Wind Turbine Rotor Blade Installation via Blade Sock and Cable Translation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and logistical challenges of using large cranes for installing and removing wind turbine rotor blades make the process expensive and inefficient.
Innovation Solution
A method and system that utilize a blade sock and cable translation devices to lift and lower rotor blades without the need for large cranes, using a blade sock to secure the rotor blade and pulley systems to control orientation and position during installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a significantly large crane is used to install or remove rotor blades, then the rotor blade can be lifted and positioned, but the cost of transport and operation becomes extremely expensive
Solution Approach 1:
The invention divides the lifting operation into two independent phases: (1) lifting the rotor blade from horizontal to vertical position using a relatively small crane, and (2) lowering the rotor blade onto the hub using gravity and a lowering device. This segmentation eliminates the need for a large crane throughout the entire operation, significantly reducing transport and operational costs while maintaining the ability to handle the rotor blade effectively.
Solution Approach 2:
Instead of using a crane to lift the rotor blade onto the hub (conventional approach), the invention inverts the process by first positioning the blade vertically and then using a controlled lowering mechanism to let the blade descend onto the hub. This inversion leverages gravity to perform the heavy lifting portion of the operation, reducing the need for expensive heavy-lift crane capabilities.
2Manufacturing precision
If a significantly large crane is used to install or remove rotor blades, then the rotor blade can be positioned accurately, but the time required for the operation increases
Solution Approach 1:
The invention segments the positioning process into distinct phases with different precision requirements. The small crane handles the initial positioning to within a limited tolerance range, and then the lowering device takes over to achieve final precise alignment on the hub. This segmentation allows each device to operate within its optimal performance range, reducing total operation time compared to using a large crane for the entire process.
Solution Approach 2:
The lowering device acts as an intermediary mechanism between the small crane and the rotor blade hub. It receives the rotor blade from the crane's limited positioning range and provides the controlled, precise lowering action needed for accurate final positioning. This intermediary function enables the system to achieve high positioning accuracy without requiring the crane to have both large lift capacity and fine positioning control simultaneously, thereby reducing operation time.
3Loss of energy
If a small crane is used to lift the rotor blade, then the cost is reduced, but the rotor blade cannot be directly placed onto the hub
Solution Approach 1:
The invention segments the installation process into two distinct operational phases performed by different devices: (1) a small crane lifts the rotor blade from horizontal to vertical position, and (2) a dedicated lowering device performs the controlled descent onto the hub. This segmentation allows the small crane to operate within its cost-effective capacity limits while the specialized lowering device handles the precise placement function, achieving both cost reduction and operational effectiveness.
Solution Approach 2:
The lowering device serves as an intermediary mechanism that bridges the capability gap between the small crane and the hub placement requirement. It receives the rotor blade from the crane's limited positioning range and provides the controlled, precise lowering action needed for accurate final positioning on the hub, enabling the small crane to successfully complete the installation task it could not perform alone.
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
Significantly reduces the costs associated with blade installation and removal by eliminating the need for large cranes, enabling safer and more efficient operations.
Implementation Method 1
The blade sock may include a sock strap configured to be moved relative to the rotor blade such that the blade tip is received within the closed-shape formed by the sock strap and the sock strap is tightened around an outer perimeter of the rotor blade
Implementation Method 2
A cable translation device may be installed within the hub and the cable translation device may be operated to lower the rotor blade relative to the hub
Data Source
AI summary
In one aspect, a method for installing a blade sock onto a rotor blade of a wind turbine may generally include positioning the blade sock adjacent to a blade tip of the rotor blade, wherein the blade sock comprises a sock strap forming a closed-shape. In addition, the method may include moving the blade sock relative to the rotor blade such that the blade tip is received within the closed-shape formed by the sock strap and moving the blade sock spanwise along the rotor blade towards a blade root of the rotor blade until the blade sock is positioned at an intermediate location defined between the blade root and the blade tip, wherein the sock strap is configured to fit tightly around an outer perimeter of the rotor blade at the intermediate location.