METHOD AND MEANS FOR LIFTING A WIND POWER TOWER DESCRIPTION OF THE INVENTION This invention relates to a method and means for raising a tower and more particularly to a method and means for raising a wind power tower where sections of the tower are place one on top of the other. Wind power devices or wind turbines are becoming more popular in the production of electric power. The wind power or wind turbine device typically comprises a generator driven by a rotor mounted on the top of a tower that can reach heights of up to 70 meters or more. The tower is usually composed of a plurality of cylindrical or tapered tower sections that are secured together in an end-to-end relationship. The tower is usually lifted by the use of a large crane. When the tower has been raised, the large crane lifts the turbine over the top of the tower. The customary method of lifting the tower is quite expensive due to the requirement that a large crane must be present at the work site. In addition, in some windy conditions, the elevation of the tower sections by means of the large crane is dangerous. A device is provided for raising a wind power tower to successively elevate tower sections on a base tower section extending upwardly from a foundation and secured thereto. Normally, the base tower section will be placed on the foundation with a small crane. The device for raising the tower comprises a skate or skid module on which is placed an energy source such as a motor, a main winch having a lifting cable extending therefrom, and a base platform of tower section on which the individual sections of the tower are successively placed to rise in the base tower section. The skid module is placed adjacent to the base tower section and anchored to the foundation by means of a plurality of screws. An adjustable support is placed adjacent to the base tower section and extends partially around it. A lower cage is initially placed at the upper end of the adjustable support and extends at least partially around the base tower section. A lower block is secured to the lower cage. The lower cage includes roller row assemblies thereon which are adapted to couple the rails on opposite sides of the sections of the tower to allow the lower cage and the associated structure to selectively move vertically over the sections of the tower. tower. An upper cage is separated above the lower cage and is interconnected thereto by means of a support frame structure which is composed of separate side panels and separate side beams. An upper block is initially fixed in a removable manner to the base tower section adjacent to the upper end thereof and is adapted to be successively fixed to the upper ends of the tower sections as they are placed over the base tower section . The main winch lifting cable extends around the upper and lower blocks in a multi-part manner with the free end thereof securing to the lower block. A bridge assembly is placed at the upper end of the upper cage and comprises a bridge, a carriage and a sliding means in the Z direction. The bridge is a trapezoidal shaped beam that straddles or forms a bridge over the upper end of the upper cage and moves in the Y direction (from front to back). The car moves with respect to the bridge in the X direction (from side to side). The sliding means in the Z direction is mounted on the carriage and moves in the Z direction (vertical). A tower section connector or oscillating connection is connected to the sliding means in the Z direction at the lower end thereof and is composed of a double gimble type junction and a load spreader. The load spreader includes four rotating load arms that selectively attach to the flange at the upper end of the tower section being transported. An auxiliary power unit is mounted on the bridge assembly to provide power to the bridge assembly and miscellaneous electrical equipment. An auxiliary winch is also placed in the sliding means in the Z direction. The wind power tower is raised as follows: (1) a small crane is used to place the base tower section in the foundation and is screwed instead; (2) the adjustable support is placed around the base tower section; (3) the patin module moves to its place and is screwed to the foundations; (4) the roller row assemblies in the lower cage open; (5) the lower cage is raised on the adjustable support; (6) the roller row assemblies are moved to an operative coupling position with respect to the rails on opposite sides of the base tower section;
(7) Side panels and side beams are assembled;
(8) a lateral side panel beam is secured to one side of the lower cage to extend upwards thereof;
(9) the other lateral side panel beam is secured to the other side of the lower cage to extend upwards thereof; (10) the upper cage is mounted on the upper ends of the side panels by means of a small crane; (11) the upper block is secured next to the section of the base tower at the upper end thereof; (12) The lifting cable extends from the main winch in the skid module and is connected to the lower block in the lower cage and to the upper block in the upper end of the base tower section whereby the movement of the lifting cable by means of the main winch it causes the lower cage and the structure supported thereby to move vertically with respect to the base tower section; (13) another tower section is placed on the base platform provided in the skid module; (14) the bridge assembly is manipulated in the upper cage to place the oscillating connection in the sliding means in the Z direction within the upper end of the tower section in the base platform; (15) the oscillating connection is secured to the flange in the platform tower section; (16) The main winch operates to cause the lifting cable to raise the lower cage, the upper cage, the interconnection support frame structure, the bridge assembly and the platform tower section upwards with respect to the base tower; (17) When the platform tower section is raised enough, the lower cage is riveted to the rails in the base tower section; (18) the bridge assembly is manipulated so that the platform tower section is placed on the base tower section and then lowered onto the base tower section; (19) the flange at the lower end of the platform tower section is screwed to the flange at the upper end of the base tower section; (20) The auxiliary winch in the bridge assembly is operated to raise the upper block of the upper end of the base tower section, after it has been disconnected from the base tower section, to the upper end of the base section. platform tower mounted on it; (21) the upper block is secured to the platform tower section mounted on the base tower section; (22) the lower cage is unraveled from the rails and moves downwards until the lower cage rests on the adjustable support; (23) the bridge assembly is manipulated to place the oscillating connection within the upper end of another tower section in the base platform; (24) Repeat the necessary steps described above until the wind power tower is completely elevated; (25) use the auxiliary winch to lower the upper block to the floor after it has been removed from the raised tower; (26) remove the bridge assembly, the upper cage, the side panels and side beams, the lower cage and the adjustable support of the raised tower; and (27) remove the skid module from the foundations.
It is therefore a principal object of the present invention to provide a device for raising an improved wind power tower. A further object of the invention is to provide a device for raising an improved wind power tower that eliminates the need for a large crane as is commonly required. Still another object of the invention is to provide a device for raising an improved wind power tower that can be used to raise towers that have a height that exceed the reach of even the largest cranes. Still another object of the invention is to provide a device for raising an improved wind power tower that is safe to use and practical in all weather conditions. Still another object of the invention is to provide a device for raising an improved wind power tower that is durable and reliable. These and other objects will be apparent to those skilled in the art. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of the apparatus for raising a wind power tower; Figure 2 is a perspective view of the skate module portion of the apparatus;
Figure 3 is a partial perspective view of the lower end of the apparatus; Figure 4 is a partial perspective view of the upper end of the apparatus illustrating the upper cage and the bridge assembly; Figure 5 is a side view of the apparatus illustrating the lower cage, etc., its highest position with respect to the base tower section; Figure 6 is a side view of the apparatus illustrating the lower cage, etc., in its lowest position supported on the adjustable support; Figure 7 is a side view of the apparatus illustrating the lower cage, etc., in its highest position with a tower section having been raised from the base platform to be placed on the base tower section; Figure 8 is a view similar to Figure 7 except that the bridge assembly has moved the platform tower section to a position on the base tower section; Figure 9 is a side view similar to Figure 8 illustrating another tower section having been raised from the base platform; Figure 10 is a top view of the apparatus; Figure 11 is a top view illustrating the relationship of the lower cage with respect to the rails of a tower section; Figure 12 is a top view of the upper block and the upper block fixing hook; Figure 13 is a side view of the upper block and upper block fixing hook; Figure 14 is a front view of the upper block and the upper block fixing hook; Figure 15 is a bottom view of the upper block and upper block clamping hook; Figure 16 is a perspective view of the sliding means in the Z direction and of the oscillating connection and its relation to the upper flange in the tower section; Figure 17 is a front view of the sliding means in the Z direction and of the oscillating connection and its relation to the upper flange in the tower section; Figure 18 is a side view of the sliding means in the Z direction and of the oscillating connection and its relation to the upper flange in the tower section; Figure 19 is a perspective view similar to Figure 16 except that the sliding means in the Z direction is shown mounted on the carriage; Figure 20 is a top view of the sliding means in the Z direction of the carriage and of the oscillating connection of Figure 19;
Figure 21 is a bottom view of the sliding means in the Z direction of the carriage and of the oscillating connection of Figure 19; Figure 22 is a side view of the sliding means in the Z direction of the carriage and of the oscillating connection of Figure 19; Figure 23 is a front view of the sliding means in the Z direction of the carriage and of the oscillating connection of Figure 19; Figure 24 is a top perspective view of the oscillating connection; Figure 25 is a bottom perspective view of the oscillating connection; Figure 26 is a top view of the oscillating connection; Figure 27 is a side view of the oscillating connection; Figure 28 is a side view of the oscillating connection; and Figure 29 is a bottom view of the oscillating connection. Referring to the drawings, the number 10 refers to a base tower section of the wind power tower to be erected. The base tower section 10 will normally be placed in a concrete foundation 12 by means of a small crane (not shown). The base tower section 10 is screwed to the foundation 12 in a conventional manner, the base tower section 10 includes a pair of longitudinally extending rails 14 and 16 secured to the opposite sides thereof with each of the rails having vertically spaced openings 18 formed therein, each of which is adapted to receive a pin 20 therein as will be described in detail below. Usually, the small crane will be used to mount a single base tower section in the foundations, but one or more tower tower sections can be mounted in the base tower section through the use of the small crane. The invention will be described as if a single base tower section were lifted through the use of a small crane with the other tower sections of the tower being lifted through the use of the apparatus of this invention. The number 22 refers to a skid or to a skid module that is composed of a tubular structure that is screwed to the foundations 12. The skid 22 includes a power unit 24 and a main winch 26 having a booster cable 28 that is extends from it. If desired, an auxiliary winch can be mounted on the skid 22 to lower the upper block to the floor at the end of the day.
Preferably, the main winch is hydraulically actuated by means of a suitable hydraulic pump in the skate 22 which is driven by the power unit. However, the main winch 26 can be mechanically driven by the power unit if desired. The power unit 24 is preferably a diesel engine but can be a gas engine or an electric motor. Preferably, the main winch, and the associated equipment can be controlled remotely. A tower base platform 29 is provided on the skate 22 to successively support the tower sections thereon. For ease of description, the number 30 will refer to the apparatus that is currently mounted movably on the tower. The apparatus 30 is initially placed on an adjustable support assembly 32 which is composed of four vertical adjustable supports 34, the lower ends of which are placed on the foundations. The upper ends of the adjustable supports 34 are preferably placed approximately 1,524 meters (sixty inches) above the foundation 12. It is recommended that the adjustable supports 34 be chained together to prevent them from falling. The apparatus 30 includes a lower cage 36 having three sides to allow the lower cage 36 to be placed around the base tower section 30 and the other sections equally. For purposes of description, the lower cage 36 will be described including sides 38, 40 and 42, each of which is comprised of a tubular structure welded together. The lower cage 36 includes four vertically arranged corner posts or legs 44. The lower end of the lower cage 36 is normally supported on the adjustable support assembly 32. The lower end of the lower block 46 is pivotally secured to the lower cage 36 by means of a clamp and pin structure 48. The lower cage 36 includes a pair of roller row assemblies 49 mounted thereon on opposite sides thereof to engage with the rails 14 and 16 on opposite sides of the tower section. An interconnection frame assembly or frame structure 50 is selectively secured to the lower cage 36 and extends upward therefrom. The frame assembly 50 includes a side panel 52 that receives the lower ends of the posts or legs 54 and 56 within the upper ends of a pair of corner posts 44 and is secured thereto by means of pins 58 (Figure 3 ). The frame assembly 50 also includes a side panel 52 'which is identical to the side panel 52 and which extends upwardly from the side 42 of the lower cage 36. The interconnect frame assembly 50 also includes side beams 60 and 62 that are removably secured to the lower cage 36 and side panel 52 to add strength and stability to the assembly 50. The side beams 60 'and 62' that are identical to beams 60 and 62 are removably secured to lower cage 36 and side panel 52 'to add strength and stability to assembly 50. Upper cage 64 is removably mounted removably at the upper end of panels 52 and 52 'side of the interconnection frame assembly 50. As can be seen in the drawings, one end of the upper cage 64 exits laterally of the frame assembly 50. The laterally exiting portion of the upper cage 64 is supported by a pair of support arms 66 and 68, whose lower ends are connected to the side panels 52 and 52 ', respectively. The number 70 refers to a bridge assembly mounted on the rails 72 and 74 of the upper cage 64. The bridge assembly 60 includes a bridge 76 comprising a pair of spaced trapezoidal shaped beams that straddle or form a bridge and move on top of the rails 72 and 74 of the upper cage 64 in the Y direction (from ahead backward) . The bridge 76 includes four rollers 78 that roll on the rails 72 and 74. A pair of hydraulic cylinders (not shown) are secured to and extend between the upper cage 64 and the bridge 76 to move the bridge 76 in the Y direction. unit 80 of superior power preferably consists of a diesel generator of 24 kW and a hydraulic pump compensated by electric pressure of 15 hp. The unit 80 provides power for the bridge assembly 70 and can power the miscellaneous electrical equipment. The 82 auxiliary winch is mounted on the bridge
76 and has a cable 83 extending therefrom. A carriage 84 is movably mounted on the upper ends of the bridge beams 76 by means of four rollers 86 and moves in the X direction (from side to side). As can be seen in Figure 19, the carriage 84 includes a pair of separate frame members 88 and 90 having a pair of frame members 92 and 94 secured to the ends thereof extending therebetween. A pair of separate forks 96 and 98 extend downwardly from the frame members 88 and 90 at the ends thereof. A hydraulic cylinder (not shown) is secured to and extends between the bridge 76 and the carriage 84 to move the carriage
84 with respect to the bridge 76. A slide assembly 100 in the Z direction is selectively mounted in a vertically movable manner on the carriage 84 to move therewith. As can be seen in Figure 19, slide assembly 100 in the Z direction is placed between frame members 88-90 and 92-94 to move in the Z (vertical) direction. The sliding assembly 100 includes four frame members 102, 104, 106, and 108 vertically arranged interconnected by clamps 110. An arcuate clamp 112 is secured to the upper ends of the posts 102 and 104 and extends therebetween. Similarly, an arcuate clamp 114 is secured to the upper ends of the posts 106 and 108 and extends therebetween. The roller assemblies 116, 118, 120 and 122 are provided in the carriage 84 which couples the posts 102, 104, 106 and 108, respectively. Carriage 84 is also provided with roller assemblies 124, 126, 128 and 130 that are also in engagement with posts 102, 104, 106 and 108, respectively. A hydraulic cylinder 132 has its base end (upper end connected to plates 134 and 136 at one end thereof by means of a pin 138. Similarly, the hydraulic cylinder 140 has its base end (upper) connected to the plates 134. and 136 at the other end by means of the pin 142. The rod ends of the hydraulic cylinders 132 and 140 are connected to the forks 96 and 98, respectively, in this way, the extension of the cylinder rods of the cylinders 132 and 140 causes the sliding assembly in the Z direction to move upward with respect to the bridge 76. Retraction of the cylinder rods within the cylinders 132 and 140 causes the slide assembly in the Z direction to move downward with with respect to the bridge 76. Preferably, the movement of the bridge, the carriage and the sliding assembly in the Z direction are operated remotely and are controlled from the floor level or from the tower by the latch workers who lift the tower. An oscillating connection or a tower connecting member 144 is secured to the lower end of the sliding assembly 100 in the Z direction and includes a double gimble-like joint 146 at its upper end and a load-bearing crosshead 148 at its lower end. The joint 146 has four posts 150, 152, 154 and 156 that extend upwards thereof which are received by and secured to the posts 102, 104, 106 and 108, respectively. The joint 146 includes a first gimble-type joint defined by pivot pins 158 and 160 and a second gimble-type joint defined by the pivot pins 162 and 164. The load crosshead 148 includes plates 166 and 168 vertically separated having four load arms 170, 172, 174 and 176 pivotally secured thereto and between them. The loading arms 170, 172, 174 and 176 each have an elongated opening 178 formed therein to be connected to the flange 180 which is secured to the upper end of the tower sections. The diameter of the plates 166 and 168 is smaller than the diameter of the opening 182 in the flange 180 so that the load spreader can pass through the opening 182 when the arms 170, 172, 174 and 176 load are folded inwards. When the load crosshead 148 has been lowered through the opening 182 by the sliding assembly 100 in the Z direction, the loading arms 170, 172, 174 and 176 pivot outwardly below the bottom surface or flanges 180. The loading arms are then screwed to the flange 180 to allow the bridge assembly to lift and transport the tower section as will be described later. The number 184 refers to a fixing hook which is used to selectively fix the upper block 186 to a tower section adjacent to the upper end thereof. The attachment hook 184 includes an angled support plate 188 that conforms to the exterior surface of the tower sections. The locking pin 190 extends from the interior surface of the plate 188 and is adapted to be received within an opening formed in each of the tower sections adjacent the upper end thereof. The clamp 192 is mounted on the outer surface of the plate 188 and has a block support arm 194 secured pivotally thereto by means of the pivot pin 196. The main winch 26 lifting cable 26 is threaded around the upper block 186 and the lower block 46 with the free end thereof tied to the structure of the lower block 46 as previously described. The method of assembling the device for lifting the tower of this invention and the method for lifting the wind turbine tower or wind power tower will be described below. A small crane is used to place the base tower section 10 in the foundation 12 with the base tower section being bolted to the foundation. The adjustable supports 34 of the adjustable support assembly 32 are placed around the lower end of the base tower section 10 and preferably are chained together to prevent them from falling. The skid or skid module 22 then moves into place and is screwed to the foundations so that the main winch 26 is close to the base tower section 10. The roller row assemblies 49 in the lower cage 36 open and the lower cage 36 rises on the adjustable support by means of a small crane. The roller row assemblies 49 in the lower cage 36 are moved to an operative coupling position with respect to the rails 14 and 16 on the opposite sides of the base tower section 10. The side beams 60 and 62 are secured to the side panel 52 and the side beams 60 'and 62' are secured to the side panel 52 '. A lateral beam side panel assembly is secured to one side of the lower cage 36 to extend upward therefrom. The other lateral beam side panel assembly is secured to the other side of the lower cage 36 to extend upward therefrom. The upper cage 64 is mounted on the upper ends of the side panels by means of a small crane and secured thereto. The attachment hook 184 having the upper block 186 secured thereto is secured to the side of the base tower section 10 at the upper end thereof by inserting the connector pin 190 into the hole or opening provided in the upper end of the housing. side wall of section 10 of the base tower. The main winch 26 lifting cable 28 is threaded around the lower block 46 and the upper block 186 with the free end of the lifting cable 28 fixed to the frame of the lower block 46 so that the movement of the lifting cable 28 by means of the main winch 26 causes the lower cage 36 and the structure supported by it to move vertically with respect to the base tower section 10. Another tower section 10a is positioned or based on the base platform 29 provided in the skate 22. The bridge assembly 70 is manipulated or moved in the upper cage 64 to place the oscillating connection 144 in the sliding assembly 100 in the direction Z so that the arms 170, 172, 174 and 176 of load are placed below the lower surface of the upper flange 180 at the upper end - of the base tower section 10. The loading arms 170, 172, 174 and 176 then move pivotally outward and are connected to the flange 180 by means of screws or the like. The main winch 26 is then operated to cause the lift cable 28 to lift the lower cage 36, the upper cage 64, the interconnect frame or structure assembly 50 and the bridge assembly 70 and the platform tower section 10a upwardly. with respect to section 10 of the base tower. When the platform tower section 10a is sufficiently raised, the lower cage is secured with pins to the rails 14 and 16. The bridge assembly 70 is manipulated so that the platform tower section 10a is placed on the section 10. of base tower and then it is lowered over section 10 of the base tower. The lower end of the platform tower section 10a is screwed to the upper end of the base tower section 10. The auxiliary winch 82 in the bridge assembly 70 operates to lift the attachment hook 184 and the upper block 186 of the upper end of the base tower section 10, after it has been disconnected from the base tower section 10. The upper end of the platform tower section 10a is mounted thereon. The attachment hook 184 is then secured to the platform tower section 10a mounted on the base tower section 10. The lower cage 36 is detached from the rails 14 and 16 and moved downward by the lifting cable 28 of the main winch 26 until the lower cage 36 rests on the adjustable support assembly 32. The bridge assembly is then once again manipulated to place the load spreader 148 of the oscillating connection 144 within the open upper end of another tower section 10b on the base platform. The necessary steps described above are repeated until the wind power tower is completely lifted. The auxiliary winch is then used to lower the upper block 186 to the floor after it has been removed from the raised tower. The bridge assembly, the upper cage, the side panels and side beams, the lower cage and the adjustable support are then removed from the raised tower. The skid module is then removed from the foundation 12. The device for raising the tower can then be moved to another location to be used to raise another tower. It can be seen that the device for lifting the tower of this invention is convenient and safe to use and allows to raise a wind power tower without the use of a large crane which is expensive and dangerous in certain climatic conditions. In this way it can be seen that the invention meets at least all of its aforementioned objectives.