Winch Hoisting System for Wind Turbine Tendon Installation
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Solution Overview
Problem
The construction of concrete wind turbine towers is limited by the need for cranes to lift post-tensioning tendons, leading to scheduling issues and increased costs due to crane availability and transportation constraints of steel materials.
Innovation Solution
A system and method that eliminates the use of overhead cranes by using a winch and hoisting cable to lift and attach post-tensioning tendons to anchor rods, allowing for flexible scheduling and reduced construction costs, utilizing precast concrete segments with match cast joints and a sheave system for tendon installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If overhead cranes are used to lift post-tensioning tendons, then the tendons can be installed at required heights, but construction scheduling is delayed and costs increase due to crane availability constraints
Solution Approach 1:
The patent extracts the crane from the construction process by implementing a ground-based winch system. The winch and cable assembly allows tendons to be lifted and positioned without requiring overhead cranes, thereby eliminating crane availability constraints while maintaining precise tendon installation positions through controlled cable deployment from ground level.
Solution Approach 2:
The patent introduces a winch and cable system as an intermediary mechanism between the ground and the tendon installation point. This intermediary system transfers the lifting function from overhead cranes to ground-based equipment, enabling simultaneous tendon installation at multiple heights without scheduling conflicts.
2Ease of manufacture
If steel tubular sections are transported to construction site, then tower sections can be assembled, but transportation constraints limit tower height due to road and bridge restrictions
Solution Approach 1:
The patent divides the tower into multiple precast concrete segments that can be manufactured locally and transported individually within size constraints. These segments are then assembled vertically using the ground-based winch system, allowing the final tower height to exceed the transport limitations of individual segments.
Solution Approach 2:
The patent transitions from horizontal transportation constraints to vertical assembly by using ground-based winches to lift segments and tendons vertically. This dimensional change allows the tower to achieve greater heights by assembling segments in the vertical dimension rather than being limited by horizontal transport capabilities.
3Strength
If precast concrete segments are used with post-tensioning tendons, then tower strength is increased to enable taller structures, but crane dependency increases construction costs and scheduling complexity
Solution Approach 1:
The patent extracts the crane dependency from the construction process by implementing a ground-based winch system. This allows precast concrete segments with post-tensioning tendons to be assembled without overhead cranes, maintaining the structural strength benefits while reducing equipment complexity and eliminating scheduling constraints associated with crane availability.
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 increases installation efficiencies and reduces construction costs by eliminating crane dependency, enabling taller towers and faster construction processes while maintaining structural integrity with precast concrete segments and post-tensioning tendons.
Implementation Method 1
A hydraulic jack may be positioned between the lower bearing plate and the upper stressing chair to force the lower bearing plate downward
Implementation Method 2
A pulley may be attached to the upper anchor rods and the hoisting cable may be threaded through the pulley
Data Source
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AI summary
A system and method for installing a post-tensioning tendon (130) in an equipment tower (100). A sheave frame (196) attaches to anchor rods (140), and a pulley (198) is mounted to the sheave frame through which a hoisting cable (197) is passed for connection to an end (138) of the tendon to lift the tendon to the anchor rods. A carriage assembly (150) having a shank (152) and a bearing plate platform (154) extending transversely from the shank for receiving a bearing plate (170) is attached to the tendon. The carriage assembly includes a deflecting surface (158) to deflect the carriage assembly away from the installed bearing plate upon lowering after tendon attachment. A pair of hydraulic jacks (210) tension the tendon to a desired load.