Lifting assembly for elevating components to a wind turbine and a method for using the lifting assembly
10865078 · 2020-12-15
Assignee
Inventors
Cpc classification
B66C23/185
PERFORMING OPERATIONS; TRANSPORTING
F05B2230/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D13/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B66C23/18
PERFORMING OPERATIONS; TRANSPORTING
B66C23/20
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A lifting assembly for elevating components to a wind turbine. The lifting assembly comprises a plurality of tower segments adapted to be arranged on top of each other to form an elongated tower, and a lifting device including a support frame for supporting the tower, a securing assembly for securing the tower to the wind turbine, and a crane having a base part and a jib rotatably connected to the base part. The lifting device comprises a platform arranged vertically moveable between a lower and an upper position. The platform has a first storage area for supporting components with a weight of more than 10 tons. The crane is mounted on the platform and is configured to move the components between the platform and the wind turbine when the platform is in the upper position. The platform is provided with an opening adapted to receive the tower segments. The crane and the first storage area are arranged on opposite sides of the opening, and one of the tower segments is a top segment having an upper part provided with a second storage area for supporting components with a weight of more than 10 tons. The invention also relates to a method for using the lifting assembly for replacing an old component of a wind turbine with a new component.
Claims
1. A lifting assembly for elevating components to a wind turbine, comprising: a plurality of tower segments which together form an elongated tower with an adjustable height, and a lifting device including: a support frame for supporting the tower, a securing assembly for securing the tower to the wind turbine, and a crane, wherein the lifting device comprises: a platform arranged moveable relative the support frame between a lower position and an upper position, and the platform has a first storage area for supporting components weighing more than 10 tons, the crane is mounted on the platform and is configured to move the components between the platform and the wind turbine when the platform is in the upper position, the platform is provided with an opening adapted to receive the tower segments, the crane and the first storage area are arranged on opposite sides of the opening and one of the tower segments is a top segment, having an upper part provided with a second storage area for supporting components weighing more than 10 tons.
2. The lifting assembly according to claim 1, wherein said top segment comprises a cap connected to said upper part and having an upper surface defining said second storage area.
3. The lifting assembly according to claim 2, wherein said cap is removably connected to the upper part.
4. The lifting assembly according to claim 2, wherein said opening, and the peripheries of the tower segments and the cap are rectangular.
5. The lifting assembly according to claim 1, wherein the lifting device comprises a drive unit for moving the platform and a power generation device configured to generate electric power to said drive unit, and the power generation device is mounted on said platform.
6. The lifting assembly according to claim 1, wherein said platform has a length of at least 4 m and a width of at least 2 m, and preferably said platform has a length of at least 6 m and a width of at least 3 m.
7. The lifting assembly according to claim 1, wherein said crane has a base part and a jib rotatably connected to the base part, and the jib has a maximum length of less than 40 m, and preferably the jib has a maximum length of less than 30 m.
8. The lifting assembly according to claim wherein the weight of the crane is more than 10 tons.
9. The lifting assembly according to claim 1, wherein the weight of the crane is less than 40 tons, and preferably less than 30 tons.
10. The lifting assembly according to claim 1, wherein the platform is provided with extendable beams, for supporting a wind turbine roof.
11. The lifting assembly according to claim 1, wherein the area of each of the first and second storage areas is at least 4 m.sup.2.
12. A method for using the lifting assembly as defined in claim 1 for replacing an old component of a wind turbine with a new component, wherein the method comprises: a) positioning the lifting device on the ground and in close proximity to the wind turbine, b) lifting the new component by means of the crane and placing the new component on the first storage area of the platform, c) moving one of the tower segments to the support frame in a vertical orientation through the opening of the platform by means of the crane, d) connecting the tower segment to the support frame, e) vertically moving the platform to an upper end of the tower segment, f) lifting another of the tower segments, placing the tower segment in a vertical orientation on the previous tower segment by means of the crane, and mechanically connecting the tower segments to each other, g) repeating the steps e-f to build the elongated tower, h) lifting the top segment and placing the top segment in a vertical orientation on the previous tower segment by means of the crane, and mechanically connecting the top segment to the previous tower segment, i) connecting the top segment to the wind turbine by means of the securing assembly, j) vertically moving the platform to the upper part of the tower segment, k) mechanically securing the platform to the top segment, l) moving the old component from the wind turbine and placing it on the second storage area by means of the crane, m) moving the new component from the platform and placing it on the wind turbine by means of the crane, n) moving the old component from the second storage area to the first storage area by means of the crane, o) removing the mechanical securing of the platform to the top segment, p) vertically moving the platform from the tower segment downwards to the previous tower segment, q) disconnecting the tower segments from each other, r) moving the tower segment to the ground by means of the crane, s) repeating the steps p-r until the platform has been moved to the last tower segment, t) moving the platform to the support frame, u) disconnecting the last tower segment from the support frame, and v) moving the last tower segment to the ground by means of the crane.
13. The method according to claim 12, wherein said component is any of a gear box, a generator, and a wind turbine wing.
14. The method according to claim 12 for using the lifting assembly, wherein the method further comprises starting the power generation devices before step b.
15. The method according to claim 12 for using the lifting assembly, wherein the method further comprises the following steps: removing the roof of the wind turbine and placing it on the extendable beams on the platform before performing step l, and lifting the roof back onto the wind turbine before step o.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention will now be explained more closely by the description of different embodiments of the invention and with reference to the appended figures.
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DETAILED DESCRIPTION
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(17) The tower is adapted to extend along its longitudinal axis A1 to a height substantially corresponding to the height of the wind turbine 5. The tower 9 is made up of a plurality of smaller tower segments 13 arranged on top of each other and connected to each other so to achieve the necessary height of the tower 9. The tower segments 13 are connected to each other with attachment means 15, e.g. bolts. The height of the tower segments can differ but is preferably of a height facilitating transport of the tower segments. Since the height of the tower 9 should substantially correspond to the height of the wind turbine 5, tower segments 13 of various heights could be needed to achieve the necessary height of the tower 9. One of the tower segments 13 is a top segment 26. The top segment 26 has an upper part 27 provided with a second storage area 28 for supporting components 3 with a weight of more than 10 ton. The top segment 26 is adapted to be arranged as the uppermost tower segment 13.
(18) The lifting device 2 comprises a securing assembly adapted to fixedly connect the tower 9 to the wind turbine 5 so to prevent the tower from swaying. The securing assembly 32 may comprises a plurality of securing devices 32 configured to clamp the tower of the wind turbine.
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(20) In the embodiment shown in
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(22) The crane 21 has preferably a weight of more than 10 ton and less 40 ton and most preferably a weight less than 30 ton. The crane 21 comprises a base part 23 connected to the platform 7 and a jib 24 rotatably connected to the base part 23. The jib 24 is adapted to lift and move the components 3 to and from the platform 7. The jib has preferably a maximum length of less than 40 m, and most preferably the jib 24 has a maximum length of less than 30 m. The lower position corresponds to the position of the platform 7 relative the tower 9 in which the platform 7 is bearing on the support frame 11. The upper position is a position at a distance above the support frame and may correspond to the highest position the platform can be moved to relative the tower, and a position in which the components 3 can be moved from the platform 7 to the upper part of the wind turbine 5. The crane 21 is configured to move the components 3 between the platform 7 and the wind turbine 5 when the platform 7 is in the upper position and preferably between the ground and the platform 7 when the platform is in the lower position.
(23) The platform 7 is arranged movable relative the tower 9 between an upper position and a lower position by means of one or more drive units 30. The drive units 30 are disposed in close vicinity to the opening 17 of the platform. The tower segments 13 are provided with one or more drive devices, such as gear racks (not shown), adapted to cooperate with the drive units 30 in order to move the platform relative the tower segments. In this embodiment, the platform is provided with four drive units 30 and the tower segments are provided with four drive devices. The drive unit 30 may comprise a motor, a gear box and a drive mechanism (not shown) including one or more drive elements, such as gear wheels, adapted to engage to the drive devices provided on the tower segments 13 in order to move the platform 7 between the upper and lower positions. Preferably the motor is an electric motor, and the driving mechanism comprises at least one gearwheel and the drive device comprises at least one gear rack.
(24) In this embodiment, the drive unit 30 is powered by a power generation device 36 configured to generate electric power to the drive unit by means of cables. The power generation device 36 is also configured to generate electric power to the crane 21. Thus, the crane 21 and the drive are powered by the power generation device 36. In this embodiment, the power generation device is arranged at the same side relative the opening 17 as the crane 21. In other embodiment, the power generation device 36 can be arranged at the same side of the opening 17 as the first storage area 19. Alternatively, the crane 21 and the drive units 30 can also be coupled to the electrical system of the wind turbine 5 and receive electrical power directly from the wind turbine, thus no power generation device is necessary.
(25) In this embodiment, the top segment 26 comprises a cap 38 covering the upper part 27 of the top segment and removably attached to the upper part 27, as shown in
(26) In this embodiment, the platform 7 is provided with extendable beams 40 adapted to support a wind turbine roof 41, as shown in
(27) The maneuver of the crane and the platform can be done in a wireless manner. Using wireless control means increases the safety of the lifting assembly since no personal needs to be positioned on the platform, while the crane and the platform is operating.
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(32) A method for using the lifting assembly to replace an old component with a new one is described herein with reference to
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(34) In
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(37) Another tower segment 13 has been lifted from the ground and placed in a vertical orientation on the previous tower segment 13 by means of the crane 21, which is also shown in
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(39) The top segment 26 is connected to the wind turbine 5 by means of the securing assembly 32, which is shown in
(40) The platform 7 is vertically moved by means of the drive unit 30 to the upper part 27 of the top segment 26 and is then mechanically secured to the top segment 26. The securing of the platform 7 to the top segment 26 can be done by using the securing means, and in doing so, the drive unit 30 no longer has to support the platform 7. This means that if the weight on the platform 7 becomes imbalanced, this will not affect the drive unit 30 and therefore the imbalance will not wear on the drive unit 30. After this, the elongated tower 9 is completed. Once the platform 7 is at the upper part 27 of the top segment 26, the crane 21 will be as close as it can be to the old component 3a on the wind turbine 5 that needs to be replaced. In this embodiment the top segment 26 has been provided beforehand with the cap 38, which is removably attached to the upper part 27 and has the surface defining the second storage area 28. The cap 38 is of the same shape as the opening 17 and the periphery of the tower segments 13 is in this embodiment rectangular, and is preferably the same size as the periphery of the top tower segment 26.
(41) Suitably, the protruding extendable beams 40 are extended once the elongated tower 9 has been built, and the wind turbine roof 41 is removed from the wind turbine 5 and placed on said beams 40 by means of the crane 21. By removing the wind turbine roof 41, the components 3 inside the wind turbine 5 will be replaceable. Preferably, the folding gangway 31 is placed with one end on the platform 7 and an opposite end on the wind turbine 5. By adding this folding gangway 31, there is an easy and safe way for people to get between the wind turbine 5 and the platform 7, which might be necessary during the replacing of the old component 3a. This set-up can be seen in
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(45) Once the old component 3a has been replaced with the new component 3b, the disassembly of the tower 9 can begin. The folding gangway 31 is removed from the wind turbine 5 and is placed on the platform 7. The wind turbine roof 41 is placed back on the wind turbine 5. This needs to be done since. The extendable beams 40 are then retracted. This can be done any time after the roof 41 has been replaced, but suitably, it is done before the platform 7 has been brought down to the support frame 11, since it is easier to retract the beams 40 if they are not directly placed on a surface, but are, at least, slightly elevated.
(46) The mechanical securing of the platform 7 to the top segment 26 is removed, which enables the platform 7 to become vertically movable from the top segment 26 downwards to the previous tower segment 13 by means of the drive unit 30. The tower segments are disconnected from each other and the tower segment 13 is moved to the ground be means of the crane 21. By using the crane 21, there is no need for an extra lifting assembly for the disassembling of the tower 9, which simplifies the disassembly. The above mentioned steps are repeated until the platform 7 has been moved to the last tower segment 13.
(47) The platform 7 is moved to the support frame 11. The last tower segment 13 is disconnected from the support frame 11 and is then moved to the ground by means of the crane 21. Again, since the crane 21 is very close to the ground, there is no need for long wires, making the solution less sensitive to wind. By moving the last tower segment 13, the lifting device 2 is liberated and can easily be lifted by a transport vehicle, e.g. a truck, and be removed from the location of the wind turbine 5.
(48) The present invention is not limited to the embodiments disclosed but may be varied and modified within the scope of the following claims. For example, in another embodiment of the invention, the tower segments of the lifting assembly can be telescopic and the platform can be fixedly attached to the top segment. Further, the crane and the first storage area can switch place so that the crane is closer to the wind turbine than the first storage area. The lifting assembly can also be used to build a complete wind turbine, including building the wind tower.