METHOD AND BLADE INSTALLATION DEVICE FOR INSTALLING A BLADE OF AN OFFSHORE WIND TURBINE

Abstract

In a method for installing a blade on a horizontal axis rotational hub of an offshore wind turbine, use is made of a blade installation device that is temporarily installed on the offshore wind turbine. The device includes a mounting part that is mounted on the foundation of the offshore wind turbine and/or on a lower portion of the wind turbine mast. A guide mast having a track is supported by the mounting part and extends parallel and adjacent to the wind turbine mast. A support bracket laterally supports the guide mast. The blade installation device further includes a blade manipulator assembly with a trolley that is movable along the track and a blade manipulator including blade engagement members. The blade manipulator is supported by the trolley via an actuating assembly including actuators. A positioning system controls the actuators.

Claims

1.-12. (canceled)

13. A method for installing a blade on a horizontal axis rotational hub of an offshore wind turbine, the offshore wind turbine comprising a wind turbine mast that is supported by a foundation and a nacelle with a horizontal axis rotational hub provided on a top end of the wind turbine mast, the method comprising: using a blade installation device that is adapted to be temporarily installed on the offshore wind turbine; transporting the blade installation device on a crane vessel to the offshore wind turbine, the crane vessel being equipped with a crane; using the crane of the crane vessel for the temporary installation of the blade installation device on the offshore wind turbine, wherein the blade installation device comprises: a mounting part that is mounted on the foundation of the offshore wind turbine and/or on a lower portion of the wind turbine mast; a guide mast that is erected vertically in an operational position, wherein the guide mast is supported by the mounting part and extends parallel and adjacent to the wind turbine mast, the guide mast having a track; a support bracket that is engaged with the wind turbine mast and laterally supports the erected guide mast; and a blade manipulator assembly comprising: a trolley engaging the track of the guide mast and being movable along the track in a vertical direction; a trolley drive for moving the trolley along the track; a blade manipulator comprising blade engagement members that are provided to secure a blade relative to the blade manipulator, wherein the blade manipulator is supported by said trolley via an actuating assembly comprising actuators, the actuators being configured to enable one or more degrees of freedom of the blade manipulator relative to the trolley; and a positioning system for controlling the actuators and thus the position of the blade that is secured relative to the blade manipulator; bringing the trolley in a lower blade receiving position thereof and arranging the blade manipulator to receive a blade in a horizontal position thereof, wherein the blade engagement members secure the blade relative to the blade manipulator; then moving the trolley along the track by the trolley drive in an upper blade installation position thereof, and operating the positioning system to control the actuators so as to bring the blade that is secured relative to the blade manipulator in a mounting position thereof; and attaching the blade in said mounting position to the horizontal axis rotational hub of the offshore wind turbine.

14. The method according to claim 13, wherein the actuators enable six degrees of freedom of the blade manipulator relative to the trolley.

15. The method according to claim 13 wherein the mounting position is vertical.

16. The method according to claim 14, wherein the mounting position is vertical.

17. The method according to claim 13, wherein the mounting position is horizontal and wherein the actuating assembly of the blade manipulator assembly comprises a lift arm having a free end, the lift arm being pivotally connected to the trolley about a horizontal lift arm pivot axis, wherein an actuator forms a lift arm drive for pivoting the lift arm, wherein the blade manipulator is pivotally connected to the free end of the lift arm about a horizontal manipulator pivot axis that extends parallel to the lift arm pivot axis, wherein an actuator forms a manipulator drive, and wherein the actuators are controlled so that a horizontal orientation of the blade is maintained during a pivoting of the lift arm around the lift arm pivot axis so as to lift the blade.

18. The method according to claim 14, wherein the mounting position is horizontal and wherein the actuating assembly of the blade manipulator assembly comprises a lift arm having a free end, the lift arm being pivotally connected to the trolley about a horizontal lift arm pivot axis, wherein an actuator forms a lift arm drive for pivoting the lift arm, wherein the blade manipulator is pivotally connected to the free end of the lift arm about a horizontal manipulator pivot axis that extends parallel to the lift arm pivot axis, wherein an actuator forms a manipulator drive, and wherein the actuators are controlled so that a horizontal orientation of the blade is maintained during a pivoting of the lift arm around the lift arm pivot axis so as to lift the blade.

19. The method according to claim 13 wherein a top end of the guide mast in the mounted and erected position thereof is below a top end of the wind turbine mast.

20. The method according to claim 13, wherein the blade installation device further comprises a hoist system with a winch, a cable and a crane boom, the crane boom being configured to be erected with respect to a top end of the guide mast and supported via the guide mast by the foundation, and wherein the hoist system is used for exchanging a component from the nacelle of the wind turbine.

21. A blade installation device configured to be temporarily installed on an offshore wind turbine for installing a blade on a horizontal axis rotational hub of the offshore wind turbine, the offshore wind turbine comprising a wind turbine mast that is supported by a foundation and a nacelle with a horizontal axis rotational hub provided on a top end of the wind turbine mast, wherein the blade installation device is transportable on a crane vessel to the offshore wind turbine, the blade installation device comprising: a mounting part that is mounted on the foundation of the offshore wind turbine and/or on a lower portion of the wind turbine mast; a guide mast that is erected vertically in an operational position, wherein the guide mast is supported by the mounting part and extends parallel and adjacent to the wind turbine mast, the guide mast having a track; a support bracket that is engaged with the wind turbine mast and laterally supports the erected guide mast; and a blade manipulator assembly comprising: a trolley engaging the track of the guide mast and being movable along the track in a vertical direction; a trolley drive for moving the trolley along the track; a blade manipulator comprising blade engagement members that are provided to secure a blade relative to the blade manipulator, wherein the blade manipulator is supported by said trolley via an actuating assembly comprising actuators, the actuators being configured to enable one or more degrees of freedom of the blade manipulator relative to the trolley; and a positioning system for controlling the actuators and thus the position of the blade that is secured relative to the blade manipulator, wherein the trolley is configured to be brought in a lower blade receiving position thereof and the blade manipulator is configured to be arranged to receive a blade in a horizontal position thereof, wherein the blade engagement members are configured to secure the blade relative to the blade manipulator, and wherein the trolley is movable along the track by the trolley drive in an upper blade installation position thereof, and wherein the positioning system is configured to be operated to control the actuators so as to bring the blade that is secured relative to the blade manipulator in a mounting position thereof allowing for the blade in said mounting position to be attached to the horizontal axis rotational hub of the offshore wind turbine.

22. The blade installation device according to claim 21, wherein the actuators enable six degrees of freedom of the blade manipulator relative to the trolley.

23. The blade installation device according to claim 21, wherein the mounting position is vertical.

24. The blade installation device according to claim 22, wherein the mounting position is vertical.

25. The blade installation device according to claim 21, wherein the mounting position is horizontal and wherein the actuating assembly of the blade manipulator assembly comprises a lift arm having a free end, the lift arm being pivotally connected to the trolley about a horizontal lift arm pivot axis, wherein an actuator forms a lift arm drive for pivoting the lift arm, wherein the blade manipulator is pivotally connected to the free end of the lift arm about a horizontal manipulator pivot axis that extends parallel to the lift arm pivot axis, wherein an actuator forms a manipulator drive, and wherein the actuators are controlled so that a horizontal orientation of the blade is maintained during a pivoting of the lift arm around the lift arm pivot axis so as to lift the blade.

26. The blade installation device according to claim 22, wherein the mounting position is horizontal and wherein the actuating assembly of the blade manipulator assembly comprises a lift arm having a free end, the lift arm being pivotally connected to the trolley about a horizontal lift arm pivot axis, wherein an actuator forms a lift arm drive for pivoting the lift arm, wherein the blade manipulator is pivotally connected to the free end of the lift arm about a horizontal manipulator pivot axis that extends parallel to the lift arm pivot axis, wherein an actuator forms a manipulator drive, and wherein the actuators are controlled so that a horizontal orientation of the blade is maintained during a pivoting of the lift arm around the lift arm pivot axis so as to lift the blade.

27. The blade installation device according to claim 21, wherein the guide mast is configured so that a top end of the guide mast in the mounted and erected position thereof is below a top end of the wind turbine mast.

28. The blade installation device according to claim 21, wherein the blade installation device further comprises a hoist system with a winch, a cable and a crane boom, the crane boom being configured to be erected with respect to a top end of the guide mast and supported via the guide mast by the foundation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The invention will further be elucidated in relation to the drawings, in which:

[0049] FIGS. 1a-1c show in a side view the transport of a blade installation device according to the invention and the mounting thereof;

[0050] FIG. 2 shows a perspective view of the blade installation device of FIGS. 1a-1c in an operational position, mounted on a floating wind turbine, the blade installation device supporting a blade;

[0051] FIG. 3 shows the blade installation device of FIG. 2 in a side view, wherein a blade installation device supports a blade in horizontal position;

[0052] FIG. 4 shows the blade installation device of FIG. 2, wherein the blade installation device supports the blade in tilted position;

[0053] FIG. 5 shows the blade installation device FIG. 2 in a side view, wherein the blade installation device supports the blade in an essentially vertical position; and

[0054] FIG. 6 shows a side view of the floating wind turbine with a blade installation device depicted in both a lower blade receiving position as shown in FIG. 3 and an upper blade installation position as shown in FIG. 5;

[0055] FIGS. 7a and 7b show a side and front view respectively of an alternative blade installation device according to the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0056] FIGS. 1a-1c and 2-6 show a blade installation device 10 according to the invention.

[0057] In FIG. 1a the blade installation device 10 is transported on a crane vessel 1, together with a number of blades 24. Crane vessel 1 comprises a crane 2, here a pedestal crane comprising a pivotable boom.

[0058] An offshore wind turbine 20 is shown, comprising a foundation 21 and a wind turbine mast 22 supported by the foundation 20.

[0059] From FIGS. 1a-1c follows that the height of the crane 2 of the crane vessel 1 is substantially less than that of the wind turbine mast 22 of the offshore wind turbine 20. Hence, the crane 2 of the crane vessel is not suitable for blade installation.

[0060] In FIG. 1b is visible how the crane 2 of the crane vessel 1 hoists the blade installation device 10 to the offshore wind turbine 20, and allows the mounting of the blade installation device 10 to the foundation 21 of the wind turbine 20, such as a floating wind turbine or a wind turbine mounted to the seabed.

[0061] Mounting part 11 of the blade installation device is mounted on the foundation 21. The guide mast 12 is supported by the mounting part 11 and provided parallel and adjacent to the wind turbine mast 22.

[0062] In FIG. 1b, an upper part of the guide mast is still to be pivoted about a pivot point 12.

[0063] In FIG. 1c the fully erected guide mast 12 is shown, wherein the guide mast 12 is supported by the mounting part 11 and extends parallel and adjacent to the wind turbine mast 22.

[0064] To bring the blade installation device 10 as shown in FIG. 1c into the operational position as shown in FIGS. 2-5 support bracket 14 is to be provided at an upper end of the guide mast 12 to engage the wind turbine mast 22 and to laterally support the guide mast 12 in the erected position.

[0065] An optional hoist system 40 is be provided at an upper part of the guide mast 12.

[0066] FIGS. 3-5 show subsequent working positions of a blade installation device 10 according to the invention.

[0067] As shown in FIGS. 1a-1c, the blade installation device 10 is configured be transported on a crane vessel, and is adapted to be mounted onto, and removed from, the foundation 21 of an offshore wind turbine 20. Thus, when the blades of a wind turbine need to be installed, or one or more blades need to be replaced, the blade installation device 10 can temporarily be installed on the foundation of the wind turbine to move blades into and out of a position in which they can be mounted to the nacelle of the wind turbine.

[0068] The blade installation device 10 comprises a mounting part 11, a guide mast 12, a support bracket 14, a blade manipulator assembly 30 and a trolley drive 36 (visible in FIG. 6).

[0069] The mounting part 11 is configured to be mounted on the foundation of the offshore wind turbine. The mounting part is, preferably, mounted to the foundation of the wind turbine, for example at the flange of the mast of the wind turbine, with which the wind turbine is mounted onto the foundation.

[0070] Once the mounting part 11 is installed, it provides a support for the guide mast 12, and allows for the guide mast to be erected on the mounting part adjacent the mast of the wind turbine 20.

[0071] The support bracket 14, mounted to or integral with the guide mast 12, is provided at a top end of the guide mast, and engages the wind turbine mast 22 to laterally support the guide mast.

[0072] The guide mast has a track 13 for guiding the blade manipulator assembly 30 in a vertical direction along a part of the wind turbine mast 22. The blade manipulator assembly 30 is adapted to be movable along the track 13.

[0073] The blade manipulator assembly 30 comprises a trolley 31, a blade manipulator 32, and a positioning system 35.

[0074] The trolley 31 is adapted to engage the track 13, and is movable along the track, thus enabling the blade manipulator assembly 30 to be moved up and down along the guide mast 12.

[0075] The blade manipulator 32 is supported by the trolley 31 via multiple actuators 33, the actuators enabling multiple degrees of freedom of the blade manipulator relative to the trolley. The blade manipulator 32 comprises blade engagement members 34 that are provided to secure the blade relative to the blade manipulator.

[0076] The positioning system 35 is configured to control the multiple actuators 33, and to thus control the position of the blade manipulator relative to the trolley

[0077] The trolley drive 36 is provided for moving the trolley 31 along the track 13 between a lower blade receiving position Pr, shown in FIG. 3, and an upper blade installation position Pi, shown in FIG. 5. Both positions are also indicated in the side view of FIG. 6.

[0078] The blade manipulator 32 is adapted to, at the lower blade receiving position Pr, be brought in a horizontal position for receiving a blade 24 in a horizontal position. This is visible in FIG. 3 and FIG. 6.

[0079] The blade manipulator is furthermore adapted to, at the upper blade installation position Pi, be brought in a vertical position for mounting the blade 24 to a nacelle 23 of the offshore wind turbine. This is visible in FIG. 5 and FIG. 6.

[0080] It is noted that, in embodiments, when in the blade installation position, the blade can be supported at an angle or inclination to the vertical, the angle being in the range of 0-45?. In the particular embodiment shown, the blade manipulator is configured to support the blade in a range of 10-20?.

[0081] FIG. 4 shows the blade 24 being supported by the blade manipulator assembly 30 at a slightly angled installation position. By enabling the blade manipulator to support the blade at such an essentially vertical position, the guide mast can be mounted at a side of the wind turbine, instead of in front of the wind turbine, and still support a blade in an installation position that allows for mounting the blade to a nacelle at the front of the wind turbine.

[0082] Furthermore, the blade manipulator assembly being configured for engaging a blade at or near its centre of gravity, and for supporting the blade in an essentially vertical position allows for the guide mast to extend along only a section of the wind turbine mast. Therefore, in the exemplary embodiment shown, a top end 12a of the guide mast 12 in the mounted and erected position is below a top end of the wind turbine mast 22, in particular below a nacelle 23 provided on the top end of the wind turbine mast.

[0083] In the exemplary embodiment shown, the blade installation device 10 further comprises an optional hoist system 40 suitable for exchanging components from the nacelle of the wind turbine, e.g. for installation or replacing the gear box or generator of the wind turbine.

[0084] The hoist system 40 comprises a winch 41, a cable 42 and a crane boom 43. The crane boom is telescopic, i.e. the crane boom is configured to be erected with respect to a top end 12a of the guide mast 12 and supported via the guide mast by the foundation 21. Thus, the hoist system allows for a mast that does not extend up to, or even above, the nacelle of the offshore wind turbine.

[0085] The blade installation device 30 enables a method for installing or maintenance of the wind turbine 20, in particular for exchanging blades of a wind turbine. The process of moving the blade into the mounting position is shown in FIGS. 2-4.

[0086] The process of installing the blade is preceded by transporting the blade installation device 10, preferably with a blade, e.g. a blade to be exchanged with a blade of the offshore wind turbine, to the offshore wind turbine with a crane vessel. In an embodiment, the crane vessel is also the blade supply vessel, i.e. the vessel that provides the blade to be installed, and that will transport the blade that is to be removed from the wind turbine.

[0087] The process of installing the blade 24 is furthermore provided by installation of the blade installation device 10 on the offshore wind turbine 20, as shown in FIGS. 1a-1c. This installation process comprises mounting the mounting part 11 of the blade installation device on the foundation 21 of the offshore wind turbine 20, and providing the guide mast in the erected position on the mounting part, with the blade manipulator assembly engaged by the track.

[0088] Preferably, the crane of the crane vessel that transported the blade installation device is used for installation of the blade installation device on the offshore wind turbine. The guide mast of the blade installation device, preferably, is configured to be erected without use of the crane of the crane vessel. In an embodiment, the mast is a telescopic mast. Alternatively, the mast is hingeable mounted on the mounting part, and is erected by being extended or erected using an internal drive. As an alternative, the guide mast may comprise multiple components and is self-erecting, like a self-erecting tower crane.

[0089] Once the blade installation device is installed on the offshore wind turbine, it can be used to move a blade in the installation position. The blade installation process comprises: [0090] operating the positioning system of the blade manipulator to bring the blade manipulator in the horizontal blade receiving position, shown in FIG. 2 [0091] operating the crane vessel to present a blade in a horizontal position to the blade manipulator; [0092] operating the blade engagement members to secure the blade relative to the blade manipulator; and [0093] operating the trolley drive and the positioning system of the blade manipulator to bring the blade manipulator from the horizontal lower blade receiving position to the upper and essentially vertical blade installation position, shown in FIG. 4.

[0094] In FIGS. 7a and 7b an alternative embodiment of a blade installation device 100 according to the invention is shown, mounted to a foundation 21 of an offshore wind turbine 20, the offshore wind turbine further comprising a wind turbine mast 22 supported by the foundation.

[0095] The blade installation device 100 comprises a mounting part 111, mounted on the foundation 21 of the offshore wind turbine.

[0096] A guide mast 112 is erected to an operational position wherein the guide mast is supported by the mounting part 111, parallel and adjacent to the wind turbine mast 22.

[0097] The guide mast 112 has a track, not shown in detail. A support bracket 114 is mounted to an upper end of the guide mast 112 and engages the wind turbine mast 22 and to laterally support the erected guide mast 112.

[0098] A blade manipulator assembly 130 is movable along the guide mast, and shown in two positions indicated by reference numbers 130 and 130 in FIGS. 7a and 7b.

[0099] The blade manipulator assembly 130 comprises a trolley 131 engaging the track and being movable along the track by a trolley drive, e.g. as discussed herein.

[0100] Blade manipulator assembly 130 further comprises a blade manipulator 132 comprising blade engagement members (not shown in detail) that are provided to secure the blade relative to the blade manipulator.

[0101] The blade manipulator assembly 130 further comprises an actuating assembly with actuators configured to enable one or more degrees of freedom of the blade manipulator 132 relative to the trolley 131.

[0102] Here the actuating assembly of the blade manipulator assembly comprise a lift arm 121 having a free end 122, the lift arm being pivotably connected to the trolley 131 about a horizontal lift arm pivot axis 126.

[0103] In an example, the lift arm has an angle of between 30 and 80 degrees with the horizontal plane after the pivoting, for example between 40 and 60 degrees, for example 45-50 degrees. In an example the lift arm has an angle of between ?30 and ?80 degrees with the horizontal plane wen receiving the blade, so prior to the upward pivoting to lift the blade, for example between ?40 and ?60 degrees, for example ?45 degrees.

[0104] At an opposite end the lift arm 121 is here provided with a counter weight 123 for counteracting a force moment exerted by the blade to be held relative to the lift arm connection to the trolley. This counterweight has the effect of displacing the center of gravity of the lift arm towards the lift arm pivot axis. Thereby, the moment arm of the force moment exerted relative to the pivot axis is reduced, and thereby, the moment itself. This may favor the load profile of the guide mast, in particular any bending stress.

[0105] The free end 122 of the lift arm is pivotal relative to the trolley 131, e.g. to reach an installation height of the blade 1040. An actuator between the trolley and the lit arm (not shown) forms a lift arm drive.

[0106] The blade manipulator 132 is pivotally connected to the free end 122 of the lift arm, which blade manipulator is pivotal about a horizontal manipulator pivot axis 127, parallel to the lift arm pivot axis 126 by means of an actuator forming a manipulator drive (not shown).

[0107] A positioning system is provided for controlling the lift arm drive and the manipulator drive and thus the position of the position of the blade 1040 secured by the blade manipulator 132 relative to the trolley 131.

[0108] Not shown is a trolley drive for moving the trolley along the track between a lower blade receiving position, with the blade manipulator assembly at the position indicted with 130, and an upper blade installation position with the blade manipulator assembly at the position indicted with 130. At the lower blade receiving position the blade manipulator 132 is brought in a horizontal position for receiving a blade 1040 in a horizontal position. In this embodiment at the upper blade installation position the blade manipulator is also in a horizontal mounting position for mounting the blade 1040 to a nacelle 23 of the offshore wind turbine.

[0109] The pivoting of the lift arm 121 combined with the vertical motion of the trolley 131, and thus of the lift arm 121 as well, allow to controllably move the horizontally oriented blade upward while making use of the stability of the guide mast 112 relative to the wind turbine. Thus, when lifting the blade, the movement of the blade is restricted to follow the movement of the free end of the arm 121, as the blade is effectively secured thereto. This is in contrast to lifting of the blade by suspending it from a hoisting cable, e.g. using a major crane onboard a vessel as in the prior art, where practice shows that the blade is susceptible to undue movement, e.g. caused by wind and/or vessel motion.

[0110] It is illustrated in FIGS. 7a, b that the blade is moved in a vertical plane that is parallel to and to the rear of the plane of motion of the lift arm 121. In appropriate embodiments, the plane of the blade is close to the plane of the lift arm 121, which reduces the moment arm of the force exerted by the weight of the blade on the guide mast 112, as it is held relatively close to the guide mast.

[0111] The lift arm version enables that, in embodiments, after the upwardly displacing of the free end of the lift arm 121 to an installation height, the free end of the lift arm, and therefore the securely held rotor blade, extends higher than the top of the guide mast 112. Thus, the lift arm 121 then functions as an extension above the guide mast 112so that the guide mast advantageously needs less height.

[0112] In an embodiment, the method further comprises, (just) prior to the mounting of the blade, aligning the blade with a hub connection of the hub for the blade. For example, the blade is aligned to cause alignment between bolts on the root of the blade with bolt holes in the blade mounting of the hub. In an example this is done by moving the blade by actuating one or more alignment actuators. This alignment mechanism may be integrated with the lift arm and/or the blade manipulator, e.g. the cradle that that accommodates the blade during installation. For example, the alignment mechanism allows for alignment in any one or more directions.

[0113] In an embodiment, the blade manipulator 132 comprises a cradle that is configured to accommodate the blade, e.g. to support the horizontally orientated blade from below, e.g. clamping the blade from above, and is configured for holding the blade horizontally.

[0114] In an embodiment, the manipulator 132 comprises a cradle that is releasable from the lift arm and that has a connector for securing the cradle to a coupler of the lift arm 121. In an embodiment, the cradle comprises an attachment portion for suspending the cradle from a crane, e.g. from a crane hook, e.g. via one or more slings. In embodiments, this allows for a method wherein the blade is first lifted by means of a crane engaging on the cradle in which the blade is secured and held horizontally. For example, the blade is transferred in this manner from a supply vessel, or from the crane vessel, to the already installed blade installation device. This cradle plus blade is then transferred by the crane and then secured via its connector to the coupler at the free end of the lift arm. Then the crane can be released from the cradle. Thus, there is no need to remove the blade from the cradle for this transfer from the vessel crane to the lift arm.