An improved method of installing large structures such as wind turbines
This document claims priority to document AU 2023902768 filed on 28 August 2023 the contents of which are hereby incorporated by reference in their entirety.
Technical field
The present invention relates to a method for installing large structure. In particular, it relates to a method of stacking sections of a large structure such as a wind io turbine.
Background
The construction of large structures, from skyscrapers to bridges, presents a series of challenges that demand planning and careful execution. The assembly of these large structures requires precision engineering and the coordination of massive components, often involving the integration of sections weighing several tonnes.
Wind turbines are an example of a large structure. Constructing wind turbines involves assembling large sections, each of which can extend up to about 100 meters in length and weigh up to about 150 tonnes. These sections are stacked on top one another. This assembly or installation of the sections takes place under the direction of a crane operator situated at ground level. However, the towering height of the wind turbines, presents challenges. The crane operator's view can be limited but precision is required to prevent costly damages during section integration.
Throughout the assembly process, technicians positioned around the points of assembly play a critical role in guiding each section into place. This task demands work at considerable heights, often beneath the suspended load. Communication between these technicians and the crane operator is frequently facilitated by handheld radios, but the reliability of these devices' battery life can pose risks. A failure of the device during the final stages of assembly could lead to severe injuries or worse.
Unpredictable weather conditions also compound the risks. Sudden fog can descend upon work sites, drastically reducing visibility and making it challenging for technicians working at heights to discern the load, further intensifying the danger they face. Moreover, the wind turbines'size can increase the challenges faced. When structures sway or shake due to external forces, workers must refrain from being on the turbine, delaying work until conditions are safer.
This worldwide practice of wind turbine construction exposes workers to substantial hazards, including the potential for falling loads or pinch point injuries. Factors such io as communication unreliability, adverse weather, and the extreme height of the structures amplify these risks, underscoring the critical need for stringent safety measures and advanced technologies to protect the well-being of those who ensure the turbine's successful installation.
Summary of invention
In a first aspect there is provided a method of installing a large structure e.g. a wind turbine, wherein an at least partially hollow first section of the large structure is aligned and coupled with a second section of the large structure, the method comprising the steps of installing the first section or identifying the first section already installed, the first section having a top edge for coupling with a bottom edge of the second section; providing a panoramic camera in the hollow of the first section, the panoramic camera able to detect at least the inner rim of the top edge of the first section; lifting, using lifting equipment, the second section and moving it near to the first section, wherein, at least during lifting, receiving live information from the panoramic camera; the live information comprising a live display of the bottom edge of the approaching second section, and static guidelines overlaid on the live display for assisting in guiding the installation of the second section; wherein the static guidelines represent an inner periphery of the top edge of the first section with decreased dimensions; controlling the movement of the second section using the live display and static guidelines to align and then couple the top edge of the first section with the bottom edge of the second section to thereby install at least a part of the large structure.
Also provided is a system for installing a large structure e.g. a wind turbine, wherein an at least partially hollow first section of the large structure is aligned and coupled with a second section of the large structure, the system comprising: a panoramic camera in the hollow of the first section, the panoramic camera lo able to detect at least the inner rim of the top edge of the first section; lifting equipment for lifting the second section and moving it near to the first section, a display coupled to the panoramic camera for receiving live information from the panoramic camera; wherein, at least during lifting, live information is received from the panoramic camera to the display; the live information comprising a live display of a bottom edge of the approaching second section, and static guidelines overlaid on the live display for assisting in guiding the installation of the second section; wherein the static guidelines represent an inner periphery of a top edge of the first section with decreased dimensions; wherein movement of the second section by the lifting equipment can be controlled using the live information and static guidelines to align and then couple the top edge of the first section with the bottom edge of the second section to thereby install at least a part of the large structure.
In an embodiment, the present method can reduce the need for personnel to assist in guiding the second section into position relative to the first section. By using the live display with guidelines, in embodiments, the operator controlling the movement of the second section can rely solely on the live display with guidelines and does not need a clear line of sight to the structure. Furthermore, there is a reduced need for personnel to be at the point of assembly to assist with the installation process.
In the construction industry, a wide range of large structures are installed, each tailored to specific functional requirements. Notable examples encompass high-rise buildings and skyscrapers, necessitating robust engineering to withstand gravitational and lateral forces. Bridges, ranging from pedestrian walkways to complex vehicular spans, demand design for load distribution and durability. Additionally, structures like dams and water treatment facilities are pivotal for water management and flood mitigation. In the realm of energy, wind turbines play a role, featuring complex assembly processes and considerable heights. Offshore platforms, designed to withstand marine environments, are integral to oil and gas exploration. In embodiments, the present invention is directed to the installation of wind turbines; however, it should be understood that it is applicable to the io installation of other large structures with similar characteristics.
Many large structures in the construction industry, including wind turbines, often incorporate hollow sections in their design and construction. Hollow sections offer various advantages such as reduced weight, improved structural efficiency, and the potential for incorporating utilities or internal components. When coupling hollow sections in construction, a substantially seamless integration can be achieved by aligning the top edge of a previously installed section with the bottom edge of a second section. This coupling method can ensure structural continuity and stability between the two sections. The top and bottom edges can be designed to interlock with one another, creating a stable assembly.
While a first section is described as assembled with a second section, it should be understood that the construction of large structures often involves the assembly of multiple sections, extending beyond just a coupling point between two sections or components. This multi-section approach to large structure assembly can allow for the creation of structures with considerable height and or span. For example, there can be a third section stacked onto to a second section; and a fourth section added to that third section and so on. Reference herein to section can be a first section or a second section (or other) unless the context makes clear otherwise.
Each section can have an interior wall. Each section can have an exterior wall. Each section has a top edge. Each section has a bottom edge. Each section can be identical. Each section can differ. If the sections differ, it may be the case that they have to be assembled in a particular order. For example, if the large structure is tapered with a wide base and a narrower top, the wider sections may require installation first before the narrower sections are then installed on top of one another in series.
This uppermost edge or top edge of a section can encompass various configurations based on engineering considerations. In some instances, the top edge may correspond to the wall thickness of the section. Alternatively, a top flange may be present to form the top edge. The top flange can augment the appearance of thickness of the section. The top edge can have an inner rim which io is the location at which the top edge meets the interior wall of the section. The top edge can have an outer rim, which is the location at which top edge meets the exterior wall of the section.
This lowermost edge or bottom edge of a section can encompass various configurations based on engineering considerations. In some instances, the bottom edge may correspond to the wall thickness of the section. Alternatively, a bottom flange may be present to form the bottom edge. The bottom flange can augment the appearance of thickness of the section. The bottom edge can have an inner rim which is the location at which the bottom edge meets the inside wall of the section. The bottom edge can have an outer rim, which is the location at which bottom edge meets the outside wall of the section.
Once the sections are coupled, the top and bottom edges or flanges can mate. The overlapping top flange and bottom flange can facilitate the incorporation of bolted connections for added stability.
The top edge can feature an undulating or interlocking profile. The profile can be configured to interlock with a correspondingly shaped bottom edge of the adjoining section. The interlocking may enhance load distribution and minimise any potential for misalignment or movement between sections.
In the present invention, there is at least one panoramic camera arranged in the hollow of the first section. For the purposes of this description, the first section is whichever section is waiting to have a section mounted thereto. Preferably, there is one camera, but more than one camera could be used if required.
The camera can be mounted by any means into the hollow of the section. The mounting means should not interfere with the top edge, since upon coupling the mounting means would be sandwiched between sections. One means for mounting the camera could involve a plurality of legs, which support the camera. Each leg can engage with the interior wall of the section. Each leg can be supported on a base. The base can be the ground or a floor for a ground-based section. If the section is raised from the ground, there could be a temporary floor provided at the io base of the section to support the legs. Alternatively, there can be a bottom flange in the section on which the legs could be supported. The legs can be telescopic to allow the height of the camera to be adjusted relative to the top edge of the section. In an embodiment, there can be three legs so that the camera is supported on tripod legs distributing weight and stabilising the camera within the section.
To assist in mounting, the camera can be provided in a housing. The housing can be adapted to engage with mounting means. The housing can also comprise protection for the camera. The protection might be from impact, the weather or other.
Alternatively, the camera could be mounted by spring-loaded support arms biased or otherwise mounted against the interior walls. This arrangement could provide uniform pressure, preventing movement of the camera. The camera could be mounted using brackets or clamps to attach the camera to structural components within the section. However, a removable mounting is preferred, because the camera is an installation guide and will be removed once the section is installed.
The camera is a panoramic camera. Panoramic cameras, also known as wide angle or fisheye cameras or hemi-spherical cameras, are specialised imaging devices designed to capture expansive visual scenes with an exceptionally wide field of view, often spanning close to 180 degrees horizontally and vertically. These cameras employ advanced optical systems, typically featuring fisheye lenses, to bend light and project the scene onto the camera sensor, resulting in a characteristic distorted image. Panoramic cameras are equipped with sensors optimised for high-resolution capture and are capable of generating immersive, all encompassing images that offer a comprehensive representation of the surroundings.
The panoramic camera can be the only camera required in the installation set up. Other installation set ups may require additional cameras installed on the interior or exterior of the incoming section. The present set up can have only the panoramic camera and no other cameras. There can be other cameras, but they may not contribute to any real installation guidance other than to ensure that the sections io are not moving in the wrong direction. In other words, these additional cameras may not be for guided installation and instead are for ensuring safety in installation. The present camera is not of the type that takes an image of a part of the periphery of the section, and which can be pivotable both in 360 degrees and upwardly and downwardly. A camera that takes an image of a part of the periphery will be required to be continuously moving and may miss something from its current field of view. The present panoramic camera captures a continuous wide field view of the periphery. The present camera can provide full visibility using one camera that has a full 180-degree view from side to above.
When mounted in the section, the lens of the camera should be arranged upwardly pointing out of the section. The camera should be disposed so that it can detect at least the inner rim of the top edge of the installed first section. The camera may also be able to see the interior wall of the first section, and surrounding environment. In use, the camera will be able to detect the incoming bottom edge of the second section.
During installation, the same person can install all sections. Alternatively, different people can install different sections as required. In one embodiment, the operator turns up and finds the first section installed and his role is to install the second section. In another embodiment, the same operator installs the first section, then installs the second section and other sections and so on.
To install a section, the second section is lifted. The lifting can be using lifting equipment. The intention of the lifting is to move the second section near to the first section. The lifting can be by any means. In an embodiment, the lifting is by crane. The crane can be lifting attachments, such as slings or hooks, to suspend the section. In some embodiments, hydraulic or pneumatic lifters could be integrated into the section's design, enabling controlled elevation using internal mechanisms. For larger structures, gantry systems could be used, providing a stable framework to hoist the section into place. Employing jacks or lifting frames positioned beneath the section offers an alternative means of elevation. Furthermore, the use of self propelled modular transporters (SPMTs) could facilitate horizontal movement, followed by vertical elevation to the target position. The selection of the optimal io lifting method depends on factors including the section's size, weight, site conditions, and safety considerations.
During lifting, the panoramic camera sends live information to a display screen. The display screen can be located near the operator. The operator can be the person in control of the second section. The operator can look at the live display of the live information and use it to control the movement of the second section. The display screen can be a TV, a PC monitor, a mobile device, a tablet or other. Any screen can be used for the live display. In an embodiment, the live information is sent to more than one live display at the same time.
The live information can comprise a live image or live display. The live image preferably includes the bottom edge of the second section. If the operator cannot see the bottom edge of the second section, the second section can be moved until it comes into the field of view of the camera. In some embodiments, the second section can be moved lower than the top edge of the first section and then lifted gradually until it first comes into view of the panoramic camera. If the camera lens is located adjacent the top edge of the first section, then as soon as the bottom edge of the second section comes in view, the operator can know that the top edge and bottom edges are substantially aligned in the horizontal plane. At that point, the second section can be lifted slightly, then moved laterally to align the top and bottom edges with one another for coupling.
Information can be transmitted from the camera to a display using various methods, both wired and wireless. Wired connections include HDMI (High
Definition Multimedia Interface), which delivers high-quality digital video and audio signals, and USB (Universal Serial Bus), allowing for data and video transfer. DisplayPort is another option similar to HDMI. Ethernet cables can also be used for data and video transmission over local networks. Wireless connections involve Wi Fi, enabling remote monitoring and control, and Bluetooth, suitable for smaller file transfers and remote control. Technologies like Miracast and Chromecast allow for wireless screen mirroring, while WiDi (Wireless Display) technology enables wireless streaming of the camera's display to compatible screens. Wireless transmitters, like wireless HDMI transmitters and video transmitters, provide io flexibility in positioning the camera and display.
The live display provided to the operator can include a timer on the screen so that the operator can see immediately if the live image is frozen. The timer can provide timing do the 1 0 0 th of a second. This safety feature can ensure that the operator stops movement of the second section immediately if the visual data freezes. If the operator did not know that the visual data had frozen, he may keep moving the section and cause injury or damage.
The live display provided to the operator can include guidelines. The guidelines can be displayed together with the live image display. The guidelines can be related to the dimensions of the top edge. For example, in an embodiment in which the top edge is 100 cm in diameter, the guidelines could appear as concentric circles at 80cm and 60cm. The size of the guidelines as concentric circles or other shape is not limited.
If the top edge is substantially circular, the guidelines can be circular. If the top edge is square shaped, the guidelines can be square shaped. Any shape can be accommodated by the guidelines. The guidelines need not be the entire shape of the top edge and can represent a part ofthe shape ofthe top edge as required. For example, in a square shaped top edge, the guidelines could be a pair of parallel lines.
The guidelines can be dotted lines. The guidelines can be coloured. There can be any number of concentric guidelines such as the 2 described above, or more such as 3 or 4. The guidelines which are closest to the edges of the actual top edge could be coloured to indicate that the second section is almost in position. The guidelines further from the top edge (the middle of the concentric set) could be coloured to indicate that the second section requires more movement to get it into the correct position. In an embodiment, a first set of guidelines is yellow and a second set of guidelines concentric with those guidelines is red.
The static guidelines represent an inner rim of the top edge of the first section with decreased dimensions The first set of guidelines can be 30, 20, 10 or 5% smaller io than the actual dimensions of the inner rim. The second set of guidelines can be relatively smaller than the first set of guidelines. The guidelines can be preprogrammed into the system prior to use. In an embodiment, a sensor can detect the inner rim of the top edge and set the guidelines automatically according to preprogrammed specifications.
During installation, the operator can control the movement of the second section using the live view and static guidelines to align and then couple the top edge of the first section with the bottom edge of the second section to thereby install at least a part of the large structure.
Just prior to coupling, the second section can be held for operator adjustment such as rotation. For example, the second section could be held at about 400 to 600 mm from contact. Personnel can then be called to ensure that the joining parts of the sections are free from obstruction and that the section can be rotated into the correct orientation. The correct orientation might be to align connections on the top and bottom edges. In some embodiments, internal structures require alignment. Wind turbines often incorporate internal ladders to provide technicians with safe access to different levels within the tower structure. These ladders play a crucial role in facilitating maintenance, inspections, and repairs. During the installation of wind turbine tower sections, ensuring the alignment of these internal ladders is important for seamless accessibility and efficient operation.
In an embodiment, when the operator has moved the second section into the largest of the guidelines on the display, which is the one just prior to coupling, the operator can be alerted to let him know the second section needs to be held for operator adjustment. The alert can be generated to an alert system coupled with the live display. The alert can come just after the second section is detected as being aligned with the widest most guidelines, or just after it passes the widest most guideline. The alert can be a series of beeps or other signal such as vibration communicated to the operator.
Once the first section and second sections are coupled, the operator can be told to lose the weight and then remove the lifting equipment. The sections can be bolted or otherwise permanently joined to one another. The panoramic camera can be retrieved. The camera than then be installed in the uppermost part of the recently installed section which is now ready to receive its next section.
In one aspect the invention provides a large structure such as a wind turbine when installed using the method or system described herein.
Brief Description of the Figures
Embodiments of the invention will now be described with reference to the accompanying drawings which are not drawn to scale, and which are exemplary only and in which:
Figures 1 is a perspective view of a camera installed in a first section according to an embodiment.
Figure 2 is a close up of the camera of Figure 1.
Figure 3 is a view of the live display, from the camera, in the vicinity of the operator.
Figure 4 shows the live information also being send to a mobile device.
Figures 5 to 7 show the movement of the second section closer to the first section.
Figure 8 shows the first section just about to couple with the second section.
Figure 9 shows the first section coupled to the second section.
Figure 10 shows the camera inside the coupled sections ready for removal.
Figure 11 is a close-up view of the guidelines.
1o Figures 12 and 13 are schematic diagrams.
Detailed Description of Embodiments of the Invention
Figure 1 shows a hollow first section 12 of the large structure. The first section is for aligning and coupling with a second section 22 of the resultant large structure. In Figure 1, the first section 12 is already installed. The first section 12 having a top edge 14 for coupling with a bottom edge 26 of the second section 22.
A panoramic camera 16 is shown in place in the hollow of the first section 12. The camera 16 is shown mounted on tripod legs 20 onto the floor. The panoramic camera is able to detect at least the inner rim 14' of the top edge 14 of the first section 12.
The uppermost edge or top edge 14 of a section 12, 22 can encompass various configurations. As shown in Figure 1, the top edge 14 corresponds to the wall thickness of the section 12. Alternatively, a top flange (not shown) may be present to form the top edge. The top edge 14 can have an inner rim 14'which is the location at which the top edge meets the interior wall of the section. The top edge 14 can have an outer rim 14", which is the location at which top edge 14 meets the exterior wall of the section.
The top edge 14 can feature an undulating or interlocking profile. As shown in Figure 1, the profile can be a step which interlocks with a corresponding profile on the second section 22.
When mounted in the section 12, the lens 18 of the camera 16 is arranged upwardly pointing out of the section 12. In use, the camera 16 will be able to detect the incoming bottom edge 26 of the second section 22 as shown in Figure 5.
To install a section, the second section 22 is lifted e.g. using a crane. The crane in the figures cannot be seen. During lifting, the panoramic camera 16 sends live information to a display screen 24. In Figures 5, 6 and 7 the top half of the Figure shows the display screen 24 and the bottom half shows the relative locations of the io sections 12 and 22. The display screen 24 can be located near the operator as shown in Figure 3 in the cab of the crane. The operator can be the person in control of the second section 22. A further operator can see the display on a mobile device 26. The live information can be sent to any number of devices. Nevertheless, the operator can look at the live information and use it to control the movement of the second section 22.
The live information can comprise a live image or live display 24. The live image preferably includes the bottom edge 26 of the second section 22. If the operator cannot see the bottom edge 26 of the second section 22, the second section 22 can be moved until it comes into the field of view of the camera 16 as shown in Figure 5.
The live display 24 provided to the operator can include guidelines 28. The guidelines 28 can be displayed together with the live image display 24. The guidelines 28 are related to the dimensions of the top edge 14. For example, as shown in the Figures the guidelines are concentric circles 28. All of the guidelines are labelled in Figure 7 but in other figures some labels are omitted for clarity. As displayed in e.g. Figure 7 the top edge is 100 cm in diameter, the guidelines could appear as concentric circles at 100cm, 80cm 60cm and 40cm. Figures 5 to 7 show the bottom section 22 moving closer and the operator uses the guidelines to guide and control the lowering of the section 22.
Figure 11 shows 3 concentric guidelines. The guideline 28A which is closest to the edge of the actual top edge 14 can be coloured to indicate that the second section is almost in position. The guidelines 28C further from the top edge (i.e. the middle of the concentric set) could be coloured to indicate that the second section requires more movement to get it into the correct position. In Figure 11 there is a guideline 28B located equidistant between guideline 28A and 28C.
Just prior to coupling, the second section 22 can be held for operator adjustment such as rotation (Figure 8). For example, the second section could be held at about 400 to 600 mm from contact. Personnel can then be called to ensure that the section is rotated into the correct orientation. In an embodiment, when the operator io has moved the second section 22 into the largest of the guidelines on the display (labelled as A in Figure 7 and Figure 11), which is the one just prior to coupling, the operator can be alerted to let him know the second section 22 needs to be held for operator adjustment.
Once the first section and second sections are coupled (Figure 9), the operator can be told to lose the weight and then remove the lifting equipment. The sections can be bolted or otherwise permanently joined to one another. The panoramic camera 16 can be retrieved. The camera can then be re-installed in the uppermost part of the recently installed section 22 which is now ready to receive its next section.
The signal from camera 16 can be sent to the operator by electronic means known to the person skilled in the art. Figures 12 and 13 are schematics that show how the signal can be transmitted from the camera 16 to the display available to the operator (or the live information available to another third party). The camera 16 can be equipped with a peer-to-peer communication system that can extend from the installed section 12 to a first nano-station located on the installed section 12 (Figure 12). The nano station can be attached to the first installed section 12 by an attachment means such as a magnet or other connection. A second nano-station can be positioned on the ground for relay to e.g. the tablet/PC display used by the operator (Figure 13).
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
Any promises made in the present description should be understood to relate to io some embodiments of the invention and are not intended to be promises made about the invention as a whole. Where there are promises that are deemed to apply to all embodiments of the invention, the applicant/patentee reserves the right to later delete them from the description and does not rely on these promises for the acceptance or subsequent grant of a patent in any country.