Wind Turbine Tower Section Assembly for Horizontal Damper Mounting
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Solution Overview
Problem
The installation of dampers in wind turbine towers is challenging due to their significant weight and size, which complicates transportation and mounting, increasing safety risks and costs, and existing methods are inefficient and unsafe, especially when dealing with heavy damper units exceeding 8 tons.
Innovation Solution
A method and system for assembling wind turbine tower sections by arranging them horizontally, using a horizontal transport system to move and mount damper units deep inside the tower section, reducing safety risks and improving efficiency by allowing the damper unit to be transported and mounted in a horizontal direction, with the option to rotate the unit for orientation changes, thus accommodating larger units through smaller openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the damper unit is installed in the uppermost section of the wind turbine tower, then the damping effect is achieved, but the weight and size of the tower section increase, making transportation and installation difficult
Solution Approach 1:
The tower is divided into multiple transportable sections, with the damper unit integrated into one specific section. This segmentation allows the heavy damper to be distributed across manageable sections rather than concentrating all weight in one piece, facilitating transportation while maintaining the damping function in the uppermost section.
Solution Approach 2:
The patent changes the installation dimension by transporting the tower section horizontally rather than vertically. The transport system includes a horizontal conveyor or rail system that moves the section with the integrated damper unit horizontally into position, then elevates it to the final vertical installation position. This dimensional change avoids the need to lift the heavy damper vertically during installation.
2Reliability
If the damper unit weight exceeds 8 tons, then the damping performance is sufficient, but telehandlers with telescopic booms can no longer lift it into place
Solution Approach 1:
The patent employs a dynamic transport system with adjustable components. The horizontal transport mechanism can adapt its capacity and configuration based on the damper unit's weight, and the elevation system can adjust its lifting points and support structures. This dynamic adaptability allows the system to handle damper units exceeding 8 tons that would be beyond the capability of fixed-capacity telehandlers.
Solution Approach 2:
The patent introduces an intermediary transport system between the ground and the final installation position. This intermediate horizontal transport mechanism serves as a mediator that receives the heavy damper unit from ground-level equipment and delivers it to the tower section, eliminating the need for telehandlers to directly lift the excessive weight.
3Ease of manufacture
If the damper is installed as a suspended load, then the installation is possible, but the health and safety risk increases due to work in the area of the suspended damper
Solution Approach 1:
The damper unit is pre-integrated into the tower section during manufacturing or pre-assembly, rather than being installed separately as a suspended load. This preliminary action ensures the damper is securely fixed before the section is transported and erected, eliminating the safety hazards associated with working beneath suspended loads during installation.
Solution Approach 2:
The patent extracts the dangerous step of installing heavy dampers as suspended loads from the installation process. By using horizontal transport and ground-level positioning mechanisms, the hazardous suspended load operation is removed entirely, replacing it with safer ground-based assembly and transport methods.
4Productivity
If the tower section is transported with the damper installed, then the damping function is ready, but uneven weight distribution causes rocking and rolling of the trailer
Solution Approach 1:
The patent applies local quality optimization by strategically positioning the damper unit within the tower section to achieve balanced weight distribution. The damper is placed at specific locations and orientations that counterbalance other heavy components in the section, ensuring even weight distribution across the transport trailer while maintaining the damping function's effectiveness.
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
This approach enables safe and efficient mounting of heavy damper units deep within the tower section, reducing the risk of instability and imbalance during transportation and assembly, allowing for improved damping performance and reduced health and safety hazards.
Implementation Method 1
the damper unit is configured to damp motions of the wind turbine tower
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A method of assembling a tower section (10) of a wind turbine tower (101) is provided. The method comprises arranging the tower section (10) of the wind turbine tower (101) in a horizontal orientation; transporting a damper unit (20) to a position inside the tower section (10) while the tower section (10) is arranged in the horizontal orientation; and mounting the damper unit (20) to the tower section (10), wherein the damper unit is configured to damp motions of the wind turbine tower (101). Further, a horizontal transport system is provided that is supported at least at one position by the tower section (10) and that comprises a movable part configured to support a damper unit (20) and to transport the damper unit (20) in a horizontal direction from a position adjacent to an end (11, 12) of the tower section (10) to a position at or adjacent to a mounting position (14) of the damper unit (20) inside the tower section (10).