Method for mounting and use of a mounting adapter for mounting rotary blades

Description

[0001] The present invention relates to a method for mounting rotor blades on a wind turbine and the use of a mounting adapter for mounting rotor blades on a wind turbine.

[0002] To install a wind turbine, a crane with a suitable hook height is required to install the nacelle, generator, and rotor blades. As the hub height increases, the hook height (i.e., the maximum height of the hook) must also be increased. However, this is not always possible, as cranes with a suitable hook height are not readily available.

[0003] WO 2020 / 187959 A1 describes a method for assembling rotor blades of a wind turbine. The aim is to simplify the assembly of the rotor blades by intelligently rotating the rotor hub and, in particular, to reduce the crane height required for this purpose.

[0004] EP 2623768 A1 discloses a mounting adapter for mounting a rotor blade. The mounting adapter has a first adapter section for connecting a rotor blade and a second adapter section for connecting to a rotor blade connector.

[0005] EP 3 001 030 A1 shows a mounting adapter for mounting rotor blades with a first section for connecting to a blade adapter and a second section for connecting to a rotor blade.

[0006] It is an object of the present invention to provide a method for assembling rotor blades on a wind turbine that enables a simplified structure with larger hub heights. It is also an object of the present invention to enable a reduced hook height of a crane during the assembly of rotor blades of a wind turbine.

[0007] This object is achieved by the method for assembling rotor blades of a wind turbine according to claim 1 and the use of a mounting adapter according to claim 7.

[0008] According to one aspect of the present invention, a mounting adapter is used for mounting a rotor blade, which can be designed as a joint adapter. The adapter is provided on one of the three rotor blade connections on the hub during assembly. The adapter has a first and a second adapter section, each with a flange surface. The first adapter section can be mounted to a rotor blade connection by means of the first flange surface. The second adapter section can be mounted to the rotor blade by means of the second flange surface. The first and second adapter sections are pivotally connected to one another via a pivot axis. Thus, the angle between the first and second flange surfaces can be varied or adjusted. According to one aspect of the present invention, the mounting adapter has, for example, two operating positions with two different angles between the first and second flange surfaces.This can be achieved, for example, by using round slings of different lengths between the first and second adapter sections. The length of the round slings can limit the maximum distance between the first and second adapter sections, and thus the maximum angle between them. The round slings prevent the first and second adapter sections from opening further.

[0009] According to one aspect of the application, the first and second adapter sections each have two parallel struts connected to the flange surface. This allows for a weight-optimized mounting adapter that still has sufficient mechanical stability.

[0010] According to one aspect of the application, the first and / or second flange surface can be configured as a continuous plate or as a continuous sheet metal, or alternatively as at least two sheet metal sections, which can be provided in the region of the first and second ends of the first and second adapter sections. The flange surfaces serve to attach the mounting adapter to a rotor blade connection of the hub and to the rotor blade root during assembly of the rotor blades.

[0011] A hydraulic unit with an adjustable length can be provided between the first and second adapter sections. This allows an angle between the first and second adapter sections to be adjusted. The first and second adapter sections can be moved relative to one another using the hydraulic unit. The ends of the hydraulic unit can be attached to the first and second adapter sections, respectively, in order to adjust the angle between the first and second adapter sections. Optionally, the hydraulic unit can be designed to actuate the first or second adapter section without a rotor blade being attached to it.

[0012] The hydraulic unit can optionally be replaced by a telescopic unit with an electric motor to adjust the length of the telescopic unit.

[0013] According to one aspect of the present invention, a method for mounting rotor blades on a wind turbine is provided. The wind turbine has a hub with three rotor blade connections, each for receiving rotor blades. The wind turbine has a longitudinal tower axis. A mounting adapter, in particular a mounting adapter as described above, is mounted on one of the rotor blade connections. The hub is rotated so that one of the three rotor blade connections is in a 3 o'clock position or at an angle of 90° relative to the longitudinal tower axis. A first rotor blade is lifted and mounted on this rotor blade connection. The mounting adapter is in a first operating position with a first angle between the first and second flange surfaces. A second rotor blade is mounted on another of the three rotor blade connections. A third rotor blade is mounted on the second flange surface of the mounting adapter.The angle between the first and second flange surfaces of the mounting adapter is changed so that the mounting adapter is in a second operating position. The third rotor blade is removed. The mounting adapter is removed and the third rotor blade is reinstalled.

[0014] According to one aspect of the present invention, the hub is rotated so that the second flange surface is parallel to the rotation axis before the third rotor blade is mounted. The third rotor blade is mounted to the second flange surface. The hub is rotated clockwise. The operating position of the mounting adapter is changed. The hub is rotated clockwise by 30°. The third rotor blade is removed. The mounting adapter is removed, and the third rotor blade is reinstalled.

[0015] According to a further aspect of the present invention, the second rotor blade is mounted on a second flange surface of the mounting adapter, which is provided parallel to the tower's longitudinal axis. The operating position of the mounting adapter is changed, and the hub is rotated, for example, clockwise. The operating position of the mounting adapter is changed so that the first and second flange surfaces are arranged substantially parallel to one another and the third rotor blade is located on the second flange surface and is oriented substantially horizontally. The rotor blade is disassembled, the mounting adapter is disassembled, and the third rotor blade is reassembled.

[0016] According to a further aspect of the present invention, a method for mounting rotor blades on a wind turbine is provided. The wind turbine has a hub with three rotor blade connections, each for receiving rotor blades. The wind turbine further has a tower longitudinal axis. A first rotor blade is mounted on a first rotor blade connection, which is located in particular at a 3 o'clock position. The hub is rotated by 30°. A second rotor blade is mounted on the third rotor blade connection, which is located in particular at an 8 o'clock position. A mounting adapter as described above is attached to a third rotor blade connection. The adapter section is unfolded to a desired angle, and the third rotor blade is mounted, with the unfolded adapter section in a 3 o'clock position. The rotor is rotated by 30°.The third rotor blade is raised, and the angle between the first and second adapter sections is shortened. The rotor is rotated by 30°. The third rotor blade is removed, the mounting adapter is removed, and the third rotor blade is reinstalled.

[0017] Further embodiments of the invention are the subject of the subclaims.

[0018] Advantages and embodiments of the invention are explained in more detail below with reference to the drawing. Fig. 1 shows a wind turbine according to one aspect of the invention, Fig. 2A each shows a view of a mounting adapter for mounting up to 2C rotor blades of a wind turbine according to a first embodiment, Fig. 3A shows various steps for mounting rotor blades of a up to 3P wind turbine according to the second embodiment, and Fig. 4A each shows a view of a mounting adapter according to a first to 4X third embodiment.

[0019] According to the invention, a tower longitudinal axis 102a can represent 0° or a 12 o'clock position. The positions of rotor blade connections of the wind turbines 100 can thus be assigned to an angle (0° to 360°) or a "time" (12 o'clock to 11 o'clock).

[0020] Fig. 1 shows a schematic representation of a wind turbine 100 .

[0021] The wind turbine 100 has a tower 102 and a nacelle 104 on the tower 102. An aerodynamic rotor 106 with three rotor blades 200 and a spinner 110 is provided on the nacelle 104. During operation of the wind turbine 100, the aerodynamic rotor 106 is set in rotation by the wind and thus also rotates a rotor 106 or rotor of a generator, which is directly or indirectly coupled to the aerodynamic rotor 106. The electric generator is arranged in the nacelle 104 and generates electrical energy. The pitch angles of the rotor blades 200 can be changed by pitch motors at the rotor blade roots of the respective rotor blades 200. The rotor blades 200 can be designed as one-piece or multi-piece.

[0022] According to the invention, the positions of the aerodynamic rotor 106 and the rotor blade connections 121, 122, 123 can be described using a clock face or using angle specifications. 0° corresponds to a 12 o'clock position and can be determined, for example, by a tower longitudinal axis 102a. 90° corresponds to a 3 o'clock position, 180° corresponds to a 6 o'clock position, and 270° corresponds to a 9 o'clock position.

[0023] Fig. 2A bis 2C Each shows a view of a mounting adapter for mounting rotor blades 200 of a wind turbine 100 according to a first exemplary embodiment. An adapter or a mounting adapter 300 according to the first exemplary embodiment has a first and a second adapter section 310, 320, which are designed to be pivotable relative to one another, ie, the angle α between the first and second adapter sections 310, 320 can be changed.

[0024] The first adapter section 310 has a first flange surface 311 and optionally two first struts 312. The two first struts 312 each have a first and second end 313, 314. The second adapter section 320 has a second flange surface 321 and optionally two second struts 322 connected to the second flange surface 321. The two second struts 322 each have a first and second end 323, 324.

[0025] The first and second flange surfaces 311, 312 can each be designed as a continuous plate or as two sheet metal sections that are connected to the two first or two second struts.

[0026] The first ends 313, 323 of the first and second struts 312, 322 are pivotally connected to one another about a pivot axis S.

[0027] Between the second ends 314, 324 of the first and second adapter sections 310, 320, two round slings 340, each with a first and second end 341, 342, can be provided.

[0028] The lengths of the round slings 340 determine the maximum angle between the first and second adapter sections 310,320.

[0029] Fig. 3A bis 3P show various steps for assembling rotor blades 200 of a wind turbine 100 according to the first embodiment. In the first step (see Fig. 3A ), a hub 120 of the wind turbine 100 with three rotor blade connections 121, 122, 123 is mounted by means of a crane hook 410 and a sling or a rope 420. In this case, a mounting adapter 300 according to the invention can already be mounted on a rotor blade connection 121, 122, 123. Alternatively, the mounting adapter 300 can be pulled upwards separately by means of the crane hook 410 and mounted on a rotor blade connection 121, 122, 123 (in particular on the first rotor blade connection 121). Subsequently (see Fig. 3B ), the hub 120 can be rotated counterclockwise so that the second rotor blade connection 122 is in a 3 o'clock position relative to a tower longitudinal axis 102a.

[0030] Afterwards (see Fig. 3C ) the mounting adapter 300 is unfolded. In particular, an adapter section is unfolded. This adapter section is held by the round slings 340 so that it cannot unfold any further. The first blade 200 is mounted, for example, by means of a blade cross member 500 on the second rotor blade connection 122 (which is located in the 3 o'clock position) (see Fig. 3D ). Here, the rotor blade 200 is mounted essentially horizontally. In the next step (see Fig. 3E ), the second rotor blade 200 is mounted on the mounting adapter 300, which is mounted on the first rotor blade connection 121. The second rotor blade 200 can be lifted essentially horizontally. The second rotor blade 200 is mounted on the first rotor blade connection 121 by means of the mounting adapter 300. The adapter section, to which the rotor blade 200 is attached, is located in a 9 o'clock position. The second rotor blade 200 can be mounted using a lifting cross member 500. In the next step (see Fig. 3F ) the second rotor blade 200 is lowered by 30° so that the second rotor blade 200 is in an 8 o'clock position.

[0031] In the next step according to Fig. 3G The second rotor blade 200 is raised by 30°, and the angle between the first and second adapter sections 310, 320 is reduced to 30°, for example. This places the second rotor blade in the 9 o'clock position.

[0032] In the next step according to Fig. 3H the second rotor blade is lowered by 30° and in step according to Fig. 3I the second rotor blade is raised again by 30° and the angle between the adapter sections of the mounting adapter 300 is reduced to zero.

[0033] In the next step according to Fig. 3J The second rotor blade is lowered again by 30° and in the following step according to Fig. 3K the second rotor blade 200 is removed from the mounting adapter. In the next step, the nacelle 150 is rotated by 180°, ie the azimuth angle is adjusted by 180°. In the next step according to Fig. 3M the second rotor blade 200 is mounted on the third rotor blade connection 123. Subsequently, according to Fig. 3N the machine house 150 is rotated by 90°, ie the azimuth angle is adjusted by 90°. According to Fig. 3O The mounting adapter is then removed using the crane hook 410. The second rotor blade connection 122 is then in an 8 o'clock position. The third rotor blade can then be Fig. 3P be mounted on the second rotor blade connection 122.

[0034] According to one aspect of the present invention, the rotor blades 200 of a wind turbine 100 are mounted using a mounting adapter 300, which is mounted on a rotor blade connection 121, 122, 123. The mounting adapter 300 has first and second flange surfaces 311, 321, which are arranged at an angle to one another. Optionally, the angle between the first and second flange surfaces 311, 321 can be adjusted. This can be achieved by using round slings 340 of different lengths. This allows, for example, an angle of 90° or 30° to be set.

[0035] According to one aspect of the present invention, the mounting adapter 300 can be mounted on a rotor blade connection 121, 122, 123 of the hub 120 of the wind turbine 100 before the hub 120 is mounted. In particular, the hub 120 can be lifted by means of the mounting arm 330 and mounted on or in the nacelle 104.

[0036] Fig. 4A bis 4X each show a view of a mounting adapter according to a third embodiment during the assembly of the rotor blades 200 of a wind turbine 100. In Fig. 4A A starting position is shown. Here, both the generator 130 and the rotor hub 120 are already mounted. Optionally, the mounting adapter 300 can be hoisted together with the generator 130 or a part of the generator 130 using the crane. Alternatively, the mounting adapter 300 can also be subsequently mounted on the generator or the generator housing 130 using the crane.

[0037] In Fig. 4B A first rotor blade 200 is mounted on a first rotor blade connection 121. The first rotor blade connection 121 or the first mounted rotor blade 200 can be in a 4 o'clock position. Fig. 4C The next step of the assembly process is shown. Here, the first rotor blade 200 is lowered by 30°, for example, using a blade cross member 500. A second rotor blade 200 is mounted, for example, using the blade cross member 500, on a third rotor blade connection 123 (see Fig. 4D ). The third rotor blade connection 123 or the second rotor blade 200 can be located in the 8 o'clock position.

[0038] In the Figuren 4E bis 4J shows how the mounting adapter 300 according to the third embodiment is mounted on the second rotor blade connection 122. As in Fig. 4E As shown, the mounting adapter 300 is located on the generator or a generator housing 130. The mounting adapter 300 is rotated ( Fig. 4E ) and tilted by 90° towards the hub 120 ( Fig. 4F ). A second adapter section 320 is mounted to the second rotor blade connection 122 ( Fig. 4G ). The second adapter section 320 is released from the generator housing 130 and can be held at a desired angle to the first adapter section 310, for example by means of the hydraulic unit 330. Subsequently, as in Fig. 4I shown - two round slings 340 are attached to the second ends of the first and second adapter sections 310, 320. In Fig. 4J It shows how the mounting adapter is rotated by 90° using the second rotor blade connection 122. This makes the mounting adapter 300 suitable for accommodating the third rotor blade and brings it into the correct position.

[0039] According to Fig. 4K The rotor hub 120 is rotated, for example, by 30°, so that the second adapter section 320 is substantially parallel to the tower's longitudinal axis of rotation. This can be achieved, for example, by pulling the second rotor blade upwards by 30°. Fig. 4L shows how the third rotor blade 200 is mounted on the first adapter section 310 of the mounting adapter 300, for example by means of a rotor blade cross member 500. In Fig. 4M the third rotor blade is lowered by 30° and Fig. 4N The rotor blade is raised again by 30° and shorter round sling joints are attached to the second ends of the first and second adapter sections 310, 320. This reduces the angle between the first and second adapter sections 310, 320. Subsequently, according to Fig. 4O the third rotor blade 200 is lowered again by 30°. According to Fig. 4P the third rotor blade 200 can be removed from the second adapter section 320 of the mounting adapter.

[0040] In the steps according to Fig. 4Q bis 4U The steps for disassembling the mounting adapter 300 from the third rotor blade connection 123 are shown. Here, the round slings 340 can be released, and the second adapter section 320 can be extended to an angle of 180° using the hydraulic unit 330. Subsequently, the second rotor blade connection 122 is rotated by 90°, and the second end of the second adapter section 320 can be fastened to the generator housing 130. Subsequently, the first adapter section 310 can be released from the third rotor blade connection 123, and the angle between the first and second adapter sections can be reduced to zero using the hydraulic unit 330, so that the first adapter section 310 is folded upward.

[0041] In Fig. 4V The rotor blade can then be mounted directly on the third rotor blade connection 123.

[0042] In the Figuren 4W and 4X The mounting adapter can then be brought into a transport position and lowered using the crane.

[0043] According to one aspect of the present invention, the crane used to assemble the nacelle 104 can also be used to assemble the rotor blades 200. Thus, it is sufficient if one crane is present at the construction site.

[0044] According to the invention, the rotor blades 200 can be mounted either horizontally or at 30°.

[0045] According to one aspect of the present application, the mounting adapter has a first and a second adapter section, which are configured to be pivotable or rotatable relative to one another. The angle between the first and second adapter sections can be, for example, 30° or 60°. Alternatively, the mounting adapter can have an operating position in which the first and second adapter sections are configured parallel to one another.

[0046] According to one aspect of the present invention, the method described above for assembling rotor blades 200 of a wind turbine can be applied in particular with a tower height of > 160 m. Bezugszeichenliste

[0047] 100 Wind turbine 102 Tower 102a Tower longitudinal axis 104 Nacelle 106 Rotor 110 Spinner 120 Hub 121 Rotor blade connection 122 Rotor blade connection 123 Rotor blade connection 130 Generator housing 150 Machine house 200 Rotor blades 300 Mounting adapter 310 First adapter section 311 First flange surface 312 First struts 313 First end 314 Second end 320 Second adapter section 321 Second flange surface 322 Second struts 323 First end 324 Second end 325 Cross brace 330 Telescopic unit / hydraulic unit 331 First end 332 Second end 340 Round sling 341 First end 342 Second end 410 Crane hook 420Cable 500Blade traverse SSwivel axis

Claims

1. Method for mounting rotor blades (200) on a wind turbine (100), wherein the wind turbine (100) has a hub (120) with three rotor blade connections (121 - 123) for receiving rotor blades (200) and a longitudinal tower axis (102a), wherein a mounting adapter (300) is used for mounting the rotor blades, wherein the mounting adapter (300) comprises a first adapter portion (310) having a first flange surface (311) suitable for being attached to a rotor blade (200) of the wind turbine (100) , and a second adapter portion (320) having a second flange surface (321) suitable for being attached to a rotor blade connection (121, 122, 123) of a wind turbine (100), characterised in that the first and second adapter portions (310, 320) are pivotable relative to one another about a pivot axis (S), wherein an angle (α), which is spanned by the first and second flange surfaces (311, 321), is variable in order to ensure at least a first and second operating position of the mounting adapter (300) with different angles (α), wherein the method comprises the following steps: Mounting the mounting adapter (300) to one of the three rotor blade connections (121 - 123), Rotating the hub (120) so that one of the three rotor blade connections (121 - 123) is in a 3 o'clock position or at an angle of 90° relative to the longitudinal axis (102a) of the tower, Lifting and mounting a first rotor blade (200) on this rotor blade connection (121, 122, 123), wherein the mounting adapter (300) is located in a first operating position with a first angle (α) between the first and second flange surfaces (311, 321), Mounting a second rotor blade (200) to a further one of the three rotor blade connections (121 - 123), Mounting a third rotor blade on the second flange surface (322) of the mounting adapter (300), Changing the angle (α) between the first and second flange surfaces (311, 321) so that the mounting adapter (300) is in a second operating position, Dismantling the third rotor blade (200), Dismantling the mounting adapter (300), and Mounting the third rotor blade (200).

2. The method according to claim 1, further comprising the steps of: Rotating the hub (120) so that the second flange surface (322) is parallel to the longitudinal tower axis (102a), before mounting the third rotor blade (200), Mounting the third rotor blade (200) on the second flange surface (322), Turning the hub (120) clockwise, Changing the operating position of the mounting adapter (300), Turning the hub (120) clockwise by 30°, Dismantling the third rotor blade (200), Dismantling the mounting adapter (300), and Mounting the third rotor blade (200).

3. Method according to claim 1, further comprising the steps of: Mounting the second rotor blade (200) on a second flange surface (321) of the mounting adapter (300), which is provided parallel to the longitudinal tower axis (102a), Changing the operating position of the mounting adapter (300), Turning the hub (120) clockwise, Changing the operating position of the mounting adapter (300) so that the first and second flange surfaces (311, 321) are arranged substantially parallel and the third rotor blade (200) is attached to the second flange surface (321) and is arranged substantially horizontally, Dismantling the third rotor blade (200), Dismantling the mounting adapter (300), and Mounting the third rotor blade (200).

4. The method according to claim 1, wherein the first adapter portion (310) has two first struts (312), which are each connected to the first flange surface (311), the second adapter portion (320) comprises two second struts (322, 323), which are each connected to the second flange surface (321).

5. The method according to claim 1 or 2, further comprising a telescopic unit (330) with variable length, which is connected to both the first and second adapter portions (310, 320) and can adjust the angle between the first and second adapter portions by changing its length.

6. The method according to any one of claims 1 to 3, wherein the first and second flange surfaces (311, 321) each comprise two sheet metal portions which are provided in the region of the first and second ends of the adapter portions (310, 320), respectively.

7. Use of a mounting adapter for mounting rotor blades (200) on a wind turbine (100), wherein the wind turbine (100) has a hub (120) with three rotor blade connections (121 - 123) for receiving rotor blades (200) and a longitudinal tower axis (102a), wherein a first rotor blade (200) is mounted on a first rotor blade connection (121), which is located in particular at a 3 o'clock position, wherein the hub (120) is rotated by 30°, wherein the second rotor blade (200) is mounted on the third rotor blade connection (123), which is located in particular at the 8 o'clock position, wherein a mounting adapter (300) is attached to a third rotor blade connection (123), wherein the mounting adapter (300) comprises a first adapter portion (310) having a first flange surface (311) adapted to attach a rotor blade (200) of the wind turbine (100) thereto, and a second adapter portion (320) having a second flange surface (321) adapted to be attached to a rotor blade connection (121, 122, 123) of a wind turbine (100), wherein the first and second adapter portions (310, 320) are pivotable relative to each other about a pivot axis (S), wherein an angle (α), which is spanned by the first and second flange surfaces (311, 321), is variable in order to ensure at least a first and second operating position of the mounting adapter (300) with different angles (α), wherein an adapter portion is unfolded by a desired angle, wherein the third rotor blade (200) is mounted with the unfolded adapter portion in a 3 o'clock position, wherein the rotor (106) is rotated by 30°, wherein the third rotor blade (200) is pulled up and wherein the distance angle between the first and second adapter portions is shortened, wherein the rotor (106) is rotated by 30°, wherein the third rotor blade (200) is dismantled, wherein the mounting adapter (300) is dismantled and wherein the third rotor blade (200) is mounted.