Wind Turbine Transformer Transport via Wall Opening Guide Rail
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Solution Overview
Problem
The existing methods for replacing transformers in wind turbines require disassembly and reassembly, leading to inefficiencies and potential damage to the tower, and are not universally applicable due to built-in components and structural weaknesses.
Innovation Solution
A method using a guide rail inserted into a wall opening of the wind turbine tower, with a modular holding device and lifting system, allows for the transportation of loads through the wall opening without disassembly, enabling the transformer to be moved as a whole and assembled in a controlled environment, avoiding tower damage and pre-equipment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the transformer is disassembled into manageable parts and removed from the tower, then the transformer can be transported through the tower, but the transformer cannot be assembled under the same conditions as in the manufacturer's assembly hall, leading to increased efficiency losses
Solution Approach 1:
The guide rail is divided into two segments: one half arranged inside the tower through the wall opening, and the other half arranged outside the tower. This segmentation allows the guide rail to span the wall opening and enable load transport without requiring complete disassembly of the transformer, while maintaining assembly conditions similar to the manufacturer's hall.
2Ease of operation
If a stationary support device with guide rail is mounted on the inner wall of the tower, then the transformer can be transported, but the tower wall has to be doubled at the appropriate point, weakening the tower wall
Solution Approach 1:
The guide rail system is extracted from the tower wall structure and repositioned to utilize the existing wall opening. Instead of mounting the guide rail on the inner wall (which would require doubling the wall), the guide rail is arranged through the wall opening with supports on both sides, eliminating the need to weaken the tower wall.
3Ease of operation
If a guide rail is pushed through to the opposite tower wall, then the load can be transported, but built-in components such as switch cabinets are in the way and prevent this
Solution Approach 1:
The wall opening serves as an intermediary element that enables the guide rail to connect the inside and outside of the tower without requiring passage through the entire tower wall. This intermediary approach allows the guide rail to be positioned at the wall opening level, avoiding interference from built-in components like switch cabinets that may be located at opposite walls.
4Productivity
If the entire transformer is replaced by disassembling and reassembling in the tower, then the replacement can be performed, but the transformer does not achieve the quality of the delivery condition
Solution Approach 1:
The guide rail system is prepared in advance and positioned through the wall opening before the transformer is moved. This preliminary setup creates a controlled transport path that allows the transformer to be moved as a complete unit rather than disassembled parts, enabling assembly in conditions similar to the manufacturer's hall and maintaining delivery quality.
Data Source
Figure 1
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AI summary
The invention relates to a method for load transport in a tower (100) of a wind turbine by means of a guide rail (1), wherein the tower (100) comprises a wall opening (30) for passing through a load (20), said method comprising the following steps: detachably attaching at least one fastening device (9) in the interior of the tower (100); suspending a holding apparatus (4) in the interior of the tower (100) on the at least one detachably arranged fastening device (9); arranging the guide rail (1) in the wall opening (30), wherein one half (21) of the guide rail (1) is held by a holding apparatus (4) within the tower (100) and the other half (22) of the guide rail (1) is held by a mounting apparatus (2) outside the tower (100); fastening the load (20) on the guide rail (1) on one side of the wall opening (30) by means of at least one guide carriage (5) which is movable along the guide rail (1); transporting the load (20) onto an opposite side of the wall opening (30) by moving the guide carriage (5). This means that losses in efficiency after repair and maintenance work on the transformer as load (20) are avoided, wherein the measure can be implemented universally in any wind turbines even without any pre-equipping work. The invention extends further to a corresponding holding apparatus and to a heavy-load replacement system for wind turbines comprising said holding apparatus.