Self-Climbing Crane for Wind Tower Erection
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Solution Overview
Problem
Conventional cranes are inadequate for constructing large wind turbines with taller towers, requiring larger booms and heavier counterweights, which increases construction costs and complexity.
Innovation Solution
A self-climbing crane system with an annular base structure, slewing lifting booms, movable radial beams, and hoisting winches that allows for efficient erection of tower ring elements, enabling faster and more cost-effective construction of taller towers with minimal elevated stations and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional cranes are used to construct taller wind towers, then the tower height can be increased, but the crane requires longer booms and heavier counterweights which increases device complexity and construction cost
Solution Approach 1:
The crane transitions from a static ground-based configuration to a dynamic self-climbing system that moves vertically along the tower. The base structure climbs the tower using hoisting winches and gripping elements, allowing the crane to access higher elevation stations without requiring progressively longer booms or heavier counterweights. This dynamic adaptation enables taller tower construction while maintaining manageable crane dimensions at each station.
Solution Approach 2:
The crane utilizes the vertical dimension of the tower structure itself as a support and mobility path. Instead of extending horizontally with longer booms to reach higher points, the crane climbs vertically along the tower using the tower's own structure as a guide and support. This dimensional shift from horizontal extension to vertical traversal eliminates the need for proportionally longer booms and heavier counterweights.
2Length of stationary object
If conventional cranes with longer booms are used, then taller towers can be erected, but larger platforms are needed on site for crane mobilization which increases construction cost
Solution Approach 1:
The base structure transitions from requiring large stationary platforms for mobilization to a dynamic climbing system that uses the tower itself as its support structure. At each elevated station, the base grips the tower and uses the tower's structure for positioning and support, eliminating the need for large external platforms. This dynamic adaptation to the tower structure reduces the required platform area significantly.
Solution Approach 2:
The tower structure serves dual purposes: it is both the structure being constructed and the support system for the crane during construction. The base structure uses the tower's own geometry and strength to position, support, and move the crane along the construction path. This self-service approach eliminates the need for separate large platforms for crane mobilization and positioning.
3Device complexity
If the number of elevated stations is reduced, then fewer docking zones are needed which simplifies the tower structure, but the crane must travel farther between stations
Solution Approach 1:
The base structure is designed with pre-configured gripping elements and hoisting mechanisms that enable immediate attachment to the tower at designated stations. The docking zones are pre-positioned at optimal locations along the tower, and the base structure is prepared with the necessary components to engage these zones quickly and reliably. This preliminary preparation reduces the overall number of stations needed while maintaining efficient travel distances between them.
Solution Approach 2:
The base structure serves multiple functions at each elevated station: it grips the tower for positioning, provides support for the lifting booms, houses the hoisting winches for vertical movement, and serves as the operational platform for tower construction activities. This multi-functionality consolidates what would traditionally require separate components and stations into a single integrated base unit, reducing the total number of elevated stations needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system facilitates faster, cost-effective erection of wind turbine towers, reduces material requirements, and increases annual energy production, thereby decreasing the levelized cost of energy, while allowing for tandem lifting capacity and easy demobilization.
Implementation Method 1
hoisting winches carried by the base structure for elevating the crane along the tower under construction
Implementation Method 2
The crane comprises roller guides configured for rolling on an external surface of the tower for guiding the base structure along the tower during its vertical displacement
Implementation Method 3
movable radial beams carried by the base structure and configured to engage into corresponding docking zones of the tower under construction to immobilize the base structure relative to the tower
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A system for the erection of a tower (T) comprising superimposed tower ring elements (E), the system comprising a self-climbing crane (1) comprising an annular base structure (110) to be positioned around the tower under construction, two slewing lifting booms (120) carried by said base structure (110), movable radial beams (130) carried by the base structure and configured to engage into corresponding docking zones (300) of the tower under construction to immobilize the base structure (110) relative to the tower and hoisting winches (111) carried by the base structure (110) for elevating the crane along the tower under construction. Also disclosed is a method for erecting a tower using such a system and a tower comprising ring elements (E) assembled using the such a method, the ring elements (E) comprising at least one of anchoring holes (565) for anchoring hoist cables (114) anchoring devices (115), brackets for securing security cables (420), openings (502) for introduction of telescopic beams (500), holes for securing temporary docking bars (230).