DE102020006544A1 - Process and equipment for erecting, equipping and operating inland wind turbines of great height and power - Google Patents

Abstract

The invention relates to a method and the equipment with an own hoist for erecting the rotatable tower (26) and for the permanent operation and servicing of an inland wind turbine for great heights and power. It thus includes a perfection of the two solutions for an inland wind turbine with a rotating tower according to patent no. DE 10 2016 014 799 B4 and a drive system for such an inland wind turbine according to the patent application with the file number DE 10 2019 008 854.9 through its application each assembly of a tower section on the vertical column by one section height and takes up its permanent position after installation of the top tower section. The in-house hoist then fulfills the necessary technical hoisting tasks for the system.

Description

The invention relates to a method and the equipment with an own hoist for erecting the tower and for the permanent operation and servicing of an inland wind turbine for great heights and power. It thus includes an improvement of the two solutions for an inland wind turbine with a rotating tower according to Patent No. DE 10 2016 014 799 B4 and a drive system for such an inland wind turbine according to the patent application with the file number DE 10 2019 008 854.9 through the use of a method for the construction and operation of an inland wind turbine using an on-site hoist.

State of the art

In order to make better use of the wind that occurs in higher layers, the goal of the operators of inland wind turbines is to penetrate these layers with larger turbines. Prof. Dr. Emeis, Stefan, head of meteorology research at KIT Karlsruhe, pointed out in his contributions that wind energy technology should use the higher air layers above the Prandtl layer - i.e. the lower layers of the tropospheric winds - to open up possibilities for higher energy yields. Under the heading "Analytical wind farm model", the results of wind measurements near Paris' "Charles Gaulle" airport are shown in a graphical representation, which proves that the greatest wind speeds occur at a height of around 300 m. Therefore, the aim of the operators of wind turbines is to advance this advantage through higher constructions in this area. The extent to which these results are used at heights of more than 300m for development through hub heights or through the work of the rotor blades must be researched in a targeted manner through long-term measurements at planned locations.

While it is sufficient in the case of the previously known wind turbines, which are smaller in comparison, to use lifting gear that is generally available for erecting them due to their smaller size, lifting gear that is designed for this purpose is only available to a limited extent for the larger plants. Such lifting devices are either large cranes available up to a limited maximum lifting height or specially adapted lifting devices such as climbing cranes or lifting devices. Both cause high rental fees or acquisition costs. Large cranes that can be used for particularly tall wind turbines are only available to a limited extent. Other problems when erecting wind turbines can also be that the planned locations are difficult to reach with the lifting gear due to the peculiarities of the landscape and/or the subsoil has to be prepared to ensure the necessary stability. A compromise when erecting wind turbines at great height is the combined use of an erection crane for erecting the mast and a mobile crane device for positioning the nacelle and attaching the rotors.

That's from the pamphlet WO 2015/158713 A1 a mobile crane device for temporary installation on an existing tower structure of a wind turbine is known. It is designed as a slewing crane and consists of a vertical tower in the working position with a boom that is articulated so that it can pivot and luff. This special crane is transported in a horizontal position on a special vehicle to the foot of a tower structure of a wind turbine, erected there, connected to the tower structure so that it can be adjusted in height and pulled by means of a winch standing on the ground via a cable to the upper end of the already assembled tower. The crane is fixed there and then used to assemble the nacelle, the rotor hub and the rotor blades. Finally, the crane device is dismantled. The crane device can then be used for further applications to assemble the nacelle, the rotor hub and the rotor blades in wind turbines with a previously erected tower.

A similar method and a crane for erecting wind turbines, in which a specially designed slewing crane moves up the vertical tower of a wind turbine by means of a non-slip moving belt, is known from the publication DE 197 41 988 A1 famous. The necessary connection of the special hoist to the tower is achieved by holding arms that wrap around the tower and are equipped with rollers. After assembly, the crane is moved down again and made available together with the transport vehicle for another use.

Both known solutions described above are used for the precise assembly of the nacelle and the rotors. Other solutions are used for the erection of the tower and to support the maintenance work that is required in the course of the operation of the plant.

That's from the pamphlet WO 2016/007241 A1 a solution is known that involves the assembly of both the tower and the nacelle, the generator, the rotor hub and the rotor blades of a wind turbine. The tower is divided in two and consists of a lower, vertically arranged section, which has a Slewing ring is provided. An upper section consisting of segments is arranged on top of this. It is designed to deviate from the vertical and can therefore be constantly aligned against the wind direction by means of a tracking device. The method for assembling the wind energy installation provides for the lower tower part with the slewing ring and at least two segments of the upper tower part fastened thereto to be preassembled in a known manner in a horizontal position. This tower body is erected and fixed in the vertical position of the lower part of the tower. A climbing crane, consisting of a column and a luffing jib arranged on it, is then fastened to the short upper part of the tower in such a way that the crane can be gradually moved upwards as construction progresses. The lifting motion is generated by a winch mounted on a ground-based carrier vehicle. A wire rope is guided from this winch over the luffing jib. On the side opposite the winch, all tower segments are first attached one after the other, pulled up, precisely positioned and screwed together. Finally, the nacelle, generator, gearbox, rotor hub and rotor blades are pulled up and installed there in a functional manner. Finally, the climbing crane is lowered again and is available for the assembly of further inland wind turbines.

For the replacement of worn main components in the nacelle of a wind turbine and the rotor with all its individual parts is from the publication EP 1 101 934 A3 an on-board hoist provided. It is designed as a slewing gantry crane and is attached to the machine frame in the gondola. A winch is fastened to the foundation at the foot of the wind turbine, from which the carrying cable is guided upwards over the deflection pulley of the crane. In order to ensure the necessary freedom of function for the on-board crane, the nacelle can be opened at the top, and at the bottom it has an opening in the floor through which the components to be replaced can be guided. To replace the components on the opposite side of the on-board crane, such as the rotor blades or the rotor hub, the gantry only needs to be swiveled around its joint to the other side. There is enough free space to move the loads. After completion of the revision work, the crane portal is placed back on the machine frame and the nacelle is closed at the top. The on-board crane remains there for its next assignments. The construction of such an inland wind turbine and the placement of the on-board crane was initially carried out using an external hoist, which, as the height of the turbine increased, was subject to more and more demanding requirements, which led to ever higher costs.

Furthermore, from the pamphlet EP 1 677 007 A2 a wind turbine known, which is equipped with a jib crane, which is used for necessary maintenance work. This maintenance crane is mounted on the nacelle with an auxiliary hoist intended only for this purpose. For this purpose, the gondola is provided with a support frame above. This maintenance crane remains on the inland wind turbine during the entire operating time and can be used at any time.

All of these known solutions are either only suitable for building or servicing an inland wind turbine up to a certain height.

This corresponds to the state of the art of wind turbines that are currently being manufactured worldwide. However, it is necessary to include a special direction of development in the state of the art for the transition to higher inland wind turbines that can now be recognized. From the Netherlands, the new tower construction technology with the new erection method has been known from the Lagerwey company since 2017/2018 and is now being implemented by the German manufacturer Enercon. As presented in the NEWS of September 14, 2017 "Lagerwey tests new climbing crane", the new tower is made of sheet metal parts folded along the tower axis and screwed together, thus offering great logistical advantages, but requires numerous demanding longitudinal and transverse screw connections and remains despite the interesting statics with the tower diameter extended to approx. 11 m, a tower subjected to bending moments, which avoids large wall thicknesses in the lower area, but with the effort to use the lower tropospheric winds, with larger drives it reaches the limits of economic efficiency. The interesting solution presented under the name "Climbing Crane" does not change that.

For larger hub heights to achieve outputs of over 5 MW, however, inland wind turbines cannot do without the use of a new static tower structure and lowered drives.

object of the invention

The aim of the invention is to create an advantageous solution for erecting, equipping and operating inland wind turbines of great height and power.

This task is solved by using a proprietary hoist, which performs the task of erecting the tower from tower sections of the same system, tower height-dependent number and dimensions. After building the tower and the completion of the equipment, the in-house hoist receives a permanent location on the system to be available for constant service, for work during the general overhaul and the possible replacement of parts.

example

Further details and advantages of the method and the use of the equipment result from the following description and the associated drawings, in which a preferred embodiment is shown.

• 1 : eine Binnenwindanlage mit drehbarem Turm auf Nabenhöhe ≥ 200 m mit Antriebssystem im Turmfuß in einer Vorderansicht und links in einer Seitenansicht und darunter die zugehörigen Draufsichten,
• 2 : ein Eigenhebezeug zum Verfahren und als Ausrüstung zur Binnenwindanlage mit drehbarem Turm ≥ 200 m Nabenhöhe und Antriebssystem im Turmfuß,
• 3 : das Eigenhebezeug beim Turmerrichten auf der Kreisringbahn und der ersten aufgesetzten Turmsektion und
• 4 : das Eigenhebezeug auf dem Dauerstandplatz oben zum Aufrüsten, Betreiben und Service auf Lebenszeit der Binnenwindanlage mit drehbarem Turm ≥ 200 m und triebstrangverzweigtem Antrieb im Turmfuß.

Show it:

• 1 : an inland wind turbine with a rotatable tower at hub height ≥ 200 m with a drive system in the tower base in a front view and on the left in a side view and below the associated top views,
• 2 : a self-propelled hoist for moving and as equipment for the inland wind turbine with rotating tower ≥ 200 m hub height and drive system in the tower base,
• 3 : the own hoist when erecting the tower on the ring track and the first tower section and
• 4 : the own hoist on the permanent stand at the top for upgrading, operation and service for the lifetime of the inland wind turbine with a rotating tower ≥ 200 m and a drive train with split drives in the tower base.

The inland wind turbine after 1 is specifically designed for operation with hub heights ≥ 200m and is used to use the wind in the lower tropospheric layers. In order to obtain reliable information about the energy yield to be expected at an intended plant location, wind measurements on site over longer periods of time in the height sections of the rotors 10 used that belong to the hub height 13 are necessary.

The rotating tower 26 is placed with its vertical column 9 and two counter-supported pressure columns 8 on a circular track 1 with the center of rotation 2 with the aim of achieving favorable dead weights, whereby between the columns 8 and 9 there is a horizontal spread on the ground and the vertical spread under the Hub height 13 arise, which together with the radius of the circular track 1 are the decisive means for the overall design and the results of the dimensioning and net mass. The responsible structural engineer can determine different standard sizes of rolled large pipes and apply these to the client. Supports and stiffeners 7 are provided between the three columns 8 and 9 of the rotatable tower 26, which absorb and transmit the dynamic forces and wind loads. In these and on these beams and stiffeners 7, the walkways and handrails are arranged for erecting the rotatable tower 26, so that the final adjustments, connections or seams are made during the final assembly.

The manufacturing process of the tower sections 18 to 21 according to "Industry 4.0" has been unusual up to now, where after the material delivery of the finished-rolled, already pre-preserved large-diameter pipes for the vertical column 9 and two pressure columns 8 (in 40-foot containers by rail or on low-loaders / tractors in finished dimensions) and already prefabricated butt welds on the pipe ends can be delivered to the future plant location. The small parts / repeat parts are delivered ready-made by the manufacturer.

In the vicinity of the plant location, temporary production sections are covered so that the complete tower sections 18 to 21 for erecting the tower 26 can be removed from the completed foundations 3 of the track or slewing ring railways and the first tower section 18 is placed. The tower sections 18 to 21 are fully equipped and prepared (elevator, ladder, electrics, lighting, installation, etc.) brought to the installation site and taken over there by the company's own hoist 12 for tower erection. The own hoist 12 is shown in the two drawings 1 each shown in a lower position and the upper end position. In the example, each tower section 18 to 21 is provided with a construction height of 10 m. This dimension can be customized differently to suit territorial and logistical conditions of final assembly.

After the placement and equipping of all tower sections 18 to 21 up to hub height 13, the flat belt pulley 11 with the large diameter is mounted behind the rotor 10 on the rotor shaft at hub height 13. Due to the limitation of the transport dimensions, the large flat belt pulley 11 is assembled from several parts (e.g. from 12 ALU cast parts as pulley segments) and completed according to a precise procedure and covered by a cover 29.

The installation of the flat belt 30 is favorable if it has been delivered at this point in time, only so that the flat belt 30 can be fitted over the large flat belt pulley 11 in the most favorable manner. Thanks to the wire-rope-reinforced construction of the belt 30, the function becomes reliable and electronic for life supervised. After erecting the rotating tower 26, the self-hoist 12 is brought into its permanent position, where it will be in service until the end of the service life of the entire system.

After completing the assembly and equipping of each tower section 18 to 21, the self-hoist 12 has to go to the next height (+10 m). This will be after 2 a riser 22 is used between each tower section 18 to 21 and its lower bracket of the own hoist 12, which consists of an electric hoist with a connected block and tackle, which is converted after each completed installation of a tower section 18 to 21 from its height to the next. After the console 35 of the self-hoist 12 on the preceding tower section 18 to 21 has been released, the self-hoist 12 slides up in its guides on the vertical column 9 by actuating the electric hoist 10 m and is attached there to the console 35 of the self-hoist 12 on the next tower section 19 to 21 reattached in the new position occupied.

The self-hoist 12 after 2 is attached with its underlying bracket 35 to the upper half of the 10 m high part of a piece of vertical column 9 of each tower section 18-21. In the floor plan, the own hoist 12 is slightly angled next to and connected to the vertical column 9 of the tower section 18 by two guide rails and continuous fitting screws. The vertical column 9 has an outer diameter of 3 m and can take over the bracket 35 with its own hoist 12 with its loads from its own mass and load moment in all positions when lifting the next tower section 19 to 21 from the point of delivery on low loaders or special trolleys. For this purpose, the own hoist 12 in the console 35 has a large, powerful hoist (multi-layer cable drum with built-in gear including electric motor). The hoisting lashing is intended to be a single-strand heavy hook block, since a total of approx. 500 m of hoisting rope must be used due to the final height and task of the company's own hoisting gear 12 at the permanent station. For the continuous use of the own hoist 12 in winter, the hoist rope (as with other deliveries to cold regions) is provided with a cold oil. Above the console 35 at the same height as the bearing surface of the preceding tower section 18 to 21 is the ball bearing slewing ring of the own hoist 12, which allows the own hoist 12 to perform a working range of 360°. On the slewing ring of the own hoist 12 is after 3 The bearing of the multi-part boom 17 and the relatively small vertical slewing gear drive are eccentrically slightly elevated above the platform. The boom 17 is a telescopic boom and is shown in the drawing in two differently inclined positions, each with three telescopic lengths. On the right side next to the jib 17, a crane cabin 33 that is glazed all around and is provided with a sunshade roof is arranged via a staircase, so that the crane driver is protected and has a good overview when he is present (otherwise by radio remote control). Such cabs are known from the truck loading crane program and are considered to be supplier products. Also on the right side of the vertical column 9 of the tower section 19 and on the console of the own hoist 12 is the riser 22, connected by the electric hoist in between.
The illustration with the arrangement of the own hoist 12 when erecting the tower on the circular track 1 and tower section 18 2 makes it clear that the contractor who erects the foundations 3 and the circular track 1 for the tower 26 bears a high level of responsibility for the vertical position of the tower 26 and for the stability of the tower 26 with the foundations 3 on the ground, as well as for the safe standing of the Circular track 1 or, alternatively, a slewing ring 31 carries. Because the accuracy of the vertical column 9 and the spread of the pressure columns 8 as well as the exact position of the pivot point in the center of rotation 2 are the prerequisites for the subsequent tower erection work from the tower section 19. If it is proven that the tower section 18 lies exactly on the circular track 1 , the process of turret erection can be picked up with turret section 19.

The own hoist 12 can be used to place the lower tower sections 18, which are the largest in terms of dimensions and net weight, as in FIG 2 shown, these tower sections also divided - left part 23 - right part 24 and rear part 25 - transport and install, so that space problems with the first tower sections 19 and more by their dimensions do not cause any disabilities. After each installation of a tower section, the internal hoist 12 has its position at the new height in preparation for the next tower section with the riser 22, i.e. to raise one tower section height (by 10 m in the example explained here). To do this, the suspension of an upper pulley block on the vertical column 9 of the tower section just assembled connects it to the cable drum gear on the lower console 35 of the electric hoist and lifts the entire own hoist 12 in its guides on the consoles during the pulley operation by the desired height of 10 m When the next tower section is assembled in its new position, the pulley block of riser 22 is reattached so that the new ascent lift is prepared.

In the 2 and 3 the internal hoist 12 as equipment of the inland wind turbine for erecting the tower is shown in its composition and function and explained below. To the placement of the first tower section 18 on the foundations 3 of the circuit 1 and the decrease can be done after the attachment of the lower bracket 35 of the hoist 12 its assembly using the equipment of the plant site.

In order to achieve a hub height of 250 m, 25 tower sections 18 to 21 are required. Such a dimensioning of the tower sections 18 to 21 is not mandatory. It can also be agreed by the client in other dimensions.

Starting from the second tower section 19, this is placed with the own hoist 12 and fully assembled. Above its slewing ring with the slewing gear drive, the own hoist 12 receives the luffing and telescoping mechanism for actuating the boom 17. An ascent to the driver's cab 33 is provided on the right-hand side. It is set up for the duration of the crane work and equipped for radio remote control. Below the console 35 for the hoist 12 on the vertical column 9 is the hoist with the multi-layer cable drum including gear and drive for the cable length designed according to the hub height 13 (here almost 550 m hoist cable) and therefore single-strand lashing. Right next to it is the small electric pulley block for riser 22.

At the bearing of the boom 17, a sheet metal apron is provided up to the level of the second telescopic part of the boom 17, so that the proper cable routing and the necessary protection against the weather is ensured. The lifting shackle 36 is provided as a single strand and must be designed for long rope lengths with a corresponding dead weight for the lashing and must be supplied with a refrigeration oil because of the inertia of the rope run in cold operation.

In 4 the intended permanent position 37 of the own hoist 12 on the top tower section 21 is shown and explained. The linking of the technology of erecting the tower with the requirement to be ready for use at any time on permanent stand 37 for the entire time the system is in operation to carry out technical lifting tasks is an outstanding advantage for the system investor. Otherwise one would have to rely on a third-party hoist with the appropriate design and performance and would have to wait until one was transported and set up. The constant whereabouts of the personal hoist 12 on the inland wind turbine makes it possible to design their service life to 30 years and more. This is another advantage compared to the wind turbines in operation today. With the individual construction and equipment of such hoists, operating times of up to 50 years have already been achieved in the past. Such long-lasting equipment is already used for repair cranes in surface mining equipment and systems and equipment in the transport sector. The own hoist 12 for setting up and operating the inland wind turbine designed for use of the high-altitude wind must master the technology of climbing by the dimension of the overall height of a tower section 18 to 21. The own hoist on permanent stand 37 above 4 is for the investor of this inland wind turbine with a rotating tower ≥ 200m and a drive train with branched drive in the tower base a technically and economically outstanding advantage compared to all conventional wind turbines in which a lot of time was lost for the actual task of bringing about high energy yield for each lifting gear task, and now By using one of the system's own hoists with permanent stand 37 for service, general overhaul - parts replacement and other tasks, the effort is reduced to just a one-time payment at the beginning.

Reference List

1

circular track

2

center of rotation

3

foundations

4

Above-ground concrete ballasting

5

Machine platform / drive

6

center of rotation of the tower

7

carriers, stiffeners

8th

Pressure columns, spread

9

vertical column

10

rotor / rotor blades

11

upper flat pulley

12

own hoist

13

hub height

14

Flat belt guide through the vertical column 9

15

height

16

Foundation for bearing the pivot point of the tower

17

boom

18

lower tower section on circular track 1

19

tower section 2

20

Tower section 3 and more, including the penultimate tower section

21

upper tower section

22

riser

23

Tower section 1, left third

24

Tower section 2, right third

25

Tower section 3, rear third

26

rotating tower

27

rotor hub

28

rotor outer diameter

29

fairing pulley

30

Flat belts (split rods, multiple)

31

Ball Slewing Ring

32

ball track

33

crane cab

34

free

35

console

36

lift lashing

37

Permanent position of the own hoist on the inland wind turbine

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102016014799 B4 [0001]
• DE 102019008854 [0001]
• WO 2015/158713 A1 [0004]
• DE 19741988 A1 [0005]
• WO 2016/007241 A1 [0007]
• EP 1101934 A3 [0008]
• EP 1677007 A2 [0009]

Claims (1)

Method and equipment for an inland wind turbine with a rotating tower (26) and a drive train with a branched drive in the tower base, consisting of identical tower sections (18 to 21) in the tower height-dependent number and dimensions of the tower sections (18 to 21), characterized in that the erection of the tower (26 ) by means of a personal hoist (12), which rises by one section height after each assembly of a tower section (19 to 21), and after installation of the top tower section (21), the personal hoist (12) takes its permanent stand 37 on the system and all necessary technical lifting tasks fulfilled.

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