Wind Turbine Tower Assembly System Using Climbing Support
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Solution Overview
Problem
The increasing size and weight of wind turbine components, particularly the tower, require expensive and complex crane systems for assembly, leading to high costs due to limited availability and transportation needs, with existing solutions like self-climbing and lattice-based structures being either complex or requiring extensive guiding systems on conical towers.
Innovation Solution
A wind turbine assembly system featuring a lifting structure with first structural support elements that transmit stresses to the tower, allowing for a smaller and simpler setup, and a climbing element that supports the lifting structure, enabling taller assembly without tower guides, using a crane with a pulley block and counterweight system to manage component hoisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a high capacity crane is used to assemble tall towers, then the tower height can be increased, but the rental and transport costs become extremely high
Solution Approach 1:
The lifting system is divided into modular components including a mobile lifting structure, structural support elements, and tower sections that can be assembled incrementally. This segmentation allows the system to build tower height progressively without requiring a single massive crane for the entire operation.
Solution Approach 2:
The lifting structure utilizes the tower itself as part of its support system during assembly. The structural support elements transfer loads to the already-assembled tower sections, allowing the tower to support its own construction process rather than requiring external crane support for the entire structure.
2Weight of stationary object
If a self-climbing structure is used to reduce crane size, then the lifting structure becomes smaller, but complex guiding systems are required on conical towers
Solution Approach 1:
The lifting structure is designed to be mobile rather than fixed, capable of moving vertically along the tower as assembly progresses. This dynamic capability allows the system to adapt to different tower heights and configurations without requiring complex fixed guiding systems for each position.
Solution Approach 2:
The structural support elements are designed with multi-functionality, serving both as load-bearing components and as positioning mechanisms. The elements can be configured to work with different tower geometries including conical shapes, eliminating the need for tower-specific guiding systems.
3Device complexity
If the lifting structure supports all loads, then no tower support is needed, but the lifting structure becomes larger and more complex
Solution Approach 1:
The load-bearing function is segmented between the lifting structure and the tower itself. The lifting structure handles dynamic assembly loads while the static tower structure carries the majority of the weight, allowing both components to be optimized for their specific functions rather than one component needing to handle all loads.
Solution Approach 2:
The structural support elements act as intermediaries between the lifting structure and the tower. These elements transfer and distribute loads from the lifting structure to the tower sections, enabling load sharing without requiring direct connection or complex load-path arrangements.
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
This system reduces assembly costs by minimizing the need for large cranes and guiding systems, allowing for efficient assembly of taller towers with reduced component complexity and transportation requirements, while maintaining structural integrity and operational simplicity.
Implementation Method 1
first structural support elements configured to transmit at least half of the stresses associated to the hoisting of a wind turbine component to the tower
Implementation Method 2
second structural support elements dimensioned to at least partly support the weight of the lifting structure
Implementation Method 3
a crane configured to displace the wind turbine component following a trajectory with at least one horizontal component
Data Source
AI summary
The wind turbine assembly system of the present invention comprises a lifting structure comprising at least first structural support elements configured to transmit stresses to the wind turbine tower during the hoisting of a wind turbine component and a crane configured to displace the wind turbine component towards the tower axis, the system further comprising a displaceable climbing element with respect to the lifting structure by means of guiding mechanisms, the displaceable climbing element incorporating second structural support elements dimensioned to at least partly support the weight of the lifting structure, where the first structural support elements are displaceable so that their relative position can vary with respect to the lifting structure.