Modular Systems for Wind Turbine Assembly

Abstract This paper presents an innovative design and construction approach for a 220mhigh wind turbine tower, designed to meet the increasing demand renewable energy specific needs of largescale projects. The leverages hybrid structural concept with concrete foundation that supports three inclined legs composite concretesteel main optimizing both stability constructability. An analysis various load conditions, including pressure, natural frequency, embodied CO 2 emissions structure, is conducted ensure sustainable efficient performance. methodology utilizes modular, segmental assembly advanced lifting techniques, allowing effective installation. also proposes adaptation challenging environment, such as deep offshore scenario, by introducing method floating system. findings demonstrate potential this tower improve generation efficiency, reduce carbon footprint, set new benchmark future

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Manufacturing wind turbine rotor blades with segmented upper molds that can be assembled around the lower mold without needing excessive overhead clearance. The rotor blade molds consist of a lower mold and a segmented upper mold. The segmented upper mold has a root end section and multiple airfoil sections. The root end section is placed next to an airfoil section, then slid into position at the root. The airfoil sections are then positioned. This allows the upper mold to be assembled around the lower mold without needing the entire height of the blade length. The segmented upper mold sections can be handled sideways for assembly/disassembly.

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A self-elevating wind turbine design that allows onsite assembly and maintenance without the need for heavy lifting equipment. The turbine has a unique substructure with upper and lower guide collars to support and elevate the tower segments. This enables stepwise vertical assembly of the turbine using hydraulic cylinders, winches, or rack/pinion systems instead of cranes. The substructure is preferably a lattice structure to maximize steel usage. The tower segments are assembled on the ground, lifted into place, and connected. The rotor is mounted first, then the rest of the tower is built up. This simplifies assembly, reduces costs, and allows easier maintenance compared to monopole towers.

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A modular louver design for wind turbine nacelles that allows customizable blade length and angles while reducing complexity and cost compared to one-piece blades. The louver blades are made of multiple connectable segments with interfaces, gutters, and fixation points. This allows adjusting blade length by adding/subtracting segments, rather than having separate blades for each nacelle size. The blades have a flat first side for smooth airflow and gutters on the second side to catch water. The segments connect using grooves for clamping elements. This modularity enables customization without needing specific blades for each frame size.

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Modular, offshore wind turbine system for large scale production of green hydrogen fuel using seawater electrolysis. The system consists of a floating tower with a wind turbine, lift pump, desalination unit, and electrolysis unit. The wind powers the pumps and electrolyzer to pump seawater, desalinate it, and split it into hydrogen. The hydrogen is exported via a riser to a pipeline or manifold on the seafloor. Multiple turbine modules can be combined into a field connected to pipelines for scalability. The system is self-contained, self-sufficient, and modular for large scale hydrogen production offshore.

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A floating wind turbine platform design that allows efficient assembly and transportation of the offshore platform. The platform has a T-shaped hull with three stabilizing buoyant columns supporting the platform. The hull is constructed in two separate pieces: a first pontoon with two columns and an inner part of the second pontoon, and an outer part of the second pontoon. These pieces float stable. They're joined at sea to complete the platform. This allows assembly at a sheltered location close to the final site. The separate pieces can be transported together on a ship, unlike a complete hull.

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Abstract The proposed concept (patent pending) is a modular, centrally located Wind Turbine Generator (WTG) floating offshore wind foundation that features simplified design, accelerated construction, and rapid assembly installation. A method for counterbalancing the also presented designed to be simple, with fast response times, ease of inspection maintenance, high reliability, remote operability. This paper explores novel approaches foundations, including new methods, aims drastically reduce overall costs, potentially by half or more. solutions are innovative have potential transform existing technologies in development energy.

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A foundation for offshore wind turbines that allows for easier and more efficient installation compared to traditional steel pile foundations. The foundation has a concrete support structure that attaches to the top of a driven pile. The concrete structure extends above the water surface and supports the wind turbine. This allows the turbine to be installed in sections on the concrete structure rather than directly on the pile. This eliminates the need to transport and install large steel piles at remote sites, as the concrete structure can be manufactured locally and assembled on site. It also allows for easier adjustment of the pile alignment during installation.

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Stabilizing wind turbines using tether cables attached to an intermediate interface module between the lower and upper sections of the tower. The module has ears that connect to the cables and bores aligned with the tower section through-holes. Threaded fasteners secure the module to the lower section. This allows tensioning the cables before attaching the upper section. The cables stabilize the tower by providing additional load support beyond the tower's self-weight. The module provides a convenient attachment point for the cables and avoids tower modifications.

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Balancing a wind turbine rotor without permanent weight additions or removal by using temporary weight balancing cartridges that can be easily inserted and removed from the blade tip. The method involves detecting rotor imbalance, calculating required counterweight, manufacturing custom cartridges with that weight, inserting them into the blade tips, and then removing them after balancing is achieved. This allows dynamic balancing without modifying the blade structure or causing long-term imbalance issues.

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Wind turbine blade with an improved access window and method for manufacturing. The blade has an access window through the shell with a recessed area at the inner surface. A closing panel with a thicker center and thinner outer tongue fits into the recess. Straps attach the tongue to the shell to prevent rotation. This provides access to internal blade parts without needing a separate hatch. The recess prevents water ingress and pressure leakage. The panel can be inserted through the window, rotated, and fixed in place. The blade segments can be separated, joined, and the panel inserted/removed to access internal structures like spar beams.

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System for manufacturing large scale composite structures like wind turbine blades using molds that provide precise placement and assembly of internal components like spar caps. The molds have apertures for pins to extend into the molded layers. The pins engage the internal components during layup to hold them in place. After layup, the pins can extend beyond the molded section to be trimmed. This prevents internal component misalignment during mold closure. Additional features like studs, cams, and actuators enable further component positioning and measurement.

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Wind-driven electricity generation system with vertical towers and rotating blades inside. The towers have protruding walls that create wind collection sections. Air pressure builds in the sections and releases through openings into an inner compartment. Drive shafts rotate from the airflow. This turns generators, pumps, or transmission gear inside. Multiple tower levels allow scaling. The rotating blades inside eliminate the need for external blades. Closable openings allow maintenance. The system captures more wind pressure and uses it inside for efficient electricity generation.

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A method for assembling wind turbine components to reduce assembly time and costs by allowing personnel to remain in the tower during lifts instead of evacuating and repositioning. The method involves lowering the component to overlap the mounting interface vertically with a threshold separation. If the separation exceeds the threshold, an indicator alerts. This ensures the component can be connected without needing to evacuate and reposition personnel between lifts. The indicator uses a transmitter/receiver to verify separation during overlapping.

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A modular mold for producing wind turbine blades that allows easy adaptation of blade length without needing to cut and replace the mold. The mold has a modular design with interchangeable tip sections that can be swapped to match updated blade geometries. The mold has a main body shell element and multiple exchangeable tip shell elements that can be fixed to the support. This allows changing the tip sections to match blade length changes without needing to modify the entire mold. The tip sections connect using flanges with aligned bolt holes for easy assembly. The modular tip sections can be different lengths to cover a range of blade tip geometries.

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Improved assembly and installation method for wind turbines on floating foundations that allows for more effective assembly of the wind turbine on-board the crane vessel. The method involves using the crane vessel's hull to receive and lift portions of the turbine's mast during assembly. This reduces the crane's height requirement when installing the turbine on the floating foundation. The crane also has a mast-engaging device to precisely position the mast on the foundation. The blades are handled using a specialized system that tilts them during installation/removal. This allows lifting the blades horizontally to the root end instead of vertically. It also involves sinking part of the mast into the vessel's hull during assembly. This reduces the crane's lifting height requirement.

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Tool for handling wind turbine tower sections during transportation and erection to make it easier and more efficient compared to traditional methods. The tool has two wheeled platforms with a frame connecting them. The frame has sections that support the ends of a sling. The tower section hangs between the sling ends supported by the frame. This allows the tower section to be moved and upended using the tool as a single unit, without needing frames or supports on each end. The tool's parallel bases and sling-hanging frame enable the tower section to be centered and balanced during handling.

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Modular wind turbine blade design with improved lightning protection at joints. The blade has multiple sections that can be transported separately and assembled on-site. To prevent lightning strikes from damaging the joints, the blade has an electromagnetic shield that extends across the joints. This shield isolates the joints from the main lightning current path, protecting the blade sections from voltage flashovers. The shielded joints allow lightning strikes to be received and safely discharged to ground without damaging the blade.

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Industrialized, cost-effective method for constructing and assembling offshore wind turbines using self-erecting lift structures, modular floating turbine sections, and specialized installation vessels. The method involves: 1) building modular floating turbine sections in a shipyard, 2) towing the sections to an offshore platform, 3) assembling the turbine on the platform using a self-erecting lift structure, 4) connecting the floating turbine to an installation base on the seafloor, 5) disconnecting the turbine from the base and raising it to float, 6) towing the assembled turbine to its final location. This allows serial production of modular turbine sections, transporting them to a central hub for assembly, and then deploying them from a fixed platform.

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A connection system for attaching a blade access system to a wind turbine nacelle that allows quick and repeated attachment without cutting holes in the nacelle housing. The system uses locking connectors that can be engaged and disengaged between the blade access system and nacelle. The connectors have compatible locking mechanisms to secure the access system to the nacelle when engaged, but allow disconnection by repositioning the connectors. This provides a repeatable and easy way to attach/detach the blade access system without needing to cut into the nacelle housing each time.

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