Installation and erection assembly for an elongated structure

Abstract

A fluid turbine comprises a rotor rotatable in use about an axis transverse to the direction of fluid flow, the rotor having a first part carrying a plurality of arcuate blades that may be arranged selectably in compact straight shapes or in arcuate shapes and a second part journalled in a base structure by two or more bearings. Another aspect of the invention discloses an installation frame, devised to support the turbine or other elongated structures in a folded arrangement for transportation on a trailer, and to support assembly and erection thereof.

Claims

1. An installation and erecting assembly for supporting assembling of an elongated structure, the structure having an upper section and a lower section each having a mating end, and erecting the assembled elongated structure on a footing, the assembly comprising: a first section receiver adapted to receive therein at least a portion of the lower section, the first section receiver comprising a lower section support for supporting at least a portion of the lower section of the elongated structure; a second section receiver disposed adjacent to the first section receiver, and comprising an upper section support for supporting at least a portion of the upper section of the elongated structure; an aligner coupled to at least one of the lower section or upper section supports, the aligner comprising an actuator set operational to translate the upper section and the lower section relative to each other and to bring the upper and lower sections into mutual alignment, for allowing mating of the respective mating ends of the upper and lower sections.

2. An assembly as claimed in claim 1, further comprising an erector coupled to the first section receiver, for imparting angular erecting motion to the elongated structure, thereby erecting the elongated structure onto the footing.

3. An assembly as claimed in claim 1 wherein the first section receiver is being disposed above the second section receiver.

4. An assembly as claimed in claim 1, wherein the actuator set comprises: a longitudinal displacer coupled to the upper section support, for imparting linear motion to the upper section; and, a lateral displacer for imparting to the upper section rotation, transverse, or vertical motion, relative to the lower section.

5. An assembly as claimed in claim 1, wherein the elongated structure comprises a wind turbine.

6. An assembly as claimed in claim 5, wherein the wind turbine is a vertical axis turbine.

7. An assembly as claimed in claim 5, wherein the wind turbine is a vertical axis fluid turbine comprising: a rotor rotatable about an axis disposed in use substantially transverse to the direction of fluid flow; a plurality of arcuate blades connected at their opposite ends to the rotor; wherein at least one blade is formed of at least three segments coupled by joints, at least two of the joints each being an articulated joint that permits the mutual inclination of two adjacent segments to be varied while the ends of the blade are coupled to the rotor.

8. An assembly as claimed in claim 5, wherein the wind turbine is a horizontal axis wind turbine.

9. An assembly as claimed in claim 1, further comprising a plurality of outriggers, wherein the outriggers are further operable to raise and lower the assembly.

10. An assembly as claimed in claim 1, further comprising a plurality of outriggers, wherein the outriggers are extendable and are operable to impart horizontal motion to the assembly.

11. An installation and erecting assembly for supporting assembling of a wind turbine having an upper section and a lower section, each having a mating end, and erecting the assembled turbine on a footing, the assembly comprising: a plurality of outriggers operable to support the assembly at selectable heights; an attachment point for attaching the assembly or a portion thereof at a known orientation relative to the footing; a first receiver adapted to receive and support therein at least a portion of the wind turbine lower section, the first receiver comprising a lower section support for supporting at least a portion of the wind turbine lower section; a second receiver disposed adjacent to the first receiver, and comprising an upper section support for supporting at least a portion of the wind turbine upper section; an aligner coupled to at least one of the upper and lower section supports, to bring the upper and lower turbine sections into mutual axial alignment, for allowing mating of the respective mating ends of the upper and lower wind turbine sections; an erector coupled to the first receiver, for imparting angular erecting motion to the wind turbine, thereby erecting the wind turbine onto the footing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Different aspects of the invention will now be described further, by way of example, with reference to the accompanying drawings, in which:

(2) FIG. 1 is a perspective view of a wind turbine generator, with its blades collapsed into a compact arrangement,

(3) FIG. 2 is a perspective view of the same wind turbine generator, with its blades extended into a curved arrangement for normal operation,

(4) FIG. 3 is a perspective view of the topmost part of the turbine, showing the upper attachment of the blades,

(5) FIG. 4 is a perspective view of a mid region of the turbine, showing the lower attachment of the blades,

(6) FIG. 5 is a side view of a single blade in curved configuration,

(7) FIG. 6 is a perspective view of there blade segments with the aerofoil outer skin of the central segment removed to exposed the inner components,

(8) FIG. 7 is a perspective view of the same three segments with further parts removed to display more components of an articulated joint,

(9) FIG. 8 is a similar perspective view to FIG. 7, showing when the three segments are in a mutually inclined position to form a curved blade,

(10) FIG. 9 is a perspective view of the components of an embodiment of an articulated joint,

(11) FIGS. 10A, 10B and 10C show sections of the articulated joints of FIG. 9 when it is unlocked, locked in a straight configuration, and locked in an inclined configuration, respectively,

(12) FIG. 11 is a plan view from above of the lower most part of the rotor of the turbine showing hydraulic power supply equipment,

(13) FIG. 12 is a side view of the part of the rotor shown in FIG. 11,

(14) FIG. 13 shows a side view of the base of the tower, with side covers removed,

(15) FIG. 14 shows a perspective view of a turbine and an installation frame, loaded onto a truck for transportation,

(16) FIG. 15 shows the truck of FIG. 14 with powered outriggers lowered from the installation frame to reach the ground and to lift the installation frame clear of the trailer of the truck when near a footing,

(17) FIG. 16 shows the installation assembly 220 standing on the ground in proximity to the footing after removal of the truck and its trailer,

(18) FIG. 17 shows the installation frame standing on the ground and positioned to allow connection of the base of the tower to the footing,

(19) FIG. 18 shows the installation frame with the upper parts of the turbine moved longitudinally to align the ends of the upper and lower parts vertically with one another,

(20) FIG. 19 shows the upper parts of the turbine upper section 211 being partially rotated in a vertical plane about a horizontal axis at one end of the installation frame,

(21) FIG. 20 shows the upper parts of the turbine fully rotated through 180 to align the upper and lower parts of the turbine axially with one another,

(22) FIG. 21 shows the same view as FIG. 20 with a gap closed between the upper and lower parts of the turbine,

(23) FIG. 22 shown the whole turbine being raised vertically,

(24) FIG. 23 shows the installation frame with the turbine in its erected position, and

(25) FIG. 24 shows the installation frame 210 raised on its outriggers 217 in readiness for transportation away from the erected turbine on a trailer.

(26) FIG. 25 depicts a perspective view of a horizontal axis wind turbine and an installation frame loaded onto a truck.

(27) FIG. 26 depicts the installation assembly with the horizontal axis wind turbine assembled ready for erection.

(28) FIG. 27 depicts the turbine in horizontal position, with two hydraulic cylinders fitted for the purpose of raising and lowering the turbine, and

(29) FIG. 28 depicts the turbine of FIG. 27 in a vertical position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(30) FIG. 1 shows a schematic view of a wind turbine 10. Three arcuate blades 12 of aerofoil cross-sectional shape are attached to a rotating, preferably tapered, vertical rotor 13, rotatably mounted on the upper end of a stationary support structure 16, known as a tower. In this view, the blades are folded into a compact, flattened arrangement for transportation and installation or for protection against extreme weather.

(31) FIG. 2 shows the turbine with blades 12 in a curved position, as for normal operation. When rotating in the presence of sufficient wind, the blades 12, by virtue of their shape, capture kinetic energy from the wind and convert it into rotational torque and motion as known, for example, from U.S. Pat. No. 1,835,018. All parts of the turbine that are situated above an upper bearing 103 are rotating elements. It is seen that the blades comprise a plurality of blade segments. The angle formed between each two adjacent segments, of at least three of those segments, is variable. The ability to vary the angle between each one of the at least three blade segments and the segment adjacent thereto, allows the blade to approximate an arcuate shape. Preferably more than three segments are provided, to allow the blade to more closely simulate the arc shape. The exact number of blade segments is dictated by a technical compromise between the economy of having few parts such as blade segments and articulated joints, strength requirements, the efficiency provided by an optimized blade shape for the wind conditions, stress distribution, and the like.

(32) The blade state may be modified at least between an open and a closed state. Optionally other states may be selected. Preferably the blade segments are substantially straight when unstressed.

(33) FIG. 3 shows the attachment of the three blades 12 by connectors 368 to an upper hub 360, which is attached to the upper rotor 13. The connectors 368 are hinged about pins 370 and supported by hydraulic cylinders 365, which assist in moving the blades between open and compact positions. The cylinders 365 are preferably of the type known as double-acting self-locking, and are thereby able to provide rigid support to the connectors 368 when fully extended, and they release their locked state only when actuated by hydraulic pressure in a closing direction. In another embodiment, hydraulic pressure may be maintained indefinitely by the hydraulic supply equipment, so that non-locking cylinders may be used. Corrugated flexible tubes 375 allow for hydraulic hoses to pass from a hollow cavity inside the rotor 13 to cavities inside the connectors 368, and thence to cavities inside the blades 12, providing control pressure to actuate hydraulic mechanisms. Heated air, other fluids, cables and or wiring may also pass into the blades 12 by the same means.

(34) FIG. 4 shows the attachment of the three blades 12 via connectors 335 to a lower hub having the form of a collar 340, which is able to slide vertically upon a lower part 302 of the rotor 13. As with the upper hub, the connectors 335 are hinged about pins 345 and supported by hydraulic cylinders 320, which assist in moving the blades between open and compact positions. The cylinders 320 are preferably of the type known as double-acting self-locking, and are thereby able to provide rigid support to the connectors 335 when fully extended, and they release their locked state only when actuated by hydraulic pressure in a closing direction. In another embodiment, hydraulic pressure may be maintained indefinitely by the hydraulic supply equipment, so that non-locking cylinders may be used. The collar 340 is moved up and down by locking hydraulic motors 330, which engage with racks 310. Hydraulic pressure is provided to the hydraulic motors via hoses passing through the blades 12, leading from the upper ends of the blades as described above. The racks 310 also provide locking between the collar 340 and the lower rotor 302, preventing relative rotation. Other examples of locking mechanisms may be implemented. It will further be clear to the skilled in the art the functions of the upper and lower hub may be interchanged, and in certain embodiments, both hubs are displaceable along the rotor, and the specifications and the claims extend to such embodiments.

(35) FIG. 5 is a side view of a single blade 12, in curved arrangement, showing the curved shape taken by the blade for normal operation. The blades are made up of segments that can be pivoted relative to one another using articulated joints. An embodiment is described below with reference to FIGS. 6 to 10.

(36) Each blade segment 410 has an outer skin 419 of aerofoil cross section 419 having internal cavities of which the walls are strengthened by reinforcements 422. In some embodiments the reinforcements are extruded. A bridge piece 423 is rigidly mounted to one end in the reinforcement 422 of one segment, and is pivotably connected to the reinforcement of the other segment to allow the two segments to pivot relative to one another.

(37) FIGS. 6 and 7 show two segments 410 of one blade 12, arranged in the compact or straight position, with and without the reinforcements 422. Flexible shroud pieces 411, preferably formed from elastomeric material, are provided to cover the joints between adjacent segments. In an alternative embodiment (not shown) the shroud pieces may extend further in the longitudinal direction of the blade, far enough to cover a complete blade segment or even a complete blade.

(38) FIG. 8 shows the same arrangement as FIG. 7, with the two segments inclined relative to one another. As seen in FIGS. 6, 7 and 8, the aerofoil outer skin 419 is secured longitudinally to the reinforcements 422 by two pins 420, inserted through holes 427 originating at the tail part of the aerofoil. These pins locate inside holes 425 drilled through the tubular reinforcements 422. Each bridge piece 423, which may be formed by way of example utilizing machining, casting or forging, provides a robust connection between each reinforcement 422 and the next, and is articulated via a hinge pin 435, to allow adjacent sections to be positioned at an angle to one another, or aligned in a straight line, selectably.

(39) FIG. 9 shows the same arrangement as FIG. 8, but with further parts removed for clarity. An articulated angle may be created between blade sections 410 about pin 435 in the following fashion. In the compact or straight position, the bridge pieces 423 are secured in position relative to the sections 422 by wedges 431, which are held in place by double-acting locking hydraulic cylinders 432, to which they are affixed by rotatable pin joints 437. The cylinders are in turn located to holes in sections 422 by bolts 433.

(40) FIG. 9 shows a perspective view of the bridge piece 423 that is secured to one of the reinforcements 422 and of a chock 431 operated by a hydraulic cylinder 432 that is mounted in the other tubular reinforcement 422. The chock 431 is in the form of a wedge that is pivotably mounted on the end of the piston rod of the hydraulic cylinder. The end of the bridge piece 423 is tapered on at least one side. Both sides of the end of the bridge piece have depressions 438 as seen in FIG. 10B, to receive mating formations 439 on the sides of the chock 431.

(41) The operation of the lockable articulated joints is best understood by reference to FIGS. 10A to 10C. In FIG. 10A, the chock 431 is retracted by the hydraulic cylinder 432 away from the end of the bridge piece 423. In this position, the bridge piece can move freely about the pin 435 to allow the two segments of the blade 12 to pivot relative to one another.

(42) When the blade segments 410 are aligned with one another, as shown in FIG. 10B, they may be locked in this position by moving the chock 431 such that it is wedged between the upper surface of the bridge piece 423 and the arresting wall formed by the reinforcement 422 of the next segment. The chock will now act to prevent any pivotal motion between the two blade segments and the formations 439 will retain the chock in this locked position without the need to resort to a locking hydraulic cylinder 432.

(43) As shown in FIG. 10C, the chock 431 can also be used to prevent articulation when the two segments are pivoted relative to one another, acting this time between the lower face of the bridge piece 423 and the inner wall of the tubular reinforcement 422.

(44) FIGS. 11 and 12 show top and side views of the lowest visible rotating part of the turbine, this being the base 455 of the rotor which is attached via the upper bearing 103 to the turbine tower 16. The adjacent parts of the turbine are removed for clarity. Hydraulic power, for positioning the blades, is provided by a hydraulic pump 452 and reservoir, 451. Access holes 457 are provided for maintenance purposes, and cylindrical covers (not shown) cover these holes when access is not required.

(45) FIG. 13 shows a side view of the base 467 of the tower 16, with side covers removed. Electrical power for the hydraulic system is provided via a brush module 461, giving electrical connections between control cabinet 465 and electrical cables enclosed by a lower driveshaft flange 468, which forms part of the rotating assembly. The driveshaft is connected to the flange 468, and thence to the generator 464 via a lower bearing 463 that is supported by a bearing carrier 470. Brakes 466 acting on a brake disk 462 are provided to stop the turbine. The driveshaft extends vertically upwards and connects to the rotor base, seen in FIG. 12, and is supported rotatably by the upper bearing 103.

(46) Yet another aspect of the invention provides for an assembly and method of installation of elongated structures which are made of at least a lower and an upper sections, each having a mating end which may be coupled to the mating end of the corresponding section. Non limiting examples of such structures include vertical fluid turbines such as by way of example, the embodiments described above, as well as horizontal axis turbines, towers, and the like. Preferably the installation structure is used both for transporting the elongated structure and for assembling and erecting it onto its base, equivalently referred to as footing.

(47) The installation assembly comprises of a frame having at least a first and a second receivers, disposed adjacent to each other, such as one receiver above the other, or in a side-by side arrangement. Each receiver is constructed to receive and support a section of the elongated structure. Preferably one or both receivers have a section support for the respective elongated structure section, which allows the section to be moved relative to the receiver. In certain embodiments, portions of the receivers themselves act as section supports. The term receiver should be construed broadly as various types of structure that provide support and/or positioning for the elongated structure sections, and not necessarily chambers or other framework that receive the section, in whole or in part, therein. Thus by way of example, in the depicted embodiments a receiver for the lower section may comprise substantial frame, while a receiver for the upper section may comprise primarily of tracks 226, which offer both support for the upper section, while further providing motion thereto as described.

(48) The installation assembly has supports, generally referred to as outriggers, which provide at least for supporting the frame at selectable heights, and preferably enables the installation assembly to lift and lower itself independent of external lifting devices such as an independent crane. The outriggers are preferably extendable, and may provide horizontal movement in certain embodiments.

(49) The installation assembly further comprises an aligner, which comprises an actuator set, which allows mutual aligning of the upper and lower sections of the elongated structure. The actuator set is capable of moving at least one of the sections of the elongated structure so as to achieve alignment therebetween, and may impart articulating, sliding, lifting, movement and the like, to at least one of the sections, to bring the upper and lower sections into mutual axial alignment, thus allowing mating of the upper and lower sections.

(50) The aligner comprises certain mechanisms, such as, by way of non-limiting example, a longitudinal displacer to controllably displace the upper section of the elongated structure, lifting mechanism to lift and/or lower at least one of the sections, an angular motion actuator for tilting a section, and the like. Preferably those movements are carried out while the elongated structure portion is supported by the corresponding section support, or by the receivers.

(51) Further, the depicted installation assembly has a base reference system allowing precise placement of the installation assembly to a footing which will support the elongated structure when mounted. The installation assembly further comprises an erector to erect the structure on its footing.

(52) Generally in order to achieve the operations of assembly and erection of the elongated structure, the installation assembly is aligned to the base at a known orientation, the aligner brings the elongated structure section into substantially axial alignment, the mating ends are mated using any desired method, and the erector moves the elongated structure into substantially vertical orientation above the base. The elongated structure is secured onto the base, and the installation assembly may be withdrawn if desired.

(53) Utilizing the installation assembly offers significant advantages over the present methods of erecting elongated structures in general, and wind turbine in particular, as the frame and elongate structure form a single unit that can easily be transported, by truck, rail, ship and the like. Additional advantage is provided by obviating the need for on-site assembly, which is much more expensive than plant assembly. Thus the preferred embodiment of this aspect of the invention provides ease of transportation as well as ease of joining the two sections of the elongated structure, and other work, to be performed near ground level, as compared to current methods which requires dangerous work at significant heights, which consumes more time and is more expensive. Furthermore, this aspect of the invention provides additional saving by obviating the need to bring and use cranes, lifts, and the like at the erection site.

(54) FIGS. 14-26 show preferred embodiments of this aspect, utilizing wind turbines, as the elongated structure for clarity.

(55) FIG. 14 shows a perspective view of an installation assembly, comprising the upper section 211 and lower section 212 of the turbine and an installation frame 210, loaded for transportation onto the trailer 213 of a truck 214.

(56) When the truck arrives at the installation site, it reverses its trailer 213 up to footing 221 as shown in FIG. 15, and hydraulically powered outriggers 217 are extended to reach the ground and raise the installation frame and the two parts of the turbine off the trailer 213 in the manner shown in FIG. 15. The electrically driven source of hydraulic power forms part of the installation frame and in case electrical supply is not available a generator 224 may be included in the installation frame 210, hydraulic or electric power may be derived from the truck, or any other convenient source. It is noted that in certain embodiments the outriggers may simply set the assembly at desired orientation, and raising and lowering may be carried out by other methods such as jacks, lifts, and the like.

(57) In the next step, shown in FIG. 16, the truck and the trailer are driven away and the frame may be lowered by the outriggers 217.

(58) FIG. 17 shows the installation assembly 220 positioned to allow connection of hinge plates 218 with hinge plates 219 in the footing 221. The hinge plates in this exemplary embodiment act as an attachment point for setting the assembly at a known orientation to the footing. Optionally, the position of the frame may be adjusted using the hydraulic outriggers and/or the truck and semi trailer by a walking motion, wherein the frame is alternately raised, horizontally moved and lowered. The skilled in the art will recognize that other devices, such as jacks, cranes, and the like may be utilized for precise relative placement of the hinge plates 218 and 219.

(59) FIG. 18 shows the installation assembly 220 with the turbine upper section 211 moved longitudinally to align with the end of the lower section 212. This motion may be actuated by roller sliding mechanisms 225 acting on longitudinal tracks 226 with power from motor units 227, which in this embodiment form a longitudinal displacer.

(60) FIG. 19 shows the installation assembly 220 with the turbine upper section 211 partially rotated in a vertical plane about one end. Hydraulic cylinders 228 move hinged sub-frames 229 about hinge joints 230, raising the turbine upper section 211 via roller slider mechanisms 225 and longitudinal tracks 226, which are connected to the turbine upper section via connectors 231. Thus in this embodiment, the hydraulic cylinders 228, sub-frame 229, and hinge joints 230 all form a lateral displacer.

(61) FIG. 20 shows the installation assembly 220 with the turbine upper section 211 fully rotated through 180 in a vertical plane about one end, to lie in a horizontal position, preferably leaving a gap between the upper section 211 and lower section 212. The gap may be adjusted by use of the roller sliding mechanisms 225. Hydraulic hoses, electrical cables, gas ducts and or other devices may now be connected between cavities enclosed by the upper section 211 and lower section 212, using access provided by the gap.

(62) FIG. 21 shows the view of FIG. 20 with the gap between the upper section 211 and the lower section 212 closed. Connectors, preferably lock-bolt fasteners, may now be used to complete the connection between flanges 232 and 233 mounted on the upper section 211 and the lower section 212.

(63) The embodiment described above is but one embodiment of the displacer actuators which operate by moving the upper section into axial alignment with the lower section. The skilled in the art would recognize that other types of motion and appropriate actuators thereto may be selected, and the selection of the desired motion and actuators to bring the two parts into alignment is a matter of technical choice.

(64) FIG. 22 shows the assembled turbine 10 raised part way to a vertical position. The turbine is released by hydraulic locking pins 235 at the connectors 231, and raised by hydraulic cylinders 234, which act as the erector for rotatably erecting the structure.

(65) FIG. 23 shows the installation frame 210 with the turbine 10 in erected position. Once the turbine 10 is erected and secured to the footing 221, the two hydraulic cylinders 234 are detached from the turbine 10, and the hinge plates 218 and 219 in FIG. 17 may be removed.

(66) FIG. 24 shows the installation frame 210 once again raised on its outriggers 217, positioned with sufficient height to clear a semi-trailer which is then used to transport the installation frame away from the installation site.

(67) Referring to FIGS. 2-4 and FIG. 7, to deploy the blades once the turbine has been erected, first the hydraulic cylinders 432 of the articulated joints between segments of the blades are retracted to free the segments. Next the lower blade hub 340 is raised using the motors 330 and the racks 310 forcing the blades to adopt the arcuate configuration shown in FIG. 2. The hydraulic cylinders 432 are then again extended to lock the blade segments in their mutually inclined operating positions, and the hydraulic motors 330 are locked in position.

(68) The above actions are reversible to collapse the blades into their straight position, either to protect the turbine against high winds or to enable the turbine to be lowered for repair.

(69) FIGS. 25 and 26 depict an example of utilizing the installation assembly for assembling and erecting a horizontal axis wind turbine. FIG. 25 depicts the assembly in the transport configuration, wherein the upper section 211A, and the lower section 212A of the horizontal axis wind turbine 211B are disposed within the respective receivers. For ease of transportation the blades 211C are folded, or alternatively shipped disassembled from the turbine. FIG. 26 depicts the horizontal wind turbine ready to be erected, with the blade extended in their operational position.

(70) FIGS. 27 and 28 depict an alternative method of raising the turbine 10, by two hydraulic cylinders 271 fitted at the base of the turbine. This alternative method has the advantage that the turbine may be raised and lowered on subsequent occasions after installation, without the need for the installation frame, provided that a source of hydraulic power is made available.

(71) The embodiment of the invention described above provides the following advantages: The turbine and erection equipment may be transported using a single truck and trailer. The turbine may be installed with only a small team of workers, no lifting equipment is required, and no workers are required to work at significant height above the ground. The turbine may be installed in a short period of time, as no lifting equipment is required, and the number of manual assembly operations is relatively small. The turbine blades may be folded flat at any time, and subsequently re-opened, without the need for any external equipment. This operation may be carried out under local control or under remote control. This is a practical advantage for locations where hurricanes are prevalent. The same installation frame may be re-used for several turbine installations. By reversing the order of the above installation operations, a method is provided whereby the turbine may be lowered and/or removed at low cost. Aspects of the design may be applied to turbines of various sizes. Taking advantage of all the above features, the turbine may be built cost-effectively in large production runs and installed quickly at comparatively low cost, while also providing the inherent advantages of vertical axis turbines, which do not require repeated re-orientation in the direction of the wind, offer pleasing appearance, have few moving parts, and do not generate the characteristic undulating noise of horizontal axis turbines associated with blades passing close to the mast.