Vacuum Lifting Tool With Automatic Spar Cap Fall Protection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The use of belts or straps as safety features for holding a spar cap during vacuum loss in the manufacturing of wind turbine blades is hazardous and time-consuming, posing risks and inefficiencies due to the need for manual intervention under suspended load (WUSL).

Innovation Solution

A lifting tool with a lifting structure, vacuum elements, and an anti-falling mechanism that automatically switches between closed and open states to securely hold and position the spar cap without manual intervention, eliminating the need for manual attachment of belts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If belts or straps are used as safety features to hold the spar cap in case of vacuum loss, then safety is improved, but the process becomes time-consuming and requires manual intervention under suspended load (WUSL)

Engineering Contradiction:

ImprovesafetyVSAvoidtime consumption

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The anti-falling mechanism is pre-configured on the lifting tool and automatically engages to prevent the spar cap from falling in case of vacuum loss. This preliminary setup eliminates the need for manual belt attachment during critical operations, reducing time consumption and eliminating WUSL risks while maintaining safety

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The anti-falling mechanism operates automatically without manual intervention. When vacuum is applied to the spar cap, the mechanism self-activates to provide safety support, eliminating the need for operators to manually attach and adjust belts under suspended load

Inventive Principle:

Principle #25Self-service

2Reliability

If belts or straps are used as safety features to hold the spar cap in case of vacuum loss, then safety is improved, but the complexity of the operation increases due to manual intervention requirements

Engineering Contradiction:

ImprovesafetyVSAvoidoperation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The anti-falling mechanism is designed to automatically detect and respond to vacuum conditions, self-activating to support the spar cap without requiring operators to manually position and secure belts. This automation reduces operational complexity while maintaining safety

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical system of belt attachment and adjustment is replaced with an automated anti-falling mechanism that uses the lifting tool's existing structure and vacuum system. This substitution eliminates complex manual operations while providing equivalent or superior safety functionality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If belts or straps are used as safety features to hold the spar cap in case of vacuum loss, then safety is improved, but the risk of injury to operators increases due to WUSL

Engineering Contradiction:

ImprovesafetyVSAvoidrisk of injury

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The anti-falling mechanism automatically activates when vacuum is applied to the spar cap, providing safety support without requiring operators to manually position belts under suspended load. This eliminates the hazardous WUSL condition entirely while maintaining safety functionality

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The anti-falling mechanism is pre-configured to automatically engage and prevent the spar cap from falling in case of vacuum loss. By having this protective mechanism ready and automatic, it counteracts the potential harmful effect of vacuum failure before it can cause injury to operators

Inventive Principle:

Principle #9Preliminary anti-action

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 lifting tool reduces labor costs, enhances safety, and increases efficiency by automatically securing the spar cap during vacuum loss, minimizing the risk of injury and time consumption.

Implementation Method 1

a plurality of vacuum elements connected to the lifting structure for releasably attaching the spar cap

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentEP4640609A1Lifting tool

Publication Date: 2025.10.29 LM WIND POWER AS

Figure 1
Figure 2~3
Figure 4

AI summary

There is provided a lifting tool 400 for placing a spar cap 500 in a blade mould. The lifting tool 400 comprises a lifting structure 410, a plurality of vacuum elements 420 connected to the lifting structure 410 for releasably attaching the spar cap 500 and an anti-falling mechanism 430 connected to the lifting structure 410. The anti-falling mechanism 430 is configured to change between a closed state for blocking a movement of the spar cap 500 and an open state for allowing a movement of the spar cap 500 relative to the anti-falling mechanism 430.