Stackable Wind Turbine Tower Assembly Without Large Cranes

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Solution Overview

Problem

The installation, repair, and decommissioning of large wind turbines require expensive and scarce large-sized crane systems, leading to bottlenecks, high costs, and extended installation times, especially in areas lacking resources or capacity for such equipment.

Innovation Solution

A method and system for assembling wind turbine towers using a lower-supported tower lift, incorporating intermediate flanges with variable shaped holes to facilitate weight handling and lifting without pinch points, allowing for the use of smaller cranes and reducing the need for permanent modifications to existing components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If large-sized crane systems are used for wind turbine installation, then lifting capacity and reach are sufficient, but equipment scarcity, cost, and installation time increase

Engineering Contradiction:

Improvelifting capacityVSAvoidinstallation speed

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The tower is divided into multiple sections that can be assembled sequentially. The lower-supported tower lift enables assembly from the bottom upward, with each section being lifted and connected in place, eliminating the need for massive single-lift operations requiring large cranes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediate lifting platform or mast is introduced as a mediator between the ground and the tower sections. This intermediate structure provides a mechanical advantage system that enables smaller cranes to lift heavy tower sections by distributing the lifting function across multiple levels and components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If conventional overhead lifting systems are used, then tower assembly is possible, but installation time and equipment requirements increase

Engineering Contradiction:

Improveassembly feasibilityVSAvoidinstallation time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

Instead of using overhead lifting systems that require the tower to be assembled from the top downward or using complex mast climbing cranes, the invention inverts the approach by using a lower-supported lift that raises sections from the bottom upward. This inversion simplifies the lifting mechanism and reduces installation time.

Inventive Principle:

Principle #13The other way round (Inversion)

3Productivity

If tower sections are lifted using traditional methods, then assembly is achieved, but environmental impact and resource consumption increase

Engineering Contradiction:

Improveassembly efficiencyVSAvoidenvironmental impact

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system uses temporary, removable lifting components and intermediate platforms that can be discarded or relocated after use, rather than requiring permanent installation of heavy lifting infrastructure. This reduces the environmental footprint while maintaining assembly efficiency.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS20250347266A1Wind turbine tower non-interference stackable system

Publication Date: 2025.11.13 CLS WIND LLC

AI summary

A tower assembly system can include OEM supplied tower sections and intermediate flange(s) that facilitate the lifting of the tower sections over a previous section without the use of conventional overhead lifting systems. A method and system for assembling a wind turbine can involve placing intermediate flanges on the top and bottom of each section without permanently modifying existing components or using OEM supplied connection points.