Renewable energy platform assembly kit and method

Abstract

The assembly kit for the offshore renewable energy system mounting platform includes a frame with three or more lateral struts, and an upright strut and an apex member, each equal to the quantity of the lateral struts. Each apex member secures two lateral struts such that the lateral struts and the apex member form a substantially planar base of the frame. Each apex member engages a first end of a corresponding upright strut to secure the upright strut to the base. The frame further includes a single transition piece that engages a second end of the upright strut to form a fixed apex of the frame. The kit further includes an assembly aid having a plurality of lateral strut supports and an upright tower. Each lateral strut support is configured to support a corresponding lateral strut on a horizontal surface located above the ground. The upright tower is arranged to engage with the upright strut such that the engaged upright struts are supported at an upright angle, respectively.

Description

[Technical field]

[0001] The present disclosure relates to a renewable energy system mounting platform, and in particular to an assembly kit for a platform arranged to support renewable energy utilization equipment within a body of water, and a method for manufacturing such a platform. [Background technology]

[0002] The global transition to renewable energy requires harnessing all forms of renewable energy to supply the planet with its energy needs.

[0003] One potential renewable energy source is wave power, an abundant and stable energy resource available in the world's vast oceans. Another is wind power, where wind speeds are higher and more stable over the ocean than on land. Summary of the Invention [Problem to be solved by the invention]

[0004] For these reasons, there is a need for offshore platforms that have the means to mount renewable energy devices that can harness wave and wind power in distant oceans. Because the cost of the platform and its assembly directly impacts the cost of the energy produced by the device, there is a need for a platform that can be cost-effectively manufactured and assembled.

[0005] In particular, there is a need for a platform that can be manufactured as a set of modular components prefabricated by a larger supply chain and then assembled into a complete platform in a non-specialized outdoor yard facility without the need for specialized shipbuilding facilities, and that does not compromise stability when deployed. [Means for solving the problem]

[0006] The present invention provides an assembly kit for an offshore renewable energy system mounting platform for placing renewable energy converters in a body of water, the platform including a plurality of individual prefabricated components assembled using an assembly aid. The assembly aid functions to enable quick and easy assembly of the individual prefabricated components of the platform, and avoids the need for additional expensive heavy equipment such as cranes that may make it difficult to align the parts to be connected. The assembly aid also reduces the need for scaffolding, which may add significant time to the assembly of the platform if erected and dismantled. The assembly aid preferably functions to hold the prefabricated components of the platform stationary to facilitate fastening or welding the components together and to provide easy access to the joints for fastening or welding. It is desirable to minimize the number and variety of the individual components of the platform to simplify manufacturing, assembly and maintenance. Preferably, the components are manufactured to interact with simple, temporary mating connections that hold the components together with the aid of the assembly aid during a step-by-step assembly process. If necessary, the mating connections may then be strengthened and rigidified by permanent fastening, such as by welding.

[0007] According to a first aspect of the present invention, there is provided an assembly kit for assembling an offshore renewable energy system mounting platform, the kit comprising a frame for the renewable energy system mounting platform, the frame comprising three or more elongated lateral struts, a plurality of elongated upright struts equal to the quantity of the lateral struts, and a plurality of apex members equal to the quantity of the lateral struts, each apex member arranged to secure two lateral struts to corresponding ends of the apex member such that the lateral struts and the apex member form a substantially planar base of the frame, each apex member further arranged to engage first ends of the upright struts such that the corresponding upright strut is secured to the base at an upright angle relative to the base, the frame further comprising: a frame for engaging second ends of the upright struts when each upright strut is arranged at the upright angle; the kit further comprises a single transition piece arranged to fit over the frame, the transition piece being arranged to form a fixed apex of the frame to form an assembled frame, the kit further comprises an assembly aid, the assembly aid comprising a number of lateral column supports corresponding to the quantity of lateral columns, and an upright tower, each lateral column support having a lateral column engagement surface arranged to engage with a lateral column such that the corresponding lateral column is supported on a horizontal plane located above the ground, the upright tower having a number of upright column engagement surfaces, each upright column engagement surface of the tower arranged to engage with a corresponding upright column such that each engaged upright column is supported at an upright angle by the upright column engagement surface.

[0008] It is understood that the number of cross-column supports corresponding to the number of cross-columns may be any number of supports for each cross-column. For example, the kit may include a single cross-column support suitable for supporting each cross-column and centrally located along the length of the cross-column during assembly of the platform. In other preferred embodiments, two or more cross-column supports are located for each cross-column, and these supports are distributed along the length of the cross-column during assembly. In embodiments with two cross-column supports for each cross-column, the cross-column supports are preferably located near each end of the corresponding cross-column during assembly.

[0009] In a preferred embodiment, the cross-support engagement surfaces conform to the shape of the corresponding cross-support and the upright support engagement surfaces conform to the shape of the corresponding upright support, such that the cross-support engagement surfaces and the upright support engagement surfaces are complementary to each other, minimizing movement of the support relative to the corresponding support engagement surfaces when engaged. This engagement preferably simplifies assembly by minimizing movement of the support when the cross-support and apex members, and the upright support, apex members, and transition pieces are permanently secured, such as by welding, between the cross-support and apex members.

[0010] In the most preferred embodiment, the shape of the lateral struts and the shape of the upright struts are one selected from the group of curved and cylindrical, which preferably provides stability against movement of the struts relative to their respective strut engagement surfaces while maintaining optimal properties of the frame, such as aerodynamic / hydrodynamic properties.

[0011] Other suitable configurations of stable connections between the cross posts and corresponding cross post engagement surfaces, and between the standing posts and standing post engagement surfaces, are contemplated, preferably using complementary mating surfaces and not adding complex locking mechanisms, to minimize complexity and assembly time.

[0012] In some preferred embodiments, the assembly aid further comprises apex member supports corresponding to a quantity of apex members, each apex member support having an apex member engagement surface arranged to engage with an apex member such that the corresponding apex member is supported on a horizontal surface located above the ground.

[0013] In some preferred embodiments, the assembly aid further comprises one or more welding stations arranged to engage with a corresponding horizontal or standing column to locate each apex member and transition piece when each horizontal column is supported on a corresponding horizontal column support and each standing column is supported on an upright tower. Such welding stations can be arranged to support one or more welding operators in an optimal position for welding the joint between the horizontal column and the apex member or between the standing column and the corresponding apex member or transition piece. In some embodiments, the assembly aid further comprises one or more habitat enclosures arranged to house the welding stations, the habitat enclosures having at least a roof arranged above the welding stations. In preferred embodiments, each habitat enclosure further comprises a floor and side walls cooperating with the roof to enclose the welding station within the welding space. It is understood that the habitat enclosure may further comprise a door to allow access for the welding operator. Thus, the habitat enclosures are desirably positioned to provide a safer welding environment protected from site-related hazards such as weather and falling objects. In a most preferred embodiment, each habitat enclosure is positioned to surround a corresponding joint between a horizontal strut and an apex member, or a corresponding joint between an erector strut and a transition piece. In this manner, the habitat enclosure preferably serves to provide complete protection around the perimeter of the horizontal or erector strut joint during welding, while also providing improved access to all areas of the joint for welding.

[0014] Preferably, the assembly kit further comprises a number of self propelled modular transporters (SPMTs) corresponding to the quantity of the horizontal columns, each SPMT being arranged to support a corresponding horizontal column of the frame on a horizontal surface located above the ground, and further arranged to transport the assembled frame in engagement with the horizontal column. In some embodiments, the horizontal column support may be or include an SPMT. Thus, in some embodiments, each horizontal column support may be arranged to transport the assembled frame in engagement with the horizontal column. The use of an SPMT to support each horizontal column can preferably assist in transporting the assembled frame from the assembly site, thereby making the assembly aid available for the subsequent assembly of the platform frame. In some embodiments, each horizontal column is an SPMT.

[0015] In some embodiments, the tower may further comprise an upper platform positioned to support an assembly worker. In some embodiments, the transition piece is preferably arranged to support a renewable energy system on the transition piece. In preferred embodiments, the renewable energy system comprises one or more of a wave energy converter and a wind turbine. In a most preferred embodiment, the renewable energy system is a wind turbine.

[0016] In a most preferred embodiment, the assembly kit comprises three lateral columns. Thus, in a preferred embodiment, the three lateral columns form a triangular planar base. The assembly kit in such an embodiment comprises three upright columns and three apex members. This arrangement of columns and apex members provides a tetrahedral platform frame. Advantageously, such a structure provides optimal stability while maintaining maximum simplicity. Advantageously, in use, the platform supports a renewable energy system, such as a wind turbine or wave energy device, and the platform is deployed in the body of water in an in-use configuration. In such a configuration, the platform is preferably moored to the seabed of an offshore body of water, and the renewable energy device is positioned to harness and convert the renewable energy source into usable energy.

[0017] In a most preferred embodiment, each of the cross struts is identical, each of the upright struts is identical, and each of the apex members is identical. Preferably, such an arrangement maximises simplicity of manufacture, assembly and maintenance.

[0018] In a preferred embodiment, each apex member includes two coplanar socket members arranged to receive the ends of the corresponding cross struts in a common plane, and an angled socket member arranged to receive the first end of the corresponding upstanding strut at an upstanding angle to the plane. It will be appreciated that in embodiments, any suitable fasteners may be provided between the cross struts and the apex members, and between the upstanding struts and the apex members. For example, each cross strut may alternatively include a socket at each end, which is arranged to receive a plug member of the corresponding apex member, and the first end of the upstanding strut may alternatively include a socket arranged to receive a plug member of the corresponding apex member.

[0019] Preferably, the assembly kit may include a plurality of cross-court supports for each corresponding cross-court, in the most preferred embodiment two cross-court supports are provided for each cross-court, with each of the pair of supports positioned near opposite ends of the corresponding cross-court for optimal weight distribution and stability during assembly.

[0020] According to a second aspect of the invention, there is provided a method of manufacturing a frame for an offshore renewable energy system mounting platform, the frame comprising three or more transverse struts and a corresponding number of apex members, each apex member arranged to secure adjacent ends of two transverse struts to form a planar base of the frame, each transverse strut forming a corresponding edge of the base, a plurality of upstanding struts equal to the number of transverse struts, each upstanding strut arranged to engage a corresponding apex member to form an upstanding edge of the frame extending from the base at an upstanding angle to the planar base, and a single transition piece arranged to secure the upstanding struts at the upstanding angle and forming the apex of the frame. The method comprises: a. positioning an upright tower having an upright column engagement surface arranged to engage a corresponding upright column of the frame at an upright angle; b. positioning each of a plurality of lateral column supports at a corresponding ground location against the upright column engagement surface such that each lateral column support is positioned to support a corresponding lateral column to form a base; c. supporting each cross post with a corresponding cross post support at a corresponding ground location; d. engaging adjacent ends of two cross struts with corresponding apex members to form a base; e. engaging a first end of each upright strut with a corresponding apex member and engaging a surface of each upright strut with a corresponding upright strut engagement surface of the tower; f. securing a transition piece to the second end of each of the engaged upright posts to form an assembled frame.

[0021] In a preferred embodiment, the method of the second aspect may be carried out using the assembly kit of the first aspect. In a preferred embodiment, step d further comprises permanently fixing the end to a corresponding apex member. Preferably, step e further comprises permanently fixing the first end to a corresponding apex member. Preferably, step f further comprises permanently fixing the second end to the transition piece. The fixing is preferably performed by welding.

[0022] In some preferred embodiments, step d further comprises surrounding the joint between the end and the corresponding apex member with a habitat enclosure prior to the permanent fastening, the habitat enclosure defining a sealed weld space around the joint. In some preferred embodiments, step e further comprises surrounding the joint between the first end and the corresponding apex member with a habitat enclosure prior to the permanent fastening. In some preferred embodiments, step f further comprises surrounding the joint between the second end and the transition piece with a habitat enclosure prior to the permanent fastening. The habitat enclosure is preferably as described herein in connection with the first aspect. In any case, steps d, e and f may further comprise, in some embodiments, dismantling each habitat enclosure after the permanent fastening.

[0023] In a preferred embodiment, the method further comprises the steps of: g. transporting the assembled frame to a first location in the body of water; h. attaching a renewable energy system to the transition piece of the assembled frame.

[0024] In some embodiments, step g preferably further comprises supporting each side strut of the assembled frame on a corresponding self-propelled modular transporter (SPMT). It is understood that in some embodiments, the side struts may be or include SPMTs.

[0025] In a most preferred embodiment, step g further comprises either loading the assembled platform onto an ocean carrier or floating the frame on the body of water. In some embodiments, step g comprises floating the frame on the body of water, and preferably step g further comprises temporarily mooring the assembled frame to the bottom of the body of water, and step h further comprises removing the assembled frame from the bottom of the body of water after the renewable energy system is attached.

[0026] In a preferred embodiment, the method further comprises the steps of: i. Transporting the assembled frame to a desired placement location on the body of water.

[0027] According to a third aspect of the invention, there is provided a method of manufacturing a frame for an offshore renewable energy system mounting platform, the frame comprising three or more transverse struts and a corresponding number of apex members, each apex member arranged to secure adjacent ends of two transverse struts to form a planar base of the frame, each transverse strut forming a corresponding edge of the base, a plurality of upstanding struts equal to the number of transverse struts, each upstanding strut arranged to engage a corresponding apex member to form an upstanding edge of the frame extending from the base at an upstanding angle to the planar base, and a single transition piece arranged to secure the upstanding struts at the upstanding angle and forming an apex of the frame. The method comprises: a. positioning an upright tower having an upright column engagement surface arranged to engage a corresponding upright column of the frame at an upright angle; b. placing each of the plurality of apex members at a corresponding ground location against the upright column engagement surface such that each apex member support is positioned to support a corresponding apex member; c. supporting each apex member using a corresponding apex member support at a corresponding ground location; d. positioning each of a plurality of lateral column supports at corresponding ground locations relative to the apex member such that each lateral column support is positioned to support a corresponding lateral column to form a base; e. supporting each cross post with a corresponding cross post support at a corresponding ground location; f. engaging adjacent ends of two cross struts with corresponding apex members to form a base; g. engaging a first end of each upright strut with a corresponding apex member and engaging a surface of each upright strut with a corresponding upright strut engagement surface of the tower; and h. securing a transition piece to the second end of each of the engaged upright posts to form an assembled frame.

[0028] In a preferred embodiment, the method of the third aspect may be carried out using the assembly kit of the first aspect. It will be appreciated that in some embodiments, step c may be performed after step d.

[0029] According to another aspect of the invention there is provided a kit of assembly aids for use in assembling an offshore renewable energy system mounting platform, the assembly aid comprising a number of lateral column supports corresponding to a quantity of lateral columns of the platform, an upright tower, each lateral column support having a lateral column engagement surface arranged to engage with a lateral column such that the corresponding lateral column is supported on a horizontal plane located above the ground, the upright tower having a number of erector column engagement surfaces, each erector column engagement surface of the tower arranged such that by engaging with a corresponding erector column of the platform, each engaged erector column is supported by the erector column engagement surface at an erect angle relative to the horizontal plane of the ground.

[0030] It is understood that any feature described in this specification as being suitable for incorporation in one or more aspects or embodiments of the present disclosure is intended to be generalizable across all aspects and embodiments of the present disclosure.

[0031] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings in which: [Brief description of the drawings]

[0032] [Figure 1A] 1 is a perspective view of an exemplary prefabricated component of a platform frame used in an exemplary embodiment of an assembly kit according to a first aspect; FIG. [Figure 1B] FIG. 2 is an exploded view of an example of the frame. [Figure 2A] 1A to 1C are diagrams illustrating an example of an assembly sequence for a platform frame using an assembly kit according to the first embodiment. [Figure 2B] 1A to 1C are diagrams illustrating an example of an assembly sequence for a platform frame using an assembly kit according to the first embodiment. [Figure 2C] 1A to 1C are diagrams illustrating an example of an assembly sequence for a platform frame using an assembly kit according to the first embodiment. [Figure 2D] 1A to 1C are diagrams illustrating an example of an assembly sequence for a platform frame using an assembly kit according to the first embodiment. [Figure 2E] 1A to 1C are diagrams illustrating an example of an assembly sequence for a platform frame using an assembly kit according to the first embodiment. [Diagram 3] FIG. 2 is a plan view of an exemplary assembly area for assembling the platform frame according to the first and second embodiments. [Figure 4] FIG. 2 is a perspective view of individual components included in an exemplary embodiment of an assembly kit according to the first aspect in an unassembled state; [Figure 5A] 5A-5C show a step-by-step assembly process for assembling the frame of FIG. 4 according to the second embodiment. [Figure 5B] 5A-5C show a step-by-step assembly process for assembling the frame of FIG. 4 according to the second embodiment. [Figure 5C]5A-5C show a step-by-step assembly process for assembling the frame of FIG. 4 according to the second embodiment. [Figure 5D] 5A-5C show a step-by-step assembly process for assembling the frame of FIG. 4 according to the second embodiment. [Figure 6A] 5A to 5D according to a second embodiment, showing a step-by-step assembly and installation process following the process shown in FIGS. 5A to 5D. [Figure 6B] 5A to 5D according to a second embodiment, showing a step-by-step assembly and installation process following the process shown in FIGS. 5A to 5D. [Figure 6C] 5A to 5D according to a second embodiment, showing a step-by-step assembly and installation process following the process shown in FIGS. 5A to 5D. [Figure 6D] 5A to 5D according to a second embodiment, showing a step-by-step assembly and installation process following the process shown in FIGS. 5A to 5D. [Figure 7] FIG. 7 is a close-up perspective view of the assembled frame of FIGS. 6A-6D after installation of the wind turbine but before deployment. [Figure 8A] 5A-5C show an alternative step-by-step assembly process for assembling the frame of FIG. 4 according to a third embodiment. [Figure 8B] 5A-5C show an alternative step-by-step assembly process for assembling the frame of FIG. 4 according to a third embodiment. [Figure 8C] 5A-5C show an alternative step-by-step assembly process for assembling the frame of FIG. 4 according to a third embodiment. [Figure 8D] 5A-5C show an alternative step-by-step assembly process for assembling the frame of FIG. 4 according to a third embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] FIG. 1A shows a perspective view of an exemplary prefabricated component of a platform frame used in an exemplary embodiment of an assembly kit according to the first aspect. The component is composed of only four separate parts, simplifying manufacturing, assembly, ongoing maintenance and part replacement. The component includes a long cylindrical frame lateral strut 102, a frame apex member 104, a long cylindrical frame upright strut 106 and a frame transition piece 108. FIG. 1B shows an exploded view of the completed frame 100 with three lateral struts 102 arranged adjacent to each other in a triangular configuration. Adjacent ends of the lateral struts 102 are each connected to an apex member 104 that forms the apex of the triangular planar base of the frame 100. Each of the three apex members 104 includes two coplanar cylindrical sockets arranged at an angle to each other. The sockets are sized and shaped to engage complementary cylindrical ends of the corresponding lateral struts 102. The angle between the two coplanar sockets of the apex member 104 is the angle that causes the planar posts to form a desired shape when engaged with corresponding cross posts 102 to form the planar base of the frame 100. The desired shape is a triangle in the preferred embodiment shown. Thus, in the embodiment shown, the sum of the angles between the coplanar sockets of the three apex members 104 is 180 degrees. In the embodiment shown, each individual angle is 60 degrees.

[0034] Additionally, the apex member 104 includes a third cylindrical socket that is disposed at an upright angle relative to the two coplanar sockets and that is disposed at an upright angle relative to the cross strut 102 when the apex member 104 engages the cross strut 102. The third socket is sized and shaped to receive a cylindrical first end of a corresponding upright strut 106 of the frame. When the apex member 104 engages the corresponding upright strut 106, the upright strut 106 is disposed at an upright angle relative to the coplanar sockets and the plane of the cross strut 102. In the illustrated embodiment 100, the upright angle is 60 degrees, such that the combination of the cross strut 102, apex member 104, and upright strut 106 form a generally tetrahedral shape. The transition piece 108 includes three identical cylindrical sockets that are sized, shaped, and angled to respectively engage with corresponding cylindrical second ends of the upright struts 106. When engaged with the cylindrical second end of the upright post 106 , the transition piece forms the apex of the tetrahedral frame 100 .

[0035] In use, the frame 100 is used to support a renewable energy system (not shown), specifically, in the embodiment shown, a wind turbine. Following assembly of the frame 100, the wind turbine is mounted on the transition piece 108 with appropriate connections on the top surface. After mounting of the wind turbine, the frame is transported offshore to a desired location for placement in the body of water.

[0036] 2A-2E show an example of a frame assembly process 200 using the assembly kits of the first and third embodiments, where the process 200 relates to the second embodiment. FIG. 2A shows a first step 202 of the process 200. This step involves supporting each of the horizontal struts 102 of the frame 100 on a corresponding pair of horizontal column supports 110 of the assembly kit. Each of the pair of horizontal column supports 110 is disposed near both ends of the corresponding horizontal column 102. Each of the horizontal column supports 110 has a curved socket portion sized and shaped to receive a portion of the corresponding horizontal column 102 and is configured to prevent the horizontal column 102 from moving laterally (perpendicular to the longitudinal axis of the column 102). The horizontal column supports 110 support the corresponding horizontal column 102 on a horizontal surface located above the ground.

[0037] Positioning the cross columns 102 on the cross column supports 110 facilitates the next step 204 of the assembly process 200, engaging the apex members 104 with their respective ends of the corresponding cross columns 102, as shown in FIG. 2B. At this stage, the apex members 104 and cross columns 102 are engaged to form the planar base of the frame 100. Once engaged, the cross column supports 110 hold the base of the frame in place while operations are performed to permanently secure each cross column 102 to its respective apex member 104. In the illustrated embodiment, the permanent fastening is accomplished by welding the apex members 104 and cross columns 102 together.

[0038] 2C, the next step 206 in the process 200 is to engage first ends of the upright posts 106 of the frame 100 with corresponding sockets in the apex member 104. The assembly kit includes a tower 112 having a curved upright post engagement portion shaped, sized and angled to receive a portion of the upright post 106, thereby supporting each upright post 106 at an upright angle relative to the planar base. A similar fastening operation is then performed between the upright posts 106 and the apex member 104, but this operation is facilitated by the upright post engagement portion of the tower 112.

[0039] In the penultimate step 208 of process 200 shown in Figure 2D, the sockets of the transition piece 108 of the frame 100 are engaged with the corresponding upright posts 106. This process is facilitated by the upright post engagement portion of the tower 112, which supports the upright post 106 at an upright angle to aid in the insertion of the second end of the post into the corresponding socket of the transition piece 108. A similar fastening operation is then performed between the upright post 106 and the transition piece 108, but this operation is facilitated by the upright post engagement portion of the tower 112.

[0040] In the final step 210 of process 200, shown in FIG. 2E, the assembly aids (cross-strut supports 110 and towers 112) are removed, leaving the fully assembled frame 100. A plan view of an exemplary area of ​​an assembly location 300 is shown in FIG. 3. The assembly location 300 is configured as a marshalling yard and has a land area 301 adjacent to a water body 303. The assembly location 300 is used to assemble the frame 100 according to the method of the second aspect using the assembly kit of the first aspect. The location 300 has a parts area 302 that houses the individual parts of the frame or frames 100 described above. The frame parts are then assembled according to FIGS. 2A-2E in an assembly area 304 with the aid of a crane 306. After assembly, the completed frame is moved to an initial loading area 308 by one or more self-propelled modular transporters (SPMTs) positioned under the base of the frame 100. The frame 100 is first loaded (312) onto a floating platform 314 floating on the water body 303, and then transported by the floating platform 314 away from the land area 301 to a more distant area 316 of the water body 303. There, the frame 100 is removed from the floating platform 316 and floated on the surface of the body of water 303. The floating frame 100 is then transported by a tugboat to a wind turbine attachment area 318 where a wind turbine 320 is attached to the transition piece of the frame 100 using a crane 322. The wind turbine 320 is separately assembled at a wind turbine assembly area 324 of the assembly site 300. In the illustrated embodiment, the floating frame 100 is moored to the seabed of the body of water 303 at the wind turbine attachment area 318, thereby providing stability to the frame during installation. After the wind turbine 320 is attached to the transition piece of the frame 100, the floating frame 100 is transported by a tugboat to the intended offshore deployment location 328 and deployed to harness the wind energy.

[0041] Figure 4 shows the individual components of an exemplary assembly kit according to the first embodiment positioned at a water's edge assembly site 400 prior to assembly. The initial assembly process shown in Figure 4 includes positioning the upright tower 112 of the assembly kit and placing each of the lateral column supports 110 of the assembly kit at a ground location corresponding to the curved upright column engagement surface 114 of the tower 112, such that each lateral column support 110 is positioned to support a corresponding lateral column 102 to form the triangular base of the frame.

[0042] 5A-5D further illustrate the individual steps of the assembly process according to the second embodiment, including supporting each horizontal column 102 by the horizontal column engagement portion 116 of the corresponding horizontal column support 110 at each location on the ground, as shown in FIG. 5A. These steps further include engaging adjacent ends of the two horizontal columns 102 with corresponding apex members 104 to form a planar base of the frame 100, as shown in FIG. 5B. FIG. 5C illustrates a subsequent step of the process, including engaging a first end of each standing column 106 with a corresponding apex member 104 and engaging a surface of each standing column with a corresponding standing column engagement surface 114 of the tower 112, such that the standing columns 106 are supported at an upright angle. The assembly process further includes securing a transition piece 108 to the second end of each engaged standing column 106 using a crane 501 to form an assembled frame, as shown in FIG. 5D. In the illustrated embodiment, each engagement step includes a welding step in which each engaged component is welded while supported by the corresponding assembly aids (the cross-strut supports 110 and the towers 112).

[0043] 6A-6D show the subsequent steps of the assembly process according to the second embodiment. In detail, FIG. 6D shows the step of supporting the base of the assembled frame, in particular the transverse struts, on a self-propelled modular transporter (SPMT) 502 for moving it from the assembly site towards the water body 508 and onto the floating platform 504. To support the assembled frame, transverse strut supports 110 are placed on the floating platform 504. The transport device further comprises a tugboat 506 that helps to load the frame onto the floating platform 504, as shown in FIG. 6B. Then, as shown in FIG. 6C, the frame is transported to a more distant area of ​​the water body 508, where the platform 504 is submerged, so that the assembled frame floats on the surface of the water body 508. Then, as shown in FIG. 6D, the floating frame is returned to land for the installation of a renewable energy system (here a wind turbine) on the transition piece of the assembled frame.

[0044] 7 shows the completed frame 702 after a wind turbine 704 is attached to the transition piece of the frame using a crane 706. A mooring system 708 is used to ensure stability during the attachment, which in this example comprises multiple mooring lines that connect the frame to the bottom of the body of water, stabilizing the floating frame within the body of water. After attachment, the floating assembled frame is transported to the desired deployment location in the body of water using a tugboat 710.

[0045] 8A-8D show steps in the assembly of a platform frame as described in relation to the above embodiment. These steps are similar to those described with reference to FIGS. 5A-5D. In the assembly sequence shown in FIGS. 8A-8D, the apex members 802 of the platform frame are positioned around an erected upright tower 804 (as shown in FIG. 8A) such that the lateral connections of the apex members 802 are aligned with corresponding lateral connections of another apex member 802 and the upright connections of the apex members 802 are aligned with corresponding upright column engagement surfaces of the upright towers 804. In the illustrated embodiment, each apex member is supported above ground level on an apex member support 806.

[0046] As shown in Figure 8B, each side post 808 of the platform frame engages at both ends with a corresponding apex member 802. A habitat enclosure 810 is then constructed around each joint between the side post and the apex member.

[0047] As shown in Figure 8C, each upstanding post 812 of the platform is supported on a corresponding upstanding post engagement surface of the tower 804 and engages at a first end with a corresponding apex member 802. A habitat enclosure 810 is then constructed around each joint between the upstanding post and the apex member.

[0048] 8D, transition pieces 814 are supported on tower 804 and engage corresponding upstanding posts 812. Habitat enclosures 810 are then constructed around each junction between the upstanding posts and the transition pieces 814.

[0049] In the illustrated embodiment, the habitat enclosure 810 serves to provide complete protection around the perimeter of the horizontal or erection column joint during welding, as well as to facilitate access to all areas of the joint for welding. Access to the habitat enclosure 810 for welding may be by any suitable access method, and in some embodiments, when the habitat enclosure is located at the junction of the erection column and the transition piece, access is facilitated by the placement of an elevator in the tower.

[0050] In the above embodiment, the frame consists of only 10 main steel components, including only four different types of parts. The transition pieces and apex members / corner nodes are made of rolled tube and welded plate construction, so their manufacturing can be easily integrated into the existing factory supply chain. The strut elements are rolled tube with some small cast features, so they can be easily integrated into the wind turbine tower supply chain. This allows the frame to be manufactured in a simple way that allows for automated mass production within the supply chain. This results in high quality at low cost, making the most of established and safe processes. The assembly has the flexibility to prioritize local content or global cost base. Distributed manufacturing allows for increased production volume and reduced supplier dependency and risk.

[0051] The assembly is explained to be performed in an outdoor marshalling yard. This configuration allows for greater tolerances and minimizes defects and rework. The specific frame setup allows for minimal welding, with only 12 semi-automated circumferential welds performed outdoors. The assembly aid provides safe access and support for the welding operations, streamlining marshalling work planning and reducing yard requirements.

[0052] The rapid assembly method described here allows for smaller space requirements in the assembly yard and also reduces the number of simultaneous assembly positions required for a given throughput. The modular components of the assembly kits described above are easy to store and can be stacked on a transport frame, further reducing installation space requirements. The wind turbine installation process described above uses a floating frame that is less than 5m with the turbine installed, maximizing facility options, especially for facilities located closer to the assembly project. The process is designed to be replicable at large scale and can be easily optimized as part of a high-volume assembly line.

[0053] The above assembly aids (cross column supports and towers) can be easily deployed on the quay wall and can be assembled repeatedly and quickly. The assembly aids preferably engage with low cost features integrated into the main steel components of the columns, apex members and transition pieces. To provide a safe working environment, the assembly aids also desirably incorporate platforms and other access and welfare features (stairs, lifts, toilets, etc.) for assembly personnel. Advantageously, the use of the assembly aids of the present invention eliminates and / or minimizes the need for carnage to keep parts in place during welding and scaffold assembly.

[0054] Mooring the frame prior to mounting the wind turbine as previously described advantageously provides a stable base for the lifting operation, thereby limiting downtime caused by weather-induced movement of the structure. Locating the turbine in the center of the structure improves stability and eliminates the need for lifting and ballasting between lifts. Asymmetric turbine placement requires careful control of ballast during lifting operations to maintain a level trim.

[0055] In use, the cylindrical struts provide aerodynamic and hydrodynamic properties to the frame, while the tetrahedral shape provides optimal stability when in use with an attached wind turbine. The frame also provides minimal resistance to headwinds and waves. In use, the embodiment includes buoyant transverse struts. The buoyancy is adjustable, and the base of the platform is submerged below the surface of the body of water using an adjustable length mooring system, and the transition piece is above the surface of the body of water. Advantageously, the buoyancy of the transverse struts optimizes the tension in the mooring system, providing maximum stability to the frame used to support the wind turbine.

[0056] Other embodiments are envisaged, for example the buoyancy tanks may be attached to the frame. Other embodiments not described above are also contemplated within the scope of the present disclosure, for example, any combination of renewable energy converters may be disposed on the frame / platform as described herein. Although the exemplary embodiment is shown supporting a wind turbine, any suitable renewable energy converter, such as a wave energy converter, or any combination of suitable renewable energy converters as described above, may be supported. The renewable energy converters may be supported by one, more than one, or all apexes of the platform. In the above example, the platform is comprised of all identical lateral supports and all identical upright supports. It is understood that in some embodiments, the platform comprises any suitable lateral and upright structural members having mating connections to one another and suitable for use with the assembly aids described above. The frame in the above example is tetrahedral in shape, with the inherent rigidity and stability of such a shape. It is understood that in some embodiments, the frame may take any suitable form within the scope of the appended claims. The present disclosure is not limited to the specific examples or configurations shown.

Claims

1. 1. An assembly kit for assembling an offshore renewable energy system mounting platform, comprising: The kit includes a frame for a renewable energy system mounting platform, the frame comprising: Three or more elongated horizontal struts; A plurality of elongated upright columns equal in number to the horizontal columns; a plurality of apex members equal to the quantity of said cross struts, each apex member arranged to secure two of said cross struts to corresponding ends of said apex member such that said cross struts and said apex member form a substantially planar base of said frame, each apex member further arranged to engage a first end of an upstanding strut such that a corresponding upstanding strut is secured to said base at an upstanding angle relative to said base; the frame further comprising a single transition piece arranged to engage a second end of each upright column when the upright column is arranged at the upright angle, the transition piece being arranged to form a fixed apex of the frame to form an assembled frame; The kit further comprises an assembly aid, the assembly aid comprising: A plurality of horizontal column supports corresponding to the number of the horizontal columns; an upright tower; each cross-post support includes a cross-post engagement surface arranged to engage a corresponding cross-post such that the cross-post is supported on a horizontal surface above the ground; an assembly kit, wherein the upright tower has a plurality of upright column engagement surfaces, each upright column engagement surface of the tower being arranged to engage with a corresponding upright column such that each engaged upright column is supported at the upright angle by the upright column engagement surface.

2. 2. The assembly kit of claim 1, wherein the lateral support engagement surface matches a shape of the corresponding lateral support and further wherein the upright support engagement surface matches a shape of the corresponding upright support.

3. 3. The assembly kit of claim 2, wherein the shape of the cross struts and the shape of the upright struts are one selected from the group consisting of curvilinear and cylindrical.

4. 4. The assembly kit according to claim 1, wherein the assembly aid further comprises one or more welding stations arranged to be located at each apex member when the apex member engages with the corresponding cross column such that each cross column is supported by a corresponding cross column support.

5. 5. The assembly kit according to claim 1, further comprising a plurality of self-propelled modular transporters (SPMTs) corresponding to the number of cross supports, each SPMT being arranged to support a corresponding cross support of the frame on a horizontal surface located above the ground, and further arranged to transport the assembled frame in an engaged state with the cross support.

6. 6. An assembly kit according to any one of claims 1 to 5, wherein each cross-strut support is arranged to carry the assembled frame in engagement with a cross-strut.

7. 7. The assembly kit according to any one of claims 1 to 6, wherein the tower comprises an upper platform arranged to support an assembly operator.

8. The assembly kit according to any one of claims 1 to 7, wherein the transition piece is arranged to support a renewable energy system thereon.

9. 9. The assembly kit of claim 8, wherein the renewable energy system comprises one or more of a wave energy converter and a wind turbine.

10. The assembly kit according to any one of claims 1 to 9, comprising three of the cross struts.

11. The assembly kit according to any one of claims 1 to 10, wherein the frame has a tetrahedral shape in an assembled state.

12. 12. An assembly kit according to any one of claims 1 to 11, wherein each of the cross struts is identical, each of the upright struts is identical, and each of the apex members is identical.

13. 13. An assembly kit according to any one of claims 1 to 12, wherein each apex member comprises two coplanar socket members arranged to respectively receive ends of corresponding cross struts in a common plane, and an angled socket member arranged to receive a first end of a corresponding upstanding strut at the upstanding angle to the plane.

14. 14. The assembly kit according to any one of claims 1 to 13, wherein the assembly kit comprises a plurality of cross column supports for each corresponding cross column.

15. 1. A method of manufacturing a frame for an offshore renewable energy system mounting platform, comprising: The frame is three or more cross struts and a corresponding number of apex members, each apex member arranged to secure adjacent ends of two of said cross struts to form a planar base of said frame, each of said cross struts forming a corresponding edge of said base; a plurality of upright struts equal to the number of cross struts, each upright strut being positioned to engage a corresponding apex member to define an upright edge of the frame extending from the base at an upright angle relative to the planar base; a single transition piece arranged to fix the erection column at the erection angle and forming a vertex of the frame; The method further comprising: a) positioning an upright tower having an upright column engagement surface arranged to engage a corresponding upright column of said frame at said upright angle; b) positioning each of a plurality of lateral column supports at a corresponding ground location against the upright column engagement surface, such that each lateral column support is positioned to support a corresponding lateral column to form the base; c) supporting each cross column using a corresponding cross column support at the corresponding ground location; d. engaging adjacent ends of two of said cross struts with corresponding apex members to form said base; e. engaging a first end of each upright strut with a corresponding apex member and engaging a surface of each upright strut with a corresponding upright strut engagement surface of said tower; f) securing said transition piece to a second end of each of said engaged upright posts to form an assembled frame.

16. The method according to claim 15, which is carried out using the assembly kit according to any one of claims 1 to 14.

17. 17. The method of claim 15 or 16, wherein step d) further comprises permanently fixing said ends to said corresponding apex members.

18. The method of any one of claims 15 to 17, wherein step e. further comprises permanently fixing the first end to the corresponding apex member.

19. The method of any one of claims 15 to 18, wherein step f further comprises permanently fixing the second end to the transition piece.

20. The method according to any one of claims 15 to 19, wherein the fixing is performed by welding.

21. g. transporting the assembled frame to a first location in a body of water; h) attaching a renewable energy system to the transition piece of the assembled frame.

22. 22. The method of claim 21, wherein step g further comprises supporting each cross column of the assembled frame on a corresponding self-propelled modular transporter (SPMT).

23. Step g is loading the assembled platform onto an ocean carrier; or 23. The method of claim 21 or 22, further comprising either: floating the frame on the body of water.

24. step g includes floating the frame on the body of water; step g further comprises temporarily mooring the assembled frame to the bottom of the body of water; 24. The method of claim 23, wherein step h further comprises removing the assembled frame from the bottom of the body of water after installing the renewable energy system.

25. The method of any one of claims 21 to 24, further comprising the step of: i) transporting the assembled frame to a desired deployment location on the body of water.

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