Wind Turbine Blade Insertion Using In-Hub Hydraulic Alignment
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Solution Overview
Problem
Existing wind turbine blade alignment and insertion systems face challenges due to limited space within the hub and displacement of the center of gravity (CoG) caused by tilt and coning, necessitating manual intervention and the use of external cranes.
Innovation Solution
A hydraulic system is integrated within the hub, utilizing two or three cylinders to redirect the load horizontally, aligning the CoG with the bearing center, and employing cables and pulleys to manage alignment and insertion without external cranes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional hoists are installed outside the hub or in the nacelle to lower the blade, then the blade alignment and insertion can be achieved, but the space requirements and line of sight constraints are not met
Solution Approach 1:
The hydraulic cylinder system is nested within the hub structure, with cylinders arranged in the limited space between the hub and blade root. The system utilizes the existing hub volume rather than requiring external installation space, effectively nesting the alignment mechanism within the turbine's internal structure.
Solution Approach 2:
The solution transitions from external vertical hoisting to internal horizontal hydraulic actuation. By changing the dimension of operation from external vertical movement to internal horizontal cylinder extension, the system eliminates the need for external space and line of sight while achieving the same blade alignment function.
2Ease of operation
If manual intervention is used to align the CoG with gripping points, then blade alignment can be achieved, but the operational efficiency is reduced
Solution Approach 1:
The hydraulic system automatically controls the CoG alignment through cylinder actuation, eliminating the need for manual chain intervention. The system self-regulates the blade position by hydraulically adjusting the CoG location to match the gripping points, improving operational efficiency while maintaining alignment precision.
Solution Approach 2:
The manual mechanical chain system is replaced with an automated hydraulic cylinder system. This substitution eliminates manual labor for CoG alignment while providing more precise and efficient control through hydraulic actuation, directly improving productivity in blade assembly and repair operations.
3Ease of operation
If external cranes are used for blade lowering, then the blade insertion can be achieved, but the operational costs and time requirements increase
Solution Approach 1:
The external crane function is extracted and replaced by an internal hydraulic lowering system. The hydraulic cylinders, anchored within the hub, provide the blade lowering capability that previously required external cranes, eliminating the time and cost associated with external equipment while maintaining the essential blade insertion function.
4Volume of stationary object
If the hub space is reduced to accommodate smaller turbines, then the turbine design is improved, but the installation of traditional alignment systems becomes impossible
Solution Approach 1:
The alignment system is segmented into multiple components that can be independently installed within the constrained hub space. The hydraulic cylinder, anchoring pins, and associated mechanisms are divided into discrete elements that can be manufactured and installed separately, making the system feasible for reduced-size hubs while maintaining full functionality.
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
Facilitates efficient blade alignment and insertion within reduced hub space by controlling CoG, reducing manual effort and eliminating the need for cranes, thereby improving operational efficiency and cost-effectiveness.
Implementation Method 1
A hydraulic system is integrated within the hub, utilizing two or three cylinders to redirect the load horizontally, aligning the CoG with the bearing center
Data Source
AI summary
A system for lowering blades without using a crane, which solves a de alignment and insertion problem resulting from the tilt and coning of the blade along the first/last 200-400 mm and the problem of space inside the hub. The system is characterized in that it moves the vertical load of the blade by 90°, converting it into a horizontal load actuated by at least two hydraulic elements and by aligning the center of gravity (CoG) of the blade vertically with the center of a bearing by using cables and pulleys. Each of the systems is disposed inside the hub, in the bottom part thereof and secured to the fixed part. The system comprises three main parts: the pulley, the hydraulic element and an axis-shift element secured with pins, one of the pins being fixed and the other adjustable. The cable bordering the end pulley comprises connectors before the point at which same passes through interior pulleys, which distribute the load evenly between the two cables.