Wind Turbine Tower Bolt Lifting Aid for Ergonomic Assembly
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Solution Overview
Problem
The assembly of large fixation bolts for wind turbine towers is cumbersome and poses a risk of ergonomic injury to workers due to their heavy weight, exceeding 15 kg.
Innovation Solution
An assembly aid comprising a mast, lifting shoe, lifting mechanism, and actuator is used to lift and position fixation bolts, reducing the need for manual handling and minimizing worker exposure to heavy loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual lifting of fixation bolts is used, then assembly simplicity is maintained, but worker safety and ergonomics deteriorate due to heavy weights exceeding 15 kg
Solution Approach 1:
A lifting device is introduced as an intermediary tool between the worker and the fixation bolt. The device includes a lifting mechanism with a gripper that can securely grasp the bolt head, and a lifting element that raises the bolt into the upper tower segment's fixation hole, eliminating the need for workers to manually lift heavy bolts weighing over 15 kg
Solution Approach 2:
The manual mechanical lifting action is replaced with an automated or semi-automated lifting mechanism. The mechanism may include motorized actuators, hydraulic systems, or pneumatic systems that provide the lifting force, substituting the worker's physical effort and reducing ergonomic damage while maintaining assembly simplicity
2Weight of moving object
If fixation bolt size is increased to meet larger tower requirements, then tower capacity is improved, but handling difficulty and worker exposure to heavy loads worsens
Solution Approach 1:
The lifting device serves as a mediator that handles the increased weight and size of fixation bolts. The gripper is designed to accommodate different bolt sizes and weights, providing a secure grasp even for bolts weighing over 15 kg, while the lifting mechanism provides sufficient force to raise these heavy components into position
Solution Approach 2:
The lifting mechanism's parameters (lifting capacity, gripper size, actuator force) are adjusted and optimized to match the increased bolt size and weight requirements. This allows the system to handle larger fixation bolts effectively while maintaining ease of operation through controlled, automated lifting actions
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 assembly aid facilitates the secure and ergonomic handling of fixation bolts, reducing the risk of injury and simplifying the assembly process without increasing costs.
Implementation Method 1
a lifting mechanism (7) for lifting the lifting shoe (5) with respect to the mast (4)
Data Source
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AI summary
The invention relates to an assembly aid (1) for securely placing a fixation bolt (2) for fixing two tower segments (3) of a tower of a wind turbine. The assembly aid (1) comprises a mast (4) for being arranged vertically and parallel aside the fixation bolt (2), a lifting shoe (5) for being moved under a bolt head (6) of the fixation bolt (2), a lifting mechanism (7) for lifting the lifting shoe (5) with respect to the mast (4) and an actuator (8) for operating the lifting mechanism (7). The invention further relates to a method for assembling two tower segments (3) of a wind turbine tower.