Wind Turbine Rotor Horizontal Pre-Assembly Adapter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wind turbine rotor assembly methods require complex and heavy assembly aids that incur high transport costs and restrict construction site space, especially for offshore turbines, due to the need for large platforms or support structures to manage assembly forces and moments.
Innovation Solution
The use of a tower system-based adapter device that allows for horizontal pre-assembly of the rotor, utilizing locally available tower systems to minimize transport weight and volume, and enabling assembly at a height above ground level, with a work platform for safe access and a cantilever arm for moment compensation, allowing for flexible and space-efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If assembly aids with high intrinsic mass are used to compensate for moments during assembly, then assembly stability is improved, but transport costs increase due to high mass
Solution Approach 1:
The assembly aid is divided into a base unit and extendable support feet. The base unit contains the counterweight for moment compensation, while the support feet can be extended or collapsed as needed. This segmentation allows the heavy counterweight to remain compact during transport while providing full stability during assembly operations.
Solution Approach 2:
The support feet are designed to be extendable and adjustable during assembly, transforming from a compact transport state to a fully extended operational state. This dynamic transformation allows the assembly aid to adapt its configuration based on operational requirements without permanently increasing transport dimensions.
2Stability of the object's composition
If long support feet are provided to increase contact surface, then assembly stability is improved, but transport volume increases due to overhanging dimensions
Solution Approach 1:
The support structure is segmented into a compact base unit and collapsible support feet. During transport, the support feet are collapsed or retracted into the base unit, minimizing the overall volume. During assembly operations, the support feet can be extended to provide the necessary contact surface and stability.
Solution Approach 2:
The support feet are designed to nest within or alongside the base unit when not in use. This nesting arrangement allows the long support feet to be stored compactly within the transport envelope of the base unit, eliminating the need for excessive transport volume while maintaining full operational capability.
3Stability of the object's composition
If additional assembly supports are added to relieve mounting aid, then assembly stability is improved, but device complexity increases due to number of components
Solution Approach 1:
The counterweight function and support structure are merged into a single integrated base unit. The counterweight is positioned within the base unit to directly compensate for moments generated during assembly, eliminating the need for separate counterweight components or additional assembly supports. This integration reduces the total number of components while maintaining assembly stability.
4Area of stationary object
If ground-level assembly is performed, then construction site area is reduced, but freedom of movement is restricted due to narrow space next to foundation
Solution Approach 1:
The assembly operation is elevated from ground level to an intermediate height platform. This vertical dimensionality change allows the assembly to be performed above the narrow space next to the foundation, providing adequate freedom of movement for workers and equipment while still utilizing a compact footprint on the construction site.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an adapter device (10) and an arrangement (1) for the horizontal pre-assembly of a wind turbine rotor (30). The adapter device (10) according to the invention for the horizontal pre-assembly of a wind turbine rotor (30) comprises a connecting piece (11) for attaching the adapter device (10) to a tower system (20) of a tower crane on the underside of the adapter device (10) and a rotor flange (12) for attaching the rotor hub (31) of the wind turbine rotor (30) to be mounted to the top of the adapter device (10). The arrangement (1) according to the invention comprises an adapter device (10) according to the invention and a tower system (20) of a tower crane, wherein the adapter device (10) is attached to the tower system (20) by its connecting piece (11).