Wind turbine tower non-interference stackable system

Abstract

The tower assembly system can include an OEM-supplied tower section and an intermediate flange that facilitates lifting the tower section over a previous section without using a conventional overhead lifting system. Methods and systems for assembling a wind turbine include placing intermediate flanges at the top and bottom of each section without permanently modifying existing components or using OEM-provided connection points.

Description

Technical Field

[0001] Cross-reference to Patent Application This patent application claims priority based on PCT (Patent Cooperation Treaty) of US Provisional Patent Application Serial No. 63 / 389,390, titled "Wind Turbine Tower Non-Interference Stackable System", filed on July 15, 2022, the entire content of which is incorporated herein by reference.

[0002] Technical Field Embodiments relate to devices, methods, and systems for assembling towers, including but not limited to wind turbine towers. Embodiments further relate to a method of stacking or installing tower sections on top of a previous section by using a lower-supported towers lift rather than a typical overhead lift used in other systems that utilize conventional cranes.

Background Art

[0003] Wind power generation is currently considered one of the cleanest and most environmentally friendly energy sources, and wind turbines have attracted attention in this regard. Wind turbines are used to convert the kinetic energy of the wind into electricity. Modern wind turbines typically include a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The rotor blades capture kinetic energy from the wind using known airfoil principles, transfer the kinetic energy by rotational energy, and rotate a main shaft that connects the rotor blades to the gearbox or directly to the generator if no gearbox is used. The generator then converts the mechanical energy into electrical energy that can be deployed to the utility grid, stored, or used for other local means. Wind turbines typically include a substantially large-sized rotor (i.e., wheel) coupled to a nacelle located at the upper end of the tower. The nacelle includes a generator for generating electricity from the rotational kinetic energy generated by the rotor.

[0004] Conventionally, such installation, repair, restart, and decommissioning measures for wind turbines have required at least one large crane system, which may need to be robust enough to reach and lift heavy loads to a significant height during the installation, repair, restart, or decommissioning of a wind turbine. Wind turbines generally extend from the ground or sea level to a height of dozens of meters. Generally, such large crane systems are few in number and costly to transport, install, and set up at the wind turbine installation site.

[0005] The installation of such large power generation capacity wind turbines may include conventional crane installation techniques and so-called "crane-less" approaches such as the adaptation of "climbing" cranes and / or tower-type cranes that are erected next to the wind turbine tower and used for the installation of the wind turbine.

[0006] Conventional crane installation techniques and so-called "crane-less" approaches may be used for the installation of such large power generation capacity wind turbines. For example, FIG. 1A shows an image of a conventional crane installation approach. On the other hand, FIG. 1B shows a crane-less approach including a tower grab system. An example of such a tower grab system is disclosed in U.S. Patent No. 10,494,235, which is hereby incorporated by reference in its entirety.

[0007] Another example of a crane - less approach is shown in FIG. 1C, which depicts a tower - crane - type application used in the installation of a wind turbine beside a wind turbine tower. Another example of crane - less installation technology can include the use of a tower crane that climbs a tower powered by the improved wind turbine. A further example of a crane - less system is one that uses a conveyor on tower - top rails or a crane on a trolley. An example of this method is disclosed in U.S. Patent No. 9,261,072, which is hereby incorporated by reference in its entirety.

[0008] FIG. 1D is a diagram showing an image of a prior - art system for raising a tower section. FIG. 1E shows a diagram of another prior - art system for assembling a tower section of a wind tower. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0009] With the increasing height and weight of wind turbines and related components, the need for (onshore) heavy - lift cranes and (offshore) heavy - lift or wind turbine installation vessels (WTIVs) is growing ever more acute. This large - scale equipment is not sufficient to supply installation or repair capabilities worldwide, which causes bottlenecks and delays in many wind farm projects.

[0010] Furthermore, the cost and time involved in installing this equipment are very high and extensive. There is a need for a better installation method that allows for parallel installations and can save the time and cost of end - users / owners.

[0011] Also, environmental damage and carbon dioxide emissions reduction are major social concerns. Our system also aims to minimize the environmental footprint by using the smallest possible cranes and minimizing the transportation volume, thus minimizing not only access roads but also the area used at the windmill site and the necessary civil engineering work.

[0012] In addition, in regions in the northern part with a particularly cold climate, the operational weather windows are short. By having the ability to extend the operational period, more efficient operation and time savings become possible.

[0013] Furthermore, there are many regions in the world where it is desired to install large-capacity wind turbines but where there are neither the resources nor the ability to obtain such large and heavy equipment. However, due to a lack of installation resources, this goal may not be achievable. Therefore, the inventors propose a solution to the above problems, aiming to enable any country, company, or individual to install the desired wind turbine capacity and size using existing small or medium-sized cranes and few resources.

Means for Solving the Problems

[0014] Summary The following summary is provided to facilitate understanding of some innovative features specific to the disclosed embodiments and is not intended as a complete description. A complete understanding of the various aspects of the embodiments disclosed herein can be obtained by taking the entire specification, claims, drawings, and summary as a whole.

[0015] Therefore, providing an improved method and system for installing a wind turbine is one aspect of the embodiments.

[0016] Providing a method and system for stacking or installing tower sections on top of the previous section by using a lower supported towers lift instead of an overhead lift as used in conventional systems is another aspect of the embodiments.

[0017] Providing a method and system for assembling a wind turbine tower that uses tower sections provided by an OEM by adding intermediate flanges (or multiple flanges) to the top and bottom of each tower section without permanently modifying existing components or using existing connection points of the OEM (manufacturer of products under a partner's trademark) is a further aspect of the embodiments.

[0018] Also, providing a flange with a variable-shaped hole recess that can handle a weight in a fixed position and allow the lifting system to be removed at any time without having pinch points is an aspect of the embodiments.

[0019] Providing a configuration for use with the aforementioned flange that can be an integral part of the original tower flange to minimize parts is a further aspect of the embodiments.

[0020] Providing a configuration that can be used for assemblies that use an external or internal elevator or lifting system is also an aspect of the embodiments.

[0021] Providing a tower assembly system that can include attachment of lifting points also at the top of the flange(s) is a further aspect of the embodiments.

[0022] As described herein, the aforementioned aspects and other objects and advantages can be achieved. In one embodiment, a method of assembling a wind turbine tower can include providing a plurality of tower sections for a wind turbine tower, where the plurality of tower sections includes a tower section and a previous tower section, and stacking the tower section on top of the previous tower section using at least one lower support tower lift.

[0023] One embodiment can further include adding at least one intermediate flange of a plurality of flanges to the top and bottom of each tower section among a plurality of tower sections without permanently modifying existing components of the wind tower or using existing connection points of the OEM.

[0024] In one embodiment, at least one flange of the plurality of flanges can be configured to have variable-shaped hole depressions that facilitate handling of the weight to a fixed position and removal of the lifting system without pinch points.

[0025] One embodiment can further include providing a plurality of flanges of different diameters and shapes and different hole diameters and hole shapes that can facilitate lifting of the plurality of flanges.

[0026] One embodiment can further include providing a form that is used for at least one flange of the plurality of flanges and is an integral part of the original tower flange to minimize parts.

[0027] In yet another embodiment, the above-described form can be used for an assembly with an external elevator, an internal elevator, or a lifting system.

[0028] In one embodiment, a system for assembling a wind tower can include: a plurality of tower sections for a wind tower, the plurality of tower sections including tower sections and previous tower sections; and at least one lower support tower lift for stacking a tower section on top of a previous tower section using at least one lower support tower lift.

[0029] In one embodiment, at least one intermediate flange can be added to the top and bottom of each tower section among a plurality of tower sections without permanently modifying the existing components of the wind tower or using the existing connection points of the OEM.

[0030] In one embodiment, at least one flange can include a variable-shaped hole recess that facilitates handling of the plumb bob in a fixed position and removal of the lifting system without pinch points.

[0031] One embodiment can further include a plurality of flanges of different diameters and shapes and different hole diameters and hole shapes that can assist in facilitating the lifting of the plurality of flanges.

[0032] One embodiment can further include a configuration that is used for at least one flange among the plurality of flanges to minimize parts and can be an integral part of the original tower flange.

[0033] In one embodiment, this configuration can be adapted for use in an assembly using an external elevator, an internal elevator, or a lifting system.

[0034] In one embodiment, a system for assembling a wind tower can include the following. A plurality of tower sections for a wind tower, a plurality of tower sections including a plurality of tower sections, a tower section and the previous tower section, at least one lower support tower lift for stacking a tower section on top of the previous tower section using at least one lower support tower lift, and a plurality of flanges.

[0035] In one embodiment, the plurality of flanges can include at least one intermediate flange.

[0036] In one embodiment, at least one intermediate flange can be added to the top and bottom of each tower section among a plurality of tower sections without permanently modifying existing components of the wind tower or using existing connection points of the OEM.

[0037] In one embodiment, the plurality of flanges can include at least one flange with a variable-shaped hole recess that allows for handling of the weight in a fixed position and removal of the lifting system without pinch points.

[0038] In one embodiment, the plurality of flanges can include flanges of different diameters and shapes.

[0039] In one embodiment, the plurality of flanges can further include different hole diameters and hole shapes to facilitate lifting of the plurality of flanges.

[0040] In one embodiment, the plurality of tower sections of the wind tower can further include an intermediate tower section located between a tower section and the previous tower section.

[0041] In one embodiment, the plurality of flanges can include one or more of a bottom support flange (BSF) and a top support flange (TSF).

[0042] Like reference numerals refer to identical or functionally similar elements throughout the separate figures, and the accompanying drawings, which are incorporated herein and form a part of this specification, further illustrate the invention and are useful in explaining the principles of the invention together with the detailed description of the invention.

Brief Description of the Drawings

[0043]

Figure 1A

Figure 1B

Figure 1C

Figure 1D

Figure 1E

Figure 2

Figure 3A

Figure 3B

Figure 4

Figure 5

Figure 6

Figure 7

DETAILED DESCRIPTION OF THE INVENTION

[0044] Like reference numerals used herein may refer to the same or similar parts or elements.

[0045] The specific values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate single or multiple embodiments and are not intended to limit the scope thereof.

[0046] Reference will now be made in detail to the subject matter, a part of which is illustrated in the accompanying drawings that form a part hereof and which show, by way of illustration, specific exemplary embodiments. However, the subject matter may be embodied in many different forms and, accordingly, the subject matter being targeted or claimed is not intended to be limited to the exemplary embodiments described herein, which are provided by way of example only. Similarly, a reasonably broad scope is intended for the subject matter being claimed or targeted. In particular, for example, the subject matter may be embodied as a method, apparatus, component, or system. Accordingly, embodiments can take the form of, for example, hardware, software, firmware, or any combination thereof (except software itself). Accordingly, the following detailed description is not intended to be construed in a limiting sense.

[0047] Throughout this specification and the claims, terms may have nuanced meanings suggested or implied by the context beyond the explicitly described meanings. Similarly, phrases such as "in one embodiment" or "in an exemplary embodiment" and variations thereof used herein do not necessarily refer to the same embodiment, and phrases such as "in another embodiment" or "in another exemplary embodiment" and variations thereof used herein do not necessarily refer to different embodiments. For example, the claimed subject matter is intended to include combinations of exemplary embodiments, in whole or in part.

[0048] In general, terms can be understood, at least in part, from their usage in context. For example, terms such as "and," "or," or "and / or" as used herein can have various meanings that may depend, at least in part, on the context in which such terms are used. Typically, when used to associate a list such as A, B, or C, "or" is intended to mean, on the one hand, A, B, and C used in an inclusive sense, and on the other hand, A, B, or C used in an exclusive sense. Further, as used herein, the term "singular or plural" is used to describe any feature, structure, or characteristic in the singular sense or to describe a combination of features, structures, or characteristics in the plural sense, at least in part depending on the context. Similarly, terms such as "a," "an," or "the" can also be understood, at least in part depending on the context, to convey either a singular usage or a plural usage.

[0049] In addition, the term "based on" may be understood not necessarily to convey a set of exclusive factors, but instead to allow, at least in part depending on the context, the presence of additional factors that are not necessarily explicitly recited. Further, the expression "at least one" may be understood to convey the meaning of "singular or plural." For example, "at least one widget" can convey the concept of "one or more widgets."

[0050] Figure 2 is a schematic view of a group of tower sections used for the assembly or installation of a wind tower according to an embodiment. The group of tower sections shown in Figure 2 includes a tower bottom section 221, a tower section 222, and a tower top section 223. The configuration shown in Figure 2 includes a non-interference flange system 201, a non-interference flange system 202, and a non-interference flange system 203, which are each indicated by the circular dashed lines shown in Figure 2. It should be noted that the circular dashed lines have corresponding systems with dimensions similar to or different from the bottom section, as may be required to match the dimensions of the OEM flange.

[0051] The assembly of the wind tower can be achieved by using the tower sections (tower bottom section 221, tower section 222, tower top section 223) provided by the OEM and adding intermediate flanges (or multiple flanges) to the top and bottom of each tower section without permanently modifying the existing components or using the existing connection points of the OEM. Each non-interference flange system can include one or more flanges, such as a flange portion 211, an interconnecting portion 212, and a rack / guide portion 213. These flanges can be configured with variable-shaped hole depressions that can handle the plumb bob in a fixed position and allow the lifting system to be removed at any time without having pinch points.

[0052] It should be noted that the term "flange" as used in the context of this specification and the assembly of sections of a wind turbine tower that supports a wind turbine can refer to a component that plays an important role when joining different sections of the tower. The flange can be flat, disc-shaped, ring-shaped, or of other forms or shapes, as described in this specification. The flange can be composed of steel or other durable materials that can withstand the loads and forces experienced by the wind turbine tower. The flange can provide a secure and rigid connection between adjacent tower sections and can ensure structural integrity and stability. Each tower section can have a flange corresponding to its end, and when two sections are assembled, their flanges can be aligned and joined using high-strength fasteners such as bolts. By carefully designing the flange, the loads and stresses applied to the joint can be evenly distributed, enhancing the overall strength and stability of the wind turbine tower.

[0053] Figures 3A - 3B are schematic diagrams of a tower intermediate flange(s) system for an unmodified OEM tower section according to one embodiment. In Figure 3A, the bottom support flange (BSF) 235 is an insert located at the bottom section of the top OEM tower section 223, which conforms to the design of the original flange of the top OEM tower 223 and enables connection to / from the rack. The top support flange (TSF) 233 is located at the top of the lower tower OEM section 221 and can be provided as an insert that conforms to the design of the original flange of the lower OEM tower section 221 and further enables connection to / from the rack. In the case of Figure 3B, the flange insert 234 can be a single insert unit that can constitute both the BSF and the TSF together.

[0054] The term "BSF" or "Bottom Support Flange" as used herein may relate to a type of flange that can be used in the assembly of a wind tower section for supporting a wind turbine. It should be noted that the BSF can be placed at the base section or the bottom most section of the wind tower, thereby providing a connection point between the wind tower and its foundation. The BSF can function as an interface between the wind tower and the foundation to distribute the loads and forces from the wind turbine and the tower itself to the foundation system. It can be designed to transmit the weight of the tower and the rotational forces generated by the wind turbine to the ground and ensure stability and structural integrity.

[0055] Figure 4 is a schematic view of a tower intermediate flange system having non-interference loading support(s) according to one embodiment. In Figure 4, the Bottom Support Flange (BSF) can be located at the bottom of the top OEM upper tower section and can be made to conform to the design of the original flange of the top OEM tower while being provided as an insert that enables connection to / from the rack. The Top Support Flange (TSF) can be located at the top of the lower tower OEM section and can be made an insert that conforms to the design of the original flange of the lower OEM tower section and enables connection to the rack. The composite sample shape generated by the upper support flange and the lower support flange can be cylindrical or a similar shape as shown by the multi-flange form 240 or the single-flange form 242 in the sequence shown in Figure 4.

[0056] Figure 5 is a schematic diagram of a tower intermediate flange system having non-interference loading support(s). In Figure 5, the bottom support flange (BSF) can be located at the bottom of the top OEM upper tower section, can be adapted to the design of the top OEM tower original flange, and can be an insert that also enables connection to / from the rack. The top support flange (TSF) can be located at the top of the lower tower OEM section and can be an insert that is adapted to the design of the lower OEM tower section original flange and enables connection to the rack. The composite shape generated by the upper support flange and the lower support flange can be a cube or a similar shape as shown in the sequence shown in the multi-flange form 250 or the single-flange form 252 in Figure 5.

[0057] Figure 6 is a schematic diagram of a tower intermediate flange system having non-interference loading support(s). In Figure 6, the bottom support flange (BSF) is an insert that can be located at the bottom of the top OEM upper tower section, can be adapted to the design of the top OEM tower original flange, and at the same time enables connection to / from the rack. The top support flange (TSF) is an insert located at the top of the lower tower OEM section, is adapted to the design of the original flange of the lower OEM tower section, and enables connection to / from the rack. The composite shape formed by the upper support flange and the lower support flange is a rhombus or a similar shape as shown in the multi-flange form 260 or the single-flange form configuration 262 in the sequence shown in Figure 6.

[0058] Figure 7 is a schematic side view of a completed tower 270 according to an embodiment. The completed tower 270 can include a tower bottom section 221, a tower section 222, and a tower top section 223.

[0059] From the above, it will be understood that a number of different embodiments are disclosed herein. For example, in one embodiment, a method of assembling a wind turbine tower can include the following. Providing a plurality of tower sections for the wind turbine tower, wherein the plurality of tower sections includes a tower section and a previous tower section, and stacking the tower section on top of the previous tower section using at least one lower support tower lift.

[0060] One embodiment can further include adding at least one intermediate flange of a plurality of flanges to the top and bottom of each tower section of the plurality of tower sections without permanently modifying existing components of the wind turbine tower or using existing connection points of the OEM.

[0061] In one embodiment, at least one flange of the plurality of flanges can be configured to have a variable-shaped hole recess that can facilitate handling the weight to a fixed position and removing the lifting system without pinch points.

[0062] One embodiment can further include providing a plurality of flanges having different diameters and shapes, as well as different hole diameters and hole shapes, which can facilitate lifting the plurality of flanges.

[0063] One embodiment can further include providing a configuration that is used for at least one flange of the plurality of flanges and is an integral part of the original tower flange to minimize parts.

[0064] In one embodiment, the configuration can further be used in an assembly equipped with an external elevator, an internal elevator, or a lifting system.

[0065] In one embodiment, a system for assembling a wind tower can include the following. A plurality of tower sections for a wind tower, the plurality of tower sections including a tower section and a previous tower section, and at least one lower support tower lift for stacking a tower section on top of the previous tower section using at least one lower support tower lift.

[0066] In one embodiment, at least one intermediate flange can be added to the top and bottom of each tower section among the plurality of tower sections without permanently modifying existing components of the wind tower or using existing connection points of the OEM.

[0067] In one embodiment, at least one flange can include a variable-shaped hole recess that facilitates handling of the plumb bob in a fixed position and removal of the lifting system without pinch points.

[0068] One embodiment can further include a plurality of flanges having different diameters and shapes, and different hole diameters and hole shapes, which can assist in facilitating the lifting of the plurality of flanges.

[0069] One embodiment can further include a configuration that is used for at least one flange among the plurality of flanges to minimize parts and can be an integral part of the original tower flange.

[0070] In one embodiment, the configuration can be adapted for use in an assembly using an external elevator, an internal elevator, or a lifting system.

[0071] In one embodiment, a system for assembling a wind tower can include the following. A plurality of tower sections for a wind tower, wherein the plurality of tower sections include a tower section and a previous tower section, a plurality of tower sections, at least one lower support tower lift for stacking a tower section on top of a previous tower section using the at least one lower support tower lift, and a plurality of flanges.

[0072] In one embodiment, the plurality of flanges can include at least one intermediate flange.

[0073] In one embodiment, at least one intermediate flange can be added to the top and bottom of each tower section among the plurality of tower sections without permanently modifying existing components of the wind tower or using existing connection points of the OEM.

[0074] In one embodiment, the plurality of flanges can include at least one flange having a variable-shaped hole recess that enables handling of a plumb bob in a fixed position and removal of a lifting system without pinch points.

[0075] In one embodiment, the plurality of flanges can include flanges of different diameters and shapes.

[0076] In one embodiment, the plurality of flanges can further include different hole diameters and hole shapes to facilitate lifting of the plurality of flanges.

[0077] In one embodiment, the plurality of tower sections of the wind tower can further include an intermediate tower section located between a tower section and a previous tower section.

[0078] In one embodiment, the plurality of flanges can include one or more of a bottom support flange (BSF) and a top support flange (TSF).

[0079] It will be understood that variations of the features and functions disclosed above, or alternatives thereto, can desirably be combined in many other different systems or applications. It will also be understood that various alternatives, modifications, variations or improvements which are now unforeseen or unanticipated may subsequently be made by those skilled in the art, which are also intended to be encompassed by the following claims.

Claims

1. A method of assembling a wind tower, comprising: providing a plurality of tower sections for the wind tower, the plurality of tower sections including a tower section and a previous tower section; stacking the tower section on top of the previous tower section using at least one lower support tower lift; A method comprising the steps of:

2. The method according to claim 1, further comprising: adding at least one intermediate flange of a plurality of flanges to the top and bottom of each tower section of the plurality of tower sections without permanently modifying existing components of the wind tower or using existing connection points of the OEM.

3. The method according to claim 2, wherein: at least one of the plurality of flanges includes a variable-shaped hole recess that facilitates handling of the plumb bob in a fixed position and removal of the lifting system without pinch points.

4. The method according to claim 1, further comprising: providing a plurality of flanges of different diameters and shapes, and different hole diameters and hole shapes to facilitate lifting of the plurality of flanges.

5. The method according to claim 1, further comprising: providing a shape that is an integral part of the original tower flange for use on at least one of the plurality of flanges to minimize parts.

6. The method according to claim 5, further comprising: using the shape in an assembly using an external elevator, an internal elevator, or a lifting system.

7. A system for assembling a wind tower, comprising: a plurality of tower sections for the wind tower, the plurality of tower sections including a tower section and a previous tower section; at least one lower support tower lift for stacking the tower section on top of the previous tower section using the at least one lower support tower lift.

8. The system according to claim 7, wherein: A system further comprising at least one intermediate flange added to the top and bottom of each tower section of the plurality of tower sections without permanently modifying existing components of the wind tower or using existing connection points of the OEM.

9. The system according to claim 8, wherein at least one flange includes variable-shaped hole depressions that facilitate handling of the weight to a fixed position and removal of the lifting system without pinch points.

10. The system according to claim 7, further comprising a plurality of flanges with different diameters and shapes, and different hole diameters and hole shapes, to facilitate lifting of the plurality of flanges.

11. The system according to claim 10, further comprising a shape that is an integral part of the original tower flange and is used for at least one of the plurality of flanges to minimize parts.

12. The system according to claim 11, wherein the shape is adapted for use in an assembly using an external elevator, an internal elevator, or a lifting system.

13. A system for assembling a wind tower, comprising a plurality of tower sections for a wind tower, the plurality of tower sections including a plurality of tower sections including a tower section and a previous tower section, at least one lower support tower lift for stacking the tower section on top of the previous tower section, and a plurality of flanges.

14. The system according to claim 13, wherein the plurality of flanges includes at least one intermediate flange.

15. The system according to claim 14, wherein the at least one intermediate flange is added to the top and bottom of each tower section of the plurality of tower sections without permanently modifying existing components of the wind tower or using existing connection points of the OEM.

16. The system according to claim 14, wherein the plurality of flanges includes at least one flange having a variable-shaped hole recess that enables handling of the weight to a fixed position and removal of the lifting system without pinch points.

17. The system according to claim 14, wherein the plurality of flanges comprises flanges of different diameters and shapes.

18. The system according to claim 15, wherein the plurality of flanges further comprises different hole diameters and hole shapes for facilitating lifting of the plurality of flanges.

19. The system according to claim 14, wherein the plurality of tower sections of the wind turbine tower further includes an intermediate tower section located between the tower section and the previous tower section.

20. The system according to claim 14, wherein the plurality of flanges further includes at least one of a bottom support flange (BSF) and a top support flange (TSF).

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