AU2021240314B2

AU2021240314B2 - A method of installing large structures such as wind turbines

Info

Publication number: AU2021240314B2
Application number: AU2021240314A
Authority: AU
Inventors: Matt Crossan
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-10-02
Filing date: 2022-06-02
Publication date: 2023-11-02
Anticipated expiration: 2041-10-02
Also published as: AU2021240314A1; AU2021240314A9

Abstract

A system, apparatus, of a movable part attached to a wind turbine and being arranged on the wind turbine in liaison with a second movable and companion part, adapted for providing a crane operator, or grounds person, or anyone in the vicinity with Bluetooth and 3D data connectivity to the system or apparatus; is able to locate the first and second wind turbine parts into position without the requirement of any individual located on the wind turbine, and not requiring clear vision. a U c~ C Figure

Description

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A method of installing large structures such as wind turbines

Technical field

The present invention relates to a method for installing large structure. In particular, it relates to a method of stacking sections of a wind turbine.

Background

Wind turbines are constructed by assembling large sections on top of each other. These sections can extend to 100 metres long and weigh up to 150 tonnes.

A crane operator works from a cab at ground level to lift sections into place. From this vantage, the turbine is assembled at heights 60 to 150 metres above ground level. The crane operator has limited visibility to the top of structure during construction.

Precision is required to avoid costly damage to the sections. As each section is added to the structure, it is carefully guided into place by technicians standing at the point of assembly. The technicians work at height, usually under the load suspended by the crane.

Technicians can use a handheld radio to communicate with the crane operator, providing instructions to help move the section into the correct position. Once the section is directly above the assembly point, the technicians manoeuvre the section into the correct orientation to align bolts and fittings.

This process is used worldwide to construct wind turbines. It places workers at considerable risk of injury from the load falling or causing pinch point injuries, such as amputations.

These risks are increased by the following factors:

Communication failure: Technicians use handheld radios to communicate with the crane operator. The battery life of these units can be unreliable. If the radio fails during the final stages of assembly, there is high risk of injury or fatality.

Adverse weather: Fog can descend unexpectedly on work sites, dramatically reducing visibility. Technicians operating at height can find it difficult to see the load, placing them at additional risk of injury.

Extreme height: Wind turbines can reach heights up to 150 metres. Under the right conditions, high structures can sway and start to shake. Workers should not be on the structure if it is moving considerably, which means work is delayed.

Summary of Invention

In a first aspect there is provided a method of installing a large structure e.g. a wind turbine, wherein a first section of the large structure is aligned and coupled with a second section of the large structure, the method comprising the steps of installing the first section or identifying the first section already installed, the first section having an exposed surface for coupling with an exposed surface of the second section; wherein there is a first sensor at or near the exposed surface of the first section, and a second sensor at or near the exposed surface of the second section, the second sensor in electronic communication with the first sensor, and a camera located between the first sensor and second sensor, lifting, using lifting equipment, the second section and moving it near to the first section, wherein, at least during lifting, receiving live visual information from the camera and live sensor information from the first sensor and the second sensor relating to their location relative to one another; and controlling the movement of the second section using the received live sensor information and live visual information to align and then couple the exposed surfaces of the first section and the second section to thereby install at least a part of the large structure.

Constructing a wind turbine involves considerable risks to workers. Industry practices require a technician to stand beneath a suspended load to ensure turbine parts are installed accurately.

These practices put workers at risk of injury or fatality. Projects may also be delayed if weather conditions require workers to be grounded.

The present invention has been designed to eliminate or at least reduce the need io for a person to stand underneath a suspended load. It provides the crane operator with a direct view of the section and the placement location.

The present system utilises a device such as either camera, magnetic, laser, infrared, ultrasonic, RFID, proximity or GPS technology. The device can be installed on the uppermost section of a structure. Live data is sent from the device to a display in e.g. the crane operator's cab.

The device can calculate precise height calculations for the alignment of e.g. tower and blades and provide a live feed of information throughout installation.

In embodiments, the crane operator will be able to control the device remotely to adjust their view of the two sections being joined.

In embodiments, he system enables a safer construction process for technicians. In embodiments, technicians will work under the suspended load for a much shorter time period, in order to install and remove the device.

In embodiments, the present system has the primary advantage of making the construction of wind turbines much safer. It achieves this by greatly reducing the need for technicians to work underneath a suspended load and reducing the risk of a communication failure between the crane operator and technician.

Using the present device, it may be possible to continue working under conditions that would normally require work to cease (for example, when there is fog or air movement causes the structure to shake).

The present device may also be suitable for use on e.g. turbines manufactured by all suppliers. These safety advantages are gained without impacting construction times.

Brief Description of the Figures

Embodiments of the invention will now be described with reference to the accompanying drawings which are not drawn to scale and which are exemplary only and in which:

Figure 1 is a front section of a wind turbine showing the sections that are a part of the tower assembly.

Figure 2 is a side section of a wind turbine showing the sections that are a part of the tower assembly.

Figure 3 is a perspective view of a wind turbine.

Figure 4 is a perspective view of a crane lowering parts for assembly.

Figure 5 is a close-up view of a turbine section being installed.

Figure 6 is a close-up view showing triangulation of the sensors.

Figure 7 shows the placement of a sensor.

Figure 8 shows how a live image can be generated during installation.

Figure 9 is an example of a screen showing the live image.

Figure 10 is a perspective view of a blade vertical alignment.

Detailed Description of Embodiments of the Invention

Figure 1 is a front section of a large wind turbine structure showing the sections that are part of the tower assembly. There are three sections shown in Figure 1. Figure 2 shows the sections from the side; and Figure 3 is a perspective view of the sections once assembled.

Figure 4 is a schematic showing the first section installed. As depicted, the first section comprises two section parts shown in the Figure in exploded view. In use io the two section parts of the first section would be joined to one another. The top of the first section previously installed has a sensor at or near the exposed surface therefor (shown as a small round circle). The exposed surface of the first section waiting for coupling with the second section is shown in Figure 4 as a thin annular wall. The second section is suspended from lifting equipment. The exposed surface of the second section waiting for coupling with the first section is being moved toward the first section. The bottom of the second section has a sensor at or near the exposed surface therefor (shown as a small round circle).

Electronic signals are sent between the sensors during installation. The sensors assist in connecting the first section previously installed and the second section incoming. Once the first and second sections meet, a signal can be sent to the operator to indicate that coupling has occurred.

Each section of the structure can have an inside wall and an outside wall. The sensors can be placed on the inside wall of a section. The sensors can be fixed to the section by magnetic forces.

The sensors can be any of the following comprising laser, infrared, ultrasonic, RFID, proximity, GPS.

In Figure 6 there are shown three sensors on a first section and three sensors on the second section. The three sensors can allow for triangulation of the sensors to determine their positions relative to one another on each section. This will allow the operator to line the sections up, within tolerance, using signals from the sensors sent to the operator.

The sensor positioned at the exposed surface of a section can be seen for example in Figure 6. The sensor positioned near the exposed surface of a section can be seen for example in Figure 5.

Figure 8 shows that a camera can be placed on the second section that is being landed to provide the person operating the lifting equipment with a live image.

io Figure 9 shows the screen showing alignment and vertical distance of the sections with X being the distance between the sections. The driver will have a live feed of information during installation. The screen with the live feed can be located near to the driver.

The movement of the second section can be controlled by a crane operator, or grounds person, or anyone in the vicinity. The movement can be controlled using Bluetooth and 3D data connectivity.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Any promises made in the present description should be understood to relate to some embodiments of the invention and are not intended to be promises made about the invention as a whole. Where there are promises that are deemed to apply to all embodiments of the invention, the applicant/patentee reserves the right to later delete them from the description and does not rely on these promises for the acceptance or subsequent grant of a patent in any country.

Claims

1. A method of installing a large structure e.g. a wind turbine, wherein a first section of the large structure is aligned and coupled with a second section of the large structure, the method comprising the steps of installing the first section or identifying the first section already installed, the first section having an exposed surface for coupling with an exposed surface of the second section; wherein there is a first sensor at or near the exposed surface of the first section, and a second sensor at or near the exposed surface of the second section, the second sensor in electronic communication with the first sensor, and a camera located between the first sensor and second sensor, lifting, using lifting equipment, the second section and moving it near to the first section, wherein, at least during lifting, receiving live visual information from the camera and live sensor information from the first sensor and the second sensor relating to their location relative to one another; and controlling the movement of the second section using the received live sensor information and live visual information to align and then couple the exposed surfaces of the first section and the second section to thereby install at least a part of the large structure.

2. The method of claim 1, wherein the live information is fed to a display accessible by the operator who does not have clear vision of the installation.

3. The method of claim 1 or 2 wherein the sensors are proximity sensors in electronic communication with one another.

4. The method of any one of claims 1 to 3, wherein there is more than one first sensor and more than one second sensor.

5. The method of any one of claims 1 to 4 further comprising the camera coupled to the second section.

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