US20160305147A1 - Wind tower erection system - Google Patents
Wind tower erection system Download PDFInfo
- Publication number
- US20160305147A1 US20160305147A1 US15/194,236 US201615194236A US2016305147A1 US 20160305147 A1 US20160305147 A1 US 20160305147A1 US 201615194236 A US201615194236 A US 201615194236A US 2016305147 A1 US2016305147 A1 US 2016305147A1
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- United States
- Prior art keywords
- gin pole
- major
- minor
- longitudinal axis
- tilting frame
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- Abandoned
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- 238000000034 method Methods 0.000 claims description 20
- 230000008439 repair process Effects 0.000 description 6
- 230000008901 benefit Effects 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 3
- 230000000087 stabilizing effect Effects 0.000 description 3
- 239000000969 carrier Substances 0.000 description 1
- 230000009194 climbing Effects 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000002803 fossil fuel Substances 0.000 description 1
- 239000011178 precast concrete Substances 0.000 description 1
- 238000009751 slip forming Methods 0.000 description 1
- 230000035899 viability Effects 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
- E04H12/34—Arrangements for erecting or lowering towers, masts, poles, chimney stacks, or the like
- E04H12/345—Arrangements for tilting up whole structures or sections thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C1/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles
- B66C1/10—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles by mechanical means
- B66C1/108—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles by mechanical means for lifting parts of wind turbines
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
- E04H12/34—Arrangements for erecting or lowering towers, masts, poles, chimney stacks, or the like
-
- F03D1/001—
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor
- F03D1/06—Rotors
- F03D1/065—Rotors characterised by their construction elements
- F03D1/0675—Rotors characterised by their construction elements of the blades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
- F03D13/10—Assembly of wind motors; Arrangements for erecting wind motors
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
- F03D13/20—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2230/00—Manufacture
- F05B2230/60—Assembly methods
- F05B2230/61—Assembly methods using auxiliary equipment for lifting or holding
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/728—Onshore wind turbines
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- Wind towers are effective in harnessing energy without consumption of fossil fuels. Generally the taller the wind tower the more efficient it is. Typically, wind towers are 60-80 meters in height.
- the present invention provides a system that satisfies this need.
- the system includes a method for erecting a wind tower having turbine and at least one blade.
- a preferred method can comprise the following steps, not necessarily in the order presented:
- the method can include the following additional steps:
- the invention also includes the mobile tilting frame itself and using the tilting frame for lowering a wind tower for repair or replacement of parts.
- the turbine and blade can be attached before or after tilting of the tilting frame of step (H).
- the base section can be attached pivotally with a pivot pin.
- the wind tower can be locked into place with either a pin or bolts.
- the method of the invention can be used to erect towers at least 150 meters tall.
- cables can be attached to the tower and support structure to stabilize these structures.
- the method can be reversed to easily tilt the tower down for major turbine repairs, rebuild, replacement and upgrades.
- the method can comprise the use of more than one major gin pole for very high towers.
- This configuration comprises at least a first and second major gin poles each having a longitudinal axis; a minor gin pole having a longitudinal axis; a first support cable connecting the first major gin pole and the minor gin pole; and a second support cable connecting the first and second major gin poles.
- the second major gin pole is greater in length than the first major gin pole, and each additional major gin pole is longer than the preceding gin pole, i.e., major gin pole 4 is longer than major gin pole 3 which is longer than major gin pole 2 .
- the tilting of the tilting frame and erection of the wind tower is accomplished in the same manner as described above for a two-stage gin pole configuration.
- FIGS. 1-16 schematically demonstrate a preferred method of erecting a wind tower according to a system having features of the present invention, wherein the steps need not necessarily be performed in the order shown in the figures and not all of the steps need be performed.
- a system according to the present invention is particularly useful for erecting tall wind towers and is described in detail for that purpose. However it can be used for other applications such as erecting antennas, oil drills and other tall, elongated, relatively narrow structures.
- a conventional wind tower 20 comprises an elongated support structure 22 having a base section 24 and a distal turbine section 26 on which is mounted a turbine 28 with blades 30 .
- a typical wind tower is about 60-80 meters in height, and the present invention can be used with conventional wind towers. However, the invention is particularly useful for tall wind towers, such as those 150 meters and taller, particularly wind towers 180 meters and taller.
- the base section 24 for such tall towers is typically from about 5 meters to 10 meters in diameter or larger.
- a foundation 32 for the wind tower 20 is formed in a. conventional manner. Typically, at least a portion of the foundation 32 is below ground level. Thereafter, as shown in FIG. 2 , a pivot base 34 is secured to the foundation 32 .
- the pivot base 34 can be built into the support structure 22 .
- the pivot base 34 preferably is provided with multiple holes, schematically represented by a single hole 36 , for receiving a pivot pin 37 ( FIG. 5 ) and one or more locking pins as described below.
- an anchor 38 is provided.
- the base or foundation of another wind tower can be used as an anchor.
- the support structure 22 is initially provided oriented parallel, or close to parallel, to the ground and supported by support brackets 39 or the like.
- the support structure 22 can be fabricated on site, can be fabricated off site and transported to the erection site, or can be fabricated in segments fabricated off site and transported to the erection site and assembled on site.
- the support structure 22 is formed on site with a machine 42 such as using the technology described in the aforementioned Keystone published patent applications.
- the elongated support structure 22 has a longitudinal axis labelled as reference number 44 in FIG. 4 .
- the base section 24 of the support structure 22 is secured to the pivot base 34 using a pivot pin (not shown), so that the support structure 22 can be pivoted to a vertical position.
- the turbine 28 and blades 30 are then secured to the distal section 26 of the support structure 22 .
- This step need not be performed in this sequence, in that the turbine and blade can be installed prior to attachment of the support structure to the pivot base or after some of the following steps.
- the turbine 28 and blades 30 are secured to the support structure 22 while the support structure 22 is easily accessible by being substantially parallel to the ground. However they can be secured after the support structure 22 is tilted to its vertical position or during the tilting process.
- a mobile tilting frame 46 is moved proximate to the pivot base 34 , the frame 46 typically being supported on and moved into place on dollies 47 or straddle cranes.
- the mobile tilting frame 46 can have its own built-in wheels rather than rely on separate dollies 47 for movement.
- the mobile tilting frame 46 comprises a major gin pole 48 and a minor gin pole 50 connected by at least one, and preferably a plurality of first support cables 52 where one end of the support cables is attached to a first end 54 of the minor gin pole 50 and the other end of the support cables 52 is attached to the major gin pole 48 at a location between its ends.
- the minor gin pole 50 is used to tilt up and stabilize the major gin pole 48
- the major gin pole 48 is used to tilt up and stabilize the tower ( FIG. 8 ).
- a second end 56 of the minor gin pole 50 is pivotally secured to the end of the major gin pole 48 that is proximate to the pivot base 34 .
- the longitudinal axis of the minor gin pole 50 is perpendicular to the longitudinal axis of the major gin pole 48 , although that angle 58 (see FIG. 8 ) can be from about 45 degrees to about 120 degrees.
- the tilting frame 46 is secured to the pivot base 34 so that it can be pivoted so that the major gin pole 48 can be substantially vertical.
- mobile means a structure that is capable of being moved readily and is not a portion of the wind tower structure or the foundation structure.
- the length of the major gin pole 48 is typically about 10% to about 50%, and preferably about 15% to about 25% of the length of the support structure 22 .
- the length of the minor gin pole 50 is typically about 10% to about 50% of the length of the major gin pole 48 .
- the minor gin pole 50 is secured to the anchor 38 with a second support cable 52 , and typically multiple cables.
- a cable is referred to herein, generally multiple cables are used, both to provide increased strength, and also to prevent undesired tilting of the structures to which the cables are attached.
- the mobile tilting frame 46 is then tilted so that the major gin pole 48 is substantially vertical, or can even be tilted beyond the vertical position. Tilting is effected with a tilting power system typically comprising a winch and a motor for driving the winch (not shown).
- the tilting power system can comprise hydraulic jacks, or a winch and motor in combination with hydraulic jacks.
- the tilting power system can be part of the mobile tilting frame 46 , or it can be a separate structure such as being placed by the anchor 38 .
- Stabilizing cables 60 are used to secure the tilting frame 46 .
- the major gin pole 48 is connected to the support structure 22 by a plurality of tilting cables 59 .
- the tilting cables 59 are secured to the top of the major gin pole 48 , before it is tilted to its vertical position, at anchor points 57 which can be terminal anchor points or sheared anchor points. There can be a single anchor point or multiple anchor points. Then the free ends of the tilting cables 59 can then be attached, after the tilting frame is tilted, to the support structure 22 .
- These cables could alternately be connected to structure 22 prior to the tilting of major gin pole 48 ( FIG. 12 ).
- the tilting rigging/cables and the stabilizing rigging/cables work in tandem to safely tilt the tower up and keep it from falling over until the bottom connection is secured.
- the tilting frame can have more than a single major gin pole, such as at least a first major gin pole 48 and a second major gin pole 48 B.
- the gin pole configuration can be increased to a 3, 4, . . . , X stage gin pole tilting frame system to accommodate very high towers.
- each additional major gin pole 48 B is longer than the first major gin pole 48 .
- the tilting frame is tilted so that the longitudinal axis of the first major gin pole 48 is no longer substantially vertical and the longitudinal axis of the second major gin pole 48 B is vertical. As depicted in FIG.
- each first major gin pole 48 is attached by a support cable 52 to an anchor and by a tilting cable 59 to the second major gin pole 48 B.
- Stabilizing cables 60 support the first major gin pole 48 .
- the last major gin pole 48 B is raised vertically, the last major gin pole 48 B is connected to the support structure 22 by a plurality of tilting cables 59 in the same manner the tilting cables 59 are connected to major gin pole 48 .
- the support structure 22 is tilted to a vertical position in the same manner described below.
- the support structure 22 is tilted to a vertical position, where it is secured in place, such as through use of one or more locking pins extending through the support structure and the pivot base 34 , and/or can be secured with bolts or the like. It is also possible to weld it in place, but preferably that is not done, so that the tower can be tilted downwardly to a horizontal position for repair/or replacing the components.
- the gin poles can be tilted to any angle between 9 and 12 o'clock, i.e., vertical or beyond vertical by 90 degrees, during the tilting of the tower.
- the hinged bottom section of the tower can consist of a double pinned connection.
- a first pin is used as a rotation point during the tilting of the tower while a second pin is inserted after the tower is tilted to the vertical position and is used to fasten and secure the tower.
- the tower can be rotated on one offset pin and the hinged section can be fastened and secured using a conventional bolted connection after the tower is tilted to its vertical position.
- the tilting frame 46 is then released from the vertical wind tower and tilted so that the major gin pole 48 is substantially parallel to the ground. Then the mobile tilting frame, as shown in FIG. 15 , can be moved to another location for storage or for erecting another wind tower or repairing another wind tower.
- the two stage gin pole tilting frame assembly can be relocated without dismantling it. The relocation can be done using lifting equipment, straddle cranes, crawler carriers, heavy hauler, SPMT (self-propelled modular transporters) or by towing.
- the tilting frame can also be relocated under its own power, such as by utilizing a power pack and generator to propel steerable wheels.
- An advantage of using this technique for erecting a wind tower with a mobile tilting frame is that the wind tower can easily be tilted back to a substantially horizontal position so that the blades, turbine, and/or top portion of the support structure can be repaired or replaced. This is effected by moving the mobile tilting frame 46 proximate to the foundation 32 , connecting the minor gin pole 50 to the anchor 38 (which can be the foundation 53 ( FIG. 9 ) of another wind tower), and then tilting the tilting frame so that the major gin pole 48 is substantially vertical and the longitudinal axis of the minor gin pole 50 is at an angle relative to the longitudinal axis of the major gin pole 48 of from about 45 degrees to 90 degrees. Then at least one tilting cable can be secured to the major gin pole 48 and the tower support structure, and using the tilting frame 46 , the wind tower can be pivoted to an orientation substantially parallel to the ground.
- a system according to the present invention has significant advantages over conventional techniques for erecting a wind tower.
- the mobile tilting frame can be reused for multiple wind towers, helping to decrease cost. Large cranes are not required.
- the system can be used for erecting towers substantially taller than conventional wind towers.
- the invention has numerous other advantages over the prior art. Towers can be erected quickly due to the easy and rapid relocation process.
- the system can be scaled up and down to accommodate different tower heights.
- the system can be increased to multiple major gin poles in the tilting frame system to accommodate higher towers, specifically for erection of tall towers (over 150 meters).
- the method of the present invention allows for a lower overall project cost when compared to the prior art.
- the method can be reversed to easily tilt the tower down for major turbine repairs, rebuild, replacement and upgrades.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Sustainable Energy (AREA)
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Abstract
Tall wind towers can be erected using a mobile tilting frame comprising a major gin pole and a minor gin pole having a longitudinal axis. The tilting frame has a support cable connecting the major/minor gin poles. The minor gin pole can pivot relative to the major gin pole so that the longitudinal axis of the minor gin pole can be perpendicular to the longitudinal axis of the major gin pole.
Description
- The present Application is divisional of U.S. patent application Ser. No. 14/632,757, titled “Wind Tower Erection System,” filed Feb. 26, 2015, which claims the benefit of U.S. Provisional Patent Application No. 61/945,619, titled “Wind Tower Erection System,” filed Feb. 27, 2014, the contents of which are incorporated herein by reference in their entirety.
- Wind towers are effective in harnessing energy without consumption of fossil fuels. Generally the taller the wind tower the more efficient it is. Typically, wind towers are 60-80 meters in height.
- It is desirable for efficiency to have taller wind towers. However, as a wind tower gets taller, it is necessary that the base be of larger diameter. The diameter of a wind tower base is limited when the wind tower is manufactured off site by freeway underpass clearances. At larger diameter bases, it is not practical to transport the base portion of a wind tower by truck through a highway system.
- Another limit on the height of wind towers is the size of a crane necessary to erect the wind tower on site.
- Technology is being developed so that a wind tower of increased height can be constructed on site so that the transportation limit on wind tower size can be avoided. For example, see Keystone U.S. Patent Publication Nos. 2011/0179623 and 2013/0074564. However, there remains the challenge of erecting a tall wind tower, particularly when the height is 100 meters or higher. Moreover, with very tall wind towers it is difficult to repair or replace the turbine, or major components such as bearings, rotors, and blades and upper portion of the wind tower. It is expensive to bring in a crane to access the top of a tall wind tower, even if such a crane is available. Although minor repairs can be made by a worker climbing the wind tower, if it is necessary to completely replace the turbine or blades or upper portion of the tower, that is not practical for very high wind towers, and the investment in the wind tower can be lost. Current technologies to build or assemble higher towers on site and in position exists (cast in place concrete, precast concrete components, slip forming); however, these methods are too slow and expensive to achieve the desired economic viability to make wind energy economical.
- Accordingly, there is a need for a system for erecting and repairing tall wind towers on site.
- The present invention provides a system that satisfies this need. The system includes a method for erecting a wind tower having turbine and at least one blade. A preferred method can comprise the following steps, not necessarily in the order presented:
-
- p A. Building a foundation for the wind tower;
- B. Providing a pivot base for the wind tower; and
- C. Providing a wind tower support structure. Preferably the support structure is made on site, but it can be made off site. The support structure has a longitudinal axis substantially parallel to the ground, the support structure having a base section and a distal turbine section for supporting the turbine and blade.
- The method can include the following additional steps:
-
- D. Attaching the base section of the wind tower to a pivot base so that the support structure can be pivoted to a vertical position;
- E. Attaching the turbine and the blade to the distal section of the support structure;
- F. Moving a mobile tilting frame proximate to the pivot base and connecting the tilting frame to the pivot base, the tilting frame comprising a major gin pole having longitudinal axis and a minor gin pole having a longitudinal axis. The tilting frame has a first support cable connecting the major and minor gin poles. The minor gin pole optionally can pivot relative to the major gin pole;
- G. Connecting the minor gin pole to an anchor with a second support cable. The anchor can be an anchor formed for this purpose, or can be the foundation of another wind tower as part of a wind tower farm;
- H. Tilting the tilting frame so that the major gin pole is substantially vertical, wherein the longitudinal axis of the minor gin pole is at an angle relative to the longitudinal axis of the major gin pole;
- I. Securing at least one tilting cable to the major gin pole and the tower support structure and thereafter pivoting at least a portion of the wind tower to a substantially vertical orientation using the tilting frame;
- J. Locking the wind tower in its substantially vertical position;
- K. Disconnecting the tilting cable from the major gin pole and pivoting the tilting frame to a position so that the longitudinal axis of the tilting frame major gin pole is substantially parallel to the ground; and
- L. Moving the tilting frame away from the pivot base.
- The invention also includes the mobile tilting frame itself and using the tilting frame for lowering a wind tower for repair or replacement of parts.
- In one method of the invention, one can secure a pivot base to the support structure, the foundation, or a separate foundation. Furthermore, in step (E) the turbine and blade can be attached before or after tilting of the tilting frame of step (H). The base section can be attached pivotally with a pivot pin. The wind tower can be locked into place with either a pin or bolts. The method of the invention can be used to erect towers at least 150 meters tall. Furthermore, cables can be attached to the tower and support structure to stabilize these structures. Lastly, the method can be reversed to easily tilt the tower down for major turbine repairs, rebuild, replacement and upgrades.
- Furthermore, the method can comprise the use of more than one major gin pole for very high towers. This configuration comprises at least a first and second major gin poles each having a longitudinal axis; a minor gin pole having a longitudinal axis; a first support cable connecting the first major gin pole and the minor gin pole; and a second support cable connecting the first and second major gin poles. In one aspect, the second major gin pole is greater in length than the first major gin pole, and each additional major gin pole is longer than the preceding gin pole, i.e., major gin pole 4 is longer than major gin pole 3 which is longer than
major gin pole 2. In this configuration, the tilting of the tilting frame and erection of the wind tower is accomplished in the same manner as described above for a two-stage gin pole configuration. - These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, the features specified below, and the accompanying drawings where:
-
FIGS. 1-16 schematically demonstrate a preferred method of erecting a wind tower according to a system having features of the present invention, wherein the steps need not necessarily be performed in the order shown in the figures and not all of the steps need be performed. - A system according to the present invention is particularly useful for erecting tall wind towers and is described in detail for that purpose. However it can be used for other applications such as erecting antennas, oil drills and other tall, elongated, relatively narrow structures.
- As shown in
FIG. 16 , aconventional wind tower 20 comprises anelongated support structure 22 having abase section 24 and adistal turbine section 26 on which is mounted aturbine 28 withblades 30. A typical wind tower is about 60-80 meters in height, and the present invention can be used with conventional wind towers. However, the invention is particularly useful for tall wind towers, such as those 150 meters and taller, particularly wind towers 180 meters and taller. Thebase section 24 for such tall towers is typically from about 5 meters to 10 meters in diameter or larger. - With reference to
FIG. 1 , afoundation 32 for thewind tower 20 is formed in a. conventional manner. Typically, at least a portion of thefoundation 32 is below ground level. Thereafter, as shown inFIG. 2 , apivot base 34 is secured to thefoundation 32. Optionally, thepivot base 34 can be built into thesupport structure 22. Thepivot base 34 preferably is provided with multiple holes, schematically represented by asingle hole 36, for receiving a pivot pin 37 (FIG. 5 ) and one or more locking pins as described below. - With reference to
FIG. 3 ananchor 38 is provided. Optionally the base or foundation of another wind tower can be used as an anchor. - With reference to
FIG. 4 , thesupport structure 22 is initially provided oriented parallel, or close to parallel, to the ground and supported bysupport brackets 39 or the like. Thesupport structure 22 can be fabricated on site, can be fabricated off site and transported to the erection site, or can be fabricated in segments fabricated off site and transported to the erection site and assembled on site. Preferably thesupport structure 22 is formed on site with amachine 42 such as using the technology described in the aforementioned Keystone published patent applications. Theelongated support structure 22 has a longitudinal axis labelled as reference number 44 inFIG. 4 . - As shown in
FIG. 5 , thebase section 24 of thesupport structure 22 is secured to thepivot base 34 using a pivot pin (not shown), so that thesupport structure 22 can be pivoted to a vertical position. - As shown in
FIG. 6 , theturbine 28 andblades 30 are then secured to thedistal section 26 of thesupport structure 22. This step need not be performed in this sequence, in that the turbine and blade can be installed prior to attachment of the support structure to the pivot base or after some of the following steps. Preferably theturbine 28 andblades 30 are secured to thesupport structure 22 while thesupport structure 22 is easily accessible by being substantially parallel to the ground. However they can be secured after thesupport structure 22 is tilted to its vertical position or during the tilting process. - As shown in
FIG. 7 , amobile tilting frame 46 is moved proximate to thepivot base 34, theframe 46 typically being supported on and moved into place ondollies 47 or straddle cranes. Themobile tilting frame 46 can have its own built-in wheels rather than rely onseparate dollies 47 for movement. - The
mobile tilting frame 46 comprises amajor gin pole 48 and aminor gin pole 50 connected by at least one, and preferably a plurality offirst support cables 52 where one end of the support cables is attached to afirst end 54 of theminor gin pole 50 and the other end of thesupport cables 52 is attached to themajor gin pole 48 at a location between its ends. Theminor gin pole 50 is used to tilt up and stabilize themajor gin pole 48, and themajor gin pole 48 is used to tilt up and stabilize the tower (FIG. 8 ). Asecond end 56 of theminor gin pole 50 is pivotally secured to the end of themajor gin pole 48 that is proximate to thepivot base 34. Generally, the longitudinal axis of theminor gin pole 50 is perpendicular to the longitudinal axis of themajor gin pole 48, although that angle 58 (seeFIG. 8 ) can be from about 45 degrees to about 120 degrees. The tiltingframe 46 is secured to thepivot base 34 so that it can be pivoted so that themajor gin pole 48 can be substantially vertical. - The term “mobile” means a structure that is capable of being moved readily and is not a portion of the wind tower structure or the foundation structure.
- The length of the
major gin pole 48 is typically about 10% to about 50%, and preferably about 15% to about 25% of the length of thesupport structure 22. The length of theminor gin pole 50 is typically about 10% to about 50% of the length of themajor gin pole 48. - With reference to
FIG. 9 , theminor gin pole 50 is secured to theanchor 38 with asecond support cable 52, and typically multiple cables. Wherever a cable is referred to herein, generally multiple cables are used, both to provide increased strength, and also to prevent undesired tilting of the structures to which the cables are attached. - As shown in
FIG. 10 , themobile tilting frame 46 is then tilted so that themajor gin pole 48 is substantially vertical, or can even be tilted beyond the vertical position. Tilting is effected with a tilting power system typically comprising a winch and a motor for driving the winch (not shown). The tilting power system can comprise hydraulic jacks, or a winch and motor in combination with hydraulic jacks. The tilting power system can be part of themobile tilting frame 46, or it can be a separate structure such as being placed by theanchor 38. Stabilizingcables 60 are used to secure thetilting frame 46. - As shown in
FIG. 11 , themajor gin pole 48 is connected to thesupport structure 22 by a plurality of tiltingcables 59. Generally the tiltingcables 59 are secured to the top of themajor gin pole 48, before it is tilted to its vertical position, at anchor points 57 which can be terminal anchor points or sheared anchor points. There can be a single anchor point or multiple anchor points. Then the free ends of the tiltingcables 59 can then be attached, after the tilting frame is tilted, to thesupport structure 22. These cables could alternately be connected to structure 22 prior to the tilting of major gin pole 48 (FIG. 12 ). - The tilting rigging/cables and the stabilizing rigging/cables work in tandem to safely tilt the tower up and keep it from falling over until the bottom connection is secured.
- As demonstrated in
FIGS. 11A-C , the tilting frame can have more than a single major gin pole, such as at least a firstmajor gin pole 48 and a secondmajor gin pole 48B. Furthermore, the gin pole configuration can be increased to a 3, 4, . . . , X stage gin pole tilting frame system to accommodate very high towers. Typically, each additionalmajor gin pole 48B is longer than the firstmajor gin pole 48. To erect the secondmajor gin pole 48B, the tilting frame is tilted so that the longitudinal axis of the firstmajor gin pole 48 is no longer substantially vertical and the longitudinal axis of the secondmajor gin pole 48B is vertical. As depicted inFIG. 11B , each firstmajor gin pole 48 is attached by asupport cable 52 to an anchor and by a tiltingcable 59 to the secondmajor gin pole 48B. Stabilizingcables 60 support the firstmajor gin pole 48. As demonstrated inFIG. 11C , after the lastmajor gin pole 48B is raised vertically, the lastmajor gin pole 48B is connected to thesupport structure 22 by a plurality of tiltingcables 59 in the same manner the tiltingcables 59 are connected tomajor gin pole 48. In the multi-major gin pole configuration, thesupport structure 22 is tilted to a vertical position in the same manner described below. - As demonstrated by
FIGS. 12 and 13 , again using a tilting power system (not shown), thesupport structure 22 is tilted to a vertical position, where it is secured in place, such as through use of one or more locking pins extending through the support structure and thepivot base 34, and/or can be secured with bolts or the like. It is also possible to weld it in place, but preferably that is not done, so that the tower can be tilted downwardly to a horizontal position for repair/or replacing the components. The gin poles can be tilted to any angle between 9 and 12 o'clock, i.e., vertical or beyond vertical by 90 degrees, during the tilting of the tower. - The hinged bottom section of the tower can consist of a double pinned connection. A first pin is used as a rotation point during the tilting of the tower while a second pin is inserted after the tower is tilted to the vertical position and is used to fasten and secure the tower. Alternatively, the tower can be rotated on one offset pin and the hinged section can be fastened and secured using a conventional bolted connection after the tower is tilted to its vertical position.
- As shown in
FIG. 14 , the tiltingframe 46 is then released from the vertical wind tower and tilted so that themajor gin pole 48 is substantially parallel to the ground. Then the mobile tilting frame, as shown inFIG. 15 , can be moved to another location for storage or for erecting another wind tower or repairing another wind tower. The two stage gin pole tilting frame assembly can be relocated without dismantling it. The relocation can be done using lifting equipment, straddle cranes, crawler carriers, heavy hauler, SPMT (self-propelled modular transporters) or by towing. The tilting frame can also be relocated under its own power, such as by utilizing a power pack and generator to propel steerable wheels. - An advantage of using this technique for erecting a wind tower with a mobile tilting frame is that the wind tower can easily be tilted back to a substantially horizontal position so that the blades, turbine, and/or top portion of the support structure can be repaired or replaced. This is effected by moving the
mobile tilting frame 46 proximate to thefoundation 32, connecting theminor gin pole 50 to the anchor 38 (which can be the foundation 53 (FIG. 9 ) of another wind tower), and then tilting the tilting frame so that themajor gin pole 48 is substantially vertical and the longitudinal axis of theminor gin pole 50 is at an angle relative to the longitudinal axis of themajor gin pole 48 of from about 45 degrees to 90 degrees. Then at least one tilting cable can be secured to themajor gin pole 48 and the tower support structure, and using thetilting frame 46, the wind tower can be pivoted to an orientation substantially parallel to the ground. - A system according to the present invention has significant advantages over conventional techniques for erecting a wind tower. The mobile tilting frame can be reused for multiple wind towers, helping to decrease cost. Large cranes are not required. Also the system can be used for erecting towers substantially taller than conventional wind towers.
- The invention has numerous other advantages over the prior art. Towers can be erected quickly due to the easy and rapid relocation process. The system can be scaled up and down to accommodate different tower heights. The system can be increased to multiple major gin poles in the tilting frame system to accommodate higher towers, specifically for erection of tall towers (over 150 meters). Furthermore, the method of the present invention allows for a lower overall project cost when compared to the prior art. Lastly, the method can be reversed to easily tilt the tower down for major turbine repairs, rebuild, replacement and upgrades.
- Although the present invention has been described with a degree of particularity, it is understood that the present disclosure has been made by way of example and that other versions are possible. As various changes could be made in the above description without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be illustrative and not used in a limiting sense. The spirit and scope of the appended claims should not be limited to the description of the preferred versions contained in this disclosure.
- All features disclosed in the specification, including the claims, abstracts, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
- Any element in a claim that does not explicitly state “means” for performing a specified function or “step” for performing a specified function should not be interpreted as a “means” or “step” clause as specified in 35 U.S.C. §112.
Claims (20)
1. A tilting frame suitable for erecting a wind tower comprising a major gin pole having a longitudinal axis and a minor gin pole having a longitudinal axis, the tilting frame having a first support cable connecting the major and minor gin poles and wherein the longitudinal axis of the minor gin pole can pivot relative to the longitudinal axis of the major gin pole at an angle of from about 45 to about 120 degrees.
2. The tilting frame of claim 1 , further comprising at least two major gin poles.
3. The tilting frame of claim 1 , wherein the major gin pole is longer than the minor gin pole.
4. The tilting frame of claim 1 , wherein the minor gin pole is 10% to 50% of the length of the major gin pole.
5. The titling frame of claim 1 , wherein the minor gin pole can pivot relative to the major gin pole so that the longitudinal axis of the minor gin pole is at an angle relative to the longitudinal axis of the major gin pole of from about 45 to about 120 degrees.
6. The tilting frame of claim 1 , further comprising a second support cable, for securing the tilting frame to an anchor.
7. The tilting frame of claim 1 , wherein the tilting frame is mobile.
8. The tiling frame of claim 1 , wherein the minor gin pole can pivot relative to the major gin pole so that the longitudinal axis of the minor gin pole can be perpendicular to the longitudinal axis of the major gin pole.
9. The tilting frame of claim 1 , wherein the tilting frame further comprises a power system to tilt the major gin pole and minor gin pole.
10. A combination comprising:
(a) the tilting frame of claim 1 ; and
(b) a wind tower comprising an elongated support structure, a turbine, and at least one blade on a surface, the support structure being attached to a foundation having a pivot base.
11. The combination of claim 10 , wherein the tilting frame is positioned proximate to the pivot base and connected to the pivot base.
12. The combination claim 10 , wherein the pivot base is built into the foundation.
13. The combination of claim 10 , wherein the pivot base is secured to a second foundation separate from the wind tower foundation.
14. The combination of claim 10 , comprising a power system for pivoting at least a. portion of the wind tower into position.
15. The combination of claim 10 , wherein the wind tower is locked into a substantially vertical position relative to the ground.
16. The combination of claim 10 , wherein the wind tower is locked into a substantially vertical position.
17. A mobile tilting frame for use in connection with a wind tower comprising:
(a) wheels to move the frame into a position proximate to the wind tower;
(b) a major gin pole having a longitudinal axis and a minor gin pole having a longitudinal axis, wherein the longitudinal axis of the minor gin pole is at an angle relative to the longitudinal axis of the major gin pole of from about 45 to about 120 degrees;
(c) at least one support cable connecting the major gin pole and the minor gin pole; and
(d) at least one tilting cable to connect or disconnect the tilting frame to the wind tower.
18. A method of lowering an erected wind tower, the wind tower comprising an elongated support structure, a turbine, and at least one blade on a surface, the support structure being attached to a foundation, the method comprising the steps of:
(a) moving a mobile tilting frame proximate to the foundation, the tilting frame comprising a major gin pole having a longitudinal axis and a minor gin pole having a longitudinal axis, the tilting frame having a first support cable connecting the major and minor gin poles;
(b) connecting the minor gin pole to an anchor with a second support cable;
(c) tilting the tilting frame so that the major gin pole is substantially vertical and wherein the longitudinal axis of the minor gin pole is at an angle relative to the longitudinal axis of the major gin pole, and
(d) securing at least one tilting cable to the major gin pole and the tower support structure and thereafter pivoting at least a portion of the wind tower to a substantially horizontal orientation using the tilting frame.
19. The method of claim 18 comprising reusing the tilting frame to lower another erected wind tower.
20. The method of claim 18 , wherein in step (a) the longitudinal axis of the minor gin pole is at an angle relative to the longitudinal axis of the major gin pole of from about 45 to about 120 degrees.
Priority Applications (1)
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US15/194,236 US20160305147A1 (en) | 2014-02-27 | 2016-06-27 | Wind tower erection system |
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US201461945619P | 2014-02-27 | 2014-02-27 | |
US14/632,757 US9388599B2 (en) | 2014-02-27 | 2015-02-26 | Wind tower erection system |
US15/194,236 US20160305147A1 (en) | 2014-02-27 | 2016-06-27 | Wind tower erection system |
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Also Published As
Publication number | Publication date |
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US20180187446A1 (en) | 2018-07-05 |
US10392827B2 (en) | 2019-08-27 |
US20150240512A1 (en) | 2015-08-27 |
US9388599B2 (en) | 2016-07-12 |
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