Wind Turbine Blade Replacement System Using Hydraulic Jacking

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Solution Overview

Problem

The existing methods for replacing wind turbine blades often require large cranes, which can cause imbalance and damage during the process, necessitating multiple crews and complex positioning to avoid tip contact with the ground or ship deck.

Innovation Solution

A system utilizing threaded support members, hydraulic jacking cylinders, bracket members, and cable climbing members to lift and lower wind turbine blades, allowing for replacement without ground-based cranes, by separating the blade from the hub and transferring support to cable climbing members for controlled descent.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If large ground or sea based cranes are used to replace wind turbine blades, then the blade replacement can be performed, but the cranes cause imbalance and impart forces to the braking system that may cause damage

Engineering Contradiction:

Improveblade replacement capabilityVSAvoidimbalance and forces to braking system

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an intermediary device - a blade replacement system with support members and hydraulic cylinders - that mediates between the blade and the turbine hub. This system allows blade replacement without using external cranes, thereby eliminating the imbalance and harmful forces that cranes would impart to the braking system while still enabling safe blade replacement operations

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the blade is positioned horizontal to ground for replacement, then the replacement process can proceed, but other blades must be moved to off-balance position requiring multiple crews and complex positioning

Engineering Contradiction:

Improveblade replacement accessibilityVSAvoidpositioning system and crew requirements

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The blade replacement system acts as an intermediary support mechanism that allows the blade to be safely detached and replaced while maintaining the turbine's balance. The support members and hydraulic cylinders provide controlled positioning without requiring other blades to be moved to off-balance positions, thereby simplifying the operation to single-crew level while maintaining ease of blade replacement

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the complex mechanical positioning system that would be required to move other blades to off-balance positions with a simpler hydraulic control system. The hydraulic cylinders provide controlled movement and positioning of the replacement blade without affecting the balance of other blades, reducing device complexity and crew requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If the blade is positioned perpendicular to ground for lowering, then the replacement can proceed, but multiple crews are required to rotate the blade to prevent tip contact with surface

Engineering Contradiction:

Improveblade replacement capabilityVSAvoidreplacement efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical rotation process that would require multiple crews with an automated hydraulic control system. The hydraulic cylinders provide controlled rotation and positioning of the blade during lowering, preventing tip contact with the surface automatically without requiring multiple crews, thereby maintaining replacement capability while improving productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables efficient and balanced replacement of wind turbine blades, reducing the need for large cranes and minimizing damage, while allowing for single-crew operation and simplified positioning.

Implementation Method 1

a hydraulic jacking cylinder (34) guided over each support member (25-27)... telescoping sections (38-40) are extended and a retaining nut (49) is threaded onto first support member (25)

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Implementation Method 2

threaded rods (not separately labeled) that extend through openings (16) in blade receiving portion (18) and engage with threaded openings (not separately labeled) previously provided with fasteners (14)

Methodology Applied

Scientific EffectThreaded engagement: Screw

Implementation Method 3

Cable climbing members (80-82) are controlled so as to climb from the free ends of each cable (64-66) toward bracket members (54)

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 4

telescoping sections (38-40) are lowered creating further separation between third wind turbine blade (9) and support hub (4)... allowing for the mounting of cable climbing members (80-82)

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentEP2725220B1Method and system for replacing a single wind turbine blade

Publication Date: 2021.07.21 GENERAL ELECTRIC CO

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AI summary

A method of replacing a wind turbine blade includes suspending the wind turbine blade from support hub 4 of a wind turbine to, connecting one or more cable climbing members 80 between the support hub for and the wind turbine blade, and lowering the one or more cable climbing members 80 and the wind turbine blade from the support hub 4.