Wind Turbine Hoisting System Load Distribution

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Solution Overview

Problem

The installation costs of wind turbines increase significantly with size due to the need for large, expensive cranes, which are often inefficient and require extensive resources, especially for offshore turbines, and existing solutions like climbing cranes or lifting frames are costly and time-consuming.

Innovation Solution

A hoisting system comprising a first hoisting device with a load-carrying joint to an existing part of the wind turbine, distributing the load with a second hoisting device, allowing for a lighter and less expensive setup that can handle the heaviest parts, and optionally using a third device for installation and load distribution, reducing the need for large cranes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a large industrial crane is used to install the heaviest parts of the wind turbine, then the installation capability is sufficient, but the installation cost and complexity increase significantly

Engineering Contradiction:

Improveinstallation capabilityVSAvoidcrane size and complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the hoisting system into multiple independent hoisting devices (first hoisting device, second hoisting device, and optionally a third hoisting device) that can operate simultaneously. Each device handles a portion of the total load, allowing the use of smaller, less complex devices instead of one large industrial crane. The segmentation is achieved through separate hoisting devices with independent control systems that coordinate to lift the heaviest parts of the wind turbine.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines the capabilities of multiple hoisting devices to achieve the total hoisting capacity required for installing the heaviest parts. By merging the load-carrying capacities of the first, second, and third hoisting devices, the system achieves the equivalent capability of a large industrial crane while using smaller, more flexible units that can be transported to remote locations more easily.

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If a climbing crane is used to install wind turbine parts, then the installation cost is reduced, but the loads exerted on the wind turbine increase requiring strengthening

Engineering Contradiction:

Improvecrane sizeVSAvoidwind turbine structure strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent segments the hoisting function across multiple devices, distributing the loads exerted on the wind turbine structure. Instead of one climbing crane bearing the entire load, the first, second, and third hoisting devices share the load, reducing the force requirement for each individual device and the associated structural strengthening.

Inventive Principle:

Principle #1Segmentation

3Reliability

If a lifting frame is installed on top of the wind turbine tower, then heavy parts can be hoisted to the tower top, but the costs remain high and much time is required for commissioning

Engineering Contradiction:

Improvehoisting capabilityVSAvoidcommissioning time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent employs preliminary action by having the first hoisting device installed on the wind turbine structure before the heaviest parts are hoisted. This allows the hoisting system to be prepared and tested in advance, reducing the commissioning time when the actual hoisting operation begins. The hoisting devices can be pre-positioned and configured, eliminating the need for time-consuming on-site assembly during the critical hoisting phase.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If the maximum hoist load of the first hoisting device is increased to handle the heaviest parts alone, then the hoisting capability is sufficient, but the device becomes more expensive and heavier

Engineering Contradiction:

Improvehoisting capabilityVSAvoidhoisting device weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent segments the hoisting load across multiple devices, allowing each individual hoisting device to be designed for a lower maximum load. The first hoisting device, second hoisting device, and third hoisting device each handle a portion of the total weight, enabling the use of lighter, less expensive devices instead of one heavy-duty hoisting device that would be required if a single device had to handle the entire load alone.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11174136B2Hoisting system for installing a wind turbine

Publication Date: 2021.11.16 LAGERWEY WIND BV

AI summary

A hoisting system for the at least one of an installation, a decommissioning and a maintenance of a wind turbine which comprises at least a foundation, a tower, a yawing part and a rotor of at least 80 m diameter with at least one blade, comprising a first hoisting device which comprises measures to establish a load carrying joint with an already built part of the wind turbine which is located above the foundation, wherein the hoisting system is characterized in that the ratio between the maximum hoist load of the hoisting device and the mass of the heaviest part is larger than 0.2 and smaller than 1 and in particular smaller than 0.8 and more in particular smaller than 0.7 and preferably smaller than 0.6, with the heaviest part being a heaviest part which is hoisted as one piece and which belongs to the yawing part of wind turbine.