieves efficient assistance and safety assurance during the climbing process.

[0006] To achieve the above objectives, the present invention may adopt the following specific technical solutions: The aforementioned auxiliary mechanical exoskeleton device for climbing wind turbine towers includes: The safety protection module includes a safety rope, a safety buckle, and a carrying system. One end of the safety rope is connected to the carrying system for fixation, and the other end is fixed to the climbing structure of the wind turbine tower through a detachable safety buckle. The main drive module includes a main control unit, a battery pack, and a back support. The main control unit and the battery pack are fixed to the shoulder strap system via the back support. The upper limb assist module is symmetrically arranged on the wearer's arms and includes an upper arm link adapted to the human upper arm, a forearm link adapted to the human lower arm, an upper limb drive component that drives the two to swing relative to each other, and an upper limb binding piece for fixing the arms. The lower limb assist module is symmetrically arranged on the wearer's legs and includes a thigh link adapted to the human thigh, a lower leg link adapted to the human calf, a lower limb drive assembly that drives the two to swing relative to each other, and a lower limb binding for fixing the legs.

[0007] Furthermore, the harness system includes shoulder straps, waist straps, and a chest strap, with pressure sensors installed on the inner sides of the shoulder straps, waist straps, and chest strap. The safety buckle has a built-in electromagnetic lock, controlled by the main control unit, which can forcibly lock in the event of a sudden fall. Combined with the built-in damper in the safety rope, it reduces the impact load to a level tolerable for the human body.

[0008] Furthermore, the main control unit integrates a posture sensor and a wireless communication module to collect the wearer's motion data in real time and control the upper limb assist module and the lower limb assist module; the battery pack is a rechargeable lithium battery and is detachably connected to the back support to power the entire assist device; the back support is made of carbon fiber and is bolted to the back strap system.

[0009] Furthermore, the upper end of the upper arm link is connected to the back support via a revolute joint, and the lower end is connected to the upper end of the forearm link via a revolute joint. The upper limb drive assembly drives the upper arm link and the forearm link to cooperate to realize the climbing action, which can perform a large range of flexion and extension, and is adapted to the range of motion of gripping the ladder.

[0010] Furthermore, the upper limb drive assembly includes an upper limb motor, a harmonic reducer, and a crank-connecting rod structure. The upper limb motor drives the crank-connecting rod structure through the harmonic reducer. The crank-connecting rod structure is eccentrically connected to the upper end of the forearm connecting rod, which can drive the forearm connecting rod to rotate at a large angle relative to the upper arm connecting rod, adapting to the arm flexion and extension movements during climbing and reducing the load on the biceps and shoulder muscles. An angle sensor is provided at the rotation joint of the upper arm connecting rod and the forearm connecting rod to provide real-time feedback of the joint position to the main control unit, thereby achieving dynamic matching of the assist force.

[0011] Furthermore, the upper end of the thigh link is connected to the back support via a hip joint system, and the lower end is connected to the upper end of the calf link via a revolute joint. A knee joint motor of the lower limb drive assembly is provided at the knee joint where the calf link and the thigh link connect. The knee joint motor is electrically connected to the main control unit and can independently drive the calf link to move relative to the thigh link. The lower limb motor of the lower limb drive assembly works in coordination with the knee joint motor to drive the thigh link and the calf link to cooperate in realizing the pedaling action during climbing.

[0012] Furthermore, the lower limb drive assembly also includes a rotating wheel pair and a moving link. The rotating wheel pair is connected to the lower limb motor for transmission. The upper end of the moving link is eccentrically rotated with the rotating wheel pair, and the lower end is connected to the upper end of the lower leg link through a rotating pair. The lower limb motor and the knee joint motor are responsible for actively generating force, while the moving link provides auxiliary buffering to reduce the load on the quadriceps muscle.

[0013] The rotating joint of the thigh link and the lower leg link is provided with a limiting protrusion, which abuts against each other to limit excessive bending.

[0014] Furthermore, the hip joint system includes a three-degree-of-freedom rotational structure, namely a waist-twisting rotation about the Z-axis, a waist-bending rotation about the X-axis, and a side waist rotation about the Y-axis, to adapt to the multi-angle adjustment needs of the torso during climbing.

[0015] Furthermore, both the upper limb and lower limb bindings are adjustable straps with a breathable padding layer on the inside and Velcro or quick-release buckles on the straps for wearing and securing, adaptable to wearers of different body types.

[0016] Compared with the prior art, the present invention has the following advantages: This invention is easy to wear, simple in structure, and highly adaptable, effectively reducing the physical exertion of wind turbine operators during climbing while ensuring their safety. The safety module provides dual protection for the wearer; the back support uses a one-piece carbon fiber structure, which is lightweight yet possesses both rigidity and toughness, and is fixed to the shoulder strap system with bolts, distributing the weight to the torso; the hip joint system includes a three-degree-of-freedom rotation structure, enabling twisting, bending, and side-bending movements, improving climbing flexibility; the main control module integrates a posture sensor and a wireless communication module, collecting climbing posture data in real time, and also supports remote communication with a ground terminal for easy status monitoring. Attached Figure Description

[0017] Figure 1 This is one of the structural schematic diagrams of the auxiliary mechanical exoskeleton device of this utility model; Figure 2 This is a schematic diagram of the structure of the auxiliary mechanical exoskeleton device of this utility model. Figure 2 ; Figure 3 This is a structural diagram of the installation and protection module of this utility model; Figure 4 This is a schematic diagram of the main drive module of this utility model; Figure 5 This is a structural schematic diagram of the upper limb assistive module of this utility model; Figure 6 This is a schematic diagram of the lower limb assist module of this utility model; Figure 7 This is a schematic diagram of the hip joint structure of the lower limb assist module of this utility model.

[0018] In the diagram: 100-Safety module, 101-Safety buckle, 102-Safety rope, 103-Shoulder strap system, 200-Main drive module, 201-Main control unit, 202-Battery pack, 203-Back support, 300-Upper limb assist module, 301-Upper limb drive component, 302-Upper arm link, 303-Forearm link, 304-Upper limb restraint, 400-Lower limb assist module, 401-Hip joint system, 402-Thigh link, 403-Movement link, 404-Lower limb motor, 405-Knee joint motor, 406-Lower leg link, 407-Lower limb restraint. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0020] like Figure 1 and Figure 2As shown, an auxiliary mechanical exoskeleton device for climbing wind turbine towers includes a safety module 100, a main drive module 200, an upper limb assistance module 300, and a lower limb assistance module 400. Each module works collaboratively with electrical wiring via mechanical connectors to adapt to the mechanical requirements of vertical climbing scenarios. Specifically, the safety module 100's shoulder strap system 103 is rigidly connected to the main drive module 200's back support 203 via bolts, forming the overall wearable base. The upper limb assistance modules 300 are symmetrically distributed on both sides of the back support 203, achieving multi-directional rotation through a ball joint structure. The lower limb assistance module 400 is connected to the lower end of the back support 203 via a hip joint system 401, adapting to the relative movement of the torso and legs. The main control unit 201 of the main drive module 200 is electrically connected to the motors, sensors, and electromagnetic locks of each module via wires, forming a closed-loop control.

[0021] like Figure 3 As shown, the safety module 100 includes a safety rope 102, a safety buckle 101, and a carrying system 103. One end of the safety rope 102 is fixed to the carrying system 103, and the other end is fixed to the climbing structure of the wind turbine tower via a detachable safety buckle 101. The carrying system 103 adopts a three-layer composite structure: an outer layer of high-strength nylon webbing, a middle layer of cushioning sponge, and an inner layer of breathable mesh fabric. The carrying system 103 includes shoulder straps, waist straps, and a chest strap. The shoulder straps, waist straps, and chest strap are connected by quick-release buckles. Pressure sensors are arranged inside the straps to monitor the contact pressure between the wearer and the straps in real time. When a sudden drop in pressure on one side is detected, indicating an imbalance, the sensor transmits a signal to the main control unit 201.

[0022] The safety rope 102 is made of Kevlar. One end is secured to the waist of the harness system 103 via a metal ring, and the other end is connected to a safety buckle. The safety buckle has a built-in electromagnetic lock, and the buckle head is designed to fit the tower ladder. When the main control unit 201 receives an imbalance signal or the acceleration sensor detects a fall acceleration, it immediately triggers the electromagnetic lock and activates the buffer damper in the middle of the safety rope 102.

[0023] like Figure 4 As shown, the main drive module 200 includes a main control unit 201, a battery pack 202, and a back support 203. The main control unit 201 and the battery pack 202 are fixed to the shoulder strap system 103 via the back support 203. The back support 203 is integrally molded from carbon fiber prepreg, and is shaped like an "I". It is bolted to the shoulder strap system 103. The back support 203 also has pre-drilled threaded holes for fixing the battery pack 202. The front is fitted with a cushioning pad using Velcro to improve wearing comfort.

[0024] The main control unit 201 is designed based on the STM32H74 microprocessor and integrates a posture sensor and a wireless communication module to collect the wearer's motion data in real time and control the upper limb assist module 300 and the lower limb assist module 400. The battery pack 202 is a rechargeable lithium battery, detachably connected to the back support 203 via a guide rail structure, providing sufficient battery life for climbing and maintenance. The battery management system features overcharge, over-discharge, and short-circuit protection; a buzzer alarm is triggered by the main control unit 201 when the battery is low.

[0025] like Figure 5 As shown, the upper limb assist module 300 is symmetrically arranged on the wearer's arms, including an upper arm link 302 adapted to the upper arm, a forearm link 303 adapted to the forearm, an upper limb drive assembly 301 for driving the relative swinging of the two, and an upper limb restraint 304 for fixing the arms. The upper end of the upper arm link 302 is connected to the back support 203 via a revolute joint, and the lower end is connected to the upper end of the forearm link 303 via a revolute joint. The upper limb drive assembly 301 drives the upper arm link 302 and the forearm link 303 to cooperate to realize the climbing action. In a specific embodiment, both the upper arm link 302 and the forearm link 303 are made of aluminum alloy, forming a revolute joint through a brass bushing, and using a self-lubricating bearing to reduce the coefficient of friction. The connection between the upper end of the upper arm link 302 and the back support 203 is a ball joint, allowing lateral rotation to accommodate the side-to-side movements during climbing.

[0026] The upper limb drive assembly 301 includes an upper limb motor, a harmonic reducer, and a crank-connecting rod structure. The upper limb motor can be a brushless motor, which is fixed to the outer side of the middle section of the upper arm connecting rod 302, with its center of gravity close to the arm to reduce motion inertia. The harmonic reducer is rigidly connected to the motor output shaft, reducing speed and increasing torque to meet the torque requirements during gripping. The crank-connecting rod structure is eccentrically connected to the upper end of the forearm connecting rod 303. When the motor rotates, the circular motion of the crank is converted into the reciprocating swing of the forearm connecting rod 303, achieving flexion and extension, and precisely matching the range of motion for gripping and climbing ladders.

[0027] An angle sensor is embedded in the rotating joint of the upper arm link 302 and the forearm link 303 to collect joint angle data in real time and transmit it to the main control unit 201. When the arm is detected to be in a grasping motion, the output torque of the upper limb motor increases linearly as the angle decreases; when the arm is extended, the assist torque decreases to reduce energy consumption.

[0028] like Figure 6As shown, the lower limb assist module 400 is used to enhance the driving force for the pedaling action of vertical climbing and removes the foot structure to avoid interference with the climbing ladder. The lower limb assist module 400 is symmetrically arranged on the wearer's legs and includes a thigh link 402 adapted to the human thigh, a lower leg link 406 adapted to the human calf, a lower limb drive assembly that drives the relative swing of the two, and a lower limb restraint 407 for fixing the legs. The upper end of the thigh link 402 is connected to the back support 203 via the hip joint system 401, and the lower end is connected to the upper end of the lower leg link 406 via a revolute joint. A knee joint motor 405 of the lower limb drive component is provided at the knee joint where the lower leg link 406 connects to the thigh link 402. The knee joint motor 405 is electrically connected to the main control unit 201 and can independently drive the lower leg link 406 to move relative to the thigh link 402. The lower limb motor 404 of the lower limb drive component works in coordination with the knee joint motor 405 to drive the thigh link 402 and the lower leg link 406 to cooperate in realizing the stepping action during climbing.

[0029] The lower limb motor 404 and the knee joint motor 405 work together to achieve coordinated drive. The knee joint motor 405 is a DC geared motor, rigidly fixed to the outer side of the upper end of the lower leg link 406 via a flange. The output shaft meshes with the lower end of the thigh link 402 via a gear pair. This motor is responsible for actively providing the driving force required for pedaling. When the main control unit 201 detects a decrease in the knee flexion angle through the angle sensor (i.e., the angle sensor at the knee joint's rotation joint collects the joint angle in real time and transmits the data to the main control unit 201), the motor output torque increases linearly to assist the lower leg in rapid extension; when the angle increases, the torque decreases to reduce energy consumption.

[0030] The lower limb drive assembly also includes a rotating wheel pair and a moving link 403. The lower limb motor 404 is connected to the drive gear of the rotating wheel pair via a coupling. The drive gear meshes with the driven gear to form a reduction transmission. The eccentric shaft on the driven gear rotates with the upper end of the moving link 403. When the lower limb motor 404 rotates, the moving link 403 moves in a circular motion with the eccentric shaft, transmitting force to the lower leg link 406 through the lower rotating pair, forming a coordinated drive with the knee joint motor 405. The knee joint motor 405 provides instantaneous explosive force, and the moving link 403 buffers the impact force through a multi-link structure. The combination of the two makes the force output of the pedaling action more in line with the human body's force curve, reducing the load on the quadriceps. Furthermore, limiting protrusions are provided at the rotating pair between the thigh link 402 and the lower leg link 406. These limiting protrusions abut against each other to limit excessive bending. In one specific embodiment, the limiting protrusion 406 is a pair of arc-shaped limiting protrusions provided at the rotating joint of the thigh link 402 and the lower leg link 406. When the knee joint angle is too small, the protrusions abut against each other to limit excessive bending and avoid damage to the knee joint caused by reverse impact force during climbing.

[0031] like Figure 7As shown, the hip joint system 401 adopts a three-layer rotational structure, including three degrees of freedom rotational structures: twisting rotation around the Z-axis, bending rotation around the X-axis, and lateral rotation around the Y-axis, adapting to the multi-angle adjustment needs of the torso during climbing. Vertical rotation around the Z-axis is used to achieve twisting rotation via a thrust bearing, adapting to the need for left-right torso posture adjustment during climbing; lateral rotation around the X-axis is used to achieve bending rotation via a radial bearing, facilitating bending over to grip the ladder below; and forward-backward rotation around the Y-axis is used to achieve lateral rotation via a joint bearing, adapting to the action of sideways movement to avoid the internal structure of the tower.

[0032] Both the upper limb binding 304 and the lower limb binding 407 of this application are adjustable straps, which adopt a composite structure of nylon webbing and breathable sponge. They are fixed by Velcro or quick-release buckles to adapt to limbs of different thicknesses and avoid restricting the natural movement of the arms.

[0033] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model 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 or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. An auxiliary mechanical exoskeleton device for climbing wind turbine towers, characterized in that, include: Safety module (100) includes a safety rope (102), a safety buckle (101) and a carrying system (103). One end of the safety rope (102) is fixed to the carrying system (103), and the other end is fixed to the climbing structure of the wind turbine tower through a detachable safety buckle (101). The main drive module (200) includes a main control unit (201), a battery pack (202) and a back support (203). The main control unit (201) and the battery pack (202) are fixed to the shoulder strap system (103) via the back support (203). The upper limb assist module (300) is symmetrically arranged on the wearer's arms and includes an upper arm link (302) adapted to the human upper arm, a forearm link (303) adapted to the human lower arm, an upper limb drive assembly (301) that drives the two to swing relative to each other, and an upper limb binding piece (304) for fixing the arms. The lower limb assist module (400) is symmetrically arranged on the wearer's legs and includes a thigh link (402) adapted to the human thigh, a lower leg link (406) adapted to the human calf, a lower limb drive assembly for driving the two to swing relative to each other, and a lower limb binding piece (407) for fixing the legs.

2. The auxiliary mechanical exoskeleton device for climbing wind turbine towers according to claim 1, characterized in that, The carrying system (103) includes a shoulder strap, a waist strap and a chest strap, and pressure sensors are provided on the inner side of the shoulder strap, waist strap and chest strap.

3. The auxiliary mechanical exoskeleton device for climbing wind turbine towers according to claim 1, characterized in that, The main control unit (201) integrates a posture sensor and a wireless communication module to collect the wearer's motion data in real time and control the upper limb assist module (300) and the lower limb assist module (400); the battery pack (202) is a rechargeable lithium battery and is detachably connected to the back support (203) to power the entire assist device; the back support (203) is made of carbon fiber and is bolted to the back strap system (103).

4. The auxiliary mechanical exoskeleton device for climbing wind turbine towers according to claim 1, characterized in that, The upper end of the upper arm link (302) is connected to the back support (203) via a rotating joint, and the lower end is connected to the upper end of the forearm link (303) via a rotating joint. The upper limb drive assembly (301) drives the upper arm link (302) and the forearm link (303) to cooperate to realize the climbing action.

5. The auxiliary mechanical exoskeleton device for climbing wind turbine towers according to claim 4, characterized in that, The upper limb drive assembly (301) includes an upper limb motor, a harmonic reducer, and a crank-connecting rod structure. The upper limb motor drives the crank-connecting rod structure through the harmonic reducer. The crank-connecting rod structure is eccentrically connected to the upper end of the forearm connecting rod (303), which can drive the forearm connecting rod (303) to rotate at a large angle relative to the upper arm connecting rod (302), adapting to the arm flexion and extension movements during climbing. An angle sensor is provided at the rotation joint of the upper arm connecting rod (302) and the forearm connecting rod (303) to provide real-time feedback of the joint position to the main control unit (201).

6. The auxiliary mechanical exoskeleton device for climbing wind turbine towers according to claim 1, characterized in that, The upper end of the thigh link (402) is connected to the back support (203) through the hip joint system (401), and the lower end is connected to the upper end of the calf link (406) through a revolute joint. A knee joint motor (405) of the lower limb drive assembly is provided at the knee joint where the calf link (406) and the thigh link (402) are connected. The knee joint motor (405) is electrically connected to the main control unit (201) and can independently drive the calf link (406) to move relative to the thigh link (402). The lower limb motor (404) of the lower limb drive assembly works in coordination with the knee joint motor (405) to drive the thigh link (402) and the calf link (406) to cooperate in realizing the stepping action during climbing.

7. The auxiliary mechanical exoskeleton device for climbing wind turbine towers according to claim 6, characterized in that, The lower limb drive assembly also includes a rotating wheel pair and a moving link (403). The rotating wheel pair is connected to the lower limb motor (404) for transmission. The upper end of the moving link (403) is eccentrically rotated with the rotating wheel pair, and the lower end is connected to the upper end of the lower leg link (406) through a rotating pair. The rotating pair of the thigh link (402) and the lower leg link (406) is provided with a limiting protrusion. The limiting protrusions abut against each other to limit excessive bending.

8. The auxiliary mechanical exoskeleton device for climbing wind turbine towers according to claim 6, characterized in that, The hip joint system (401) includes three degrees of freedom rotation structures: a twisting rotation about the vertical direction of the Z-axis, a bending rotation about the left and right direction of the X-axis, and a lateral rotation about the front and back direction of the Y-axis, which can adapt to the multi-angle adjustment needs of the torso during climbing.

9. An auxiliary mechanical exoskeleton device for climbing wind turbine towers according to any one of claims 1-8, characterized in that, Both the upper limb binding (304) and the lower limb binding (407) are adjustable straps with a breathable padding layer on the inside and Velcro or quick-release buckles on the straps for wearing and securing.

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