Claims:WE CLAIM:
1. A system for de-erection and re-erection of a blade 16 of a wind turbine, said system comprising:
• a bracket 25 disposed over a circumference over a profile of said blade 16 and assembled in line with at least one clamp 25a and at least one connecting plate 26;
• at least one first pulley 34 mounted at the base of said wind turbine;
• at least one second pulley 35 mounted on a blade 16’ adjacent to said blade 16, said second pulley 35 positioned vertically in line with said first pulley 34;
• at least one third pulley 36 mounted on said blade 16’ adjacent to said blade 16, said third pulley 36 positioned vertically in line with said first pulley 34;
• at least one fourth pulley 37, wherein a gun tackle arrangement 38 is formed by said third pulley 36 with said fourth pulley 37;
• a lifting line 31 coupled to said first pulley 34 and said second pulley 35 in a first configuration for lifting at least said gun tackle arrangement 38 and coupled to said first pulley 34, said third pulley 36 and said fourth pulley 37 and attached back to said third pulley 36 in a second configuration for lifting at least said blade 16;
• at least one holding mechanism 39 attached to said fourth pulley 37, said holding mechanism 39 adapted to hold said bracket 25;
• at least one load bearing mechanism 29 configured for pulling and releasing of said lifting line 31, wherein said lifting line 31 is wound around said load bearing mechanism 29 and one end of said lifting line 31 is attached to said load bearing mechanism 29;
• a pulley lifting tool 49 configured for lifting and lowering of said gun tackle arrangement 38;
• a portable hoist 47 placed between a blade pitch slewing ring bearing 17 and a first web belt 40;
• a traction hoist 30 or a chain hoist 50 connected with said pulley lifting tool 49 and configured for lifting said gun tackle arrangement 38;
• a receptacle 42 disposed over said blade 16; and
• a load supporting mechanism 44 connected to an operative bottom portion of said blade 16 and configured to support said blade 16 during de-erection and re-erection thereof.
2. The system as claimed in claim 1 further comprises of a jig 23 mounted at the bottom of tower of said wind turbine, said jig 23 adapted to mount said at least one first pulley 34.
3. The system as claimed in claim 1 further comprises of a first web belt 40 mounted at the adjacent blade 16 of said wind turbine, said second web belt 41 adapted to mount said second pulley 35.
4. The system as claimed in claim 1 further comprises of a jig 24 mounted at the top of adjacent blade 16 of said wind turbine, said jig 24 adapted to mount said third pulley 36.
5. The system as claimed in claim 1 further comprises of a second web belt 41 mounted at the top of adjacent blade 16 of said wind turbine, said second web belt 41 adapted to mount said third pulley 36.
6. The system as claimed in claim 1 further comprises of a rope access adapted to carry at least one individual to assemble of said wind turbine.
7. The system as claimed in claim 1, wherein said first pulley 34 is a one-way pulley.
8. The system as claimed in claim 1, wherein said second pulley 35 is a one-way pulley.
9. The system as claimed in claim 1, wherein said third pulley 36 is at least a two-way pulley.
10. The system as claimed in claim 1, wherein said fourth pulley 37 is a one-way pulley.
11. The system as claimed in claim 1, wherein said load supporting mechanism 44 and said load bearing mechanism 29 is chosen from a group consisting of a crane, manual force 45 and at least one tagline rope 43.
12. The system as claimed in claim 1, wherein said at least one lifting line 31 is selected from a group consisting of rope, metallic clamp, chain and belt.
13. The system as claimed in claim 1, wherein said first web belt 40, said second web belt 41 or said receptacle 42 or said web belt 42a is a polyester type.
14. The system as claimed in claim 1, wherein said holding mechanism 39 is a hook/or metallic components.
15. The system as claimed in claim 1, wherein said bracket 25 is a steel component.
16. A method for de-erection of a blade 16 of a wind turbine comprising the following steps:
• positioning said blade 16 to be removed in a six o’clock position;
• locking said blade 16 in a six o’clock position;
• assembling a jig 23 at the bottom of said wind turbine;
• assembling a jig 24 at the top of an adjacent blade 16’;
• assembling a pulley lifting tool 49 at the top of a hub of said turbine;
• attaching at least one first web belt 40 on said adjacent blade 16’;
• attaching at least one second web belt 41 on said adjacent blade 16’;
• mounting at least one first pulley 34 on said jig 23 at the bottom of said wind turbine;
• mounting at least one second pulley 35 on said adjacent blade 16’ at the first web belt 40;
• mounting at least one third pulley 36 on said adjacent blade 16’ at the second web belt 41 or at said top jig 24;
• mounting at least one fourth pulley 37 forming a gun tackle arrangement 38 with said third pulley 36;
• attaching bracket 25 over a circumferential length of said blade 16;
• attaching receptacle 42 over a circumference at the bottom of said blade 16;
• attaching at least one tag line rope 43 on said bracket 25;
• attaching at least one tag line rope 43 on said receptacle 42;
• attaching at least one lifting line 31 from a load bearing mechanism 29 over said first pulley 34, said third pulley 36, said fourth pulley 37 back to said third pulley 36;
• attaching said fourth pulley 37 with a holding mechanism 39 to said bracket 25;
• attaching a load supporting mechanism 44 to an operative bottom portion of said blade 16; and
• lowering said blade 16 by operating said lifting line 31.
17. The method according to claim 16, wherein the step of attaching a bracket 25 over a circumferential length of blade 16 of a wind turbine comprises:
• positioning said blade 16 being attached the bracket 25 in a ten o’, twelve o’clock, two o’ clock position;
• connecting with the specific torque said by torqueing tool;
• operating with the holding mechanism 39 said by load bearing mechanism 29;
• pulling with the use of said load supporting mechanism 44, said lifting line 31;
• guiding said bracket 25 over said blade 16 to be dismantle;
• attaching bracket 25 over said blade 16; and
• tightening specific torque said bracket 25.

18. A method for re-erection of a blade 16 of a wind turbine comprising the following steps:
• positioning a mounting face of hub 15 for said blade 16 being installed in six o’clock position;
• aligning said blade 16 with said hub 15;
• attaching a bracket 25 over circumference of said blade 16;
• attaching a fourth pulley 37 to said bracket 25 with a holding mechanism 39;
• attaching a load supporting mechanism 44 to an operative bottom portion of said blade 16;
• attaching a lifting line 31 to a load bearing mechanism 29;
• operating said load bearing mechanism 29 to lift said bracket 25 carrying said blade 16; and
• installing said blade 16 inside said hub 15.
19. The method according to claim 18, wherein the step of installing said blade 16 inside said hub 15 is succeeded by steps comprising:
• by rope access a individual to allow at least one individual within to remove the fasteners of said bracket 25 once said blade is re-erected in said hub 15;
• releasing said lifting line 31 from said traction hoist 30 to lower said the gun tackle arrangement 38; and
• positioning the rotor hub 15 said dismantle to lower said bracket 25 along with connecting plate 26.
, Description:FIELD
The present disclosure relates to the field of blade failures like damages and broken leads to de-erection and re-erection of a wind turbine blade at various hub heights, different terrains and various shapes of the blade.
DEFINITION
Gun Tackle Arrangement: The expression ‘gun tackle arrangement’ used hereinafter in this specification refers to, a type of a ‘block and tackle arrangement’ of at least two pulleys with a rope and a cable threaded between them, and used for lifting heavy loads. By increasing the number of parts of the rope that act on the load, a mechanical advantage (i.e., ratio of the load and the pulling force required) equal to the number of sections of the rope supporting the load is achieved. In a gun tackle arrangement, the mechanical advantage is equal to 2.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
A wind turbine is a device used to convert the wind energy into electrical energy by the rotary motion of its blades. Wind energy conversion is the fastest growing means of renewable electricity generation in the world. Due to the significant increase in use of wind turbines globally, a reliable and cost-effective condition monitoring technique is essential to maintain the availability and to improve reliability of the wind turbines. Wind turbines are located in harsh environments which makes their maintenance very difficult. A wind mill consists of various parts such as blade, gearbox, tower, generators, etc.
The installation of wind turbine is initialized by crane. After installing and maintain the machines, during regular use, failures mostly occur on the blades. During operation, the tip of a large wind turbine blade travels at around 400 km/hr, i.e., the tip travels 3 million kilometres a year (at 90% uptime). Also the blade is exposed to heavy strains and a harsh environment (hail, rain, UV radiation, salt, cold/heat, lightning, mass particles, etc.). The turbine blades are also subjected to failure and other form of damages caused by the reasons such as lightning, birds striking and mass particles hitting the blade resulting damages/failures such as cracks, physical stresses or defects at the blade tip or other available areas. So, complex repairs and maintenance work is required on these blades and wherever required, replacement of blade is sought.
The key challenge in the maintenance of the wind turbine is the de-erection and re-erection of its blades. The conventional methods of de-erecting and re-erecting the turbine blades make extensive use of a crane. Some of the disadvantages associated with this conventional method include the requirement of mobilization of large capacity cranes, the requirement of a large amount of fuel to operate the crane, large trucks to transport the crane parts and inaccessibility for the cranes when wind turbines are located on uneven terrains. Repair and maintenance of a blade or multiple blades done using a crane is difficult and expensive. It is difficult to reach the place and more interruption of road curvy routes, hills, corners. Time required to travel is significant. More number of support frames and accessories are required. Pathway conditions can be rough. Additional support vehicle adds to the locking time. Crane pad needs to be prepared and constructed as per each location. Local permitting issues may arise. Enormous quantity of fuel may be consumed. Cost of crane movement. A large number of operators and supporters are required to operate. It takes more time for assembly of booms.
There is, therefore, need for a system for raising and lowering of wind turbine blades which ameliorates the above mentioned issues.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a system and a method for raising and lowering of wind turbine blades.
Another object of the present disclosure is to provide a system and a method for raising and lowering of wind turbine blades, which minimizes the use of a crane.
Another object of the present disclosure is to provide a system and a method for raising and lowering of wind turbine blades, which is suitable for any capacity, any type and variable height of wind turbines.
Yet another object of the present disclosure is to provide a system and a method for raising and lowering of wind turbine blades, which is independent of terrain where the wind turbine is installed.
Still another object of the present disclosure is to provide a system and a method for raising and lowering of wind turbine blades, which is inexpensive.
Yet another object of the present disclosure is to provide a system and a method for raising and lowering of wind turbine blades, which is convenient.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
In accordance with the present disclosure there is provided a system for de-erection and re-erection of a blade of a wind turbine. The system includes:
• Holding Jig mounted at the bottom shell circumference of the wind turbine. For ankle type tower, the holding sling is used in bottom brace leg to connect first pulley.
• At least one first pulley mounted at the bottom of the wind turbine.
• Position the failure blade in 10’o clock position, remove the barrel nut and attach the bracket/clamp lock plate, then blade clamp/bracket along with connecting plate in first Quadrant.
• Pitch the blade into every quadrant; attach the bracket/clamp lock plate, then blade clamp/bracket along with connecting plate in second, third & fourth Quadrant accordingly.
• Assemble the holding bracket fastening by removal the specific blade studs in corresponding to that secured barrel nuts are removed.
• Attach the third pulley holding jig in right hand side adjacent blade bearing flange in 10’o clock position.
• Position the blade in 2’o clock position, attach the third pulley holding jig in left hand side adjacent blade bearing flange and positioning the blade into 6’o clock position.
• Attach the second pulley connected with web belt on adjacent blade on both side.
• At least one third pulley mounted on at least one blade adjacent to the blade in holding jig, the at least one third pulley positioned in line with the at least one first pulley.
• At least one fourth pulley, the at least one fourth pulleys forming a gun tackles arrangement with the at least one third pulley.
• Lifting the third and fourth pulley gun tackle arrangement fixing in top holding jig by the second pulley placed in adjacent blade with the support of traction hoist (optional).
• Pulling the rope of second pulley positioned in line with the at least one first pulley by traction hoist placed in load bearing mechanism.
• Lifting the third and fourth pulley gun tackle arrangement to top holding jig by the pulley lifting tool mounted in the hub with the support of chain hoist or traction hoist mechanism (optional).
• Attach the third and fourth pulley gun tackle arrangement to top holding jig or second web belt with the support of manual force.
• Attach the fourth pulley in holding brackets/clamp connected by the metallic lifting equipments with the support of manual force.
• Both number of Loads bearing system or Electrical winch is placed the selective distance and degree from the turbine.
• A lifting line coupled to the at least one first pulley, the at least one third pulley, the at least one fourth pulley and attached back to the at least one third pulley.
• At least one load bearing mechanism configured for pulling and releasing of the lifting line to enable vertical motion of the holding bracket disposed over the blade.
• A load supporting mechanism connected to an operative bottom portion of the blade and configured to support the blade during de-erection and re-erection thereof; and
• At least one holding mechanism attached to the at least one fourth pulley, the at least one holding mechanism adapted to hold the holding bracket.
The system of this mechanism comprises a set of plurality of components for lowering and raising a single blade from hub. Mainly the blade is lowered and raised by the use of a holding bracket, which is fixed outside of the blade root profile with the connector pin instead of removing the secured barrel nut in the blade. A number of bracket parts is attached with reference to the position of removal of barrel nut and studs in the blade. The method of the present disclosure involves rotating the single blade in ten-o’ clock position and/or twelve-o’ clock position and/or two-o’ clock position for assembling the blade holding bracket in necessary quadrants and then facing it towards erecting position of six-o’clock position in which it points downwards parallel to the wind turbine tower. A pulley set-up, which is mounted through the adjacent blades attached by web belt or top holding jig, is connected with the holding bracket pulley, which is mounted on the outer surface of the damaged blade by means of a wire rope. The wire rope is wound on the drum of an electrical winch which is located on ground surface at adjacent side of the blade position and the tower. By using a winch mechanism arrangement are used to operate the integral plurality part for lowering and rising of the single blade by a blade holding bracket/clamp. Before the arrangement of blade bracket tool is attached to the blade by the support of a turbine hoist. The blade is further serviced at ground level and/or envisaged for the replacement as decided by.
In accordance with the present embodiment, there is provided a method for de-erection of a blade of a wind turbine comprising the following steps.
• positioning the blade being removed and lowering down in a six o’ clock position;
• rotating and locking the blade in the six o’ clock position;
• assembling a holding jig at the bottom of the wind turbine;
• mounting at least a first pulley on jig hook in provisions;
• mounting at least a third pulley in adjacent blade top jig hook plate or web belt attached into the blade;
• mounting at least a fourth pulley forming a gun tackle arrangement with said at least third pulley at both adjacent places;
• attaching a blade bracket/clamp over a profile of the blade with the support of fastener pins;
• attaching a lifting line from a load-bearing mechanism over the first pulley groove, the at least one third pulley groove, the at least one fourth pulley groove back to the at least one third pulley groove and hold up;
• attaching a load supporting mechanism in line with an operative failure/bottom portion of the blade;
• attaching a tag line rope in blade bracket/clamp and/or tail end socks to guide;
• lowering the blade by operating the lifting line; and
• using the load supporting mechanism and/or a tail pick crane to position the blade and place the blade into a holding jig on the ground at horizontal position.
Typically, the step of attaching a blade bracket over a blade of a wind turbine comprises:
• lifting a blade bracket/clamp, top jig and lock plate by machine head hoist;
• positioning the blade in ten o’ clock position, removing the barrel nut and attach the bracket/clamp lock plate, then blade held by clamp/bracket along with connecting plate in first quadrant;
• pitchign the blade into every quadrant; attaching the bracket/clamp lock plate, then blade held by clamp/bracket along with connecting plate in second, third and fourth quadrant accordingly;
• fastening the blade bracket pins;
• attaching the third pulley holding jig in right hand side adjacent blade bearing flange in ten o’ clock position and two o’ clock position;
• positioning the blade into 6 o’ clock position, attach the second pulley connected with first web belt on adjacent blade on both sides;
• at least one third pulley mounted on at least one blade adjacent to the blade in holding jig, the at least one third pulley positioned in line with the at least one first pulley;
• at least one fourth pulley, the at least one fourth pulleys forming a gun tackles arrangement with the at least one third pulley;
• lifting the third and fourth pulley gun tackle arrangement fixed to top holding jig by the second pulley placed in adjacent blade (optional)
• lifting the third and fourth pulley gun tackle arrangement fixed to second web belt lifting tool placed in the hub (optional)
• pulling the rope of second pulley positioned in line with the at least one first pulley by traction hoist placed in load bearing mechanism;
• attaching the third and fourth pulley gun tackle arrangement to top holding jig; and
• attaching the fourth pulley in holding brackets/clamp connected by the metallic lifting equipments.

In accordance with the present disclosure there is provided a method for re-erection of a blade of a wind turbine comprising the following steps:
• positioning a mounting face of hub for the blade being installed in six o’clock position;
• locating the blade in line with the hub face location;
• fastening lock plate by removal the specific blade studs in corresponding to that secured barrel nuts are removed;
• attaching a blade bracket/clamp over at least a portion of the blade according to the quadrant;
• fastening the blade bracket/clamp in all necessary quadrants;
• attaching a tag line rope into blade bracket hook and tail end socks for guiding;
• existing lifting line coupled to the at least one first pulley, the at least one third pulley, the at-least one fourth pulley and attached back to the at least one third pulley;
• attaching the fourth pulley to the blade bracket with a holding mechanism;
• attaching the lifting line to a load bearing mechanism;
• operating a load bearing mechanism or electrical winch to pulling the rope through chain of pulley;
• at-least one individual guiding the tag line rope;
• installing the blade inside the hub; and
• fastening between the blade and hub flanges by required torqueing value.
Typically, the step of installing the blade inside the hub is succeeded by steps comprising:
• fastening the studs between blade and hub with respective torque;
• accessing to allow at least one individual to loosen the lock plate and blade bracket and connecting plate and third pulley and fourth pulley and pulley lifting tool once the blade is re-erected in the hub;
• releasing the tagline from the blade bracket/clamp and tip socks; and
• necessary dismantled accessories to assemble into the hub as it is.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A system and method for de-erection and re-erection of a blade of a wind turbine of the present disclosure will now be described with the help of the accompanying drawings, in which like process is represented throughout the drawings, wherein:
Figure 1 illustrates a simplified representation of an isometric view of existing placed wind turbine in wind park;
Figure 2 illustrates the top view of a blade for de-erection and re-erection;
Figure 2a is the front view of barrel nut removal and assembly of bracket fittings projection in blade of Figure 2;
Figure 3 illustrates the front view of a bracket and bracket clamp fixing in the blade in ten -o’ clock position and Figure 3a the illustrates system of blade is pitching in same position of bracket fixing in the first quadrant of the blade of Figure 3;
Figure 3B illustrates the front view of a bracket clamp and connecting plate fixing in the blade in second quadrant and the illustrates system of top jig is fixing in same position of adjacent blade for erection of the blade of Figure 3;
Figure 3C illustrates an embodiment of an inventive bracket clamp and connecting plate fixing in the blade opposite side in two-o’ clock position and the illustrates system of top jig is fixing in same position of adjacent blade for erection of the blade of Figure 3;
Figure 3D illustrates an embodiment of an inventive bracket in the blade in six-o’ clock position for erection;
Figure 4 illustrates the front view of a ground winch, a tower bottom jig and a first pulley of the system of Figure 1;
Figure 5 illustrates a simplified representation of portable hoist fixing in adjacent blade for lifting first web belt;
Figure 6 illustrates a side view of lifting of second web belt and gun tackles arrangement of the system by traction hoist system;
Figure 6A illustrates an embodiment of lifting the gun tackles arrangement of the system and Figure 6B illustrates of lifting the part by traction hoist system for attachment of Figure 6;
Figure 7 illustrates a top view of pulley lifting tool fixing in hub for lifting second web belt and/or gun tackle arrangements;
Figure 7A illustrates a simplified representation of traction hoist fixed in pulley lifting tool for lifting second web belt and/or gun tackle arrangements;
Figure 7B illustrates a simplified representation of chain hoist fixed in pulley lifting tool for lifting second web belt and/or gun tackle arrangements;
Figure 8 illustrates a perspective view of attachment of the system for erecting the blade by top jig method;
Figure 8A illustrates a view of attachment of the system for erecting the blade by web belt system;
Figure 9 illustrates the front view system of erecting the blade by top jig method attachments;
Figure 10 illustrates the side view system of erected blade for changing the position from vertical position to horizontal position by fixing the web belt by load supporting mechanism;
Figure 10A illustrates the side view system of fixing the web belt by load supporting mechanism and manual force with the help of man basket of Figure 10;
Figure 11 illustrates a view of system of a blade lowering to the ground;
Figure 11A illustrates a projection of web belt assembly in tip belt of Figure 11;
Figure 12 illustrates a view of system of a blade positioning in the stand; and
Figure 12A illustrates a projection of blade fixing in the stand and gun tackles arrangement for assembly in bottom jig of Figure 12.
LIST OF REFERENCE NUMERALS
11. Terrain/Ground Surface
12. Foundation/Base
13. Tower
13a. Bottom Shell
13b. Middle Shell
13c. Top Shell
14. Rotor
15. Hub
16. Blade being lowered/raised
16’. Blade adjacent to the blade being lowered/raised
16a. Blade Flange
17. Blade Pitch Slewing Ring Bearing
18. Barrel Nut
19. Blade Stud
19a. Blade Stud Holes
20. Bearing Stud
21. Nacelle
21a.Main Shaft
21b.Gearbox
21c.Generator
21d.Transformer
22. Machine head hoist
23. Bottom Jig/Anchor bolt jig
24. Top Jig
25. Bracket
25a. Bracket Clamp
26. Connecting Plate
27. Stud/Pin/Bolt for joint
27a. Nut for joint
28. Lock Plate
29. Winch/Load Bearing Mechanism
30. Traction hoist
31. Wire rope/Lifting line
32. Counter Weight Platform
32a. Peg
32b. Counter Weight
33. Control Panel
34. First Pulley
35. Second Pulley
36. Third Pulley
37. Fourth Pulley
38. Gun tackles Arrangement
39. Holding Mechanism
40. First web Belt
41. Second Web belt
42. Receptacle (Tip belt)
42a.Web belt
43. Tagline
44. Load supporting Mechanism
45. Man basket
46. Manual force
47. Portable Hoist
48. Blade stand
49. Pulley lifting tool
49A. Vertical post
49B. Lifting arm
49C. Lifting Hooks
49D. Stay support
49E. Base
50. Chain Hoist
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including” and “having” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
The disadvantages associated with the conventional system of de-erecting and re-erecting a blade of a wind turbine, are primarily attributed to the use of a crane in the process. It is difficult to use a crane when wind turbines are installed on inaccessible terrains. Cranes also consume a considerable amount of fuel and its emission is high, hence adding to the operation cost of the conventional system and pollute the air. Hence the wind turbine breakdown replacement for breakdown time is high. Further, cranes impose limitations on the operational height of the de-erection and re-erection tasks. Some of the key objectives of the proposed system are to limit the use of cranes and easy mobilization of the resources required for de-erecting and re-erecting the blade of a wind turbine.
This invention discloses a method and a system related to lowering and raising a single rotor blade of a wind turbine from the wind turbine’s hub at six-o’clock position.
FIG.1 illustrates a simplified representation of an isometric view of existing placed wind turbine comprising the components of an arrangement of bottom shell 13a constructed in foundation 12, further at-least one shells placed above from the bottom shell 13a, top shell 13c is connected to the machine head 21 which consists of main shaft 21a (not shown), gearbox 21b (not shown), generator 21c (not shown), transformer 21d (not shown) and other accessories components in mechanical, electrical or hydraulic. The machine head of nacelle 21 is applicable for the present invention is direct drive or gearless drive and/or geared turbine. A nacelle 21 is positioned at top of the wind turbine shell 21c or tower and it houses wind turbine generating machine head 21 comprises the rotor 14. The at-least three rotor blades 16 attached to the rotor hub 15 of wind generating machine which consists of hydraulic accessories etc. A machine base may be located in anywhere like on-shore, sea shore and off-shore from the rotor blade 16 for lifting and removal of a blade 16 from ten-o’ clock or twelve-o’ clock (optional) or two-o’ clock position. A nacelle 21 is positioned at top of the wind turbine tower is applicable in various type of shell like brace or ankle tower and/or closed type tower and/or hybrid tower which raises at-least from twenty five meter height. The material of blade 16 may variable in glass-fiber reinforced plastic (GRP) or other materials that have been tried include steel or various composites and/or carbon-filament-reinforced-plastic (CFRP) or equivalent material. As attached at-least one number of the machine head hoist 22 is permanently or else temporarily mounted on the machine head 21 for lifting the required tools or equipments or components from the ground 11.
The wind turbine captures the wind, which it turns activates the rotor 14. The rotor 14 and the wind turbine blades 16 spin the main shaft 21a (not shown) which in turn activates the generator 21c (not shown) via an optional intermediate gear 21b (not shown). The wind turbine blades 16 and are subjected to constant failure and damages, thereby requiring regular maintenance. The inner elements of the hub 15 and the nacelle 21 which include the slewing ring bearing 17 also require constant maintenance, which requires the removal of the wind turbine blade 16. The system uses portable resources which when attached to the wind turbine offers the necessary contraption, utilizing the strength of the wind turbine structure to de-erect and re-erect the wind turbine blade 16.
The salient resources needed for de-erecting and re-erecting the wind turbine rotor blade 16 are at least one load bearing mechanism 29 with the necessity of at-least one counter weight 32b and peg 32a , at-least one traction hoist 30, at-least one portable hoist 47, at-least one chain hoist 50, at-least one pulley lifting tool 49, at-least one man basket 45, at least one first pulley 34, at least one second pulley 35, at least one third pulley 36, at least one fourth pulley 37, at least one top jig 24, at least a segment of tower bottom jig 23, at least a segment of blade bracket/ or clamp 25a, at least a segment of connecting plate 26 for blade bracket 25, at least a segment of lock plate 28 and stud or pin or bolt 27 for barrel nut holes and other joints, at least one lifting line 31 from traction hoist 30, at least one lifting line 31 from portable hoist 46, at least one lifting line 31 from chain hoist 50, at least one lifting line from load bearing mechanism 29, at least one receptacle 40 for adjacent blade, a customized receptacle 42 for blade tail end, at least one load supporting mechanism 44 for supporting the wind turbine rotor blade 16, at least one tag line rope 43 and at least one holding mechanism 39 to attach the fourth pulley 37 to the blade bracket 25, at-least one tag line 43 for guiding the blade.
The main objective of the holding mechanism 39 is to attach the at least one fourth pulley 37 to the blade bracket clamp 25A. The at least one third pulleys 36 and at least one fourth pulley 37 form a Gun Tackle configuration 38. The at least one fourth pulley 37 contains the holding mechanism 39. The holding mechanism is preferably a pulley hook 39. The machine head/or nacelle 21 of the wind turbine contains a load bearing system which is called as hoist 22 (not shown). The nacelle winch 22 lifting line (not shown) from the winch is used to lift the various kind of tools and equipments required to execute the operation of the wind turbine blade de-erection and re-erection.
The second main objective of the assembly of the bracket 25 is to attach the at-least one blade bracket clamp 25A, at-least one connecting plate 26, at-least one lock plate 28 which is connecting with the support of at-least one stud/or pin or bolt 27 for joints along with the respective nut 27A and at-least one holding mechanism hooks for holding the objects of the blade 16 for lifting or lowering from the wind turbine.
In a preferred embodiment, the winch is used as a load bearing mechanism 29 as it can be easily transported and has a large power to size ratio. The four main factors that affect the selection of the winch are the lifting capacity, breaking strength of rope, rating, load pulling vs lifting, other loads, power and duty cycle. Some other factors that affect the winch selection with reference to its application for de-erecting and re-erecting wind turbine blade 16 are line speed, solenoid type, motor rating/type and its use. The necessity of load bearing system 29 to be placed at-least one counter weight 32b (not shown) and peg 32a (not shown) is too derived for bear up against the load with the selection of suitable load factor.
FIG.2 A simplified representation of a present invention of an arrangement for lifting and lowering the rotor blade 16 from six-o’ clock position on a rotor hub 15 of a wind turbine generating system is applicable for various types of terrains 11. As well as the required position in the ground, the machine head/nacelle 21 should be yawing and stopping in suitable direction for lifting or lowering the component placing into the ground 11. The failure of the blade 16 positioning on a rotor hub 15 as six-o’ clock for marking the attached studs to removal at-least one number of stud 19 in each quadrant by hydraulic and/or manual tools. The specified connected studs 19 are removal from the attachment of rotor hub 15 with a failure blade 16. Further it positioning the blade into six-o’ clock position to ten-o’ clock position and enables the rotor lock. As per illustration the barrel nuts 18 is removed from the detached studs. Drive the provision of barrel nut 18; the lock plate 28 is attached by the fasteners to connect the blade bracket clamp 25A along with the connecting plate 26 which is described detail in FIG.3. The pitch drive is firmly fixed to the rotor hub is mounted inside a rotor hub 15 it comprises the pitch drive is a gear wheel, which intersect with the inner gear of the flange is otherwise called as blade pitch slewing ring bearing 17. Thus pitch drive acting as a swiveling movement of its corresponding to the rotor hub 15, which requires position to adjust and stop the movement in certain level or fully which means its acting as the swivel axis of the rotor blade 16 is roughly parallel to the longitudinal axis of the blade and/or the pitching of the blade 16 is done by manually/ or hydraulically with respect to the swiveling movement of its corresponding rotor blade 16.
The blade bracket clamp 25A and its in-line assembly with the segment of connecting plate 26 raised by the tower hoist 22 from ground to machine head 21 which is manually shifted and attached as per illustration says to mount the blade clamp 25 in first quadrant over the circumference of the blade profile by lock plates 28 at ten-o’ clock position. The bolts or pins 27 and nuts 27A are connecting the outer blade bracket clamp 25A and lock plates 28 with respect to the respective torque which is shown in FIG.2A.
FIG.3A As of now in position of the blade 16, the first number of blade bracket clamp 25A is attached to the first quadrant with the support of manual force 46. At least one manual force 46 access by rope techniques according to the work positioning, the bracket clamp 25A is attached to the circumferentially with respect to the outer blade root. The holes provision of blade bracket clamp 25A is transversally to the barrel nut holes of the blade 16 enter the fasteners along a substantial length to tighten the blade bracket clamp 25A with respective torque of Figure 2A. Further it comprises, the connecting plate 26 is attached by the blade bracket clamp 25A to circumferentially with respect to the blade root portion for cover the first quadrant. Enter the stud/ or pins 27 and nuts 27A for tightening with respective torque to mounting gap between bracket clamp 25A and blade 16. Drive the blade 16 as required direction of revolution to variable pitch against the axis of rotation. Further the second part of blade bracket clamp 25A to be attached in second quadrant and the connecting plate 26 is disposed circumferentially with respect to the profile of outer blade root. The fasteners is used to provision of holes available between blade bracket clamp 25A and blade 16 to be tightened; symmetrically, the second part of blade bracket clamp 25A and connecting plate 16 holding fasteners or pins 27 is vice versa.
FIG. 3B shows the explanation of first adjacent blade 16 to the blade bracket 25 fixing blade, the number of studs or bolts 20 associated with the blade pitch slewing ring bearing flanges may be preferentially about the selective fasteners to be removed by manually equipped tools or hydraulic equipments. Thus preferred removed studs or pins 20 and nuts 27A at-least three numbers from the respective provision of blade pitch slewing ring bearing 17; the top blade jig 24 is attached to the bearing flanges. The suitable length of pins or fasteners 27 is engaging holes to the longitudinal axis to the circle diameter as to line up with tighten to provide the specific torque values attained by torqueing tools.
FIG.3C illustration of this present invention embodiment, the rotor lock (not shown) is disengage and rotate the hub 15 from ten-o’ clock position to two-o’ clock position, further it enables the rotor lock by manually or hydraulically or vice versa to holding the further movement of the rotation of the rotor 14. Further it comprises, the third position of the blade bracket clamp 25A is attached to the rotor blade 16 with respect to the circumferential of the outer blade profile in root side and the selective barrel nut holes to engaging the fasteners 27 by fixing the respective torque which is access to fix the blade bracket clamp 25A by rope techniques to reach the working positions like climbing, caving, etc. Further it exceeds the connecting plate 26 to be attached with blade bracket clamp 25A in third quadrants from the joint of second quadrant. At vice versa, the fourth quadrant attachment is required to pitch the blade 16 accordingly for fixing the blade bracket clamp 25A, further engage the fasteners/ or pins 27 and nuts 27A in transverse axis to the blade barrel nut holes with applying by specified torque value for holding by twisting force. Herein further mounting the connecting plate 26 to complete the quadrant over the circumferential said at top of the outer blade profile and tighten the fasteners like pin or bolts 27 and nuts 27A with respective torque. More particularly, the adjacent blade (left side)to the failure blade the attached specified studs 20 is removed from blade pitch slewing ring bearing 17 holes around the circumference of the rotor hub 15. The second top jig 24 plates is mounting on adjacent rotor blade pitch slewing ring bearing 17 outer flanges in line up symmetrically with respect to the removed nut 27A and studs from the holes. A plurality of fasteners like stud or pin 27 and nut 27A is provided to the attachment of top jig 24 for the respective holes symmetric to the adjacent blade pitch bearing holes. The respective tightens is facilitate to the nuts 27A by the specific torque value with selective equipped tools.
FIG.3D As per the present invention of method, the rotor hub 15 is enables in holding position, rotated from two-o’ clock position to six-o’ clock position and enables the holding in rotor hub 15 for further rotation movement. Then it further comprises to engage the rotor disc lock to ensure the blade bracket 25 attachments by manual force 46. The failure blade 16 is preferentially direction to pitch the respective position to fixing the receptacle 42 according to the blade profile in tail end.
FIG.4 illustrates an embodiment of the tower bottom jig 23 is a ring like structure, which according to one embodiment is circular in shape or anchor bolt jig 23 (not shown) attached to the bottom of the wind turbine tower 13 according to the circumferential shape or wire rope attached to the lattice tower (not shown). The tower bottom jig 23 includes the means to mount the first pulley 34 thereon. In one embodiment, the tower bottom jig 23 is made of standard steel and the first pulley 34 is made of both steel and nylon. Typically, the tower bottom jig 23 is designed depending on various factors such as the tower bottom circumference, the load to be balanced by the pulley attached to the tower bottom jig 23 and the convenience of attaching and releasing the tower bottom jig 23 from the bottom of the tower 13. In one embodiment, the tower bottom jig 23 is clamped around the tower bottom 13 and fastened with the use of bolts and pins 27 and nuts 27A (not shown) for holding the first pulley 34, including used to lifting line 31 between load bearing mechanism 29 and second pulley 35 for lifting or lowering the load.
FIG.5 illustrates embodiments of portable hoist 47 constructed by rope drum, wire rope 31, motors, and other related functional controls are present in the system to operate by electrically and it’s fixing in the adjacent blade to the failure blade 16 for lifting the first web welt 40 with holding mechanism 39 is hereby metallic components. The symmetric view of selective bolts or studs 27 and nuts 27A in the provision to be removed, corresponding to the portable hoist 47 fixing in the adjacent blade 16 of blade pitch slewing ring bearing 17. Then mounting the portable hoist 47 with fastens the suitable studs or bolts or pins 27 with nuts 27A to tighten the attachments. Then the wire rope 31 is lowering to the ground 11 for lifting the first web belt 40 with holding mechanism. The rotor blade 16 may include the first web belt 40 is attached to the adjacent blade 16 of the six-o’ clock position blade 16. The manual force 46 is enables to rope access by connected the metallic joints in first web belt 40 and it’s further attached by the second pulley 41. Further it comprises the portable hoists wire rope 31 is lowering to the ground for coupled the traction hoists wire rope 31 and lifting to attach from the first pulley 34 in-line with the second pulley 35 and lowering into the ground. Then the portable hoist wire rope 31 is rewind the part of rope drum and demounted from blade pitch slewing ring bearing 17. Further in the term of placed in the ground of load bearing mechanism wire rope 31 is removed from the drum and connected to the third pulley 36 in line with the fourth pulley 37 with the holding mechanism 39 of clamp or wedge socket to closed the end part of wire rope 31 in the term to called as gun tackle arrangement 38.
FIG.6 illustrates a perspective view of lowering the traction hoist wire rope 31 attaching the gun tackle arrangement 38 in adjacent blade 16 in both sides. The first pulley 34 carries the lifting line 31 from the traction hoist 30 and it is placed above the load bearing mechanism 29 installed on the ground 11. The first pulley 34 attachment is in-line with second pulley 35 grooves which is perpendicular direction of the both pulley groove. i.e the second pulley 35 is attached to the first web belt 40 in adjacent blade 16. The wire rope 31 releasing from the load bearing mechanism 29 and its end is threaded through the third pulley 36 groove and further threaded between fourth pulley 37 mounting in ground, preferentially used to lift up or lift down the failure blade 16. One aspect of present embodiment of the third pulley 36 is at least two way and fourth pulleys 37 is at least one way are assembled together to form blocks and then blocks are paired so that one is fixed and one moves with the load during erection of blade 16. This lifting arrangement assembly according to the block-and-tackle arrangement 38 formerly used for raising or lowering a blade 16 and the pulley may be fabricated from a plate of alloy steel and nylon or similar material. This second web belt 41 with holding mechanism 39 and gun tackle arrangement (third pulley in-line with fourth pulley system arrangement) 38 rising by operating control of pulling the wire rope from traction hoist 30 of shown in FIG.6A for holding the bracket 25. Further it comprises the second web belt 41 cum gun tackle arrangement 38 is attached next to the first web belt 40 to the adjacent blade of the six-o’ clock position blade 16 with the additional supports to complete by manual force 46 . To accomplish the attached second web belt 41 is closed by metallic joints is otherwise say as holding mechanism 39.
As illustrated in the FIG 6A, according to one embodiment, two second pulleys 35 are mounted on the first web belt 40 in two wind turbine blades 16 adjacent to the blade being lifting the third pulley 36 and fourth pulley 37 threaded part is say as gun tackle arrangement of wire rope along with second web belt 41. The rope is pulled from traction hoist 30 connected the first pulley 34 in bottom jig 23 and in-line with the second pulley 35 for raising the gun tackle arrangement 38 in positioning to attach the second web belt(optional) 41 or top jig 24 and bracket 25 respectively as shown in the arrangement of FIG.8 and FIG.8A. The gun tackle arrangement 38 may be attached to the second web belt (optional) 41 or top jig 24 and blade bracket 25 withhold by holding mechanism 39 and it is accessed by rope access manual force 46. In one embodiment the rope access manual force 45 is working in wide range of work at height positioning developed from techniques used in climbing and caving, which applies practical rope work to allow manual force 46 to access required locations without the use of any platform.
Herein the system further includes a receptacle 42 constructed of at least one of a belt according to the tip of the blade profile. The traction hoist rope 30 is lowering and attached to the receptacle 42 being lifted and attaching a tip of the blade and tighten the strap. According to one embodiment the receptacle 42 is lifted and attached by the wire rope 31 from traction hoist 30, and connected to the first pulley 34 in-line with second pulley 35. Further the traction hoist rope 31 is released from second pulley 35 and first pulley 34 subsequently re-rolled in the drum. Further the operation is co-ordinated the load bearing mechanism rope 31 is attached on the first pulley 34, then attached to the arrangement of gun tackle system 38 which is extensively attached to the top jig 24 or second web belt (optional) 41 and bracket 25. The wire rope 31 selection is depending on design factors such as weight of the blade 16, the surface curvature of the blade 16, wind velocity, gusty load and other load calculation. The blade bracket 25 further has provisions to get attached to the fourth pulley 37 with the assistance of a holding mechanism 39. In one embodiment, the blade bracket 25 is a steel or equivalent material. The advantage of using blade bracket 25 is its high load carrying capacity, and its ability to hold its shape. According to one embodiment, fixing the adjacent blade receptacle is a first web belt 40 and second web belt (optional) 41 is designed to carry 7 times the weight of the wind turbine blade 16 or fixing the adjacent blade top jig 24 is designed to carry 2 times the weight of the wind turbine blade 16.
More particularly in the operation of de-erecting the wind turbine blade 16 begins with ensuing different safety considerations. An appropriate location is identified in order to install the load bearing mechanism 29 which is operated by manual force 46. In one embodiment, load bearing mechanism includes two electric winches 29 installed at suitable positions and at equal distances from the center axis of the wind turbine. Typically, the installation is done by driving at least one peg 32a (not shown) through a platform into the ground. Further, counter weights 32 in the form of concrete blocks (not shown), are also provided to the platform attached to the load bearing mechanism 29. The key purpose of the pegs 32a and the concrete blocks is to balancing the load, stability of mechanical system, make lifting the load more efficient, avoid slip and sliding of the load bearing mechanism 29 during operation.
FIG.7 illustrates a top view of pulley lifting tool 49 placed in the hub. According to one embodiment, the pulley lifting tool 49 is fabricated by number of parts like vertical post 49A, lifting arm 49B, lifting hooks 49C, base 49E, stay support 49D and made it is by steel which is designed to carry 2 times the FOS(Factor of safety) or maximum size of the lifting component such as gun tackle arrangement 38, lifting line 31, traction hoist 30 and chain hoist 50. The installation of the pulley lifting tool 49 is lifted by machine head hoist 22 and further it comprised to fixing the pulley lifting tool 49 in top of the hub 15. The required bearing stud 20 are removed by hydraulic or manual tool accessories, further the base 49E is fixed to adjacent blade bearings 17, the corresponding fixing holes are symmetrically match with between base 49E and blade bearing 17 bolt holes. Then enter the selective studs and nuts 27 are used to tight by suitable torque. Further fix the vertical post 49A in top of the base by suitable bolt and nut for joint 27, then the lifting arm 49B is placed in the vertical post 49A based on the projection of holes. Then the lifting hook 49C is extensively welded in the edge of the lifting arm 49B. The lifting arm 49B is designed to carry the suitable load for using lifting purpose. In opposite to that lifting arm 49B post, the stay support 49D is connected to the hub 15 or machine head 21 permanent anchorage points and stay lifting hook part in lifting arm 49B.
FIG.7A illustrates an embodiment represents the second alternative option for lifting the gun tackle arrangement system 38 and its assembly in adjacent blade 16 for removing the failure blade 16 by traction hoist 30 is placed on the lifting hooks attached with the pulley lifting tool 49. With respect to right hand side, the wire rope 31 is released from the drum to lift down in ground surface 11, and then threaded the gun tackle arrangement 38 along with web belt 41 attachments by traction hoist 30 rope 31 and lifting from the ground surface 11. By operating the traction hoist 30 control systems, the gun tackle arrangement system 38 are reached the nearest point in the adjacent blade 16’, the rope access manual force 46 is access to support the assembly of gun tackle attachment 38 in adjacent blade 16’. Once complete the assembly, ensure the gun tackle wire rope arrangement 38 in line with respect to exact pulley groove, then the fourth pulley hook 37 is connect into the blade bracket 25 hooks by holding mechanism 39. Similar to the right hand side, rotate the lifting arm 49B in left hand side and follow the same preparation of gun tackle arrangement 38 fixing in adjacent blade 16 or further more alternate option as well as without second web belt 41, the gun tackle arrangement system 38 in lifting by traction hoist 30 and fixing in top jig 24 directly and it’s forth pulley 37 hook is connected to bracket 25 hook.
FIG 7B illustrates an embodiment explained the third alternative option for lifting the gun tackle arrangement system 38 and its assembly in adjacent blade 16 for removing the failure blade 16 by chain hoist 50 is placed on the lifting hooks attached with the pulley lifting tool 49. With respect to right hand side, the wire rope/lifting line 31 is released from the chain hoist 50 drum to lift down in ground surface 11, and then threaded the gun tackle arrangement 38 along with web belt 41 attachment by chain hoist 50 rope and lifting from the ground surface 11. By operating the chain hoist 50 control systems, the gun tackle arrangement system 38 are reached the nearest point in the adjacent blade 16, the rope access manual force 46 is access to support the assembly of gun tackle attachment 38 in adjacent blade 16. Once complete the assembly, ensure the gun tackle wire rope arrangement 38 in line with respect to exact pulley groove, then the fourth pulley 37 hook is connect into the blade bracket 25 hooks by holding mechanism 39. Similar to the right hand side, rotate the lifting arm 49B in left hand side and follow the same preparation of gun tackle arrangement 38 fixing in adjacent blade 16 or further more alternate option as well as without second web belt 41, the gun tackle arrangement system 38 in lifting by chain hoist 50 and fixing in top jig 24 directly and it’s fourth pulley 37 hook is connected to bracket 25 hook.
FIG.8 illustrates according to an embodiment, the installation also includes two rope guide stands (not shown) for supporting tag lines 43 in bracket 25 attached to the root of the blade 16 and receptacle 42 attached to the tip of the blade 16. In one embodiment, the turbine is yawed and the wind turbine blade 16 to be removed is brought to a six-o’clock position. In one embodiment the rotation of the wind turbine blade 16 to the six-o’clock position is done manually or electrically or hydraulically, however, it may be done with the assistance of external tools or by the force of the wind. Once the wind turbine blade 16 to be removed assumes the six-o’clock position, at least one lock (not shown) is applied on the rotor disc to avoid any further rotation. In one embodiment, the lock is of brake disc type. The locking is at least of a mechanical/hydraulic type. This is followed with the torque release in failure blade 16 according to the bolt pattern. In one embodiment, the torque release is conducted for about 50% of the blade studs 19 (not shown) in an alternate manner. This is followed by the release of the blade studs 19 performed from a group of any one of them is consisting of hydraulic, electric and mechanical. The bolts and pins (not shown) 27 are fastened either manually, hydraulically or pneumatically. Further the operation is simultaneously coordinated between both operators of the load bearing system 29 to take up taut evenly between load bearing system(left side and right side) 29. In one embodiment says the operator 45 is qualified by trained or certified. According to the load, the first wire ropes 31 may be tightened through the first pulley 34 attached to the bottom jig 23 in left side; the wire ropes 31 may be tightened through the third pulley 36 attached to the jig in right side. A first lifting line 31 from a first pulley 34 to the third pulley 36 further in-line with the gun tackle arrangement (connected between third pulley and fourth pulley) 38 in left side and right side with frequent interval. Once the wire ropes 31 may be held tightly in position, the load bearing system control is stopped as even length coordinated operation; the balance rotor blade stud nuts 19 are loosened to its maximum looseness, allowing the final at-least four studs 19 to be in locking condition.
Once all the connections and the joints are cross checked, the remaining stud nuts 19 holding the wind turbine blade 16 to the hub 15 are released. A load bearing system 29 may further operated as per differential length of the wire rope 31 distance between blade 16 and its hub flange according to the tension/tightening of the wire rope 31. The rotor blade tagline 43 may be guided as the manual force 45; the tag line rope 43 is attached to supporting and guiding the controls of direction. In one embodiment a plurality of taglines 43 may be attached to the rotor blade 16 for lateral support during lifting and lowering. The operation of the load bearing mechanism 29 releases the blade with a downward descent hence de-erecting the wind turbine blade 16 from the attachment of the hub 15., where the load supporting mechanism 44 can operate, a rope coupled to the first pulley 34 attached at the bottom jig 23 of the tower 13; further connected with third pulley 36 in top jig 24/second web belt 41 and finally attached to the fourth pulley(Gun tackle arrangement) using holding mechanism 39 is connected with the blade bracket 25 connected on the wind turbine blade 16. Operation control is coordinated between the operators of both load bearing mechanisms rope 31 is to drooping evenly.
FIG.9 illustrates a tremendous view of erecting the blade evenly by operating the load bearing mechanism 29. According to one embodiment, the lifting line is a wire rope 31 load supporting mechanism is say as pick ‘n’ carry crane 44 and the man basket is to carry the person/manual force 46 and required tools to lift. When the rotor blade 16 is at a nearest point, the winch 29 operation is stopped and blade tip is attached to the load supporting mechanism 44 by web belt 42a which is attached on the time of receptacle 42. Figure 10 illustrates the side view system of erected blade for changing the position from vertical position to horizontal position by fixing the web belt by load supporting mechanism. As detail view represented in FIG.10A shows a projection of one manual force 46 is reached by the man basket 45, with the support of another load bearing mechanism is holding the man basket 45 to access the web belt holding between web belt 42a and load supporting mechanism 44. Further the manual force 46 is reach the nearest portion of the blade tip, the web belt 42a in tip side of the blade is couple the load supporting mechanism 44 hook, which is attached to the tip of the blade 16.
FIG.11 illustrates the operation control is coordinated from vertical orientation to horizontal orientation of the blade. The lowering of the blade is operating between the operators of both load bearing mechanisms rope 31 is to drooping evenly. The changes are occurred in the orientation of the wind turbine blade 16 from vertical position to horizontal position according to load supporting mechanism 44 movements. The load bearing mechanism 29 controls the movement of the blade, the complete lowering is coordinated by load bearing mechanism 29 accomplishment of horizontal position of FIG.11A.
FIG.12 illustrates the position of the blade in portable stand 48. Once the wind turbine blade 16 positioned is parallel to the surface of the ground 11 and placing into the root stand 48 as well as tip stand 48 simultaneously; further corresponding to the operation control of load bearing mechanism 29 and load supporting mechanism 44 of manual force 46. Further reaches the exact position of the blade 16 into stand 48, all the necessary load supporting mechanism hooks, bracket 25, holding mechanism of fourth pulley 37, receptacle 42, fasteners like bolt/pin/stud 27, nuts 27A and other attachments are demounted from the blade 16. Once removing the attachment, the necessary items are placed as it is such as bracket 25, load supporting mechanism 44, etc.; the fourth pulley 37 is removed from the bracket hook and hold in bottom jig hook shows as in FIG.12A.
In order to re-erect the wind turbine blade 16, the process, as mentioned above, is reversed to the lowering operation. A replacement of rotor blade 16 is positioned on the ground directly underneath and perpendicular to the hub 15. The blade bracket 25 is attached to the rotor blade 16. The load bearing mechanism wire rope 31 is connected the holding mechanism 39 to blade bracket hooks in-line with first pulley 34, gun tackle arrangement 38 of third pulley 36 and fourth pulley 37. In order to re-check visually and comply the attachments/or fittings/or holding of every tools to the raising the component in 360 degree. The operation is coordinated and controlled the wire rope 31 in required tightness to fit snugly on new blade/service blade 16. Further the tag lines 43 are attached to the bracket 25 in root of the blade 16 and receptacle 42 in tip of the blade.
Specifically the attachment is described previously. At least one load bearing mechanism 29 installed on the ground pulls on the lifting line 31. The replacement of new/service blade 16 is raised using the coordinated operation control is followed by load bearing system 29 and load supporting mechanism 44. This causes the wind turbine blade 16 to change orientation from a horizontal position to a vertical position. When the blade 16 reaches a vertical direction, the load bearing mechanism 29 operations is stopped and the corresponding load supporting mechanism holding 44 is disconnected and removed from the part. Further the lateral movement of the replacement blade 16 is controlled with the taglines 43. The load bearing system 29 is operated according to the desired movement, until the rotor blade 16 gets close to enough to the face of the hub flange to mount with the blade 16. The team in the nacelle 21 re-connects all the bolts and fittings which were taken apart while re-erecting the wind turbine blade studs 19 with the correct holes to aligning zero position of the blade 16. Further it’s aligned in exact position, the load bearing system 29 operation is stopped and the tightening the nuts on the studs 19 with specified torque according to be followed the bolt torqueing pattern.
Further ensures the value of the torque in blade stud nuts 19, in and around the disturbed item of other electrical/ hydraulic accessories to be fitted in the rest of the same position. The tag lines 43 are removed from the respective position of the tip side of the blade 16 and root side of the blade 16 attached to the bracket 25. The holding system 39 of fourth pulley 37 is disconnected from the blade bracket hooks. By using the traction hoist wire rope 31, the gun tackle arrangement 38 and second web belt 41 is being removal or removal from hub of wind turbine tower 13 for lowered to the ground. The lifting lines 31 are then lowered to the ground. In the same position of rotor 14, the second pulley block 35 attached with first web belt 40 is removal and then lowered from the adjacent blade 16 root. The gun tackle arrangement 38 is dismantled and re-rolled the wire rope 31 into winch rope drum. The wire rope 31 of traction hoist 30 is lowered and re-winds the wire rope 31 into the drum. The bottom jig 23 and the first pulley 34 is removal from the circumference of the tower 13. The rotor locks are released and the rotor 14 is positioned for removal of the bracket 25 and its connecting plate 26 on the blade root side (first quadrant). The required pitch angle is operated to rotate the blade 16 for removal the connecting plate 26 and bracket 25 is attached in the second quadrant. Simultaneously the top jig 24 is removed from the adjacent blade of the rotor. Enter the respective studs 19 to tighten the right position of the blade stud holes. Then the rotor 14 is to positioned for removal of the third quadrant and fourth quadrant brackets 25, connecting plate 26 and top jig 24 vice versa., Finally all the barrel nuts 18, blade studs 19 are entered the replaced blade holes and tightened the stud nuts 27A with specified torque respectively. Alternatively, lowering the gun tackle arrangement can be carried out through pulley lifting tool by traction hoist or chain hoist.
The most significant advantage of this invention is more than half part of the damaged blade or uneven size of the broken blade can also be easily brought down by this concept of blade holding bracket tool. So, this solution has the advantage of easy mobilization of winch, traction hoist and other equipments, as the cost is meagre and easily carries through. Only two operators are required to operate the electrical winch and/or traction hoist. Minimum time is required to assemble on the ground surface where the winch can be located. Correspondingly the nacelle is yawed as required for positioning the blade to carry out the de-erection and re-erection activities. Easy unloading of new blade and loading of damaged blade is possible wherever the work is being executed. This method and system, consumes less fuel and is eco-friendly, almost negligible risk and less execution time also when comparing to the conventional crane method and hence the benefits are passed on to the concerned.
This invention of lowering and raising the single blade from rotor hub with blade holding bracket tool is applicable for all hub heights and different types of tower like closed type tubular tower, lattice tower and hybrid tower accordingly. Specifically, it is designed to use on horizontal axis wind turbine models in both pre-bent and straight bent blades. It is applicable for different drives of gear and direct drive or gearless in horizontal axial wind turbine
When an element is referred to as being “mounted on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a system and method for de-erection and re-erection of a blade of a wind turbine, which:
• works for KW and MW class wind turbines;
• can be performed by the first operative tools i.e., a blade bracket/clamp;
• can be performed by the second operative tools i.e., a load bearing mechanism/winch;
• can be performed by the alternative supportive operative tools i.e., a pulley lifting tool or traction hoist or chain hoist or portable hoist;
• effectively neglected the heavy duty cranes as equal to wind turbine height;
• effectively minimizes the use of a pick-and-carry crane;
• can perform the operation at greater heights;
• works for any type of wind turbine tower models;
• is portable;
• is cost-effective;
• can be used on any type of terrains;
• is time effective;
• is green technology; and
• is reduced down-time and hence improved machine availability.

The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.