MATING AND DEMATING OF SURFACES OF TWO STRUCTURES

Abstract

A method for mating a first surface of a first structure to a second surface of a second structure, the method comprising: providing a device at least comprising: a first body adapted for insertion at least in a through hole of the first surface; and a second body adapted for insertion at least in a through hole of the second surface, the first body being further adapted for being mechanically coupled with a second body, and the second body being mechanically coupled with the first body; inserting at least a first portion of the first body in the through hole of the first surface; inserting the second body in the through hole of the second surface when the first and second surfaces are spaced apart by a distance; providing an apparatus for winding the second body; arranging the second body on the apparatus; and pulling one of the first and second structures towards the other one of the first and second structures by winding the second body with the apparatus.

Claims

1. A method for mating a first surface (5) of a first structure (3,4,8,9) to a second surface (6) of a second structure (3,4,8,9), each of the first and second surfaces (5,6) having a through hole (50,51) formed therein for receiving a bolt (40) or a guiding pin, the method comprising: providing a device (10) at least comprising: a first body (11,12) adapted for insertion at least in the through hole (50) of the first surface (5); and a second body (15) adapted for insertion at least in the through hole (51) of the second surface (6), the first body (11,12) being further adapted for being mechanically coupled with a second body (15), and the second body (15) being mechanically coupled with the first body (11,12); inserting at least a first portion of the first body (11,12) in the through hole (50) of the first surface (5); inserting the second body (15) in the through hole (51) of the second surface (6) when the first and second surfaces (5,6) are spaced apart by a distance; providing an apparatus (30) for winding the second body (15); arranging the second body (15) on the apparatus (30); and pulling one of the first and second structures (3,4,8,9) towards the other one of the first and second structures (3,4,8,9) by winding the second body (15) with the apparatus (30) while: the first body (11,12) is at least inserted in the through hole (50) of the first surface (5); the second body (15) is at least inserted in the through hole (51) of the second surface (6); and the first and second surfaces (5,6) are spaced apart; wherein the device (10) further comprises means for mechanically coupling either the first body (11,12) with the first surface (5) or the second body (15) with the second surface (6), and the means for mechanically coupling are: one or more expanding bodies at least arranged on a perimeter of the first portion or the second body (15), the one or more expanding bodies being adapted to expand so as to exert a compressing force between the through hole (50) of the first surface (5) and at least the first portion of the device (10) or between the through hole (51) of the second surface (6) and the second body (15); and adhesive arranged at least on the perimeter of the first portion or the second body (15).

2. The method of claim 1, further comprising: removing the second body (15) from the second surface (6) after the pulling step; and providing a fastening device after the step of withdrawing and when: both the first and second surfaces (5,6) are not spaced apart, and the through holes (50,51) thereof are aligned.

3. The method of any one of the preceding claims, wherein the pulling step is carried out additionally while the through holes (50,51) of the first and second surfaces (5,6) are not aligned.

4. The method of any one of the preceding claims, wherein the first body (11,12) is shaped such that it cannot be entirely pulled through the through hole (50) of the first surface (5) in a direction of insertion of the first body (11,12) in the through hole (50) of the first surface (5).

5. The method of any one of the preceding claims, wherein the first portion has a thread formed thereon, and the through hole (50) of the first surface (5) has a thread formed thereon.

6. The method of any one of the preceding claims, wherein at least an outer surface of the one or more expanding bodies is made of a high friction material.

7. The method of any one of the preceding claims, further comprising mechanically coupling the first body (11,12) with the second body (15) either prior to both inserting steps, or after both inserting steps.

8. The method of any one of the preceding claims, wherein the first structure (3,4,8,9) is suspended from a machine (90,91) during one or more of the following steps: inserting at least the first portion of the first body (11,12) in the through hole (50) of the first surface (5); inserting the second body (15) in the through hole (51) of the second surface (6); arranging the second body (15) on the apparatus (30); and pulling one of the first and second structures (3,4,8,9) towards the other one of the first and second structures (3,4,8,9).

9. The method of any one of the preceding claims, wherein each of the first and second structures (3,4) is a part (3,4) of a tower (2) of a wind turbine (1), one of said parts optionally being a nacelle of a wind turbine (1).

10. The method of any one of the preceding claims, wherein the first structure (8) is a rotor blade (8) of a wind turbine (1) and the second structure (9) is a hub (9) of a wind turbine (1).

11. The method of any one of the preceding claims, each of the first and second surfaces (5,6) has a plurality of through holes (50,51) formed therein for receiving a bolt (40) or a guiding pin, and the method further comprises: providing a plurality of the devices (10); inserting each device (10) of the plurality of the devices in a different through hole (50,51) of both the first and second surfaces (5,6); providing a plurality of apparatuses (30) for winding the second body (15) of a device (10) of the plurality of devices; and arranging the second body (15) of each device (10) of the plurality of devices on a different apparatus (30) of the plurality of apparatuses; wherein pulling one of the first and second structures (3,4,8,9) towards the other one of the first and second structures (3,4,8,9) is carried out by winding the second body (15) of each device (10) of the plurality of devices with the plurality of apparatuses (30).

12. A device (10) for mating a first surface (5) of a first structure (3,4,8,9) to a second surface (6) of a second structure (3,4,8,9), the device (10) comprising: a first body (11,12) at least having a first portion adapted for insertion at least in a through hole (50) of the first surface (5) for receiving a bolt (40) or a guiding pin; a second body (15) adapted for insertion at least in a through hole (51) of the second surface (6) for receiving a bolt (40) or a guiding pin, the first body (11,12) being further adapted for being mechanically coupled with the second body (15), and the second body (15) being mechanically coupled with the first body (11,12); and an apparatus (30) for winding the second body (15); wherein the device (10) further comprises means for mechanically coupling either the first body (11,12) with the first surface (5) or the second body (15) with the second surface (6), and the means for mechanically coupling are: one or more expanding bodies at least arranged on a perimeter of the first portion or the second body (15), the one or more expanding bodies being adapted to expand so as to exert a compressing force between the through hole (51) of the first surface (5) and at least the first portion of the device (10) or between the through hole (51) of the second surface (6) and the second body (15); and adhesive arranged at least on the perimeter of the first portion or the second body (15).

13. The method of any one of claims 1-11, or the device (10) of claim 12, wherein the second body (15) is both elongated and flexible.

14. The method of any one of the claim 1-11 or 13, or the device (10) of any one of claims 12-13, wherein the first body (11,12) is a metallic body and the second body (15) is one of: a chain, a rope and a cable.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0109] To complete the description and in order to provide for a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate embodiments of the invention, which should not be interpreted as restricting the scope of the invention, but just as examples of how the invention can be carried out. The drawings comprise the following figures:

[0110] FIG. 1 shows mating of parts of a tower of a wind turbine in accordance with an embodiment.

[0111] FIGS. 2A-2B and 3 show devices for mating the surfaces of two structures in accordance with embodiments.

[0112] FIGS. 4A-4D show a device and a method for mating the surfaces of two structures in accordance with embodiments.

[0113] FIGS. 5 and 6A-6C show mating of blades to wind towers in accordance with embodiments.

[0114] FIGS. 7A and 7B shows a device for mating and/or demating the surfaces of two structures in accordance with an embodiment.

[0115] FIGS. 8A-8G show a method for mating the surfaces of two structures in accordance with an embodiment.

DESCRIPTION OF WAYS OF CARRYING OUT THE INVENTION

[0116] FIG. 1 shows mating of parts 3, 4 of a tower of a wind turbine in accordance with an embodiment.

[0117] A first part 3 of the tower mounted on ground and securely attached thereto by means of a foundation (not illustrated). A second part 4 of the tower is to be arranged on top of the first part 3 and mated thereto so as to erect the tower. The second part 4 is suspended from the boom of a crane 90 that lifts the second part 4 above the first part 3, and by way of a plurality of devices 10, which will be described next, the second part 4 is to be aligned with the first part 3 so that surfaces thereof can be mated.

[0118] The devices 10 assist in both moving the second part 4 for alignment thereof with respect to the first part 3, and reducing the distance spacing apart the two parts 3, 4 until the second part 4 rests on top of the first part 3, at which point the second part 4 can be released from the means of the crane to lift it and having it suspended.

[0119] Upon erecting the different parts of the tower, a tower 2 as illustrated in FIGS. 5 and 6A-6C is provided.

[0120] FIGS. 2A-2B show a device 10 for mating the surfaces of two structures in accordance with an embodiment. The two structures may be, for instance but without limitation, two parts of a tower of a wind turbine (such as the one of FIG. 1), including an offshore wind turbine, whereas the surfaces 5, 6 thereof to be mated are tower flanges.

[0121] The device 10 comprises a first body 11 and a second body 15; the first body 11 is adapted to be mechanically coupled with the second body 15. As best seen in FIG. 2B, the first body 11 has a portion thereof inserted in one through hole 50 of the plurality of through holes 50 of a first surface 5, which is part of a first structure. The second body 15, which is mechanically coupled with the first body 11 (preferably, an end of the second body 15 is attached to the first body 11, as in this example) is inserted in a through hole 51 of the plurality of through holes 51 of a second surface 6, which is part of a second structure. For the sake of clarity only, the through hole 50 where the first body 11 is inserted in will be hereinafter referred to as first hole 50, whereas the through hole 51 where the second body 15 is inserted in will be hereinafter referred to as second hole 51. Even though only part of the surfaces 5, 6 has been illustrated, they are flanges with respective through holes 50, 51 intended to be aligned ones with respect to the others for arranging fastening devices in each corresponding pair of through holes 50, 51.

[0122] In this embodiment, the second body 15 is further inserted in the first hole 50; in other embodiments in which the first body 11 completely fills the first hole 50, the second body 15 is not inserted in the first hole 50 but only in the second hole 51.

[0123] An apparatus 30 for winding the second body 15 is also provided for mating the two surfaces 5, 6; in this embodiment, the apparatus 30 is a winch. In this embodiment, the apparatus 30 has been attached to the second structure, and more particularly to the second surface 6 (from a face thereof not to be mated). In order to ease the attachment of the apparatus 30 to the second surface 6, a support 31 is arranged between the apparatus 30 and the second surface 6; the support 31 is e.g. a supporting plate.

[0124] The second body 15 is woundable on a drum of the winch 30 and, as shown in FIGS. 2A-2B, a portion of the second body 15 is wound on the drum. As seen in both FIGS. 2A-2B, the second body 15 is elongated. Accordingly, in a situation such as the one depicted in FIG. 1, the structures are pulled such that one of the structures moves towards the other one of the structures; this is achieved by winding the second body 15 with the apparatus 30. By winding the second body 15, the second body 15 pulls the first body 11 towards the apparatus 30, which in turn pulls the first surface 5 (and, thus, the first structure) towards the second surface 6 (and, thus, towards the second structure).

[0125] The first body 11 pulls the first surface 5 thanks to its coupling with the surface 5, which in this case is due to the shape of a portion of the first body 11 that cannot be entirely pulled through the through hole 50 of the first surface 5. In other embodiments, the first body is mechanically coupled with the first surface 5 with other means.

[0126] The device 10 preferably also comprises a third body 16 through which the second body 15 passes. The third body 16 is adapted for being inserted, at least partially, in the second hole 51 so that the second body 15 does not collide with the second hole 51, something that results in friction and, hence, mechanical stresses and erosion in the second body. In some embodiments, the third body 16 and the support 31 are integrally formed, i.e. both are formed as a single piece.

[0127] One or some other through holes 50, 51 of the first and second surfaces 5, 6 can be used for arranging further devices 10, for example, thereby distributing the load among the different devices whenever one of the structures is pulled towards the other.

[0128] FIG. 3 shows a device 10 for mating the surfaces 5, 6 (i.e. flanges) of two structures in accordance with an embodiment.

[0129] The device 10 of this embodiment is similar to the one described with reference to FIGS. 2A-2B, but in this embodiment the apparatus 30 is arranged on a foundation of the second structure 6 or in a structural member of the second structure 6, e.g. a girder, a working deck, etc.

[0130] FIGS. 4A-4D show a device 10 and a method for mating the surfaces 5, 6 of two structures in accordance with embodiments.

[0131] The first surface 5 comprises a plurality of through holes 50, including the aforementioned first hole 50 where a first body 12 of the device 10 is introduced. The second surface 6 comprises a plurality of through holes 51, including the aforementioned second hole 51 where a second body 15 of the device 10 is introduced. In this example, the first surface 5 is a blade root whereas the second surface 6 is a surface belonging to a hub of a wind turbine.

[0132] The device 10 comprises the first body 12, which is similar to a bolt (like the bolts 40 in the through holes 50 of the first surface 5). The first body 12 is adapted to be mechanically coupled with the second body 15 by way of the member 13 that, in this embodiment, is a shackle. The first body 12 is inserted in the first hole 50 and protrudes from the other side thereof.

[0133] The device 10 comprises the second body 15, which is inserted in the second hole 51 and mechanically coupled with the first body 12, in particular the second body 15 has an end thereof attached to the member 13. In this case, the second body is not inserted in the first hole 50 owing to the presence of the first body 12 therein.

[0134] Again, the apparatus 30 is provided and attached to the second structure by way of the support 31. The second body 15 is arranged on the apparatus 30 so that a portion of the second body 15 is wound on the drum of the apparatus 30.

[0135] As seen in FIG. 4A, the first surface 5 is spaced apart from the second surface 6. In this example, the through holes 50, 51 of the first and second surfaces 5, 6 are substantially aligned, but in other examples they are not (for example, in the scenario of FIG. 1). By winding the second body 15, the first surface 5 (and, thus, the first structure) comes closer to the second surface 5 (and, thus, to the second structure) as illustrated in FIG. 4B. The first body 12 is, at the same time, inserted in the second hole 51.

[0136] While the distance between the surfaces 5, 6 is less than e.g. 5 centimeters, preferably less than 2 or 1 centimeters, and preferably is as close to 0 millimeters as possible, nuts 45 are arranged on the bolts 40 in other through holes 50, 51 for effecting the mating of the surfaces 5, 6. This is illustrated in FIG. 4C.

[0137] Turning to FIG. 4D, once the nuts 45 have been arranged on the bolts 40, the apparatus 30 and the second body 15 are both removed, and the first body 12 is kept inserted in both the first and second holes 50, 51, and a nut 45 is arranged thereon, thereby providing a bolted joint with the first body 12 of the device 10.

[0138] FIG. 5 shows mating of a blade 8 to a wind tower 1 in accordance with an embodiment.

[0139] A plurality of devices 10 is used for mating one of the blades 8 to, for example, a hub 9 of the wind tower 1.

[0140] A crane 90 with a boom lifts the blade 8 to be mated, and the devices 10 are provided between the blade 8 and the hub 9 so as to effect the mating between the surfaces of both the blade 8 and the hub 9.

[0141] Preferably, the devices 10 described with reference to FIGS. 4A-4D are used for mating the blade 8 to the hub 9 since the first body 12 can be reused as a bolted joint. Therefore, as part of the device is maintained on the structures, the mating is simpler than if the device had to be completely removed before providing a fastening device, for example.

[0142] FIGS. 6A-6C show mating of a blade 8 to a wind tower 1 in accordance with an embodiment.

[0143] In this embodiment, the blade 8 is first supported by a foldable frame 91 that has a first frame 92 and a second frame 93 mechanically coupled such that the first frame 92 can pivot and move relative to the second frame 93, as best seen in FIG. 6B. The foldable frame 91 preferably has wheels for movement thereof.

[0144] While supported on the foldable frame 91, a plurality of devices 10 is arranged in the blade 8 and hub 9 of the wind tower 1 so as to lift the blade 8 and effect the mating thereof to the hub 9.

[0145] By pulling the second body of the devices 10, for example by winding the second bodies by means of apparatus as the apparatus 30 described with reference to FIGS. 2A-2B and 4A-4D, the blade 8 is progressively lifted. At one point the blade 8 does not rest on the foldable frame 91 anymore as shown in FIG. 6C, then the foldable frame 91 can be removed and the second body of the devices 10 can be pulled further until it reaches the hub 9 and the mating is effected. Not only the distance between the two surfaces to be mated is reduced, but also any misalignment between the through holes of the two surfaces is also reduced and, at some point, the through holes become aligned thanks to the devices 10.

[0146] FIGS. 7A and 7B shows a device 60 for mating and/or demating the surfaces of two structures in accordance with an embodiment. The two structures may be, for instance but without limitation, two parts of a tower of a wind turbine (such as the one of FIG. 1), including an offshore wind turbine.

[0147] The device 60 comprises a first body 61, a second body 65, and means 70 for mechanically coupling the first body 61 with a first surface (not shown) such that the first body 61 is rotatable with respect to the first surface.

[0148] The first body 61 is similar to a bolt, and comprises a first portion 62 with a thread formed thereon, and a second portion 63 that is conical. The second body 65 is a nut that, in this embodiment, is comprised of two parts that are to be mechanically coupled for forming the nut. In other embodiments, the second body 65 is integrally formed, i.e. with a single part, or with more than two parts, e.g. three parts, four parts, etc. The provision of a plurality of parts may simplify the insertion of the second body 65 in a through hole of a surface. Moreover, the second body 65 preferably has an inner diameter that is between 0.5% and 5.0% smaller than an outer diameter of the first body 61 (at least of the first portion 62); in this way, when the first body 61 is inserted in the second body 65, the greater diameter of the first body 61 presses against the inner surface of the second body 65 and, consequently, compressing it against walls of the through hole where the second body 65 is inserted, thereby securing the second body 65 within the through hole.

[0149] The first body 61 and the second body 65 form a screw mechanism in which the first body 61 operates as a screw in the mechanism by way of its first portion 62, and the second body 65 operates as a nut in the mechanism by way of threads 66 (as best seen in FIG. 8C) formed in an inner side thereof. The screw mechanism makes possible to change the distance between two surfaces so that they are more spaced apart or less space apart, depending on the relative rotation between the first body 61 and the second body 65, i.e. the direction of rotation of one with respect to the other.

[0150] The means 70 for mechanically coupling the first body 61 with the first surface are a rollers' mechanism formed by a plurality of parts adapted for insertion in a through hole of the first surface. When all the parts are coupled together, the cavity of the means 70 is conical so as to receive the second portion 63 of the first body 61. An inner side of these parts has ribs formed thereon for allowing rotation of the first body 61 (whenever mating or demating is to be effected) with respect to the first surface with reduced friction.

[0151] In other embodiments, and like the second body 65, the means 70 are formed by a single part, or by fewer parts than four, or more parts than four.

[0152] Preferably, the outer side of both the second body 65 and the means 70 (that is to say, the side to come into contact with walls of the through holes they are inserted in) has a material featuring a high friction coefficient so as to more reliably attach the second body 65 and the means 70 within the respective through holes.

[0153] The second body 65 (preferably each part thereof) and the means 70 (preferably each part thereof) both are preferably provided with respective flaps 67, 72 for easing manipulation thereof.

[0154] FIGS. 8A-8G show a method for mating the surfaces of two structures in accordance with an embodiment.

[0155] The method is carried out by means of a device 60 as described with reference to FIGS. 7A-7B.

[0156] In FIG. 8A is shown that the means 70 are to be attached to a through hole 50 of the first surface 5, hereinafter first hole 50, whereas the second body 65 is to be attached to a through hole 51 of the second surface 6, hereinafter second hole 51.

[0157] FIG. 8B shows the means 70 already inserted in the first hole 50 such that they form a cavity for receiving the first body 61 of the device 60. FIG. 8C shows the second body 65 already inserted in the second hole 51 such that it forms a cavity for receiving the first body 61 of the device 60; as seen in this figure, the second body 65 has threads 66 formed on the inside, which cooperate with the threaded portion 62 of the first body 61 so as to provide a screw mechanism.

[0158] FIG. 8D shows the first body 61 about to be introduced in the first and second holes 50, 51 through the second surface 6, that is to say, being first introduced in the second body 65. In those preferred embodiments in which the inner diameter of the second body 65 is smaller than the outer diameter of the first body 61, the first body 61 compresses the second body 65 against the sides of the second hole 51.

[0159] As shown in FIG. 8E, the second portion 63 of the first body 61 passes through the means 70 that are compressed against the sides of the first hole 50 due to the geometry and dimensions of both the second portion 63 and the means 63. This compression, in turn, mechanically couples the first body 61 with the first surface 5.

[0160] Upon rotating the first body 61 while inserted in the second body 65 and mechanically coupled with the first surface 5, the two surfaces 5, 6 become demated as illustratively represented in FIGS. 8F and 8G by way of arrows (indicating the movement of the surfaces 5, 6 and the rotation of the first body 61 relative to the second body 65). This is attained thanks to the second portion 63 and the cavity of the means 70 because the second portion 63 presses against the inner side of the means 70 (due to the geometry and dimensions thereof) and, accordingly, the means 70 exert a force on the first surface 5 for moving it away from the second surface 6.

[0161] When the surfaces 5, 6 space apart, the device 60 supports at least part of the weight of one of the structures. Therefore, depending on the mass of the structures, a plurality of such devices 60 may need be arranged in other through holes 50, 51 of the first and second surfaces 5, 6 for effecting demating while supporting the weight.

[0162] As it can be appreciated from the method illustrated in FIGS. 8A-8G, when the two surfaces 5, 6 are to be demated, it is rather complex to have a crane, for example, attached to one of the two surfaces 5, 6 (or structures thereof) for demating them due to the little or no separation at all between both surfaces 5, 6. In contrast, the device 60 uses the through holes 50, 51 of each surface 5, 6, which are intended to be used for the mating of the structures (thus, bolted joints are usually provided), to attach to the surfaces and demate them; accordingly, as the through holes 50, 51 are provided with bolted joints, one or several bolted joints are withdrawn from respective through holes 50, 51 so that one or more devices 60 can be arranged. After demating the surfaces 5, 6 (as in FIGS. 8F and 8G), thanks to the separation a crane may attach to one of the surfaces 5, 6 (or structures thereof) for then lifting said surface and move it.

[0163] In the embodiment illustrated in FIGS. 8A-8G, a demating procedure has been shown. With the same device(s) 60, however, a mating procedure may be effected as well. In this sense, reversing the process described in relation to these FIGS. 8A-8G, the first and second surfaces 5, 6 (and, thus, the first and second structures) become mated. In this respect, it is worth pointing out that again the problem with the attachment of e.g. a crane to a surface 5, 6 (or a structure thereof) exists because when the two surfaces 5, 6 are close together (a separation distance of e.g. 15 cm, 10 cm, etc.), the crane must detach the surface 5, 6 so that the two surfaces 5, 6 may come into contact, however there is still separation between the two surfaces 5, 6 when this occurs, so the weight of one of said structures is not supported by the crane anymore when mating is to be completed. Therefore, before the crane detaches the surface 5, 6, one or more devices 60 are inserted in respective first and second holes 50, 51 so that the device(s) 60 support/s the weight of one of the structures when the crane is detached, and then the mating process is completed thanks to the screw mechanism of the device(s) 60, which make possible to move surface 5, 6 towards the other by rotating the first body 61.

[0164] These problems are usually encountered by climbing cranes known in the art, thus the present method and device can be advantageously used in a mating or demating procedure involving a climbing crane.

[0165] Although not illustrated, in some embodiments, the second body 65 is part of the through hole 51 of the second surface 6. To this end, the through hole 51 has threads formed in an inner side thereof so that the first body 61 can be introduced in the through hole 51 and use the threads of the through hole 51 as the nut of the screw mechanism.

[0166] In this text, the terms first, second, third, etc. have been used herein to describe several devices, elements or parameters, it will be understood that the devices, elements or parameters should not be limited by these terms since the terms are only used to distinguish one device, element or parameter from another. For example, the first body could as well be named second body, and the second body could be named first body without departing from the scope of this disclosure.

[0167] In this text, the term “comprises” and its derivations (such as “comprising”, etc.) should not be understood in an excluding sense, that is, these terms should not be interpreted as excluding the possibility that what is described and defined may include further elements, steps, etc.

[0168] On the other hand, the invention is obviously not limited to the specific embodiment(s) described herein, but also encompasses any variations that may be considered by any person skilled in the art (for example, as regards the choice of materials, dimensions, components, configuration, etc.), within the general scope of the invention as defined in the claims.