WO2025229014A1

WO2025229014A1 - A tower crane provided with an object manipulator system

Info

Publication number: WO2025229014A1
Application number: PCT/EP2025/061751
Authority: WO
Inventors: Wing Sum LEE
Original assignee: Itrec BV
Current assignee: Huisman Equipment BV
Priority date: 2024-04-29
Filing date: 2025-04-29
Publication date: 2025-11-06
Anticipated expiration: 2026-10-29
Also published as: NL2037577B1

Abstract

A tower crane (1) comprises a crane base (10), tower segments (20) which are configured to be stacked onto one another in order to erect a crane tower (30), and a slewable jib unit (50). The tower crane comprises an object manipulator system is configured to manipulate an object suspended from the load connector (71, 80) and comprises a manipulator arm device (100) with a manipulator trolley (110) engaging the first trolley track (22), a manipulator trolley drive (120), and an arm (130) having an inner end and an outer end. The inner end of the arm is connected to the manipulator trolley. The arm or the at least one mobile arm segment (146) is pivotal about a Z-axis hinge. The system further comprises a tagline device (150) wherein the tagline is configured to be extended between the tagline engagement point (160, 165) on the mobile arm segment of the arm on the one hand and the load connector or the object supported by the load connector on the other hand.

Description

A TOWER CRANE PROVIDED WITH AN OBJECT MANIPULATOR SYSTEM

The present invention relates to the field of tower cranes. For example, the inventive tower crane is envisaged for the use in the field of wind turbines, e.g. when assembling a wind turbine, installing or de-installing a wind turbine rotor blade, etc.

For example, in WO2023118352 a tower crane is disclosed which is configured to be arranged on a support, e.g. a support at or near a foot of a wind turbine mast. The tower crane comprises a crane base configured to be placed on the support, tower segments which are configured to be stacked onto one another in order to erect a crane tower which is composed of the tower segments on the crane base, and a crane tower lifting unit configured to perform lifting actions in the process of stacking of the tower segments. The slewable jib unit comprises: a crane housing to be mounted on top of the crane tower, wherein the crane housing is provided with a slew bearing; a lifting jib having an inner jib end and an outer jib end, wherein the inner jib end is mounted to the crane housing.

The tower crane is configured to, with the slewable jib unit connected to a tower segment, erect the crane tower by stacking the tower segments onto one another to lengthen the crane tower under the slewable jib unit.

The known tower crane further comprises a hoisting system with a hoisting winch and an associated hoisting cable extending to a load connector, which hoisting system is configured to support an object from the lifting jib. Multiple of the tower segments are each provided with a first trolley track member which extends along the tower segment allowing to form a continuous first trolley track along a length of the crane tower.

In WO2023118352 it is disclosed that, in embodiments, the crane is further provided with a tagline system, e.g. with a track formed by one or more tagline rails or guide wires extending along the height of the crane for tagline trolleys. One or more taglines are then provided that can connect, for example, to a blade lifting tool that is used in hoisting a wind turbine blade. For example, one or more taglines rails are present on the crane tower segments.

Generally, as known in the art, the tagline system serves to stabilize and/or orient the object when handled by the tower crane. For example, in case the object is a wind turbine blade, it is desired to avoid and/or reduce sway motion of the rotor blade (e.g. induced by wind and/or motion of jib unit, e.g. by slew motion of the jib unit). For example, it is desired to orient the rotor blade quite accurately relative to the mounting structure in the course of mounting the rotor blade to the rotor hub. For example, the alignment needs to be such that a multitude of bolts extending from a root end of the blade can be introduced into holes in a mounting structure on the rotor hub of the wind turbine.

The present invention aims to provide a more effective and versatile system for stabilizing and/or orienting the object which is handled by the crane, e.g. for use in the field of wind turbines.

The invention provides a tower crane according to claim 1 .

One or more of the tower segments, e.g. all or most of the tower segments, are each provided with a first trolley track member which extends along the tower segment allowing to form a first trolley track along the crane tower. For example, a trolley track member is a rail integrated with the structure of the tower segment, e.g. at a corner of the tower segment, e.g. two parallel rails on a tower segment. In practical embodiments, the first trolley track may extend along most or all of the height of the crane tower. In yet another embodiment, the first trolley track only extends in an upper region of the crane tower. In practical embodiments, the first trolley track extends to the top of the crane tower.

The tower segments which make up the crane tower may be more or less the same, but in embodiments tower segments may differ from one another, e.g. in length, cross-section, and/or design. Preferably, tower segments are fixed length tower segments, yet in embodiments one or more tower segments are each telescopically extensible by a suitable lifting unit.

The tower segments may be of square or rectangular cross-section, but other cross-sections are also possible, e.g. circular. For example, rails are present at corners of the cross-section to form a trolley track at one or opposed sides of the crane tower.

The tower segments may be latticed tower segments with vertical main chords and bracing members connecting the vertical main chords, e.g. four main chords to form a square or rectangular cross-section. In another embodiment, some or all of the tower segments are box-like tower segments with vertical side walls. The hoisting winch may be located in the jib unit. In another embodiment, preferably in view of weight, the hoisting winch is to be mounted on the crane base or on the support, with the hoisting cable extending along the crane tower (inside or outside) to the jib unit. The latter approach reduces the weight at the top of the tower, e.g. in view of the option that the hoisting cable is reeved in a multi-fall arrangement, which requires a significant length of the hoisting cable.

The tower crane further comprises an object manipulator system configured to manipulate an object suspended from the load connector, the object manipulator system comprising:

- a manipulator arm device, comprising:

- a manipulator trolley configured to engage the first trolley track and being movable along the track in vertical direction,

- a manipulator trolley drive configured to move the manipulator trolley along the first trolley track,

- an arm having an inner end and an outer end, wherein the inner end of the arm is connected to the manipulator trolley, and wherein the arm comprises at least one mobile arm segment having a tagline engagement point, wherein the arm or the at least one mobile arm segment is pivotal about a Z-axis hinge.

The object manipulator system further comprises a tagline device comprising a tagline winch and an associated tagline, wherein the tagline is configured to be extended between the tagline engagement point on the mobile arm segment of the arm on the one hand and the load connector or the object supported by the load connector on the other hand.

Instead of having a tagline direction generally towards the crane tower, as suggested in the prior art WO2023118352, due to the provision of the arm the tagline engagement point(s) can be situated and held in an advantageous spatial position relative to the crane tower. Thereby the tagline(s) can extend in a favourable direction to the load connector or object supported by the load connector, even when the lifting jib is arranged in various slew positions and/or is slewed during a lifting job. This approach allows for a favourable direction of the tagline(s) and thereby an enhanced effectiveness of the tagline(s) in view of stabilizing and/or orienting the object, e.g. a wind turbine rotor blade or other wind turbine component.

Due to the arm or the at least one mobile arm segment being pivotal about a Z-axis hinge, the orientation of the arm can be set and/or made to follow the slew position or slew motion of the lifting jib. So, for example, when the lifting jib is to be set in a certain slew position for a hoisting job, the arm or the at least one mobile arm segment thereof can be pivoted into an appropriate corresponding angular direction due to the presence of the Z-axis hinge. Or when, for example, the lifting jib is made to perform a slew motion during a hoisting job, the arm (e.g. by an associated actuator) can be made to generally follow the slew motion of the lifting jib, so that the tagline(s) remain(s) in a favourable direction.

In practical embodiments, the manipulator trolley drive will be operated, e.g. automatically as a slave to the operation of the hoisting system, so that the arm follows the vertical motion of the load connector and/or the object supported by the load connector during lifting and/or lowering. This does not mean that the vertical motion of the manipulator trolley and/or the actual height thereof should be the same as the vertical motion and/or the height of the load connector and/or the object supported by the load connector during a hoisting job. For example, the arm can be maintained during a hoisting job at a level which is lower or higher than the load connector and/or the object supported by the load connector, or the arm can be lower at one stage of the job and higher at another stage of the job, etc. It will be appreciated that the relative height of the arm to the load connector or object may impact the direction and thereby the effect of the tagline(s) extending between them.

The arm can be designed and/or operated so that the spatial position(s) of the tagline engagement point(s) relative to the crane tower, when seen from above, is/are effectively stationary during handling of the object by means of the tower crane, apart from the up or down motion of the load connector/object during lifting and lowering by means of the hoisting system.

For example, the arm is hinged to the manipulator trolley at its inner end via a Z-axis hinge allowing the entire arm to be pivoted in a horizontal plane. Preferably, an actuator is arranged between the manipulator trolley and the arm to cause said pivoting of the arm, e.g. into a selected position appropriate for a certain slew position of the lifting jib, or to perform a pivoting motion, e.g. to follow a slew motion of the lifting jib. For example, the actuator is a hydraulic cylinder.

In an embodiment, the arm is configured to be set into a selected one of a variety of configurations by adjusting the relative position of the at least mobile arm segment of the arm, e.g. of multiple, e.g. all, mobile arm segments of the arm, so that the arm has a desired shape. This selected configuration of the arm may then be maintained during a lifting job. As explained herein, preferably, the arm is an articulated arm allowing for variety of configurations of the arm. For example, each hinge of the arm has an associated locking device configured to lock the hinge once the desired angle has been set.

In an advanced embodiment, a controllable arm actuator assembly is provided which comprises one or more arm actuators associated with the arm and a controller, e.g. one arm actuator between the manipulator trolley and the arm, e.g. the inner arm segment, and a further arm actuator for each further mobile arm segment. This allows for the actuators to be operated under control of the controller so that the configuration of the arm can be varied, e.g. even when the arm is at an elevated height, e.g. even during a lifting job. For example, the configuration of the arm can be varied when the arm is at or near the top end of the crane tower.

In an embodiment, the controllable arm actuator assembly is configured and operated to allow for moving the engagement point(s) to create a controlled spatial motion of the engagement point(s), e.g. during a lifting job.

The arm actuator assembly may be configured for controlled motion of the at least one mobile arm segment of the arm so as to provide for a plurality of stationary spatial positions of the tagline engagement point relative to the crane tower and/or for a controlled spatial motion of the tagline engagement point relative to the crane tower.

For example, the arm is configured to be operated so that the engagement point(s) is/are in one spatial position relative to the crane tower when the manipulator trolley is in a lower height relative to the tower and so that the engagement point(s) is/are in another spatial position relative to the crane tower when the manipulator trolley is in at a greater height relative to the crane tower. For example, the one spatial position of the engagement point(s) when the manipulator trolley is in a lower height relative to the tower corresponds to a pickup phase of a rotor blade by means of a blade lifting tool, and the other spatial position of the engagement point(s) when the manipulator trolley is in at the greater height relative to the tower corresponds to a mounting phase wherein the rotor blade is mounted to a mounting structure of a rotor hub of a wind turbine.

In embodiments, the tower crane is positioned and erected close to and along the mast of the wind turbine, e.g. in view of the installation of a wind turbine blade or other component.

Due to the dimensions of the wind turbine blade, in practice, the lifting point of the wind turbine blade will be located at a substantial horizontal distance away from the crane tower. Preferably, the arm is so long that the tagline engagement point(s) thereon can be arranged in relative proximity to the lifting point, e.g. to the blade lifting tool, e.g. to one lateral side of the blade lifting tool.

For example, the arm has a length of at least 10 meters, e.g. of at least 25 meters in view of the present and proposed dimensions of wind turbine rotor blades.

In embodiments, the tagline device comprises two tagline winches and associated taglines, wherein two distinct tagline engagement points are provided on the arm, of which at least one tagline engagement point is provided on the mobile arm segment of the arm. For example, two distinct tagline engagement points are provided on one mobile arm segment of the arm.

In embodiments, the arm is configured to provide for motion of the at least one mobile arm segment solely in a horizontal plane. This allows for a robust and practical design of the arm.

In embodiments, the arm is connected at its inner end to the manipulator trolley via a Z-axis hinge, so a hinge having a vertical hinge axis.

In embodiments, the arm is an articulated arm having multiple interconnected mobile arm segments including an inner arm segment which is connected to the manipulator trolley and one or more further arm segments, wherein the inner arm segment is connected to the manipulator trolley via an inner hinge, and wherein arm segments of the arm are connected to one another via an intermediate hinge.

In a practical embodiment of the articulated arm, the inner hinge and the one or more intermediate hinges are Z-axis hinges to provide swing motion of the arm segments in a horizontal plane.

In a practical embodiment of the articulated arm, the arm comprises at least two further arm segments. In a practical embodiment the arm has three further arm segments, so four arm segments in total.

In a practical embodiment, the articulated arm is configured to assume a straight configuration and one or more folded configurations when seen from above, e.g. the arm segments folding about the Z-axis hinges. In a practical embodiment of the articulated arm, the first trolley track is on one side of the crane tower, and the arm is configured to assume a folded configuration wherein an outer arm segment extends at the opposite side of the crane tower. As will be explained herein, this allows for effective use of the tower crane when handling wind turbine components like the nacelle, rotor hub, or a mast section of the wind turbine.

In a practical embodiment, the articulated arm, e.g. in the straight configuration, is pivotal about a Z-axis hinge relative to the manipulator trolley.

In a practical embodiment, the arm segments are fixed length arm segments. In another embodiment, one or more of the arm segments are telescopic. The latter is, however, less desirable in view of the structural complexity of the articulated arm.

As discussed, the articulated arm can be provided with one or more actuators to allow for pivoting of each arm segment relative to the adjoining arm segment, the actuators being connected to the controller.

As discussed, each hinge of the articulated arm can be provided with a locking device configured to lock the hinge, e.g. a mechanical locking device wherein a locking pin is to be placed into a selected set of holes through two overlapping members of the locking device. The locking device can be manual or can be motorized for remote operation.

In a practical embodiment, the tagline engagement point is arranged on an outer arm segment of the arm. For example, multiple tagline engagement points are arranged on the outer arm segment. It will be appreciated that multiple engagement points can be arranged over the length of the arm, e.g. on multiple arm segments.

In a practical embodiment, each tagline winch is mounted on the arm or on the manipulator trolley. Preferably, the one or more tagline winches are mounted on the arm, so as to avoid complex reeving of the tagline(s). For example, one or more tagline winches are mounted on an outer arm segment.

In a practical embodiment, a tagline sheave is mounted at the tagline engagement point on the arm allowing the tagline to pass from the tagline winch over the tagline sheave to the load connector or to the object supported by the load connector. For example, a mobile arm segment is provided with two tagline winches and two taglines, wherein for each tagline a respective tagline sheave is provided, the tagline sheaves being spaced apart from one another so as to provide two spaced apart tagline engagement points. Preferably, in use, the taglines extend to distinct points on the load connector, or the object supported by the load connector.

In practical embodiments, a tagline extends in a single-fall arrangement between the tagline engagement point on the arm and the load connector or the object supported by the load connector. In another embodiment, a tagline extends in a double-fall arrangement.

In practical embodiments, a tagline winch is configured to control tagline tension and/or tagline length, e.g. an electronically controlled winch.

In an embodiment, a tagline engagement point is displaceable relative to the arm, e.g. along the length of the arm, e.g. relative to the associated arm segment. For example, a tagline engagement point is formed by a linear movable connector for a tagline sheave, which is displaceable, e.g. by an associated drive, along the length of a mobile arm segment.

In an embodiment, the tower crane comprises a crane tower lifting unit configured to perform lifting actions in the process of stacking of the tower segments.

In an embodiment, e.g. as discussed in WO2023118352, the tower crane further comprises one or more stabiliser devices each configured to horizontally connect the crane tower to an external tall structure, e.g. a wind turbine mast. For example, multiple tower segments are each provided with a second trolley track member on a side of the tower segment opposite the first trolley track member, which second trolley track member extends along the tower segment allowing to form a continuous second trolley track along a length of the crane tower, wherein the one or more stabiliser devices each comprise a stabiliser trolley configured to be mounted to the second trolley track, wherein the tower crane is provided with one or more stabiliser trolley drive devices configured to move the stabiliser device along the second track. For example, the trolley drive device comprises a winch and winch driven cable allowing to raise and lower the stabiliser trolley(s) along the second trolley track.

In an embodiment, the load connector is a blade lifting tool configured to lift a wind turbine rotor blade. For example, the blade lifting tool is configured to connect the at least one tagline to the blade lifting tool, e.g. to two taglines, preferably connected to the blade lifting tool at spaced apart connection points. In an embodiment, the controllable arm actuator assembly is configured to cause a controlled displacement of the at least one tagline engagement point during a mounting motion of the rotor blade towards a blade mounting structure.

The present invention also relates to a method for lifting or lowering an object using the tower crane as discussed herein, wherein the tagline extends between the tagline engagement point on the mobile arm segment of the arm on the one hand and the load connector or the object supported by the load connector on the other hand.

In an embodiment, the arm actuator assembly is operated to establish controlled motion of the at least one mobile arm segment of the arm so as to provide for a plurality of stationary spatial positions of the tagline engagement point relative to the crane tower and/or for a controlled spatial motion of the tagline engagement point relative to the crane tower, e.g. wherein the object is a wind turbine component.

For example, the load connector is a blade lifting tool configured and operated to lift a wind turbine rotor blade, wherein tagline extends between the tagline engagement point on the mobile arm segment of the arm on the one hand and the blade lifting tool.

For example, the method comprises mounting the rotor blade with a root end thereof to a blade mounting structure of a wind turbine. For example, the controllable arm actuator assembly is configured to cause a controlled displacement of the at least one tagline engagement point during a mounting motion of the root end of the rotor blade towards a blade mounting structure.

The tower crane is highly effective when handling a rotor blade of a wind turbine as the tagline(s) extending between the arm and the blade lifting tool can be oriented in a favorable direction. In embodiments, the arm can be arranged to extend generally alongside, yet laterally spaced from, the rotor blade with the one or more, e.g. two, taglines extending between the arm and the blade lifting tool and/or the rotor blade. This provides lateral stabilization of the rotor blade, e.g. to reduce or eliminate the effect of wind on the rotor blade during hoisting/lowering and/or during mounting/dismounting the rotor blade to/from the mounting structure on the rotor hub.

It will be appreciated, as further explained below with reference to the drawings, that the tower crane can be effectively used for handling other objects, in particular other wind turbine components. For example, the object can be a wind turbine nacelle or part of a wind turbine nacelle, e.g. a rotor hub, a gearbox, a generator component.

In embodiments, the tower crane can be used for the assembly (or even disassembly) of the mast of a wind turbine, wherein mast sections are mounted on top of one another. The mast section which is handled by the tower crane can be stabilized and/or oriented by means of the tagline(s) extending between the mast section and the arm of the manipulator system.

The tower crane can comprise one or more of the details discussed in WO2023118352 or in non-published application NL2037518, which are incorporated herein by reference.

In a practical embodiment, the lifting jib is pivotally mounted to the crane housing around a lifting jib pivot axis. A first luffing assembly is configured to pivot the lifting jib between a horizontal orientation and an upward orientation, e.g. a vertical upward orientation.

In a practical embodiment, the jib unit further comprises a counter jib having an inner end and an outer end, wherein the inner end of the counter jib is pivotally mounted to the crane housing around a counter jib pivot axis, and wherein the counter jib, e.g. at the outer end thereof, is provided with a counter ballast. A second luffing assembly is configured to pivot the counter jib between a horizontal orientation and an upward orientation, e.g. a vertical upward orientation.

In an embodiment, the first and second luffing assemblies are independently operable from each other.

In an embodiment, a luffing assembly comprises a luffing winch and an associated luffing cable. In another embodiment, or in combination, the luffing assembly (further) comprises a luffing cylinder(s).

In an embodiment, the lifting jib and the counter jib are configured to both be in the upward orientation during the process of stacking of the tower segments.

In an embodiment, the tower crane is provided with a crane tower lifting unit which is configured and operated to perform a lifting action in the process of erecting the tower crane, preferably with the slewable jib unit connected to an upper tower segment. This allows to erect the crane tower by stacking the tower segments onto one another from below to lengthen the crane tower under the slewable jib unit. Herein the method for erecting the tower crane comprises a crane tower assembly phase, in which the crane tower is erected by stacking one or more tower segments one-by-one from below under the slewable lifting jib unit to form the crane tower, in which crane tower assembly phase the crane tower lifting unit lifts the already assembled part of the crane tower. Preferably, during the lifting of the assembled part of the crane, the lifting jib and, possibly, the counter jib are in the upward orientation, e.g. both in vertical or near vertical orientation.

In practical embodiments, the lifting unit is arranged on the support or on the crane base and is configured to stepwise lift the crane tower from below to allow for a further tower segment to be arranged and connected under the already assembled portion of the crane tower. In another embodiment, yet less preferred, the lifting unit is arranged at the top of the crane tower, so that the tower segments are stacked on top of one another from above. A drawback of the latter is the increased weight at the top of the crane tower formed by the lifting unit and/or the structural complexity, e.g. in view of the desire to have the trolley track(s), at least for the manipulator system, extend to the top of the crane tower.

In the process of erecting the crane tower, one or more stabiliser devices are preferably mounted to the crane tower.

In embodiments, the crane tower lifting unit comprises a vertical lifting column and a lifting tool which is movable along the vertical lifting column, wherein - during the crane tower assembly phase - the lifting tool engages a tower segment, e.g. at the lower end thereof, and lifts an already assembled part of the crane tower including the tower segment to such a height that a further tower segment can be placed under the crane tower, and wherein the crane tower is subsequently connected to the further tower segment, e.g. the already assembled part of the crane tower being lowered and connected to the further tower segment.

The tower crane can be embodied for use on land, e.g. for handling of components of an onshore wind turbine. Herein, for example, an auxiliary crane, e.g. a road-driven mobile crane, can be used for handling the arm of the manipulator system.

For example, the arm is modular, e.g. arm segments being handled as modules of the arm which are to be joined at the hinge(s). For example, the arm is assembled on the ground or onboard a vessel and then lifted to be mounted to the manipulator trolley. The tower crane can be embodied for use offshore, e.g. configured to be erected along an offshore wind turbine, the wind turbine comprising a wind turbine mast mounted on an offshore foundation, e.g. mounted on a monopile foundation or on a floating foundation.

For example, the crane base may be configured to be mounted on or near a lower end of the wind turbine mast, e.g. on support brackets provided on a lower end of the wind turbine mast or on the offshore foundation. For example, the crane base is annular and encircles the wind turbine mast or a part of the foundation. For example, the crane tower lifting unit is mounted on the crane base. For example, the slewable jib unit is placed in an installation position at or in proximity of the crane tower lifting unit. For example, the tower segments are arranged in their vertical orientation, e.g. side by side, on the crane base, e.g. in an array extending over an arc-segment of the annular crane base, e.g. the crane base comprises a tower segment transfer device, e.g. a tower segment transfer trolley which is configured and operated to move the tower segments in succession from their respective storage position to an installation position where the tower segment is assembled with the crane tower.

In embodiments, the blade lifting tool comprises a frame which is suspended from the crane, e.g. from a crane hook, wherein the blade lifting tool comprises a blade holding assembly which is mobile mounted relative to the frame, e.g. along a length of the rotor blade supported by the blade holding assembly, and wherein the blade lifting tool comprises a controllable motion actuator device between frame and blade holding assembly. This, for example, allows to align the center of the mass of the blade with the vertical line through the hoisting cable. It may also allow to perform a mounting motion of the rotor blade wherein the root end of the blade is advanced to the mounting structure of the rotor hub.

In embodiments, one or more sensors are provided on the tower crane and/or the load connector, and/or on the object which is handled by the tower crane. The one or more sensors may be configured to measure one or more of position, motion, angular orientation, and speed of motion in one or more directions, e.g. all six degrees of freedom. For example, one or more sensors are mounted on the arm and/or on the load connector, e.g. on the blade lifting tool, to allow control of position and/or orientation of the arm, and thereby of the one or more tagline engagement points, relative to the load connector and/or object.

For example, inertial measurement sensor(s) is/are arranged on the arm and/or on the load connector and/or object, allowing to measure one or more of position, motion, angular orientation, and speed of motion in one or more directions, e.g. all six degrees of freedom. In embodiments, one or more wind speed sensors are mounted on the tower crane and/or the load connector, and/or on the object which is handled by the tower crane.

In embodiments, one or more sensors are provided to measure tagline tension and/or tagline length between the arm and the load connector and/or object.

In embodiments, one or more camera’s are provided on the tower crane and/or the load connector, and/or on the object which is handled by the tower crane.

In embodiments, the jib unit is remotely controlled, e.g. from the ground or from a vessel near the offshore wind turbine, e.g. the slewing and/or luffing being remotely controlled. The same applies for the hoisting system of the tower crane.

In embodiments, the tagline winch(es) is/are remotely controlled, e.g. from the ground or from a vessel near the offshore wind turbine.

In general, one or more sensors, e.g. as discussed above, may be linked to a tower crane controller to enhance operation thereof, e.g. the controller being adapted, e.g. programmed, to perform one or more stages of a lifting job, or possibly most or the entire lifting job, in a (semi-) automated manner. For example, the tower crane controller is configured as a computerized crane controller linked to the slew drive, the luffing arrangement (when present), the hoisting winch, the tagline device, any one or more actuators of the arm, etc. For example, the computerized crane controller is programmed or programmable to perform a routine providing a coordinated pattern of motions and operations of the tower crane, so that the load connector and/or the object supported thereby moves along a predefined trajectory during a hoisting job, e.g. during hoisting and/or lowering of the object.

In embodiments, in addition to the arm and tagline device associated with the arm as discussed herein, the tower crane can be provided with a secondary tagline system which provides for one or more additional taglines which, as in the mentioned prior art WO2023118352, extend from the crane tower to the load connector and/or the object supported by the load connector. For example, one or more tagline trolleys are mounted for travelling over the first trolley track, e.g. below the manipulator trolley, wherein one or more taglines (operated by associated tagline winches) extend from the tagline trolley on the crane tower to the load connector and/or the object supported by the load connector. In an embodiment, an additional tagline(s) extends from the manipulator trolley to the load connector and/or the object supported by the load connector. For example, when handling a wind turbine rotor blade the secondary tagline system may provide tagline(s) effective in longitudinal direction of the rotor blade, wherein the arm and the associated tagline device establishes tagline control primarily in lateral direction of the rotor blade. In embodiments, the one or more tagline winches of the secondary tagline system can be arranged on the manipulator trolley.

For example, the offshore tower crane is erected in a method further comprising the following steps:

- transporting the tower crane to the offshore wind turbine, e.g. using two cranes on a crane vessel;

- mounting the crane base on the lower end of the wind turbine mast or on the offshore foundation, preferably the crane base being mounted on support brackets provided on the lower end of the wind turbine mast or on the offshore foundation.

The invention will now be described with reference to the drawings. In the drawings:

- fig. 1 shows an example of a tower crane according to the invention used for installation of a wind turbine rotor blade,

- fig. 2 shows a top part of figure 1 on a larger scale,

- fig. 3 shows the top part of figure 1 on a larger scale in side view,

- fig. 4 shows the tower crane of figure 1 from a different direction,

- fig. 5 shows a top part of figure 4 on a larger scale,

- fig. 6 shows the mounting of the rotor blade from above with the tower crane of figure

1 ,

- fig. 7 shows the articulated arm of the tower crane of figure 1 in a first configuration,

- figs. 8a - c show an example of a hinge in the articulated arm of the tower crane of figure 1 , fig. 9 shows the articulated arm of the tower crane of figure 1 in a second configuration, fig. 10 shows the articulated arm of the tower crane of figure 1 in a third configuration, fig. 11 shows the articulated arm of the tower crane of figure 1 in a fourth configuration,

- fig. 12 shows the articulated arm of the tower crane of figure 1 in a fifth configuration,

- fig. 13 shows use of the tower crane of figure 1 in the installation of a nacelle component on a wind turbine mast,

- fig. 14 shows a top part of figure 13 on a larger scale,

- fig. 15 shows the use of the tower crane of figure 1 in the installation of a rotor hub,

- fig. 16 shows a top part of figure 14 on a larger scale from another angle, fig. 17 illustrates in a view from above the use of the arm in the installation of a rotor hub

- fig. 18 shows the use of the tower crane of figure 1 in the assembly of a wind turbine mast.

In the figures an example of a tower crane 1 is shown, which is configured to be arranged on a support, e.g. a support 2 at or near a foot of a wind turbine mast. In the figures, the crane is show for use onshore at the site of assembly of a wind turbine 200. The support 2 here is formed by a so-called hard pad adjacent or combined with the foundation of the mast 201 of the wind turbine 200. As discussed, the tower crane may also be configured and used in an offshore setting, e.g. wherein the support may be formed on the lower end of the mast, or by an offshore foundation, e.g. a bottom fixed or floating offshore foundation.

The wind turbine 200 further has a nacelle 202, a rotor hub 203 with mounting structures 204 (here three) for rotor blades 205. The nacelle 202 is equipped with a generator, possibly with a gearbox between the rotor hub and the generator. In other embodiments, the wind turbine comprises a direct drive generator, so that there is no gearbox.

The mast 201 may, in embodiments, be assembled at the site by assembly of mast sections 201a, b on top of another.

The tower crane 1 comprises:

- a crane base 10 which is configured to be placed on the support 2,

- tower segments 20 which have been stacked onto one another, here from below, in order to erect crane tower 30 which is composed of the tower segments 20 on the crane base 10,

- a crane tower lifting unit 40 which has been used to perform lifting actions in the process of stacking of the tower segments 20.

Possible embodiments and/or details of the crane base, and/or of the tower segments, and/or of the stabiliser devices are disclosed in WO2023118352.

The tower crane 1 further comprises a slewable jib unit 50 which comprises: a crane housing 51 which has been mounted on top of the crane tower, here already at the start of erecting the crane tower 30, wherein the crane housing is provided with a slew bearing 52 allowing for slew motion, preferably over 360 degrees about a vertical slew axis by means of a slew drive; a lifting jib 55 having an inner jib end and an outer jib end, wherein the inner jib end is pivotally mounted to the crane housing around a lifting jib pivot axis. A first luffing assembly 56 is configured to pivot the lifting jib between a horizontal orientation and an upward orientation, e.g. a vertical upward orientation.

The jib unit further comprises a counter jib 60 having an inner end and an outer end, wherein the inner end of the counter jib is pivotally mounted to the crane housing around a counter jib pivot axis. The counter jib, e.g. at the outer end thereof, is here provided with a counter ballast 61 . A second luffing assembly 66 is configured to pivot the counter jib 60 between a horizontal orientation and an upward orientation, e.g. a vertical upward orientation.

In an embodiment, the first and second luffing assemblies 56, 66 are independently operable from each other.

In an embodiment, a luffing assembly 56, 66 comprises a luffing winch and an associated luffing cable. In another embodiment, or in combination, a luffing assembly (further) comprises a luffing cylinder(s).

The crane tower lifting unit 40 is configured and operated to perform a lifting action in the process of erecting the tower crane, preferably with the slewable jib unit 50 connected to an upper tower segment 20. This allows to erect the crane tower by stacking the tower segments onto one another from below to lengthen the crane tower under the slewable jib unit. Herein the method for erecting the tower crane comprises a crane tower assembly phase, in which the crane tower is erected by stacking one or more tower segments one-by- one from below under the slewable lifting jib unit to form the crane tower, in which crane tower assembly phase the crane tower lifting unit lifts the already assembled part of the crane tower.

In an embodiment, the lifting jib 55 and the counter jib 60 are configured to both be in the upward orientation during the process of stacking of the tower segments 20, e.g. both in vertical or near vertical orientation. Possible embodiments and/or optional details of the lifting unit 40 and/or the jib unit 50 are disclosed in WO2023118352.

The tower crane 1 further comprises a hoisting system with a hoisting winch (e.g. at the crane base) and an associated hoisting cable 70 extending to a load connector, which here comprises a crane hook 71.

In figures 1 - 7 a blade lifting tool 80 is part of the load connector and is suspended from the crane hook 71, here via slings 300. As known in the art, the tool 80 is configured to support a wind turbine rotor blade 205.

Multiple tower segments 20 are each provided with a first trolley track member which extends along the tower segment to form a first trolley track 22.

The tower crane 1 comprises an object manipulator system configured to manipulate an object suspended from the load connector. The object manipulator system comprises:

- a manipulator arm device 100, comprising:

- a manipulator trolley 110 configured to engage the first trolley track 22 and being movable along the track 22 in vertical direction,

- a manipulator trolley drive 120 configured to move the manipulator trolley 110 along the first trolley track, e.g. a rack and pinion drive or otherwise,

- an arm 130 having an inner end and an outer end, wherein the inner end of the arm is connected to the manipulator trolley 110.

Multiple tower segments 20 are each also provided with a second trolley track member on a side of the tower segment opposite the first trolley track member, which second trolley track member extends along the tower segment allowing to form a continuous second trolley track 23 along a length of the crane tower.

The tower crane further comprises one or more stabiliser devices 90 each configured to horizontally connect the crane tower to the wind turbine mast 201.

The stabiliser devices 90 each comprise a stabiliser trolley 91 mounted to the second trolley track 23. The tower crane is provided with one or more stabiliser trolley drive devices 93 configured to move the stabiliser devices 90 along the second trolley track 23. Here the stabiliser trolley drive devices comprise a winch and cable arrangement. Possible embodiments and/or details of the stabiliser devices are disclosed in, for example, WO2023118352.

The arm 130 is pivotal about a Z-axis hinge 131 relative to the manipulator trolley 110 by an actuator 132, here one or more hydraulic cylinders. The Z-axis hinge 131 provides a vertical hinge axis, so that the entire arm can sway or pivot relative to the crane tower 30 in a horizontal plane.

The arm 130 has a length of at least 10 meters, e.g. at least 25 meters, here even more as the center of the blade lifting tool may be more than 30 meters away from the root end of the rotor blade for large capacity (e.g. 10 MW or more) wind turbines.

The actuator 132 is arranged between the manipulator trolley 110 and the arm 130 to cause a pivoting of the arm.

The arm 130 is an articulated arm having multiple interconnected mobile arm segments including an inner arm segment 140 which is connected to the manipulator trolley 110 and one or more further arm segments. In this example, the arm has four arm segments, including the inner arm segment 140, an outer arm segment 146, and two intermediate arm segments 142, 144.

The inner arm segment 140 is connected to the manipulator trolley via the inner Z-axis hinge 131 . A first intermediate Z-axis hinge 141 connects the arm segment 140 to arm segment 142. Second intermediate Z-axis hinge 143 connects arm segment 142 to arm segment 144, and third intermediate Z-axis hinge 145 connects arm segment 144 to outer arm segment 146. So, in this embodiment, the inner hinge 132 and the intermediate hinges each are embodied as a Z-axis hinge to provide pivotal motion of the arm segments solely in a horizontal plane.

The arm segments 140, 142, 144, 146 each are fixed length arm segments.

The arm segments 140, 142, 144, 146 each are embodied as a latticed structure with horizontal main chords and bracing members connecting the horizontal main chords.

Each intermediate hinge of the arm 130 has an associated locking device configured to lock the hinge once the desired angle has been set. The angle of the inner arm segment 141 is set and locked by the actuator 132 in this example. It is shown that, in an embodiment, the locking devices 143 can each be embodied as a mechanical locking device, e.g. wherein a locking pin is to be placed into a selected set of holes through two overlapping locking members 143a, 143b of the locking device, wherein each locking member has a series of holes. The locking device can be manual or can be motorized for remote operation.

The object manipulator system further comprises a tagline device 150. In this example, the tagline device comprises two tagline winches 151a, b and an associated taglines 152a, b.

Two distinct tagline engagement points 160, 165 are present on the arm 130, longitudinally spaced from one another. Here the two distinct tagline engagement points 160, 165 are provided on one mobile outer arm segment 146 of the arm.

In use, each tagline 152a, 152b extends between the respective tagline engagement point on the mobile arm segment 146 of the arm on the one hand and the load connector or the object supported by the load connector on the other hand. For example, both taglines 152a, b extend from outer arm segment 146 to the blade lifting tool 80.

It is shown that each tagline 152a, b extends in a single-fall arrangement between the tagline engagement point on the arm and the load connector or the object supported by the load connector. In another embodiment, a tagline extends in a double-fall arrangement.

In an embodiment, the tagline winch(es) 151a, b are mounted on the load connector, e.g. on the blade lifting tool 80. The engagement points 160, 165 may then be formed as connectors for the ends of the taglines, or for a sheave when the taglines are in a double-fall arrangement.

In practical embodiments, a tagline winch 151a, b is configured to control tagline tension and/or tagline length, e.g. an electronically controlled winch.

It is shown that the tagline winches 151a, b are mounted on the arm, here on the outer arm segment 146.

A tagline sheave 161 , 166 is mounted at each tagline engagement point 160, 165 on the arm segment 146 allowing the tagline 152a, b to pass from the tagline winch over the tagline sheave to the load connector 80 or to the object supported by the load connector. In an embodiment, a tagline engagement point is displaceable relative to the arm, e.g. along the length of the arm, e.g. relative to the associated arm segment.

The figures show that the articulated arm 130 can be brought in a straight configuration and in one or more folded configurations.

Some figures show that whilst the first trolley track 22 is on one side of the crane tower 30, the arm 130 can be brought in a folded configuration wherein the outer arm segment 146 extends at the opposite side of the crane tower 30, where track 23 is present.

As shown in figures 1 - 6 the load connector can comprise a blade lifting tool 80 configured to lift a wind turbine rotor blade 205.

It is shown that the blade lifting tool 80 is connected to the at least one tagline 152a,b.

Figure 9 illustrates that the arm 130 can be brought in a straight shape or configuration, wherein all arm segments are aligned with each other. The entire arm 130 can be pivoted in a horizontal plane by operation of actuator 132.

Figure 10 illustrates that the arm 130 can be brought in a folded configuration, wherein at least some of the interconnected arm segments are at an angle relative to one another. The shape of the arm 130 may be set so as to remain the same throughout the hoisting job, e.g. with the entire arm 130 being pivoted by operation of the actuator 132, e.g. to follow a slew motion of the lifting jib 55.

Figures 11 and 12 show different folded configurations of the arm 130. As can be seen, the arm 130 may be configured to extend from the side of the crane tower 30 where the track 22 and the manipulator trolley 110 are located along either side of the crane tower. This may involve pivoting of the inner arm segment 141 and suitable selecting the angle setting of the intermediate Z-axis hinges of the arm 130.

Figures 13 and 14 illustrate the use of the tower crane 1 of figure 1 in the installation of a nacelle 202 on a wind turbine mast 201 .

The nacelle 202 is suspended by hoisting slings 300 from crane hook 71. Here the arm 130 is in a folded configuration such that the one or more taglines 152a, b are directed away from a lateral side of the nacelle 202. The outer arm segment 146 is generally parallel to the lateral side of the nacelle 202 and the one or more taglines 152a, b extend in between the arm segment 146 and the nacelle 202. This configuration is highly effective when handling the nacelle.

It is shown that the arm 130 may be pivoted about the Z-axis hinge 131 when the lifting jib 55 is slewed as the nacelle 202 is positioned above the top end of the mast 201. As discussed, the arm 103 may now follow the slew motion of the jib, so that the taglines 152a, b remain in a favorable direction to stabilize and/or position the nacelle 202. It is shown that the outer arm segment 146 is effectively between the nacelle 202 and the crane tower 30 when the nacelle 202 is installed.

Figures 15 and 16 illustrate the use of the tower crane 1 in the installation of a rotor hub 203. Here the arm 130 is, at least at the installation height of the hub 203, in a folded configuration such that the one or more taglines 152a, b are directed away from the nose end of the rotor hub 203 to the arm 130. Here, as preferred, the outer arm segment 146 extends in front of the nose of the rotor hub 203 and the one or more taglines 152a, b in between the arm segment 146 and the rotor hub 203. This configuration is highly effective when installing the rotor hub 203 to the nacelle. Possibly the rotor hub includes a direct drive generator or the rotor hub is connected to a direct drive generator present in the nacelle.

As shown in figure 15, in embodiments, the arm 130 is already in the desired configuration when lifting of the rotor hub 203 is started, e.g. the arm only being reconfigurable before its use, so lacking an actuator assembly allowing to reconfigure the shape of the arm 130.

Figure 17 illustrates the use of the actuator 132 to sway the entire arm 130 about the Z-axis hinge 131 relative to the manipulator trolley 110. This may, e.g., be done in order to have the arm 130 follow a slew motion of the lifting jib when handling the object. In this example, the rotor hub 203 is swung from an initial lifting position, wherein the rotor hub 203 is lifted along the mast 201 to the installation height, to an installation position adjacent the nacelle 202. The arm 130 can be operated to follow this slew motion, so that the taglines 152a, b can maintain an optimal orientation when it comes to stabilizing and/or positioning of the rotor hub 203 relative to the nacelle 202. Figure 18 shows the use of the tower crane 1 of figure 1 in the assembly of a wind turbine mast 201. By way of example, it is shown that mast section 201a is to be placed on already assembled mast section 201b.

The stabiliser devices 90 engage on the already assembled part of the mast 201 to stabilize the yet not fully extended crane tower 30. Extension of the crane tower 30 can be done stepwise as the mast 201 becomes taller. The devices 90 may then be moved up as well.

It is shown in figure 18 that the arm 130 has been brought in a shape or configuration which allows for the outer arm segment 146 to become located, when at the installation height, at the other side of the crane tower 30, effectively between the mast section 201a that is to be installed and the crane tower. The taglines 152a, b are extended between the mast section 201a, here secured to the mast section at or near the lower end thereof, and the arm segment 146.

It is shown in figure 18 that the lifting jib 55 is nearly vertical for handling a mast section 201a, whereas the counter arm 60 is pivoted further outward to provide the desired counter ballasting. This is achieved by suitable operation of the luffing assemblies.

It is shown in figure 18 that the entire arm 130 can be swung in the horizontal plane, e.g. to have a different position of the arm 130 during lifting (or lowering) than when at an installation height for the wind turbine component to be installed.

Claims

C L A I M S

1. Tower crane (1) which is configured to be arranged on a support (2), e.g. a support at or near a foot of a wind turbine mast (201), wherein the tower crane comprises:

- a crane base (10) configured to be placed on the support,

- tower segments (20) which are configured to be stacked onto one another in order to erect a crane tower (30) which is composed of the tower segments on the crane base,

- a slewable jib unit (50) which comprises:

• a crane housing (51) to be mounted on top of the crane tower, wherein the crane housing is provided with a slew bearing (52);

• a lifting jib (55) having an inner jib end and an outer jib end, wherein the inner jib end is mounted to the crane housing,

- a hoisting system comprising a hoisting winch and an associated hoisting cable (70) extending to a load connector (70,80), which hoisting system is configured to support an object (201a; 202; 203; 205) from the lifting jib, wherein one or more of the tower segments (20) are each provided with a first trolley track member which extends along the tower segment to form a first trolley track (22), wherein the tower crane further comprises an object manipulator system configured to manipulate an object suspended from the load connector, the object manipulator system comprising:

- a manipulator arm device (100), comprising:

- a manipulator trolley (110) configured to engage the first trolley track (22) and being movable along the first trolley track in a vertical direction,

- a manipulator trolley drive (120) configured to move the manipulator trolley along the first trolley track,

- an arm (130) having an inner end and an outer end, wherein the inner end of the arm is connected to the manipulator trolley, and wherein the arm (130) comprises at least one mobile arm segment (146) having a tagline engagement point (160, 165), e.g. wherein the arm (130) has a length of at least 10 meters, e.g. at least 25 meters, wherein the arm (130) or the at least one mobile arm segment is pivotal about a Z-axis hinge (131), and wherein the object manipulator system further comprises: a tagline device (150) comprising a tagline winch(151a,b) and an associated tagline (152a,b), wherein the tagline is configured to be extended between the tagline engagement point (160,165) on the mobile arm segment (146) of the arm (130) on the one hand and the load connector (71 , 80) or the object (201 a, 202, 203) supported by the load connector on the other hand.

2. Tower crane according to claim 1, wherein the arm (130) is hinged to the manipulator trolley at its inner end via a Z-axis hinge (131) allowing the entire arm to be pivoted in a horizontal plane, wherein, preferably, an actuator (132) is arranged between the manipulator trolley (110) and the arm (130) to cause a pivoting of the arm.

3. Tower crane according to claim 1 or 2, wherein a controllable arm actuator assembly is provided which comprises one or more arm actuators (132) associated with the arm and a controller, e.g. one arm actuator between the manipulator trolley and the arm, e.g. the inner arm segment, and a further arm actuator for each further mobile arm segment.

4. Tower crane according to any one or more of claims 1 - 3, wherein the tagline device comprises two tagline winches (151a, b) and an associated taglines (152a, b), and wherein two distinct tagline engagement points (160,165) are present on the arm, of which at least one tagline engagement point is provided on the mobile arm segment of the arm, e.g. wherein the two distinct tagline engagement points (160,165) are provided on one mobile arm segment (146) of the arm.

5. Tower crane according to any one or more of claims 1 - 4, wherein the arm (130) is configured to provide for motion of the at least one mobile arm segment (140,142,144,146) solely in a horizontal plane.

6. Tower crane according to any one or more of claims 1 - 5, wherein the arm (130) is an articulated arm having multiple interconnected mobile arm segments (140,142,144,146) including an inner arm segment (140) which is connected to the manipulator trolley (110) and one or more further arm segments, wherein the inner arm segment is connected to the manipulator trolley via an inner hinge (131), and wherein arm segments of the arm are connected to one another via an intermediate hinge (143), preferably, wherein the inner hinge (131) and the one or more intermediate hinges (143) each are embodied as a Z-axis hinge to provide pivotal motion of the arm segments (140,142,144,146) solely in a horizontal plane, preferably, wherein the arm (130) comprises at least two further arm segments including an outer arm segment (146), e.g. has three further arm segments including an outer arm segment, e.g. wherein the one or more tagline engagement points (160,165) are on the outer arm segment.

7. Tower crane according to claim 6, wherein the articulated arm (130) is configured to assume a straight configuration and one or more folded configurations when seen from above, e.g. wherein the first trolley track (22) is on one side of the crane tower, and wherein the arm (130) is configured to assume a folded configuration wherein an outer arm segment (146) extends at the opposite side (23) of the crane tower.

8. Tower crane according to any one or more of claims 1 - 7, wherein the arm segments (140,142,144,146) each are fixed length arm segments.

9. Tower crane according to any one or more of claims 1 - 8, wherein the tagline engagement point (160,165) is arranged on an outer arm segment (146) of the arm, e.g. wherein multiple tagline engagement points are arranged on the outer arm segment.

10. Tower crane according to any one or more of claims 1 - 9, wherein each tagline winch (151a, b) is mounted on the arm (130) or on the manipulator trolley, preferably, wherein a tagline sheave (161 ,166) is mounted at each tagline engagement point on the arm (130) allowing the tagline to pass from the tagline winch over the tagline sheave to the load connector (80) or to the object (201a, 202, 203) supported by the load connector.

11. Tower crane according to any one or more of claims 1 - 10, wherein a tagline engagement point is displaceable relative to the arm, e.g. along the length of the arm, e.g. relative to the associated arm segment.

12. Tower crane according to any one or more of claims 1 - 11 , wherein the tower crane further comprises one or more stabiliser devices (90) each configured to horizontally connect the crane tower to an external tall structure, e.g. a wind turbine mast (201) .preferably wherein multiple tower segments (20) are each provided with a second trolley track member on a side of the tower segment opposite the first trolley track member, which second trolley track member extends along the tower segment allowing to form a continuous second trolley track (23) along a length of the crane tower, and wherein the one or more stabiliser devices (90) each comprise a stabiliser trolley configured to be mounted to the second trolley track, wherein the tower crane is provided with one or more stabiliser trolley drive devices configured to move the stabiliser device along the second track.

13. Tower crane according to any one or more of claims 1 - 12, wherein the load connector comprises a blade lifting tool (80) configured to lift a wind turbine rotor blade (205), e.g. wherein the blade lifting tool is configured to connect the at least one tagline (152a,b) to the blade lifting tool.

14. Tower crane according to claim 3, wherein the controllable arm actuator assembly is configured to cause a controlled displacement of the at least one tagline engagement point during a mounting motion of the rotor blade towards a blade mounting structure of a wind turbine.

15. Method for lifting or lowering an object using the tower crane according to any one of more of claims 1 - 14, wherein the tagline (152a,b) extends between the tagline engagement point (160,165) on the mobile arm segment (146) of the arm on the one hand and the load connector (80) or the object (201 a, 202, 203) supported by the load connector on the other hand, wherein, preferably, the load connector is a blade lifting tool (80) configured and operated to lift a wind turbine rotor blade (205), wherein tagline (152a,b) extends between the tagline engagement point on the mobile arm segment of the arm on the one hand and the blade lifting tool.