Rotor Blade Support Structure for Crane-Free Wind Turbine Installation
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Solution Overview
Problem
The installation and servicing of rotor blades in wind turbines, particularly offshore and floating wind turbines, are challenging due to the need for precise alignment and stability under varying weather conditions, often requiring large cranes and being limited by sea and wind conditions.
Innovation Solution
A method and toolkit using a support structure with a support means and connection means to align the rotor blade at an angle of less than 45° to the horizontal plane, allowing for precise control and rigidity to support the rotor blade, enabling installation and servicing without cranes, even in adverse conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large crane is used to handle rotor blades during installation, then the rotor blade can be supported and positioned, but the operation is limited to certain weather conditions such as calm seas and low wind speeds
Solution Approach 1:
The patent replaces the crane-based mechanical handling system with a support structure that uses a base on the wind turbine tower, a connection means, and a support surface to hold the rotor blade. This substitution eliminates the need for external cranes and enables operations in adverse weather conditions including high winds and rough seas
Solution Approach 2:
The support structure allows the rotor blade to be held at various angles relative to the horizontal plane (including angles of at least 45°), providing multi-dimensional positioning capability that enables installation from different orientations and improves adaptability to varying weather conditions
2Reliability
If a large crane is used to support the rotor blade, then the rotor blade can be held in position, but the costs, time and effort required for mounting increase
Solution Approach 1:
The invention extracts the support function from the external crane system and integrates it directly into the wind turbine structure through the base-mounted support structure. This eliminates the need for heavy external equipment and reduces the time, cost, and effort required for rotor blade installation while maintaining mounting stability
Solution Approach 2:
The support structure is self-contained and mounted on the wind turbine tower itself, allowing the wind turbine to support its own rotor blade during installation without requiring external assistance from cranes. This self-service capability improves mounting efficiency and reduces operational costs
3Force
If the rotor blade is held at a steep angle during installation, then it can be supported vertically, but precise alignment and control become more difficult
Solution Approach 1:
The support structure provides dynamic positioning capability, allowing the rotor blade to be held at adjustable angles including shallow angles of at least 45° to the horizontal plane. This dynamic adjustment enables precise alignment in the horizontal direction while maintaining vertical support capability, improving both alignment precision and control during installation
Data Source
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AI summary
Method for installing a rotor blade (1) on a wind turbine (2) comprising the steps of supporting the rotor blade (1) in a mounting position (9) by a support structure (10) in such a way, that, at least in a supported section (11) of the rotor blade (1), a longitudinal direction (12) of the rotor blade (2) extends at an angle of less than 45° to a horizontal plane (20), wherein the support structure (10) comprises a support means (13) forming a support surface (21) that is contacting an outer surface (39) of the rotor blade (2), while the rotor blade (2) is supported by the support structure (10), a base (14), and a connection means (15) that connect the support means (13) to a connection area (16) of the base (14) that is arranged at a height below the lowest point (47) of the support surface (21), wherein the connection means (15) is sufficiently rigid to vertically support at least part of the combined weight of the support means (13) and the rotor blade (1) and to allow for a transfer of forces that have a force component within the horizontal plane (20) and/or of a torque between the support means (13) and the connection area (16) of the base (14), mounting the rotor blade (1) to a rotatable component (6) of the wind turbine (2), in particular to a hub, while the rotor blade (1) is supported by the support structure (10), and moving or disassembling the support structure (10) and/or rotating a nacelle (5) to allow for a rotation of the rotatable component (6).