Apparatus and method for vertically lifting and installing variable-diameter unbalanced-load device

Abstract

An apparatus for vertically lifting and installing a variable-diameter unbalanced-load device, the apparatus comprising: a track (10) and a track-type transport device (20) mounted on the track (10); and further comprising: a lifting frame (30), comprising a plurality of support columns (31) and, connected at the upper portions of the support columns, a mounting rod (32), wherein the lifting frame (30) is disposed transversely above the track (10); and further comprising: a plurality of groups of lifting centralized-control apparatuses (40) mounted at different orientations on the outer side of the lifting frame (30), wherein the lifting centralized-control apparatuses (40) are used, after the track-type transport device (20) transports a variable-diameter unbalanced-load device into the lifting frame (30), for stably lifting the variable-diameter unbalanced-load device to a mounting position. Additionally disclosed is a method for vertically lifting and installing a variable-diameter unbalanced-load device. The apparatus and the method are highly versatile, reduce installation difficulty, are successful at reducing risks such as severe weather, have a high safety coefficient, can adapt to the requirements of complex lifting working conditions such as variable-diameter tower sections and unbalanced loads, occupy a small amount of space, involve little auxiliary installation work, and are relatively economical in installation.

Description

A vertical lifting and installation device and method for variable diameter unbalanced load equipment Technical Field

[0001] The present invention relates to the technical field of engineering construction, and in particular to a device and method for vertically lifting and installing variable-diameter unbalanced load equipment. Background Art

[0002] The installation of high-tower equipment, such as wind turbines, has always been a challenge. Traditionally, large crawler cranes have been used, requiring the use of other small and medium-sized lifting equipment. This has resulted in low installation efficiency and poor economic efficiency. With the continuous advancement of wind turbine technology, wind turbine towers are becoming taller and taller. Simply using larger crawler cranes to increase the lifting height and weight will become increasingly difficult, and economic efficiency will also decline. For these reasons, a more efficient, economical, and versatile installation or removal device and method is needed.

[0003] However, installing wind turbines and other equipment using a lifting method presents two significant difficulties: First, wind turbine towers are variable-diameter towers, typically tapering at the top and widening at the bottom, making it difficult to arrange the lifting equipment; second, the turbine's upper machine room, generator, blades, and other equipment cannot achieve complete torque balance between the front and rear, which can introduce the risk of unbalanced loading during the lifting process. These are key issues that must be addressed when installing wind turbines using a vertical lifting method. This patent effectively addresses these issues through innovative and rational design.

[0004] Summary of the Invention

[0005] In view of the deficiencies in the prior art, the present invention provides a vertical lifting and installation device for variable-diameter unbalanced load equipment to solve the above problems.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is: a vertical lifting and installation device for variable-diameter unbalanced load equipment, which includes a track and a track-type transfer device installed on the track; a lifting frame, the lifting frame is a truss structure, including multiple pillars and installation rods connected to the upper part of the pillars, and the lifting frame spans above the track; it also includes multiple groups of lifting control devices installed at different positions on the outside of the lifting frame, and the lifting control device is used to smoothly lift the variable-diameter unbalanced load equipment to the installation station after the track-type transfer device transfers the variable-diameter unbalanced load equipment to the lifting frame.

[0007] In a preferred solution, the rail-type transfer device includes a transfer frame, the bottom of which is equipped with rollers adapted to the rail, and the top is provided with a plurality of supporting cylinders for fixing variable-diameter unbalanced load-type equipment, the piston rods of the supporting cylinders are connected to support pads, a transfer frame hydraulic station and a transfer frame electric control box are provided on the transfer frame, and the transfer frame hydraulic station is electrically connected to the transfer frame electric control box; and a rail clamp is also included.

[0008] In the preferred solution, each group of the lifting control device includes three continuous stretching hydraulic hoists, a lifting hydraulic station that provides power for the three continuous stretching hydraulic hoists, and a lifting electrical control box that controls the lifting hydraulic station. A plurality of fixed pulleys are arranged on the mounting rod, and the fixed pulleys are used for allowing the steel strand group of the continuous stretching hydraulic hoist to pass through and lift variable-diameter unbalanced load equipment.

[0009] In a preferred embodiment, the continuous stretching hydraulic hoist includes a support base and a continuous stretching hydraulic jack hinged on the support base, and a steel strand group reel arranged behind the continuous stretching hydraulic jack. The continuous stretching hydraulic jack is connected to the lifting hydraulic station, and the motor of the steel strand group reel is connected to the lifting electrical control box; in each group of lifting control devices, one of the continuous stretching hydraulic hoists is connected to the wind rope, and the other two continuous stretching hydraulic hoists are connected to the steel strand group, and the steel strand group of each continuous stretching hydraulic jack is connected to an anchor assembly.

[0010] In a preferred embodiment, the lifting frame includes three or four columns, which are installed on both sides of the track, and the height of the mounting rod is greater than the height of the track-type transfer device; the mounting rod is circular, and multiple fixed pulleys are evenly distributed on the mounting rod at equal angles.

[0011] In a preferred embodiment, the anchor assembly includes two groups of anchors connected to the steel strand group in sequence; the anchor includes a cylindrical shell, and also includes multiple groups of anchor seats evenly distributed in an annular shape in the shell, the anchor seats are fixedly connected to the shell, and each group of anchor seats is correspondingly provided with an anchor plate and a locking plate; the connection method between the steel strand group and the anchor assembly is: after all the steel strands pass through the anchor at the front end, any two adjacent steel strands are respectively locked on different anchors.

[0012] The present invention also provides a method for vertically lifting and installing variable-diameter unbalanced load equipment, comprising the following steps:

[0013] S1 Auxiliary work before lifting: including foundation construction, installation of fan foundation section, installation of lifting frame, installation and commissioning of lifting centralized control device;

[0014] S2 wind turbine lifting assembly: Install lifting points at equal angles in the circumferential direction of each tower section of the wind turbine tower, assemble the third tower section, the second tower section and the first tower section of the wind turbine tower, and the wind turbine room, generator and blades on the top of the first tower section, connect the steel strand group of one of the continuous tensioning hydraulic hoists in each set of lifting centralized control devices to the third tower section, connect the steel strand group of another continuous tensioning hydraulic hoist in each set of lifting centralized control devices to the second tower section, connect the guy rope of the last continuous tensioning hydraulic hoist in each set of lifting centralized control devices to the first tower section, start the lifting centralized control device to lift the installed equipment as a whole to more than the height of one tower section, so that the new tower section can be positioned and installed. The connection method between the steel strand group and the tower section is: after all the steel strands pass through the anchor at the front end, any two adjacent steel strands are locked on different anchors respectively;

[0015] S3 Transfer and put the new tower section into place: according to the number of transfer racks selected, hoist one tower section for each transfer rack, and start the support cylinders respectively to make the support tiles press the tower section tightly. Then transport the tower sections into the lifting rack in the order of assembly and proceed to the next step.

[0016] S4 Connecting and lifting the new tower section: Loosen the connection between the steel strand group connected to the second tower section and the lifting point of the second tower section, and install it on the lifting point of the new tower section. After all the steel strand groups are evenly stressed, loosen the support tiles and the tower section, slowly lift the new tower section and connect the top of the new tower section with the bottom of the third tower section; then control the lifting centralized control device in a coordinated manner, steadily lift the installed tower section and the equipment as a whole by one tower section height, move another transfer frame equipped with a tower section to the bottom of the installed tower section, lock the rail clamp to the track, and repeat the above operation to complete the connection of all wind turbine towers;

[0017] S5 fan is connected to the foundation section: After the tower section connected to the foundation section is connected to the other tower sections of the fan tower, the installed fan is lifted to the height of one tower section, the tower section transfer frame is moved out of the lifting frame, and then the lifting centralized control device is controlled in a linked manner to slowly lower the installed tower section of the fan and the entire equipment, and the fan tower is connected to the foundation section;

[0018] S6: Fan confirmation debugging: debug all parts and equipment of the fan;

[0019] S7: Removal of auxiliary devices: Remove the lifting frame, lifting centralized control device and transfer frame, and the installation is complete.

[0020] In the preferred solution, S2 is carried out by hoisting with a mobile crane, which specifically includes the following steps:

[0021] S2-1: Use a mobile crane to lift the third tower section onto the foundation section. Connect the steel strands of one of the continuous tension hydraulic hoists in each lifting control unit to the third tower section. Adjust the third tower section to be vertical and tighten the steel strands to bear the load.

[0022] S2-2: Use a mobile crane to lift the second tower section to the top of the third tower section, connect and secure the second tower section to the third tower section coaxially, and connect the steel strand set of the other continuous tension hydraulic hoist in each lifting centralized control device to the second tower section;

[0023] S2-3 activates a mobile crane to lift the first tower section to the top of the second tower section, and fixes the first tower section and the second tower section coaxially, and connects the guy rope of the last continuous tension hydraulic hoist in each set of lifting control devices to the first tower section.

[0024] In a preferred solution, S2 is performed by hoisting using the installation device of the present invention, specifically comprising the following steps:

[0025] S2-1 first uses the transfer frame to transfer the second tower section to the installation position in the lifting frame, drives a continuous tension hydraulic hoist in each lifting control device, connects its anchors to the lifting points of this tower section, tightens them, and then lifts the second tower section to a clear height higher than that of the first tower section;

[0026] S2-2 then uses the transfer frame to transfer the third tower section to the installation position in the lifting frame, drives the other continuous tension hydraulic hoist in each lifting control device, connects and tightens its anchors to the lifting points of this tower section, slowly lifts the third tower section to a position that fits with the second tower section, and connects and tightens the second tower section to the third tower section;

[0027] S2-3 Use a crane to lift the first tower section to the top of the second tower section. Without releasing the hook of the crane, connect and tighten the first tower section to the second tower section. Then, connect the guy rope of the last continuous tension hydraulic hoist in each lifting control device group to the first tower section and tighten it.

[0028] S2-4 hoist and adjust the wind turbine room, generator and blades in an overall vertical and stable state. After installation, lock the rotatable or movable parts.

[0029] In the preferred solution, after S2 is completed, that is, after the installation of the main functional components of the wind turbine is completed, functional debugging is carried out first, and after the debugging is qualified, the subsequent tower sections are lifted and connected.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] 1. Economical installation. This device and method eliminates the need for expensive large crawler cranes. The required installation equipment is universal, resulting in economical installation. This device is particularly advantageous for installing taller and heavier wind turbines or tower-type equipment.

[0032] 2. It occupies less space and requires less auxiliary installation work. The large crawler crane hoisting method requires a larger space for crawler crane installation and hoisting work, especially the large crawler crane boom assembly, and the tower section turning and unloading by cooperation with other cranes also require a larger space. Since the hoisting weight of all components of this device and method is relatively small, it can be completed with only an ordinary wheeled crane, and does not require a large crawler crane boom assembly site. The multi-transfer rack can store part of the wind turbine tower section while installing, further reducing the requirements for the site, and also greatly reducing the auxiliary work such as large crawler crane installation and boom assembly. It has great advantages for installing wind turbines in mountainous areas, greatly reducing the cost investment and site construction period.

[0033] 3. It can adapt to the requirements of complex lifting conditions such as variable diameter tower sections and unbalanced loads. Since the diameter of each section of the wind turbine tower is different, this patent uses lifting steel strands to connect the lifting points so that they are not affected by changes in the diameter of the tower sections. The diameter change will only cause a slight change in the angle between the steel strands and the lifting points. Because the hydraulic steel strand lifting equipment has a large lifting capacity surplus, it can solve this problem very well. For the upper machine room, generator, blades and other equipment of the wind turbine, it is impossible to achieve complete torque balance between the front and rear parts, which brings the risk of overload during the lifting process. On the one hand, this patent adopts the method of vertical three-dimensional lifting of multiple anchor points of the lifting cylinder steel strand to enhance the stability and dynamic adjustment ability of the lifting process. On the other hand, by setting a group of multi-point wind-catching hydraulic steel strands, the overall verticality of the tower section can be automatically or manually adjusted at any time, effectively overcoming the interference of overload.

[0034] 4. Installation and preparation can be performed in parallel, resulting in high installation efficiency. This device and method can complete installation and tower section transfer preparation simultaneously and in parallel, greatly shortening preparation time, ensuring installation continuity, and reducing total installation time.

[0035] 5. Strong ability to resist risks such as severe weather and a high safety factor. The original super-large crawler crane lifting method is difficult to observe due to the limited vision of the crawler crane driver due to high-altitude operations. It is easy to become unstable and cause safety accidents and risks in severe weather conditions such as strong winds. Compared with the installation method of large crawler cranes, this device and method has a large hydraulic steel strand lifting capacity, strong correction and adjustment capabilities, and good synchronization of the hydraulic lifting device, which can reach the millimeter level. All dimensions of the lifting process are adjustable and under control. In the event of sudden strong winds, the steel strands can be quickly tightened and locked, with strong risk resistance and greatly improved safety, avoiding the problem of large crawler cranes being slow to drop the hook and easy to overturn when lifting at high altitude in strong winds.

[0036] 6. Reduce the difficulty of debugging and improve debugging efficiency. The device and method of this patent divide debugging into preliminary debugging and confirmatory debugging. Preliminary debugging is completed when the fan is at a low installation height, which facilitates fault handling and improves debugging efficiency. Confirmatory debugging is completed after the fan is hoisted. Before the fan is put into operation, only the final inspection and confirmation is carried out. Once all errors are correct, it can be put into normal operation, which greatly improves the debugging quality, increases safety, and shortens the construction period.

[0037] 7. High versatility. The core equipment of this patented system, the lifting frame and lifting control device, are easy to transfer, highly versatile, and simple to maintain. They can be used not only in wind turbine installation and other tower equipment installation, but also in a wide range of other engineering fields, with high utilization rate and good economic efficiency. Unlike the original installation method, the super-large crawler crane has poor versatility. For example, when used in applications with low lifting capacity, the installation and removal are difficult, which often outweighs the benefits. As a result, the super-large crawler crane has a low utilization rate, generally high maintenance costs, and often poor economic efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] FIG1 is a schematic structural diagram of a transfer rack according to the present invention.

[0039] FIG2 is a schematic structural diagram of the lifting frame of the present invention.

[0040] FIG3 is a schematic diagram of an installation state of S2 in the method of the present invention.

[0041] FIG4 is a schematic diagram of another installation state of S2 in the method of the present invention.

[0042] FIG5 is a schematic diagram of another installation state of S2 in the method of the present invention.

[0043] FIG6 is a schematic diagram of an installation state of S3 in the method of the present invention.

[0044] FIG7 is a schematic diagram of another installation state of S3 in the method of the present invention

[0045] FIG8 is a schematic diagram showing the connection state of the steel strand group and the tower section in the present invention.

[0046] FIG9 is a schematic structural diagram of the lifting centralized control device in the present invention.

[0047] FIG10 is a schematic structural diagram of the anchor in the present invention.

[0048] FIG11 is a schematic structural diagram of the rail clamp of the present invention.

[0049] In the above drawings: 10. Track; 20. Track-type transfer device; 21. Transfer frame; 22. Roller; 23. Support cylinder; 24. Support tile; 25. Transfer frame hydraulic station; 26. Transfer frame electric control box; 27. Rail clamp; 30. Lifting frame; 31. Pillar; 32. Mounting rod; 33. Fixed pulley; 40. Lifting control device; 41. Continuous tensioning hydraulic hoist; 411. Support base; 412. Continuous tensioning hydraulic jack; 413. Steel strand assembly drum; 42. Lifting hydraulic station; 43. Lifting electric control box; 44. Guy rope; 45. Steel strand assembly; 50. Anchor; 51. Shell; 52. Anchor seat; 53. Anchor plate; 54. Locking plate. DETAILED DESCRIPTION

[0050] In order to enable those skilled in the art to better understand the technical solution of the present invention, the preferred embodiments of the present invention are described below in conjunction with specific embodiments. However, it should be understood that the drawings are only for illustrative purposes and cannot be understood as limiting this patent; in order to better illustrate this embodiment, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of the actual product; for those skilled in the art, it is understandable that some well-known structures and their descriptions in the drawings may be omitted; the positional relationships described in the drawings are only for illustrative purposes and cannot be understood as limiting this patent.

[0051] As an embodiment of the present invention, referring to Figures 1 and 2, a vertical lifting and installation device for variable-diameter unbalanced load equipment is provided, which includes a track 10 and a track-type transfer device 20 installed on the track 10; a lifting frame 30, the lifting frame 30 is a truss structure, including three pillars 31 and installation rods 32 connected to the upper part of the pillars 31, and the lifting frame 30 spans above the track 10; and also includes multiple groups of lifting control devices 40 installed at different positions on the outside of the lifting frame 30. The lifting control device 40 is used to smoothly lift the variable-diameter unbalanced load equipment to the installation station after the track-type transfer device 20 transfers the variable-diameter unbalanced load equipment to the lifting frame 30. Among them, each group of the lifting control device 40 includes three continuous stretching hydraulic hoists 41, a lifting hydraulic station 42 that provides power for the three continuous stretching hydraulic hoists 41, and a lifting electrical control box 43 that controls the lifting hydraulic station 42. A plurality of fixed pulleys 33 are arranged on the mounting rod 32. The fixed pulley 33 is used for allowing the steel strand group of the continuous stretching hydraulic hoist 41 to pass through and lift variable diameter unbalanced load equipment. In this embodiment, the columns 31 are installed on both sides of the track 10, and the height of the mounting rod 32 is greater than the height of the track-type transfer device 20; the mounting rod is circular, and can also be square or other cross-sectional forms, and a plurality of fixed pulleys 33 are evenly distributed on the mounting rod 32 at equal angles; the fixed pulley 33 preferably adopts an angle-adjustable form to adapt to the angle change of the steel strand.

[0052] The number and structural form of the lifting frame pillars are matched with each other based on comprehensive considerations such as the overall weight of the lifting wind turbine, the foundation geology and the bearing capacity design of the embedded parts, and the capacity of the lifting control device. To ensure the passage of the transfer frame, the lower part of the lifting frame is at least slightly higher than the height of one tower section, and no horizontal or diagonal braces that affect the passage of the transfer frame are set in the direction of passage. The lifting frame structure preferably adopts pins and bolts for easy installation and reuse. Walkways, ladders and operating platforms are arranged on the lifting frame structure as needed to ensure the safety and convenience of operation; the lifting frame is reliably installed on a solid foundation through a pre-buried foundation. The lifting frame, lifting control device, track and foundation section are preferably arranged and constructed together to form an overall force and simplify the structure.

[0053] In this embodiment, the rail-type transfer device 20 includes a transfer frame 21, and a roller 22 adapted to the rail 10 is installed at the bottom of the transfer frame 21, and a plurality of support cylinders 23 for fixing variable-diameter unbalanced load equipment are arranged on the top. The piston rod of the support cylinder 23 is connected to the support shoe 24, and a transfer frame hydraulic station 25 and a transfer frame electric control box 26 are arranged on the transfer frame 21. The transfer frame hydraulic station 25 is electrically connected to the transfer frame electric control 26; it also includes a rail clamp 27. After being transferred to the predetermined position, in order to facilitate the lifting operation, the rail clamp 27 is used to firmly lock with the rail 10 to prevent the rail-type transfer device 20 from being displaced and causing safety hazards. For the specific structure of the rail clamp 27, please refer to Figure 11.

[0054] In this embodiment, referring to Figure 9, the continuous stretching hydraulic hoist 41 includes a support base 411 and a continuous stretching hydraulic jack 412 hinged on the support base 411, and a steel strand group reel 413 arranged behind the continuous stretching hydraulic jack 412, the continuous stretching hydraulic jack 412 is connected to the lifting hydraulic station 42, and the motor of the steel strand group reel 413 is connected to the lifting electric control box 43; in each group of lifting control devices, one of the continuous stretching hydraulic hoists is connected to the wind rope 44, and the other two continuous stretching hydraulic hoists are connected to the steel strand group 45, and the steel strand group of each continuous stretching hydraulic jack is connected to an anchoring assembly.

[0055] During implementation, a centralized lifting control device can be installed at each leg of the lifting frame, or a single lifting control device can be installed across several legs. Whether the centralized lifting control devices are located separately or together, the lifting electrical control cabinet and lifting hydraulic station, which serve as the drive and control devices for the centralized lifting control devices, can be located separately or together. Even if located separately, signal connections must be established via control lines or a network to facilitate coordinated control during the lifting and lowering of the wind turbine tower sections. A standardized container or frame structure is preferred for improved versatility and ease of layout and transport. The container or frame can be single- or multi-layered, securely connected to pre-set ground anchor points or lifting frame connection points to withstand the tensile forces during the wind turbine lifting process. The centralized lifting control device can utilize steel strands or wire ropes depending on the application. A reel is used to store the steel strands or wire ropes, and a continuous-tension hydraulic jack is used to pull the steel strands or wire ropes. Steel strands are preferred and, for ease of description, are referred to as steel strands below. A hinge or turntable is used to adjust the direction and angle of the hydraulic cylinder in accordance with the angle of the steel strands, depending on the height of the lifting tower section.

[0056] In the above embodiment, referring to Figure 10, the anchoring assembly includes two groups of anchors 50 connected to the steel strand group in sequence; the anchor 50 includes a cylindrical shell 51, and also includes a plurality of groups of anchor seats 52 evenly distributed in a ring shape in the shell, the anchor seats 52 are fixedly connected to the shell 51, and each group of anchor seats 52 is correspondingly provided with an anchor plate 53 and a locking plate 54; the connection method of the steel strand group 45 and the anchoring assembly is: after all the steel strands pass through the anchor at the front end, any two adjacent steel strands are respectively locked on different anchors.

[0057] When connecting the steel strand group to the wind turbine tower section, first connect the anchor at the tail end to the lifting point on the tower section, then adjust the relative distance between the anchor at the front end and the anchor at the tail end to adapt to the lifting point distance on the wind turbine tower, and then hinge the front end anchor to another lifting point on the wind turbine tower with a pin. During the lifting process, the anchor at the front end can be rotated to a certain angle to adapt to the force under different lifting conditions to achieve stability.

[0058] In this embodiment, the number of lifting points on the tower also matches the number of anchors, and each set of continuous tension hydraulic jacks is provided with a steel strand tension detection device to synchronously detect and compare the tension of each steel strand. If a large deviation from the design value is found, an alarm will be immediately issued for inspection and troubleshooting.

[0059] The present invention takes the installation of a wind turbine tower as an example to introduce the installation method of the present invention. Referring to Figures 3 to 8, all installation work is completed according to the steps of auxiliary work before lifting, fan lifting and assembly, new tower section transfer section in place, new tower section connection and lifting, fan and foundation section connection, fan confirmatory debugging, and auxiliary device removal. For ease of understanding, the tower sections are named from high to low according to the fan, that is, the tower section where the blades are installed is the first tower section, and the second tower section, the third tower section, etc. are located downwards. In the drawings of the present invention, for ease of clear display, the steel strand group is represented by a single straight line. It is actually a steel strand group formed by multiple steel strands distributed in a circle. Those skilled in the art should be aware of the steel strand group arrangement used in conjunction with the continuous tension hydraulic jack. At the same time, this patent displays different steel strand groups in bold in different drawings to facilitate understanding and distinguishing the connection relationship between different steel strand groups and the wind turbine tower sections.

[0060] Now install it in steps:

[0061] S1 Pre-lift Auxiliary Work: This includes foundation construction, installation of the wind turbine foundation section, installation of the lifting frame, and installation and commissioning of the lifting centralized control device. Foundation construction includes the construction of the lifting frame, lifting centralized control device, tower section transfer frame rails, and wind turbine tower section positioning. Joint layout and construction are preferred to reduce engineering workload, improve the load-bearing structure, and enhance reliability through joint force distribution. The wind turbine foundation section should be installed in place in advance to avoid installation difficulties due to significant interference later. The lifting frame and lifting centralized control device should be installed and commissioned in place in advance to ensure that all devices function properly.

[0062] S2 wind turbine lifting assembly: refer to Figures 2 to 5, install lifting points at equal angles in the circumferential direction of each tower section of the wind turbine tower, assemble the third tower section, the second tower section and the first tower section of the wind turbine tower, and the wind turbine room, generator and blades on the top of the first tower section. During the installation of each tower section, the steel strand group is connected to the steel strand group and tightened to bear the force, so that the steel strand group of one of the continuous stretching hydraulic hoists in each group of lifting control devices is connected to the third tower section, the steel strand group of another continuous stretching hydraulic hoist in each group of lifting control devices is connected to the second tower section, and the guy rope 44 of the last continuous stretching hydraulic hoist in each group of lifting control devices is connected to the first tower section. Start the lifting control device to lift the installed equipment as a whole to more than the height of one tower section, so that the new tower section can be put in place and installed. Refer to Figure 10, where the connection method between the steel strand group and the tower section is: after all the steel strands pass through the anchor at the front end, any two adjacent steel strands are locked on different anchors respectively.

[0063] S3 Transfer and put the new tower section into place: According to the number of transfer racks selected, hoist a tower section for each transfer rack, and start the supporting cylinders respectively so that the supporting tiles can press the tower section tightly. The tower sections are transported to the lifting rack in the assembly order and go to the next step. According to the number of tower section transfer racks selected, hoist a tower section for each tower section transfer rack. The tower section should be installed vertically on the corresponding transfer rack in accordance with the tower section installation order. The circumferential positioning angle of the tower section on the transfer rack should be reasonable and should match the circumferential installation angle of the previous tower section to facilitate the alignment between the two tower sections and the connection between each lifting steel strand group and the lifting lifting point. Before the tower section transfer rack is moved, the supporting cylinders of the transfer rack should be driven to press the tower section together to ensure that the tower section is in a stable vertical state. Then, the transfer rack should be driven to move along the track to the installation position below the installed tower section. The track clamp should be securely locked to the track. For the locked state, please refer to Figure 11.

[0064] The tower section transfer rack can also be used in conjunction with multiple sections. In this case, the transfer racks are connected by transfer rack hinges and can share a common control system for overall joint control. The advantage of using multiple tower section transfer racks in conjunction is that multiple tower sections can be loaded at once, making lifting more continuous and efficient.

[0065] S4 Connection and lifting of new tower section: Refer to Figures 6 and 7, loosen the connection between the steel strand group connected to the second tower section and the lifting point of the second tower section, and install it to the lifting point of the tower section on the tower section transfer frame. After all the steel strand groups are evenly stressed, loosen the support of the support tiles and the tower section, slowly lift the new tower section and connect the top of the new tower section with the bottom of the third tower section; then control the lifting control device in linkage, steadily lift the installed tower section and the equipment as a whole by one tower section height, move another transfer frame equipped with tower sections to the bottom of the installed tower section, lock the track clamp with the track, repeat the above operation to complete the connection of all wind turbine towers; when multiple groups of transfer frames are activated at the same time, the transfer frame equipped with tower sections is in a waiting state for installation, and the transfer frame that has hoisted the tower section in the previous step has also been moved out of the lifting frame, and the new tower section can be hoisted simultaneously. By operating simultaneously, the preparation and waiting time can be shortened to ensure continuous installation. During the installation process, if there is severe weather such as excessive wind that is not suitable for installation, the wind rope cylinder and two sets of lifting rope cylinders should be controlled immediately to ensure that the entire installed tower section is in a vertical state and tighten each set of steel strands to ensure the stability of the overall structure.

[0066] S5 fan is connected to the foundation section: After the tower section connected to the foundation section is connected to the other tower sections of the fan tower, the installed fan is lifted as a whole by one tower section height, and the tower section transfer frame is moved out of the lifting frame. Then, the linkage control lifting centralized control device is used to slowly lower the installed tower section of the fan and the equipment as a whole, accurately align and adjust the holes with the foundation section flange, connect the bolts and tighten them, and connect the fan tower as a whole to the foundation section. After this step is completed, the overall structure of the fan has been installed.

[0067] S6: Fan confirmation debugging: debug all parts and equipment of the fan.

[0068] S7: Auxiliary Equipment Removal: Remove the lifting frame, lifting centralized control device, and transfer frame, and the installation is complete. The guy rope connected to the first tower section can be unhooked and removed by personnel from the access hole to the operating platform outside the tower section using a lifting device.

[0069] This patent preferably adopts a control method that combines on-site sub-control and summary master control. On-site sub-control refers to the subsystems such as the lifting control device and the tower section transfer frame having operation modes such as on-site equipment operation and on-site wireless remote control; summary master control refers to the method of aggregating the signals of the lifting control device and the tower section transfer frame and other subsystems, as well as the signals of multiple other wind turbine lifting devices, to the on-site or remote control room by wireless or wired means, and performing overall system control through the transmission of cameras and various sensor signals. The master control can also be automatically controlled or manually controlled according to the program settings, ensuring the safety and efficiency of the lifting process.

[0070] The device and method can also be used for dismantling a fan, where the dismantling step is the reverse operation of the installation step.

[0071] In this embodiment, an automatic verticality measuring device is installed on the wind turbine tower section to ensure that the verticality deviation of the overall structure is within a reasonable range during the overall lifting of the wind turbine. The verticality can be measured using mechanical, optical instrument, electronic and other measurement methods.

[0072] In this embodiment, a wind speed measuring device is installed on the wind turbine tower section to measure the wind speed level during the wind turbine hoisting process. If the wind speed is too high, the hoisting operation is suspended immediately. The wind speed measuring device can use the wind turbine's own device or a temporary measurement device provided by this system. The measurement signal needs to be connected to the master control system. The tower section access hole and operating platform are used to facilitate the installation and removal of the steel strand lifting points.

[0073] Since the diameter of each section of the wind turbine tower is different, this embodiment uses lifting steel strands to connect the lifting points so that they are not affected by changes in the diameter of the tower sections. Changes in diameter will only cause a slight change in the angle between the steel strands and the lifting points. Since the continuous tension hydraulic hoist in this embodiment has a large excess lifting capacity, it can solve this problem well.

[0074] In addition, the machine room, generator, blades and other equipment on the upper part of the wind turbine cannot be arranged with completely equal torque balance at the front and rear ends, which brings the risk of overloading during the lifting process. On the one hand, this patent adopts a continuous stretching hydraulic jack with multiple anchor points for vertical three-dimensional lifting to enhance the stability and dynamic adjustment capability of the lifting process. On the other hand, by setting up a group of multi-point wind-catching hydraulic steel strands, the overall verticality of the tower section can be automatically or manually adjusted at any time, effectively overcoming the interference of overloading.

[0075] As a preferred embodiment of the present invention, step S2 of the above embodiment is performed by hoisting with a mobile crane, and specifically includes the following steps:

[0076] S2-1: Use a mobile crane to lift the third tower section onto the foundation section. Connect the steel strands of one of the continuous tension hydraulic hoists in each lifting control unit to the third tower section. Adjust the third tower section to be vertical and tighten the steel strands to bear the load.

[0077] S2-2: Use a mobile crane to lift the second tower section to the top of the third tower section, connect and secure the second tower section to the third tower section coaxially, and connect the steel strand set of the other continuous tension hydraulic hoist in each lifting centralized control device to the second tower section;

[0078] S2-3 activates a mobile crane to lift the first tower section to the top of the second tower section, and fixes the first tower section and the second tower section coaxially, and connects the guy rope of the last continuous tension hydraulic hoist in each set of lifting control devices to the first tower section.

[0079] The guy ropes are connected to the wind-handling points on the first tower section of the wind turbine via a lifting point. Each set of hoist ropes is connected to the same tower section via at least two vertical anchors. Two sets of hoisting control units are connected to the upper and lower tower sections, respectively. Correspondingly, the first tower section is equipped with multiple wind-handling points, while the other tower sections are equipped with several sets of hoisting points. The guy rope and hoisting points are evenly distributed around the circumference of the tower section at equal angles, matching the positions where the steel strand ends should be suspended.

[0080] As a preferred embodiment of the present invention, step S2 in the above embodiment is performed by hoisting using the installation device of the present invention, and specifically includes the following steps:

[0081] S2-1 first uses the transfer frame to transfer the second tower section to the installation position in the lifting frame, drives a continuous tension hydraulic hoist in each lifting control device, connects its anchors to the lifting points of this tower section, tightens them, and then lifts the second tower section to a clear height higher than that of the first tower section;

[0082] S2-2 then uses the transfer frame to transfer the third tower section to the installation position in the lifting frame, drives the other continuous tension hydraulic hoist in each lifting control device, connects and tightens its anchors to the lifting points of this tower section, slowly lifts the third tower section to a position that fits with the second tower section, and connects and tightens the second tower section to the third tower section;

[0083] S2-3 Use a crane to lift the first tower section to the top of the second tower section. Without releasing the hook of the crane, connect and tighten the first tower section to the second tower section. Then, connect the guy rope of the last continuous tension hydraulic hoist in each lifting control device group to the first tower section and tighten it.

[0084] S2-4 hoist and adjust the wind turbine room, generator and blades in an overall vertical and stable state. After installation, lock the rotatable or movable parts.

[0085] As a preferred embodiment of the present invention, after S2 is completed, that is, after the installation of the main functional components of the wind turbine is completed, functional debugging is first performed, and after the debugging is qualified, the subsequent tower sections are lifted and connected.

[0086] In the above embodiment, after S2 is completed, preliminary debugging is carried out. The advantage is that debugging is carried out at a lower installation location, which is convenient for confirming the integrity and reliability of the installed equipment and facilitating the repair of faulty equipment. The main debugging work can be completed at this stage. After the overall installation of the fan is completed, only confirmatory debugging is required, which reduces the overall debugging workload, avoids high-altitude debugging, and reduces the difficulty and danger of debugging operations.

[0087] In the description of the present invention, the continuous tension hydraulic jack 37 is a device cited in the standard DL / T 5400-2007 Technical Specifications for Sliding Formwork Construction of Hydraulic Structures, and is also an existing device disclosed in the Chinese patent application document with publication number CN100424003C. Therefore, the specific structure of the existing device is not described in detail in the description of this patent. Those skilled in the art should know that it does not affect the implementation of this patent.

[0088] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A vertical lifting and installation device for variable diameter unbalanced load equipment, characterized in that: include: Rails and rail-mounted transfer devices mounted on rails; A lifting frame is a truss structure, comprising a plurality of pillars and mounting rods connected to the upper portions of the pillars, and the lifting frame spans over the track; Multiple sets of lifting control devices are installed at different positions on the outside of the lifting frame. The lifting control devices are used to smoothly lift the variable-diameter unbalanced load equipment to the installation position after the track-type transfer device transfers the variable-diameter unbalanced load equipment into the lifting frame.

2. The vertical lifting and installation device for variable-diameter unbalanced load equipment according to claim 1 is characterized by: The rail-type transfer device includes a transfer frame, a roller adapted to the track is installed at the bottom of the transfer frame, a plurality of supporting cylinders for fixing variable-diameter unbalanced load equipment are arranged on the top, the piston rods of the supporting cylinders are connected to support pads, a transfer frame hydraulic station and a transfer frame electric control box are arranged on the transfer frame, and the transfer frame hydraulic station is electrically connected to the transfer frame electric control box; it also includes a rail clamp.

3. The vertical lifting and installation device for variable-diameter unbalanced load equipment according to claim 1 is characterized by: Each group of the lifting control device includes three continuous stretching hydraulic hoists, a lifting hydraulic station that provides power for the three continuous stretching hydraulic hoists, and a lifting electrical control box that controls the lifting hydraulic station. Multiple fixed pulleys are arranged on the mounting rod, and the fixed pulleys are used for allowing the steel strand group of the continuous stretching hydraulic hoist to pass through and lift variable-diameter unbalanced load equipment.

4. The vertical lifting and installation device for variable-diameter unbalanced load equipment according to claim 3 is characterized by: The continuous stretching hydraulic hoist includes a support base and a continuous stretching hydraulic jack hinged on the support base, and a steel strand group reel arranged behind the continuous stretching hydraulic jack. The continuous stretching hydraulic jack is connected to the lifting hydraulic station, and the motor of the steel strand group reel is connected to the lifting electric control box; in each group of lifting control devices, one of the continuous stretching hydraulic hoists is connected to the wind rope, and the other two continuous stretching hydraulic hoists are connected to the steel strand group, and the steel strand group of each continuous stretching hydraulic jack is connected to an anchor assembly.

5. The vertical lifting and installation device for variable-diameter unbalanced load equipment according to claim 3 is characterized by: The lifting frame includes three or four columns, which are installed on both sides of the track. The height of the mounting rod is greater than the height of the track-type transfer device; the mounting rod is circular, and multiple fixed pulleys are evenly distributed on the mounting rod at equal angles.

6. The vertical lifting and installation device for variable diameter unbalanced load equipment according to claim 4 is characterized in that: The anchor assembly includes two groups of anchors connected to the steel strand group in sequence; the anchor includes a cylindrical shell, and also includes multiple groups of anchor seats evenly distributed in an annular shape in the shell, the anchor seats are fixedly connected to the shell, and each group of anchor seats is correspondingly provided with an anchor plate and a locking plate; the connection method between the steel strand group and the anchor assembly is: after all the steel strands pass through the anchor at the front end, any two adjacent steel strands are respectively locked on different anchors.

7. A vertical lifting and installation method for equipment with variable diameter and unbalanced load, characterized by: The following steps are involved: S1 Auxiliary work before lifting: including foundation construction, installation of fan foundation section, installation of lifting frame, installation and commissioning of lifting centralized control device; S2 wind turbine lifting assembly: Install lifting points at equal angles in the circumferential direction of each tower section of the wind turbine tower, assemble the third tower section, the second tower section and the first tower section of the wind turbine tower, and the wind turbine room, generator and blades on the top of the first tower section, connect the steel strand group of one of the continuous tensioning hydraulic hoists in each set of lifting centralized control devices to the third tower section, connect the steel strand group of another continuous tensioning hydraulic hoist in each set of lifting centralized control devices to the second tower section, connect the guy rope of the last continuous tensioning hydraulic hoist in each set of lifting centralized control devices to the first tower section, start the lifting centralized control device to lift the installed equipment as a whole to more than the height of one tower section, so that the new tower section can be positioned and installed. The connection method between the steel strand group and the tower section is: after all the steel strands pass through the anchor at the front end, any two adjacent steel strands are locked on different anchors respectively; S3 Transfer and put the new tower section into place: according to the number of transfer racks selected, hoist one tower section for each transfer rack, and start the support cylinders respectively to make the support tiles press the tower section tightly. Then transport the tower sections into the lifting rack in the order of assembly and proceed to the next step. S4 Connecting and lifting the new tower section: Loosen the connection between the steel strand group connected to the second tower section and the lifting point of the second tower section, and install it on the lifting point of the new tower section. After all the steel strand groups are evenly stressed, loosen the support tiles and the tower section, slowly lift the new tower section and connect the top of the new tower section with the bottom of the third tower section; then control the lifting centralized control device in a coordinated manner, steadily lift the installed tower section and the equipment as a whole by one tower section height, move another transfer frame equipped with a tower section to the bottom of the installed tower section, lock the rail clamp to the track, and repeat the above operation to complete the connection of all wind turbine towers; S5 fan is connected to the foundation section: After the tower section connected to the foundation section is connected to the other tower sections of the fan tower, the installed fan is lifted to the height of one tower section, the tower section transfer frame is moved out of the lifting frame, and then the lifting centralized control device is controlled in a linked manner to slowly lower the installed tower section of the fan and the entire equipment, and the fan tower is connected to the foundation section; S6: Fan confirmation debugging: debug all parts and equipment of the fan; S7: Removal of auxiliary devices: Remove the lifting frame, lifting centralized control device and transfer frame, and the installation is complete.

8. The vertical lifting and installation method for variable diameter unbalanced load equipment according to claim 7 is characterized in that: S2 is hoisted by a mobile crane and includes the following steps: S2-1: Use a mobile crane to lift the third tower section onto the foundation section. Connect the steel strands of one of the continuous tension hydraulic hoists in each lifting control unit to the third tower section. Adjust the third tower section to be vertical and tighten the steel strands to bear the load. S2-2: Use a mobile crane to lift the second tower section to the top of the third tower section, connect and secure the second tower section to the third tower section coaxially, and connect the steel strand set of the other continuous tension hydraulic hoist in each lifting centralized control device to the second tower section; S2-3 activates a mobile crane to lift the first tower section to the top of the second tower section, and fixes the first tower section and the second tower section coaxially, and connects the guy rope of the last continuous tension hydraulic hoist in each set of lifting control devices to the first tower section.

9. The vertical lifting and installation method for variable diameter unbalanced load equipment according to claim 7 is characterized in that: S2 is performed by hoisting using the installation device of the present invention, and specifically includes the following steps: S2-1 first uses the transfer frame to transfer the second tower section to the installation position in the lifting frame, drives a continuous tension hydraulic hoist in each lifting control device, connects its anchors to the lifting points of this tower section, tightens them, and then lifts the second tower section to a clear height higher than that of the first tower section; S2-2 then uses the transfer frame to transfer the third tower section to the installation position in the lifting frame, drives the other continuous tension hydraulic hoist in each lifting control device, connects and tightens its anchors to the lifting points of this tower section, slowly lifts the third tower section to a position that fits with the second tower section, and connects and tightens the second tower section to the third tower section; S2-3 Use a crane to lift the first tower section to the top of the second tower section. Without releasing the hook of the crane, connect and tighten the first tower section to the second tower section. Then, connect the guy rope of the last continuous tension hydraulic hoist in each lifting control device group to the first tower section and tighten it. S2-4 hoist and adjust the wind turbine room, generator and blades in an overall vertical and stable state. After installation, lock the rotatable or movable parts.

10. The vertical lifting and installation method for variable diameter unbalanced load equipment according to claim 7 is characterized in that: After S2 is completed, that is, the installation of the main functional components of the wind turbine is completed, functional debugging is carried out first, and after qualified debugging, the subsequent tower sections are lifted and connected.