Wind Turbine Lifting Rig with Adjustable Frame
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Solution Overview
Problem
Current wind turbine construction methods, particularly in moderate wind resource regions, require taller and larger towers, which are economically challenging due to transportation restraints and the need for large cranes, making steel towers non-competitive and precast concrete towers less viable in the US.
Innovation Solution
An adjustable frame system with actuators and booms that allows for the lifting and mounting of wind turbine components to taller towers without a large crane, utilizing a telescoping crossmember and hydraulic actuators to expand or contract the frame to accommodate varying tower diameters, and a 4-drum lifting hoist system for secure attachment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If taller towers and larger turbines are used to access stronger winds in moderate wind resource regions, then wind energy competitiveness is improved, but construction cost and complexity increase due to transportation restraints and need for large cranes
Solution Approach 1:
The tower is divided into multiple precast concrete segments that are transported and assembled section by section. This segmentation allows standard-sized components to be used, avoiding the need for transporting single large tower sections, thus reducing transportation constraints and construction complexity while enabling taller tower heights.
Solution Approach 2:
A specialized lifting rig with a telescoping boom is introduced as an intermediary device to handle the assembly process. The rig includes a telescoping boom that can extend and retract, allowing precise positioning and lifting of tower segments without requiring conventional large cranes, thereby reducing construction complexity.
2Length of moving object
If precast concrete towers are used instead of steel tubular towers, then transportation restraints are reduced, but labor costs, shipping distances, weight and number of loads increase
Solution Approach 1:
The lifting rig incorporates a telescoping boom that can dynamically adjust its length. The boom extends when needed to reach higher tower segments and retracts when not needed, optimizing the number of loads and reducing overall complexity while maintaining the ability to handle tall tower constructions efficiently.
3Length of stationary object
If larger diameter towers are used for taller structures, then wind access is improved, but transportation restraints make steel towers non-competitive at 120m to 160m hub heights and higher
Solution Approach 1:
The tower is constructed from multiple standardized precast concrete segments that can be easily transported and assembled. This segmentation approach allows for taller towers with larger diameters without the transportation difficulties associated with monolithic steel structures, making manufacturing and assembly more competitive.
Solution Approach 2:
The conventional steel tubular tower construction method is replaced with a precast concrete segment assembly system. This substitution allows for taller and larger diameter towers while avoiding the transportation and assembly complexities of steel structures, improving ease of manufacture for high-altitude applications.
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
Enables the construction of wind turbines with towers over 200 meters and 4MW turbines, reducing costs by eliminating the need for large cranes and allowing assembly of concrete towers with self-climbing formwork techniques, enhancing installation efficiency and safety in higher winds.
Implementation Method 1
the adjustable frame comprises one or more actuators configured to reduce or expand the interior space defined by the adjustable frame. In certain embodiments, the actuator(s) comprise hydraulic cylinder(s).
Implementation Method 2
The lifting hoist may comprise a 4-drum lifting hoist. In accordance with certain embodiments, the system comprises one or more lifting hoist sheaves mounted in the wall of near the top of the tower
Implementation Method 3
a lifting hoist and a lifting hoist cable configured to lift and/or lower the adjustable frame on the tower
Implementation Method 4
the first boom and the second boom are joined by a telescoping crossmember
Implementation Method 5
one or more attachment brackets positioned near the top of the tower, wherein the attachment brackets are configured to secure the adjustable frame in position near the top of the tower
Data Source
AI summary
The present disclosure provides a system for lifting and mounting components of a wind turbine assembly to the top of a wind turbine tower without the requirement of a large crane to reach the top of the tower. The system comprising: an adjustable frame defining an interior space sized to receive the tower, wherein the adjustable frame comprises one or more actuators configured to reduce or expand the interior space defined by the adjustable frame; a first boom attached to the adjustable frame, the first boom rotatable with a first boom actuator; and a second boom attached to the adjustable frame, the second boom rotatable with a second boom actuator, and wherein the first boom and the second boom are joined by a telescoping crossmember.