A WINDMILL CONSTRUCTION AND A METHOD FOR ASSEMBLY OF A WINDMILL CONSTRUCTION

Abstract

A windmill construction (10), comprising a rotor-nacelle assembly (12) with blades (14), a tower (16), a substructure (20) and a foundation (22). The substructure (20) comprises a first guide collar (24) and a second guide collar (26) for support of the tower (16), said first guide collar (24) being located in a lower part of the substructure (20) and said second guide collar (26) being located in an upper part of the substructure (20). The substructure (20) comprises a jack-up assembly (30) for receipt of modular tower segments (18), said tower segments (18) are arranged to be assembled in the substructure (20) and erectable by the jack-up assembly (30) to produce an assembled tower (16). The invention is also directed to a method for assembly of a windmill construction.

Claims

1. A windmill construction (10), comprising: a rotor-nacelle assembly (12) with blades (14), a tower (16), a substructure (20), and a foundation (22), the substructure (20) and the foundation (22) being integrated with each other, wherein the substructure (20) comprises a first guide collar (24) and a second guide collar (26) for support of the tower (16), said first guide collar (24) being located in a lower part of the substructure (20) and said second guide collar (26) being located in an upper part of the substructure (20), and the substructure (20) comprises a jack-up assembly (30) for receipt of modular tower segments (18), said tower segments (18) are arranged to be assembled in the substructure (20) and are erectable by the jack-up assembly (30) to produce an assembled tower (16).

2. The windmill construction (10) according to claim 1, wherein the first guide collar (24) and the second guide collar (26) each has an aperture allowing through going axial movement of the tower segments (18).

3. The windmill construction (10) according to claim 1, wherein the first guide collar (24) and the second guide collar (26) are closable and openable.

4. The windmill construction (10) according to claim 1, wherein the first guide collar (24) and the second guide collar (26) comprises elastic dampers.

5. The windmill construction (10) according to claim 1, wherein the substructure (20) comprises a third guide collar (28) located between the first guide collar (24) and the second guide collar (26), wherein the third guide collar (28) has a closable and openable aperture allowing through going axial movement of the tower segments (18).

6. The windmill construction (10) according to claim 1, wherein the third guide collar (28) comprises an elastic damper.

7. The windmill construction (10) according to claim 1, wherein the substructure (20) is a lattice structure.

8. (canceled)

9. The windmill construction (10) according to claim 1, wherein each tower segment (18) is a tubular pipe section or a lattice section.

10. The windmill construction (10) according to claim 1, wherein each tower segment (18) comprises flanges (18a) for attachment to abutting tower segments (18).

11. The windmill construction (10) according to claim 1, wherein the tower segment (18) is a tubular section equipped with vertical guide rails (38) for connection to the jack-up assembly (30).

12. The windmill construction (10) according to claim 11, wherein the jack-up assembly (30) comprises hydraulic pressure cylinders (32) attachable to the tower segment (18), said hydraulic pressure cylinders (32) comprise lower and upper claws (34,36) for gripping and locking onto T shaped vertical guide rails (38) on the tower segment (18), and wherein the hydraulic pressure cylinders (32) are activatable to force the tower segments (18) upwards during assembly of the tower (16).

13. The windmill construction (10) according to claim 1, wherein the jack-up assembly (30) comprises a rack and pinion system (40,42), said rack and pinion system (40,42) being activatable to force the tower segments (18) upwards during assembly of the tower (16).

14. The windmill construction (10) according to claim 1, wherein the jack-up assembly (30) comprises a winch system (52) connected to a support platform (54), said winch system (52) being activatable to force the platform (54) and the tower segments (18) upwards during assembly of the tower (16).

15. The windmill construction (10) according to claim 1, wherein the tower (16) and/or the tower segments (18) comprises attachment lugs (62) for guy lines (60).

16. The windmill construction (10) according to claim 1, wherein the jack-up assembly (30) is located on or adjacent the first guide collar (24).

17. The windmill construction (10) according to claim 1, wherein the foundation (22) comprises a storage-and assembly room (44) for unassembled tower segments (18).

18. The windmill construction (10) according to claims 1, wherein the jack-up assembly (30) is arranged to elevate assembled tower segments (18) in a vertical direction to a height corresponding to one tower segment (18), allowing assembly of a new tower segment (18) to a previously assembled and elevated tower segment (18).

19. The windmill construction (10) according to claim 1, wherein the foundation (22) comprises a downward directed conical support (50) as a bearing point against a bearing structure (64).

20. The windmill construction (10) according to claim 1, wherein the foundation (22) is supported on an elastic bearing structure (64).

21. The windmill construction (10) according to claim 1, wherein the foundation (22) comprises a crane (70).

22. A method for assembly of a windmill construction (10) according to claim 1, the method comprising the steps: assembling the substructure (20) with a first guide collar (24) and a second guide collar (26) for support of the tower (16), building the tower (16) by assembling modular tower segments (18) using a jack-up assembly (30), said jack-up assembly (30) elevates assembled tower segments (18) in a vertical direction through said first and second guide collars (24,26).

23. The method according to claim 22, comprising stepwise building of the tower (16) by elevating assembled tower segments (18) in the vertical direction to a height corresponding to one tower segment (18), allowing assembly of a new tower segment (18) to a previously assembled and elevated tower segment (18).

24. The method according to claim 22, comprising the steps of mounting the rotornacelle assembly (12) and blades (14) on top of a first part of the tower (16) extending above the substructure (20), and to assemble and elevate tower segments (18) carrying the first part of the tower (16) with the rotor-nacelle assembly (12) and blades (14) to a desired height.

25. The method according to claim 24, comprising the steps of assembling tower segments (18) to construct said first part of the tower (16).

26. The method according to claim 24, comprising the step of inserting said first part of the tower (16) in the substructure (20).

27. The method according to claim 22, comprising the step of assembling on site the substructure (20) on the foundation (22) using a crane (70) mounted on the foundation (22).

28. The method according to claim 22, comprising the step of assembling the substructure (20) as a lattice structure on the foundation (22).

29. The method according to claim 22, comprising the steps of transporting the windmill construction (10) to an offshore platform (72,72), wherein the rotor-nacelle assembly (12) and blades (14) are preinstalled on top of a first part of the tower (16) extending above the substructure (20), and to assemble and elevate tower segments (18) carrying the first part of the tower (16) with the rotor-nacelle assembly (12) and blades (14) to a desired height.

30. The method according to claim 22, comprising the step of connecting guy lines (60) to the tower (16).

31. The method according to claim 22, comprising the steps of connecting guy lines (60) to one or more tower segments (18) after the assembled tower segments (18) have been elevated in the vertical direction through and above said second guide collar (26), and adjusting tensioning of the guy lines (60) during elevating of the tower (16).

Description

DESCRIPTION OF THE FIGURES

[0062] Embodiments of the present invention will now be described, by way of example only, with reference to the following figures, wherein:

[0063] FIG. 1 shows a first embodiment of a windmill construction according to the invention.

[0064] FIG. 2 shows a second embodiment of a windmill construction according to the invention.

[0065] FIG. 3 shows a third embodiment of a windmill construction according to the invention.

[0066] FIG. 4 illustrates a very tall windmill construction according to the invention.

[0067] FIG. 5 illustrates sequentially building of a windmill construction according to the invention.

[0068] FIG. 6 illustrates building of a windmill construction according to the invention on an offshore platform.

[0069] FIG. 7 illustrates a windmill construction according to the invention on a floating offshore platform.

[0070] FIGS. 8 and 9 shows an example of a jack-up assembly used in the windmill construction according to the invention.

[0071] FIG. 10 shows a further example of a jack-up assembly used in the windmill construction according to the invention.

[0072] FIGS. 11 to 15 illustrates assembly and jack-up of tower segments in the windmill construction according to the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0073] The present invention is related to a windmill construction, such as a windmill construction 10 comprising a rotor-nacelle assembly 12 (RNA) with blades 14, and a vertical tower 16 supported by a substructure 20 and a foundation 22. The substructure 20 and the foundation 22 can be integrated with each other, and thus be viewed as one structure. The substructure 20 is preferably a lattice structure, as clearly shown in particularly FIG. 3. The foundation 22 can also be a lattice structure, or a more traditional support structure. The windmill construction 10 is a jacked windmill construction, and may also be called a self-elevating windmill construction.

[0074] The substructure 20 comprises a first guide collar 24 and a second guide collar 26 for support of the tower 16, as seen particularly in FIGS. 1 and 2. The first guide collar 24 is located in a lower part of the substructure 20 and the second guide collar 26 is located in an upper part of the substructure 20, such that the first and second guide collars 24,26 supports the tower 16 during erection and after the tower 16 is erected. The substructure 20 must therefore be a support structure erected to a sufficient height for the first and second guide collars 24,26 to be spaced apart a vertical distance enough to provide lateral support to the tower 16. As shown in FIGS. 1-4 the substructure 20 can be a support structure of pyramid shape and that has at least upper and lower supporting guide collars 24,26 taking up lateral forces.

[0075] The substructure 20 further comprises a jack-up assembly 30 for receipt of modular tower segments 18, providing what can be called a stepwise tower building block concept. The tower segments 18 are assembled in the substructure 20 and erectable by the jack-up assembly 30 to produce an assembled tower 16. The jack-up assembly 30 is preferably provided in a lower part of the substructure, for instance on or at the first guide collar 24.

[0076] The first guide collar 24 and the second guide collar 26 comprises each an aperture allowing through going axial movement of the tower 16 or the tower segments 18, said apertures, which may be being closable and openable. The first guide collar 24 and the second guide collar 26 can also comprise elastic dampers, such as elastic rubber parts, that can absorb vibration from the tower 16 and thus reduce background noise

[0077] The foundation 22 may also be supported on an elastic bearing structure 64, for instance as seen in FIGS. 11-15, to further provide noise reduction.

[0078] The substructure 20 of the windmill construction 10 can further comprise a third guide collar 28 located between the first guide collar 24 and the second guide collar 26, wherein the third guide collar 28 similar has a closable and openable aperture allowing through going axial movement of the tower 16 or the tower segments 18. The third guide collar 28 may optionally comprise an elastic damper, such as elastic rubber parts, for reduction of background noise.

[0079] The first guide collar 24, the second guide collar 26 and possibly the third guide collar 28 may be a circular collar having an internal aperture. In one embodiment, the aperture can be closable by using wedges in the aperture between the collar and the tower 16 or the tower segments 18, and openable by removing the wedges. In a second embodiment, the circular collar can be made up of two semi-circular parts, each being connected to a pressure cylinder pushing or retracting the semi-circular parts to and from each other. The aperture is thus closable by pushing the semi-circular parts towards each other to clamp the tower 16 or the tower segments 18 in between them, and openable by retracting the semi-circular parts.

[0080] The jack-up assembly 30 can be basically any known hoisting or lifting mechanism capable of elevating the tower 16 and the tower segments 18 during assembly, and to elevate assembled tower segments 18 in a vertical direction at least to a height corresponding to one tower segment 18, allowing assembly of a new tower segment 18 to a previously assembled and elevated tower segment 18.

[0081] FIG. 1 shows a jack-up assembly 30 comprising a winch system 52 connected to a support platform 54. The winch system 52) is activatable to force the platform 54 and the tower segments 18 upwards during assembly of the tower 16. The jack-up assembly 30 comprises gripping members gripping and holding the lower tower segments 18 prior to being elevated and during assembly of a next tower segment 18 to a previously assembled and elevated tower segment 18.

[0082] FIG. 2 shows another example of a jack-up assembly 30 with gripping elements gripping and holding the lower tower segments 18 prior to being elevated and during assembly of a next tower segment 18 to a previously assembled and elevated tower segment 18.

[0083] FIGS. 8 and 9 show the jack-up assembly 30 as hydraulic pressure cylinders 32 attachable to the tower segment 18. The hydraulic pressure cylinders 32 comprise for instance lower and upper claws 34,36 for gripping and locking onto T shaped vertical guide rails 38 on the tower segment 18. The hydraulic pressure cylinders 32 are similar activatable to force the tower segments 18 upwards during assembly of the tower 16, and to grip and hold the lower tower segments 18 prior to being elevated and during assembly of a next tower segment 18 to a previously assembled and elevated tower segment 18.

[0084] FIG. 9 shows a further example of the jack-up assembly 30, comprising a rack and pinion system 40,42. The rack and pinion system 40,42 is activatable to force the tower segments 18 upwards during assembly of the tower 16, and to grip and hold the lower tower segments 18 prior to being elevated and during assembly of a next tower segment 18 to a previously assembled and elevated tower segment 18.

[0085] FIG. 8-10 further illustrates that each tower segment 18 can be a tubular pipe section or lattice section of circular and cylindrical shape, for instance equipped with vertical guide rails 38 for connection to the jack-up assembly 30. Each tower segment 18 comprises flanges 18a for attachment to other tower segments 18.

[0086] The tower 16 may however also be built as a lattice structure with three to four vertical corners, for instance with a similar shape as a traditional jack-ups, which often is triangular, or the tower can be built with a similar shape as traditional tower crane, which often is square. Hence, the tower segments 18 may be of a multisided lattice structure, for instance with three or four sides.

[0087] The windmill construction 10 according to the invention can be placed onshore or offshore, as illustrated in FIG. 5. FIG. 6 illustrates building the windmill construction 10 on an offshore platform 72 with legs, and FIG. 7 illustrates the windmill construction 10 on a floating offshore platform 72. A semi assembled windmill construction 10 according to the invention can be shipped to the offshore platform 72,72 by a barge 74, or the windmill construction can be fully assembled on the offshore platform 72,72.

[0088] FIG. 4 illustrates a very tall windmill construction 10 according to the invention, for instance taller than 250 m. Such a height will improve noise influence and may also reduce bird collisions. To stabilize the tower 16, the tower 16 and/or the tower segments 18 can comprises attachment lugs 62 for guy lines 60 running down to the foundation 22 or to anchor points on the ground or on the seabed.

[0089] The windmill construction 10 can comprise a crane 70, for instance on the foundation 22 as seen in FIGS. 5-7, thus rendering use of mobile cranes superfluous. The crane 70 can assist in building the substructure 20 of the windmill construction 10, as seen from top left in FIG. 5, and possibly also to mounting the rotor-nacelle assembly 12 with blades 14 on the tower 16 prior to starting to assemble the tower segments 18. The crane 70 can receive parts from a barge 74 in case of building offshore or from a truck 76 in case of building onshore.

[0090] FIGS. 11 to 15 illustrates assembly and jack-up of modular tower segments in the windmill construction according to the invention.

[0091] As seen in FIG. 11, the lower part of the substructure 20 or the foundation 22 can comprise a storage and assembly room 44 for storage of tower segments 18 and for assembly of tower segments 18.

[0092] After assembling the substructure 20 with the first guide collar 24 and the second guide collar 26, the tower 16 is built by assembling the modular tower segments 18 using the jack-up assembly 30, wherein said jack-up assembly 30 elevates assembled tower segments 18 in a vertical direction through said first and second guide collars 24,26.

[0093] The tower 16 can in one embodiment be built entirely of modular tower segments 18. When the first tower segments 18 are erected and guided through the second guide collar 26, the rotor-nacelle assembly 12 and blades 14 are mounted on top of the uppermost tower segment 18, and assembling and elevating of subsequent tower segments 18 commences to build the complete tower 16.

[0094] In another embodiment, a first part of the tower 16, being a conventional tower part, carrying the rotor-nacelle assembly 12 and blades 14 can be mounted on top of the uppermost tower segment 18 that has been erected above the second guide collar 26.

[0095] In a further embodiment, the first part of the tower 16, being a conventional tower part, carrying the rotor-nacelle assembly 12 and blades 14 is inserted in the substructure 20, for instance as seen in FIG. 3, and landed on a tower segment 18 erected above the first guide collar 24 in the lower part of the substructure 20. Assembling and elevating of subsequent tower segments 18 commences thereafter to build the complete tower 16.

[0096] When the windmill construction shall be placed offshore, the windmill construction 10 can be transported to the offshore platform 72,72 with the rotor-nacelle assembly 12 and blades 14 preinstalled on top of the first part of the tower 16 extending above the substructure 20, and thereafter to assemble and elevate tower segments 18 carrying the first part of the tower 16 with the rotor-nacelle assembly 12 and blades 14 to a desired height.

[0097] FIG. 12-14 illustrates stepwise building of the tower 16. In FIG. 12 the jack-up assembly 30 starts lifting previous build tower segments. In FIG. 13, the previous assembled tower segments 18 have been elevated in the vertical direction to a height corresponding to one tower segment 18, thus allowing assembly of a new tower segment 18 to a previously assembled and elevated tower segment 18, as seen in FIGS. 14 and 15. The jack-up assembly 30 can then repeat the process until desired tower 16 is reached.

[0098] Guy lines 60, as seen particularly in FIG. 4, may improve buckling length of the tower and could possibly also reduce the total weight of the tower structure. The guy lines 60 are during assembly connected to one or more tower segments 18 after the assembled tower segments 18 have been elevated in the vertical direction through and above said second guide collar 26. During elevating of the tower 16 and tower segments 18, the tensioning of the guy lines 60 are adjusting. To tension the guy lines 60, a constant tension winch placed on the ground or placed on the foundation can be used. After final height has been reached, the guy lines are final tensioned and permanently anchored on the ground. The winch can then be removed and be used on the next windmill construction.

[0099] Offshore it can be possible to use lump weights connected to the end of the guy lines, and which are lifted up from the ocean floor during elevating of the tower 16 and tower segments 18.

[0100] The guy lines 60 can for instance be wires, tubulars, synthetic fiber cables or similar that can be tensioned.