Wind Turbine Power Cable Support Rail for Offshore Reconnection

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Solution Overview

Problem

The handling of high-voltage power cables in wind turbines, particularly offshore, is challenging due to their weight and the need for managing cable length variations during transportation and installation, which requires a mechanism to safely store and guide the cable within the tower and connect it to switch gear units.

Innovation Solution

A cable support system comprising a half-wheel structure with rollers and a guiding system fixed to the wind turbine tower, allowing vertical movement along linear rails, facilitated by a hoist, to manage and connect the power cable securely within the tower and to switch gear units.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If the power cable is pulled extra length and stored in the bottom of the tower for transportation, then the cable length is sufficient for reconnection scenarios, but the cable weight makes it difficult to handle manually

Engineering Contradiction:

Improvecable lengthVSAvoidmanual handling

Core Design Contradiction:

Length of moving objectVSEase of operation

Solution Approach 1:

A cable support system acts as an intermediary between the heavy cable and the guiding mechanism. The support system includes a support structure with a support surface that contacts the cable, and a support wheel that rolls along the guide rail, enabling controlled movement of the heavy cable without direct manual handling.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces manual mechanical handling with an automated guiding system. The cable support system moves along fixed guide rails within the tower, substituting human effort with a mechanical guidance mechanism that controls cable position during transportation and installation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If a hoist is used to pull the cable from the drum in the conventional method, then the cable can be installed, but the cable is difficult to control and store safely during transportation

Engineering Contradiction:

Improvecable installationVSAvoidcable storage safety

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The cable handling system is segmented into distinct functional components: a cable support system for holding the cable, a guiding system with rails for controlled movement, and a support wheel mechanism. This segmentation allows each component to perform its specific function reliably - the support system holds the cable safely, while the guiding system controls its movement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cable support system is designed to be movable along the guide rails, transitioning between static storage positions and dynamic installation positions. The support wheel enables the system to move smoothly along the rails, providing dynamic control over cable positioning during both transportation and installation phases.

Inventive Principle:

Principle #15Dynamics

3Area of stationary object

If the cable is coiled up in the uppermost platform of the tower, then space is utilized, but the cable cannot be easily guided down into the foundation or transition piece at the installation site

Engineering Contradiction:

Improvestorage space utilizationVSAvoidcable guidance

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

The guiding system utilizes the vertical dimension of the tower by installing guide rails along the tower's height. The cable support system moves vertically along these rails, enabling smooth guidance from the upper storage platform down to the foundation or transition piece at the bottom, effectively using the tower's vertical space for cable management.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Device complexity

If manual handling of the cable is attempted, then no additional mechanism is needed, but the high weight of the cable (around 20 kg/m) makes it unsafe and difficult to handle

Engineering Contradiction:

Improvehandling mechanismVSAvoidcable handling

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The cable support system serves as an intermediary that bears the weight of the heavy cable, allowing operators to control the cable's position without directly handling its full weight. The support structure with its support surface and support wheel mechanism distributes and manages the cable's weight, making it safe and easy to operate.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12529359B2Handling a power cable of a wind turbine

Publication Date: 2026.01.20 SIEMENS GAMESA RENEWABLE ENERGY AS

AI summary

An arrangement for handling a power cable of an offshore, wind turbine for transportation and/or connecting to a switch gear and/or reconnecting, the arrangement including: a cable support system adapted to support a portion of the power cable; a guiding system being fixedly connectable or connected to a wind turbine tower and being adapted to guide the cable support system along a linear, vertical, track is provided.