Climbing Device for Tower Segment Assembly
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Solution Overview
Problem
The assembly of tall towers, particularly for wind turbines, is challenging due to the difficulty in transporting and placing heavy segment components, which requires costly and inflexible crane operations, and is often hindered by adverse weather conditions.
Innovation Solution
A climbing device that can move within the tower, utilizing multiple climbing elements with drive mechanisms and a control system to ascend and descend, allowing for the transportation of components and personnel, and enabling the assembly of towers with reduced reliance on external cranes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heavy segment components are transported from production site to erection site, then the tower can be assembled, but heavy transport is required which is associated with high costs and inflexible timing
Solution Approach 1:
The tower is divided into multiple segment components that can be manufactured separately and assembled in sequence. The climbing device itself is segmented into modular units (base body, climbing elements, drive mechanisms) that can be transported and installed incrementally, allowing the tower to be built section by section rather than requiring complete assembly in one operation.
Solution Approach 2:
The climbing device transports subsequent segment components using its own integrated lifting mechanism, eliminating the need for external heavy transport equipment. The device serves itself by carrying its own weight and the weight of upcoming segments, reducing dependency on external infrastructure.
2Ease of manufacture
If heavy segment components are handled on site during tower construction, then the tower can be assembled, but in adverse weather conditions the erection is often stopped due to wind forces acting on the segments
Solution Approach 1:
The climbing device is designed with movable and adjustable components that can adapt to varying wind conditions. The climbing elements can be repositioned along the tower, and the device can pause or reverse movement when wind conditions become unfavorable, allowing flexible response to changing weather rather than complete work stoppage.
Solution Approach 2:
Segment components are prepared and positioned in advance at ground level before being lifted. The climbing device assembles the tower incrementally, allowing segments to be pre-positioned and secured before adverse weather conditions affect the construction site.
3Manufacturing precision
If precise setting of segment components is required at heights above 50 meters, then the tower can be assembled with accuracy, but this is associated with difficulties in relation to crane operation
Solution Approach 1:
The climbing device extracts the positioning and lifting functions from external cranes and integrates them into a self-contained system that travels with the construction process. This eliminates the need for complex crane operations at height by bringing the lifting capability directly to each assembly point.
Solution Approach 2:
The climbing device acts as an intermediary between the ground and the tower segments, providing a stable platform and integrated lifting mechanism that simplifies the transfer and positioning of segments. It mediates the complex coordination between multiple crane operations by consolidating these functions into a single moving system.
4Stability of the object's composition
If a crane with large cantilever is used for tower assembly, then sufficient stability is achieved, but such cranes are associated with high costs
Solution Approach 1:
The climbing device transitions from ground-based crane operations to vertical movement along the tower structure itself. By moving the assembly platform up the tower and using the tower's own structure as the support, the system eliminates the need for large external cantilevers while maintaining stability through the tower's inherent structural rigidity.
Solution Approach 2:
The tower structure serves itself by providing the support and stability previously requiring external cranes. The climbing device uses the tower's own structure as its track and support system, eliminating the need for separate heavy stabilization infrastructure.
Data Source
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AI summary
The invention relates to a climbing device (1) for carrying out a movement relative to a tower (102, 202), a partial ring segment for a tower, a tower, a wind turbine and a method for producing a tower. The invention relates to a climbing device (1) for carrying out a movement relative to a tower (102, 202), comprising a main body (5) having a longitudinal extension from a first end (6) to a second end (7), wherein the second end is facing a base (112) of a tower in an operating state, at least one first climbing element (10) having an extension between a first inner end and a first retaining end (12), at least one second climbing element (20) having an extension between a second inner end and a second retaining end (22), wherein the first climbing element is arranged and configured to carry out a first retaining movement (19) of the first retaining end relative to the main body, with a first retaining movement direction being orthogonal to the longitudinal extension, and/or to carry out a first climbing movement (18) of the first retaining end relative to the main body.