Peripheral Lifting System for Wind Turbine Tower Assembly
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Solution Overview
Problem
The assembly of modern wind turbines has become complicated due to their increasing size, requiring taller and more costly cranes, which are scarce, and existing solutions fail to adequately manage the loads and stresses during assembly, particularly vertical loads and bending moments.
Innovation Solution
A lifting system with three peripheral lifting systems arranged in a triangular shape, capable of lifting and lowering 12-meter tower modules, which eliminates the need for large cranes by distributing loads naturally and providing stable seating on the terrain, and includes a method for mounting a complete nacelle and tower without additional boom cranes, suitable for both latticed and solid towers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If wind turbines continue growing in size and power generation capacity, then energy production increases, but assembly becomes more complicated requiring taller and more costly cranes
Solution Approach 1:
The wind turbine tower is divided into multiple transportable modules that can be assembled incrementally. Each module can be transported separately and then connected to form the complete tower structure, enabling assembly of tall towers without requiring excessively tall cranes.
Solution Approach 2:
A specialized lifting system with multiple lifting points acts as an intermediary mechanism between the ground and the tower modules. This lifting system enables vertical assembly of tower modules without requiring a single tall crane, distributing the lifting function across multiple coordinated components.
2Length of stationary object
If taller cranes are used to assemble larger wind turbines, then assembly capability increases, but cost and availability worsen due to scarcity and rental costs
Solution Approach 1:
The tower is segmented into modules that can be assembled in stages using smaller, more available cranes or lifting equipment, rather than requiring a single tall crane. This reduces equipment rental costs and improves availability.
Solution Approach 2:
Tower modules are prepared and positioned in advance at or near the assembly location. This preliminary preparation allows the actual assembly to be performed with smaller equipment, reducing the need for expensive tall cranes during the critical assembly phase.
3Productivity
If existing lifting solutions are used, then assembly can proceed, but load management is insufficient particularly regarding vertical loads and bending moments
Solution Approach 1:
The lifting system incorporates multiple lifting points distributed around the tower perimeter, each capable of independently managing local loads. This distribution of lifting functions improves overall load management by preventing concentration of vertical loads and bending moments at single points.
Solution Approach 2:
The lifting system is designed to counterbalance the weight and moments of tower modules during assembly. By positioning lifting points and adjusting lifting forces, the system creates counteracting forces that neutralize bending moments and control vertical loads, improving reliability during the assembly process.
Data Source
Figure 1
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AI summary
The invention relates to a system for assembling a wind turbine without using cranes, which has lifting systems (8) arranged peripherally to the tower (3), with a lifting platform (11), a base (10) and an internal lifting mechanism. The lifting platform (11) engages with different coupling tools (16, 18 and 2x) that can be supported on an auxiliary column (15) and thereby raise or lower the consecutive modules of the tower (3). The assembly method consists of: preparing the foundation (5) on the floor (6) or on the offshore platform, installing the basic module (7), arranging the lifting systems (8) peripherally. In the case of an offshore wind turbine, the underwater section is assembled and after opening a hole in the platform the lifting system itself will enable said underwater section to be immersed until it reaches the bottom. Once said section is attached, the gondola (4) is attached and raised, the upper module (14) of the tower is placed in the gap created, the lifting platforms (11) are lowered, the auxiliary column (15) and the connection flange (16) are installed, the gondola (4) is raised with the top module of the tower (14), the module (17) is placed in the gap created, the auxiliary column (15) is disconnected and the lifting platforms (11) are lowered, the auxiliary column (15) and the connecting piece (18) are installed, the gondola (4) is lifted with the module (14) and the module (17). The above process is repeated using the other modules until the end of the assembly.