Wind Turbine Assembly System Segmented Lifting

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Solution Overview

Problem

Conventional crane systems for wind turbine assembly are expensive due to high rental and transportation costs, and existing alternative solutions like self-climbing and lattice-based structures face challenges with stress, complexity, and adaptability, especially with tall towers.

Innovation Solution

A wind turbine assembly system featuring a main lifting structure and a secondary lifting structure that operates from above the center of gravity of the main structure, with optional supplementary fixing structures and a controlled counterweight system to reduce stress and facilitate efficient lifting and assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional cranes with main lifting structure are used to withstand the load of tower sections and wind turbine components, then the lifting capacity and stability are sufficient, but the rental and transportation costs become excessively high

Engineering Contradiction:

Improvelifting capacityVSAvoidassembly cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The lifting system is divided into two distinct structures: a main lifting structure that withstands the load of tower sections and components, and a secondary lifting structure that lifts the main lifting structure itself. This segmentation allows each structure to be optimized for its specific function, reducing the overall cost and complexity while maintaining sufficient lifting capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The secondary lifting structure enables the main lifting structure to be lifted and repositioned without requiring external heavy-duty cranes. The system uses its own secondary structure to service the main structure, reducing dependency on expensive external equipment and lowering rental and transportation costs.

Inventive Principle:

Principle #25Self-service

2Ease of manufacture

If self-climbing structures are used to reduce costs, then the assembly cost decreases, but the system becomes more complex and requires adaptation to conical tower shapes

Engineering Contradiction:

Improveassembly costVSAvoidsystem complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The system separates the load-bearing function (main lifting structure) from the positioning function (secondary lifting structure). This segmentation simplifies the design of each component, allowing the main structure to be simpler and less adaptive, while the secondary structure handles the complexity of positioning and climbing operations.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If lattice-based bridge crane structures are used, then the adaptability to different tower types improves, but the transportation requirements increase due to large dimensions

Engineering Contradiction:

Improvetower type adaptabilityVSAvoidtransport dimension

Core Design Contradiction:

Adaptability or versatilityVSLength of moving object

Solution Approach 1:

The lifting system is segmented into functional modules that can be transported separately and assembled on-site. The main lifting structure and secondary lifting structure are distinct components that can be transported in smaller sections, reducing transportation requirements while maintaining adaptability through modular assembly.

Inventive Principle:

Principle #1Segmentation

4Device complexity

If the secondary lifting structure operates from below the center of gravity of the main lifting structure, then the lifting mechanism is simpler, but the stress on the lifting structure increases significantly

Engineering Contradiction:

Improvelifting mechanism complexityVSAvoidstress on lifting structure

Core Design Contradiction:

Device complexityVSStress or pressure

Solution Approach 1:

Instead of operating the secondary lifting structure from below the center of gravity of the main lifting structure, the system inverts the approach by operating from above the center of gravity. This inversion reduces the stress and moments on the lifting structure, creating a more efficient and safer lifting mechanism.

Inventive Principle:

Principle #13The other way round (Inversion)

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 the stress on lifting structures, lowers assembly costs, and allows for efficient assembly of tall wind turbines by maintaining the main lifting structure above its center of gravity, enabling safer and more economical tower and component lifting.

Implementation Method 1

a secondary lifting structure configured to perform the lifting of the main lifting structure with respect to the wind turbine tower, wherein the secondary lifting structure comprises lifting means for the main lifting structure which operate from a height above the centre of gravity of the main lifting structure

Methodology Applied

Scientific EffectCenter of gravity: Gravitation

Data Source

PatentUS10815687B2Wind turbine assembly system and associated method

Publication Date: 2020.10.27 ACCIONA WINDPOWER

AI summary

The present invention relates to a wind turbine assembly system which proposes an alternative to conventional cranes, having a main lifting structure configured to withstand the load of at least one tower section or at least one wind turbine component, and at least one secondary lifting structure configured to perform the lifting of the main lifting structure with respect to the wind turbine tower, in addition relating to a wind turbine assembly method according to the previous system, as well as the wind turbine assembled with the previous method.