US20020084142A1 - Guide rail climbing lifting platform and method - Google Patents

Abstract

A guide rail system is used to erect towers, to place equipment on towers and for maintenance of towers. The guide rail may be added to existing towers. a climbing lifting platform is attached to the guide rails and is used to transport items up and down the tower. The platform may also be used to carry up tower sections during erection of the tower.

Description

CROSS-REFERENCE TO RELATED APPLICATIONSSTATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
• Not Applicable.[0001]
BACKGROUND OF THE INVENTION
• The present invention relates to lifting devices and, more specifically, to a platform capable of both lifting heavy objects that are needed for elevated construction and facilitating the modular construction of tall structures.[0002]
• Many construction projects require the moving of materials and machinery up hundreds of feet above the ground. Some examples of projects that would require the lifting of materials are the construction of office buildings or high rise apartment complexes. Often the construction of towers or industrial smokestacks, such as concrete towers or steel towers, requires the lifting of heavy modular units to complete construction. One example of a tower that requires a lifting device for both the modular construction of the tower and for lifting heavy machinery to the top of the tower is a wind turbine tubular tower. These wind turbine tubular towers can easily reach 300 feet in height and upon completion require the lifting of a wind turbine generator and rotor blade assembly to the top of the wind turbine tubular tower.[0003]
• Different methods are commonly used when either constructing towers or lifting heavy objects to great heights. Often a large industrial crane is used to facilitate these sort of construction projects. The large industrial cranes can assist in lifting the various components needed for the modular assembly of construction projects. Additionally, large industrial cranes can also place heavy machinery on the top of towers as needed.[0004]
• For loads over 120,000 pounds and heights over 300 feet few cranes currently exist that can be used on public roads at a reasonable expense. Unfortunately, there are disadvantages to relying on the use of large industrial cranes in some construction situations. Depending on the terrain, it may be difficult to place the crane in a suitable operational position. In some situations, there may not be enough room to either properly position the large industrial crane or even to move the crane to the project site. Wind turbine farms are just one example of a situation in which it is difficult to use a large industrial crane. Wind turbine farms usually have many wind turbine tubular towers placed in close proximity to each other to maximize the amount of energy that can be generated by the wind turbine farm. Often the roads throughout the wind turbine farm are too small to be used by a large industrial crane in order to erect additional wind turbine tubular towers. Furthermore, the use of a large industrial crane that has suitable height and load capabilities for either the assembly or repair of wind turbine tubular towers is often overly expensive.[0005]
• Wind turbine farms may be scattered over many square miles. Large industrial cranes may be transported into such farms, but often must be disassembled and reassembled over and over in order to reach each of the wind tower locations. This loses valuable time and increases the costs tremendously.[0006]
• The transportation of large industrial cranes through wind turbine farms also presents problems when existing wind turbine generators or existing wind turbine tubular towers need to be repaired. Wind turbine generators and wind turbine tubular towers are often struck by lightning that can damage the wind turbine generator or rotor blades, thus necessitating the repair or replacement of the wind turbine generator and parts of the wind turbine tubular tower.[0007]
• High piers or towers, such as observatory towers, also require the use of lifting devices, such as cranes, to facilitate construction. However, the use of cranes is subject to many of the drawbacks detailed above.[0008]
• Another method that can be utilized to facilitate the construction of towers is to use helicopters to lift modular components during the construction of the towers. The use of helicopters, however, is expensive and is often an impractical solution once budgetary concerns are considered.[0009]
• The art described in this section is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention, unless specifically designated as such. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists.[0010]
BRIEF SUMMARY OF THE INVENTION
• The present invention provides a guide rail climbing lifting platform that overcomes the above drawbacks and provides a device that does not require as much physical space to access a project site. The guide rail climbing lifting platform is capable of supporting the tremendous weights necessary to facilitate the modular assembly of towers. Furthermore, the present invention is an ideal device for lifting heavy machinery to elevated points along tall structures. The inventive guide rail climbing lifting platform uses a hydraulic system to travel along guide rails that are attached to the side of a structure. The guide rails can either be an integral part of the structure or they can be attached to a structure using a retrofitting process. The rails transfer the weight of the lifting platform and the payload directly to the base platform. The vertical load is not placed on the tower.[0011]
• This guide rail climbing lifting platform allows more economical and efficient repairs to be made to existing towers due to the present invention's efficient design. The guide rail climbing lifting platform is a far less expensive option than using a comparable large industrial crane of similar lifting capabilities (measured in terms of the height to which an object can be lifted and in terms of the amount of weight that can be lifted).[0012]
• Furthermore, the present invention is ideally suited for the construction and repair work that must be performed in wind turbine farms. The guide rail climbing lifting platform does not require large amounts of operational space proximate to the base of the tower. Furthermore, the guide rail climbing lifting platform can be transported along much smaller roads than large industrial cranes are capable of using.[0013]
• Accordingly, the guide rail climbing lifting platform of the present invention provides both a convenient and economical way for erecting towers in a modular fashion and provides an economical way for lifting heavy machinery to points along a vertical structure.[0014]
BRIEF DESCRIPTION OF THE DRAWINGS
• A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:[0015]
• FIG. 1 is a side elevational view of a guide rail climbing lifting platform, shown at two different positions along a tower, in accordance with the present invention;[0016]
• FIG. 2 is a greatly enlarged partial side elevational view of a portion of the guide rail climbing lifting platform of FIG. 1;[0017]
• FIG. 3 is a greatly enlarged side elevational view of another portion of the guide rail climbing lifting platform of FIG. 1;[0018]
• FIG. 4 is an enlarged cross-sectional view of a tower segment of FIG. 1 taken along the line[0019]4-4 of FIG. 1;
• FIG. 5 is a top plan view of the guide rail climbing lifting platform positioned at the top of a partially constructed steel tower;[0020]
• FIG. 6 is a top plan view of the largest tower segment being supported by an adjustable carriage assembly;[0021]
• FIG. 7 is a side elevational view of the tower segment of FIG. 6 supported by the adjustable carriage assembly of FIG. 6;[0022]
• FIG. 8 is a top plan view of the smallest tower segment being supported by the adjustable carriage assembly of FIG. 6;[0023]
• FIG. 9 is a side elevational view of the smallest tower segment being supported by the adjustable carriage assembly of FIG. 6;[0024]
• FIG. 10 is a side elevational view of a guide rail climbing lifting platform positioned to transfer an additional tower segment onto the end of a previously positioned tower segment;[0025]
• FIG. 11 illustrates the alignment of a nacelle, that encloses a wind turbine generator mounted on a short tower segment, with the top of a partially constructed tower;[0026]
• FIG. 12 is a side elevational view of the guide rail climbing lifting platform of FIG. 1, shown in two positions, transporting the short tower segment and the nacelle of FIG. 11 to the top of the tower;[0027]
• FIG. 13 is a side elevational view of the guide rail climbing lifting platform supporting the short tower segment on a carriage assembly at the top of the partially constructed tower;[0028]
• FIG. 14 is a hydraulic circuit illustrating the various components used to control the operation of the guide rail climbing lifting platform;[0029]
• FIG. 15 is a partial enlarged view of the hydraulic circuit of FIG. 14;[0030]
• FIG. 16 is a partial enlarged view of the hydraulic circuit of FIG. 14;[0031]
• FIG. 17 is a partial enlarged view of the hydraulic circuit of FIG. 14;[0032]
• FIG. 18 is a front elevational view of the guide rail climbing lifting platform of FIG. 1, shown in two positions, transporting a rotor blade assembly to the top of the tower;[0033]
• FIG. 19 is a side elevational view of the guide rail climbing lifting platform of FIG. 1, shown in position to place the rotor blade assembly onto a wind turbine generator;[0034]
• FIG. 20 is a front elevational view of the guide rail climbing lifting platform of FIG. 1, shown transporting a single rotor blade between the base of the tower and the rotor blade assembly; and[0035]
• FIG. 21 is a side elevational view of the guide rail climbing lifting platform of FIG. 1, secured to the rotor blade projecting downwards from the rotor.[0036]
DETAILED DESCRIPTION OF THE INVENTION
• Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “lower,” and “upper” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the guide rail climbing lifting platform assembly and designated parts thereof. The terminology includes the words above specifically mentioned, derivatives thereof and words of similar import.[0037]
• In many instances only one of a pair of components that are recited is actually shown in FIGS.[0038]1-13. When only one component (e.g. thefirst latch pin46a) of a pair of recited components (e.g. the first and second latch pins46a,46b) is actually shown in the referenced figure, it is understood that the second component of the recited pair is symmetrically positioned on the opposite side of the platform assembly and that the second component operates in a similar fashion.
• Referring to the drawings in detail, wherein in like numerals indicate like elements throughout, there is shown in FIGS.[0039]1-21 a preferred embodiment of a guide rail climbing lifting platform, also referred to as a platform assembly, generally designated10. The guide rail climbing lifting platform is an ideal device for erecting modular wind turbine tubular towers and for lifting heavy machinery or devices. As shown in FIG. 1 and discussed in more detail hereinafter, theplatform assembly10 can transport atower segment84 to the top of asteel tower72. By incrementally moving upward along the guide rails40, theplatform assembly10 is able to move from a lower position, shown at the bottom of FIG. 1, to an upper position, shown at the top of FIG. 1. Once thetower segment84 is positioned at the upper end of thesteel tower72, thetower segment84 is ready to be aligned over and attached to thesteel tower72. Thus thesteel tower72 can be formed usingmultiple tower segments84, each of which can be anywhere from 40 to 50 feet long.
• The guide rail climbing lifting device allows for the modular construction of towers without the use of a large heavy industrial crane. While a light crane (not shown) is necessary to place the[0040]tower segment84 onto theplatform assembly10 shown at the bottom of FIG. 1, the size of the crane required is much smaller than that which would be necessary if thetower segment84 were to be lifted by a crane directly to the top of thesteel tower72.
• While in the drawings depicting the preferred embodiment a[0041]steel tower72 is shown as being approximately 300 feet in height, it is understood by those of ordinary skill in the art from this disclosure that the present invention is not limited to towers of any particular height. Nor is the present invention limited to any particular size of the individual tower segments. For instance, theplatform assembly10 can be used to construct towers taller than 300 feet usingindividual tower segments84 that are each 20 feet long. Additionally, the guide railclimbing lifting platform10 can also be used with concrete towers.
• Referring now to FIGS. 1 and 5, the guide rail[0042]climbing lifting platform10 supports thetower segment84 on the left side of thesteel tower72 and has a first and asecond carriage track20a,20bthat each extend along opposite sides of thesteel tower72. In FIG. 1 only thefirst carriage track20acan be seen. As theplatform assembly10 transports upwards along theguide rail40 towards the top of thesteel tower72, the first and second carriage tracks20a,20bextend beyond the right side of thesteel tower72. Once theadditional tower segment84 has been brought to the top of thesteel tower72, the distance denoted “x” between thecenter line85 of thetower segment84 and thecenter line73 of thesteel tower72 is approximately 10 feet. The distance “x” varies depending on the structure being climbed, the size of the guide rail climbing lifting platform, and the weight of the objects being lifted by theplatform assembly10.
• FIG. 3 shows a portion of the[0043]platform assembly10. The guide rail climbinglifting platform assembly10 has a first and asecond carriage track20a,20bthat do not extend past the guide rails40. As such, the guide railclimbing lifting platform10 of FIG. 3 is preferable for lifting machinery and objects upwards along structures that are wider than the upper portion of theplatform assembly10, such as apartment buildings, office buildings, aircraft hangers, stadiums, and warehouses.
• Both types of the guide rail[0044]climbing lifting platform10 use the same mechanisms to travel along the guide rails40 and operate in a similar manner. As such, the climbing operation of both guide railclimbing lifting platforms10 will be described with reference to the components shown in the guide rail climbing lifting platform of FIG. 3. The guide rail climbing lifting platform shown in FIGS.1-13 and18-21 also possesses and utilizes each of the components detailed in FIG. 3. The omission of some of these components in FIGS.1-13 and18-21 is only for the purpose of simplifying the figures.
• Referring to FIG. 3, the operation of the[0045]platform assembly10 is as follows. Initially, first and the second latch pins46a,46bare engaged with the guide rails40. The lower end of theplatform assembly10 has a pair oflower wheels52 that abut and roll along the guide rails40. Eachlower wheel52 is rotatably mounted on afirst cylinder support34. Eachfirst cylinder support34 is secured to alower deck32 that extends therefrom. A vertical support or strut38 extends upwardly generally parallel to the guide rails40 from the end of thelower deck32 closest to the guide rails40. Alower flange58 is attached in a cantilever fashion to an outer edge of eachvertical support38 usingbolts60 proximate to thelower deck32. The distal end of thelower flange58 includes an aperture for slidably receiving therespective latch pin46aor46b.The first and second latch pins46a,46bextend from thelower flange58 into registry with a correspondingly sizedpin receiving hole70 in the guide rails40. There are a series ofpin receiving holes70 spaced along the length of the guide rails40 at predetermined intervals, as described in more detail hereinafter. The first and second latch pins46a,46band thepin receiving holes70 cooperate to fix theplatform assembly10 to the guide rails40 at a selected vertical position, as is also described in more detail hereinafter.
• The upper end of the[0046]platform assembly10 is secured to the guide rails40 using a pair ofupper flanges62. Oneupper flange62 is attached to the upper end of eachvertical support38 and extends therefrom generally perpendicularly in a cantilever fashion. Eachupper flange62 is secured to itsvertical support38 via standard fasteners, such asbolts60. The distal end of eachupper flange62 includes a pair ofupper wheels56 that sandwich itsrespective guide rail40. That is, oneupper wheel56 is located on either side of arespective guide rail40. Since theupper flanges62 are braced viaupper wheels56 against both sides of the guide rails40, theplatform assembly10 is maintained at a constant orientation relative to the guide rails40. Additionally, theupper flanges62, and the associatedupper wheels56, prevent the rotation of theplatform assembly10 around thelower flanges58.
• With reference to FIG. 3, the[0047]platform assembly10 is also vertically fixed along the guide rails40 by the first and second slide pins48a,48b,as described in more detail below. The first and second slide pins48a,48bare reciprocally mounted within a correspondingly sized aperture in first andsecond slide assemblies55 that are separately mounted to roll along each of the guide rails40. The first andsecond slide assemblies55 are attached to the distal end of the first andsecond lift rods43a,43b,respectively. The first andsecond lift rods43a,43bextend from first andsecond lift cylinders42a,42bthat are attached to theplatform assembly10 proximate to thelower deck32.
• While in the preferred embodiment the first and[0048]second lift cylinders42a,42bare pinned to theplatform assembly10 atcylinder support34, it is understood from this disclosure that the present invention is not limited to the method of securing the first andsecond lift cylinders42a,42bto theplatform assembly10. For instance, the first andsecond lift cylinders42a,42bcan be bolted to theplatform assembly10 at various locations along the platform assembly that would allow the first andsecond lift rods43a,43bto properly operate, as explained in more detail hereinafter.
• The first and[0049]second lift rods43a,43bare attached to the first andsecond slide assemblies55, respectively, via apin connection44. Eachslide assembly55 engages theguide rail40 using fourslide wheels54 for eachguide rail40. Twoslide wheels54 are arranged on both sides of theguide rail40 to maintain stability in theslide assembly55. FIG. 3 shows the platform assembly after having secured the first and second slide pins48a,48bto the guide rails40.
• To begin the lifting process, with the first and second slide pins[0050]48a,48blocked to the guide rails40, the first and second latch pins46a,46bare disengaged from the guide rails40. Once the first and second latch pins46a,46bhave been disengaged from the guide rails40, the first andsecond lift rods43a,43bare retracted into the first andsecond lift cylinders42a,42b.This causes theplatform assembly10 to move in the upward direction, as viewed in FIG. 3. While moving upward, both theupper wheels56 and thelower wheels52 roll along the sides of the guide rails40.
• As the first and[0051]second lift rods43a,43bare retracted into the first andsecond lift cylinders42a,42b,theplatform assembly10 moves upwards until the first and second latch pins46a,46bare aligned with the next set ofpin receiving holes70 in the guide rails40. Once the first and second latch pins46a,46bare aligned with the next set ofpin receiving holes70 in the guide rails40, the first and second latch pins46a,46bare engaged with thepin receiving holes70 in the guide rails40. Thus, theplatform assembly10 is vertically supported by both the latch pins46a,46band the slide pins48a,48b.
• Next, the first and second slide pins[0052]48a,48bdisengage from theguide rail40 and the first andsecond lift cylinders42a,42bdrive the first andsecond lift rods43a,43bupwards. This causes eachslide assembly55 to travel upward along the guide rails40 until the slide pins48a,48bare aligned with the next set of pin receiving holes70. The pairs ofpin receiving holes70 are preferably located approximately every 10 feet along the guide rails to correspond with the stroke distance of the first andsecond lift rods43a,43b.However, it is understood that thepin receiving holes70 could be spaced along the guide rails40 at other intervals so long as the distance of each interval is not greater than the stroke distance of the first andsecond lift cylinders42a,42b.
• Then, once the first and second slide pins[0053]48a,48bare aligned with the next pair ofpin receiving holes70 in the guide rails40, the first and second slide pins48a,48bare engaged with the guide rails40. Thus, theplatform assembly10 is again supported by both the first and second latch pins46a,46band by the first and second slide pins48a,48b.This sequence of operations is repeatedly performed until theplatform assembly10 reaches the desired position along the guide rails40.
• The top portion of the[0054]platform assembly10, as viewed in FIG. 5, is formed using first and second lower support beams18a,18bto support and underlie each of the first and second carriage tracks20a,20b.As shown in FIG. 3, anequipment deck16 is positioned inside of theplatform assembly10. Theequipment deck16 can be used to store supplies (not shown) and is also used to support a diesel poweredpump unit50 and certain components of a hydraulic system described below (not shown in FIG. 3). The left most side of theplatform assembly10, as viewed in FIGS.1-3, is constructed using first and second side support beams12. The firstside support beam12 is attached at one end to thelower deck32 and at the opposite end to the firstlower support beam18a.The second side support beam12 (not shown) is attached at one end to thelower deck32 and at the opposite end to the second lower support beam18b.Side support beams14 are similar tobeams12 but are on the right most side of the platform of FIG. 1.
• The structural components of the[0055]platform assembly10 are preferably constructed of a high strength light weight material, such as steel, and joined in a manner well known to those of skill in the art, such as by fasteners or by welding. It is understood by those of ordinary skill in the art from this disclosure that the present invention is not limited to constructing theplatform assembly10 in any particular manner so long as it is capable of traversing the guide rails40 and can support heavy loads.
• The guide rails[0056]40 are attached to the tower using a plurality of tower mounts66 that are directly attached to thesteel tower72. The guide rail supports68 are attached to the tower mounts66. The guide rail supports68 engage the guide rails40 and stably maintain the guide rails40 in an aligned position. As can be seen in FIG. 3, the guide rails40 are preferably assembled in 10 feet segments when they are retrofit onto an existing tower. While the preferred embodiment usesguide rails40 that are already attached to the tower that is being climbed by theplatform assembly10, it is understood by those of skill in the art that the present invention is not limited to use with towers having pre-existing guide rail structures. For instance, theplatform assembly10 can be used to incrementally installguide rails40 in 10 feet increments along a pre-existing tower.
• As shown in FIG. 4, the tower mounts[0057]66 can be directly formed or welded onto thesteel tower72. Furthermore, the guide rails40, the guide rail supports68, and the tower mounts66 can be integrally constructed with thesteel tower segments84 to simplify the construction of thesteel tower72. While the preferred embodiment uses theplatform assembly10 to self erect steel towers, it is understood by those of ordinary skill in the art from this disclosure that the present invention is not limited to use with steel towers. For instance, theplatform assembly10 can be used with concrete towers, such as those that are used to form high piers, and can be used to construct observation towers, or other similar vertical structures. To attach tower mounts66 to the concrete tower, inserts are formed in the concrete tower as the tower is being slip formed in a manner well understood by those of ordinary skill in the art (not shown). Then the tower mounts66 are secured inside of the inserts (not shown).
• When trying to retrofit steel towers for use with the guide rail[0058]climbing lifting platform10, the guide rails40 are attached by bolting the tower mounts directly to the steel tower. It is understood by those of ordinary skill in the art from this disclosure that theplatform assembly10 of the present invention can be used in a retrofit manner with existing towers regardless of the material with which the existing tower is constructed.
• Referring to FIG. 5, a top plan view of the[0059]platform assembly10 shows theplatform assembly10 attached to a partially constructedsteel tower72. The end of thetower segment84 that forms the top of the partially constructedsteel tower72 has aninner flange86. Aninner flange86 is located at both ends of eachtower segment84 to allow the various tower segments to be bolted together. Eachinner flange86 has a plurality of bolt holes74 that are located in theinner flange86. Attached to, or formed with, thesteel tower72 are tower mounts66 that are connected to the guide rail supports68. Attached to theguide rail support68 that is shown in the lower portion of FIG. 5 is aladder80. Afall arrester82 is attached to theladder80 to increase the safety with which a worker can traverse theladder80. As also shown in FIG. 5, the first and second slide pins48a,48bare engaged with thepin receiving holes70 in the guide rails40.
• The upper portion of the[0060]platform assembly10, as shown in FIG. 5, is constructed using the first and second carriage tracks20a,20bthat are each supported by the first and second lower support beams18a,18b,respectively. The first and second carriage tracks20a,20band the first and second lower support beams18a,18bare connected using afirst cross beam26 and asecond cross beam28. While in the preferred embodiment the first and second carriage tracks20a,20bare connected using only two cross beams, as mentioned above, it is understood by those of skill in the art that the present invention is not limited to the manner in which the upper portion of theplatform assembly10 is formed. For instance, the upper portion of the platform may be formed using first and second carriage tracks20a,20bthat are connected by more than two, e.g. four, cross beams. Depending on the height, weight, or type of machinery that is to be lifted and depending on the type of structure to be climbed, it could be preferable to have a solid platform, that does not have ahole30 therein, or it could be preferable to have an upper portion of the platform that does not extend beyond the guide rails. Using a platform assembly that has first and second carriage tracks20a,20bthat do not extend beyond the guide rails40 would be useful when using the platform assembly with office buildings and apartment buildings. This would allow for the easy transportation of large or heavy objects to various levels of the office building or the apartment building.
• The first and second carriage tracks[0061]20a,20band the first and second cross beams26,28 define an A-shaped structure wherein theopening30 is in the upper portion of theplatform assembly10. In addition, the first and second carriage tracks20a,20bextend beyond the guide rails40 to flank both sides of thesteel tower72. The extension of the first and second carriage tracks20a,20balong both sides of thesteel tower72 is shown, in a side elevational view, in FIG. 1 and, in a top plan view, in FIG. 5.
• Referring to FIG. 2, a load can be supported on an[0062]adjustable carriage assembly90 that moves along the carriage tracks20a,20bvia guidedcontinuous roller bearings92. In addition, first and second transversehydraulic cylinders182a,182bare used to laterally control the motion of theadjustable carriage assembly90 on top of the carriage tracks20a,20b.
• Referring to FIG. 6, a[0063]tower segment84 is supported by anadjustable carriage assembly90 that is slidably guided along the first and second carriage tracks20a,20b(shown in FIG. 5). Thetower segment84 has four bolt-onbrackets94 that are attached around the circumference of thetower segment84. The bolt-onbrackets94 vertically support thetower segment84 on top of theadjustable carriage assembly90. The bolt-onbrackets94 each have a bearingsurface94athat engages theadjustable carriage assembly90.
• The[0064]tower segment84 shown in FIG. 6 has the largest diameter that can be accommodated by theadjustable carriage assembly90. As also shown in FIG. 7, thecarriage assembly90 is constructed using lateral carriage beams96 that support bolt-onbrackets94 on opposite sides of thetower segment84. The lateral carriage beams96 are bolted intobolt holes102 that are located in the carriage cross beams98. Both the lateral carriage beams96 and the carriage cross beams98 are adjustable to allow thecarriage assembly90 to supporttower segments84 having various diameters.
• As shown in FIG. 7, two of the four bolt on[0065]brackets94 are supported by the carriage cross beams98 and the remaining bolt-onbrackets94 are supported by the lateral carriage beams96. As shown in phantom, the bottom end of thetower segment84 extends below the upper surface of the platform engaging carriage beams104. The platform engagingcarriage beams104 move along the first and second carriage tracks20a,20busing guidedcontinuous roller bearings92. The guidedcontinuous roller bearings92 each engage, via rollers (not shown), the side of the first or second carriage tracks20a,20bthat faces upwardly. In addition, the guidedcontinuous roller bearings92 also have rollers (not shown) that engage the bottom and/or side surface of the first and second carriage tracks20a,20bto grip the first and second carriage tracks20a,20b.Thus, the guidedcontinuous roller bearings92 both prevent theadjustable carriage assembly90 from disengaging from the first and second carriage tracks20a,20band maintain theadjustable carriage assembly90 in proper alignment over the first and second carriage tracks20a,20b.
• Referring now to FIG. 2, as detailed above, the platform engaging[0066]carriage beams104 are not adjustable and are held in a constant position, that is aligned over the carriage tracks20a,20b,by the guidedcontinuous roller bearings92. Thecarriage assembly90 is transversely secured by the first and secondtransverse cylinders182a,182b(only one is shown) which also control the horizontal position of thecarriage assembly90, as described in more detail below. Thetransverse cylinders182a,182balso prevent thecarriage assembly90 from being displaced laterally along the first and second carriage tracks20a,20bof theplatform assembly10.
• The first and second[0067]transverse cylinders182a,182bare each attached to theplatform assembly10 via atransverse brace110 in the form of a pillow block. Eachtransverse brace110 is mounted at the end of itsrespective carriage track20a,20bdistal from thetower72. Thehydraulic cylinders182a,182bare attached to thetransverse brace110 by a pin connection110a.Thehydraulic cylinders182a,182beach include an extendabletransverse rod184a,184bwhich is connected to its respectiveadjustable carriage beam104 of thecarriage assembly90 using a slidingblock106. That is, the firsttransverse rod184ais attached via the slidingblock106 to one platform engagingcarriage beam104 and the second transverse rod184bis attached to the other, oppositely positioned, platform engagingcarriage beam104 via another slidingblock106. Each slidingblock106 is pinned to the end of one of the first and secondtransverse rods184a,184band to one of the platform engaging carriage beams104. The carriage beams104 have a plurality of slidingblock receiving holes108 spaced at predetermined intervals along the length of thecarriage beam104, for reasons described hereinafter.
• Referring now to FIGS. 1 and 2, the stroke of each[0068]transverse rod184a,184bis approximately 4 feet. As such, to move thecarriage assembly90 the approximate 10 feet between thecenter line85 of thetower segment84 and thecenter line73 of thesteel tower72 requires that successive operations using thehydraulic cylinders182a,182btake place, as described in more detail below. The center line oftower72 andlift platform10 is designated ascenter line76. While in the preferred embodiment thetransverse rods184a,184bhave a stroke of 4 feet, it is understood by those of ordinary skill from this disclosure that the hydraulic cylinders may be constructed using hydraulic rods having a larger stroke distance. For instance, transverse cylinders having a stroke distance of 15 feet can be used with theplatform assembly10. In addition, non-hydraulic mechanisms may be used which are well known in the art such as a rack and pinion system. Whentransverse cylinders182a,182bthat are used have a greater stroke distance than the distance between thecenterline85 of theadditional tower segment84 and thecenterline73 of thesteel tower72, thecarriage assembly90 can be properly positioned over thesteel tower72 using only one extension of thetransverse rods184a,184b.The changes to the preferred embodiment necessary to incorporate larger hydraulic cylinders, such as those having stroke distances in excess of 15 feet, are well known to those of ordinary skill in the art in light of this disclosure.
• The incremental movement of the[0069]adjustable carriage assembly90 will be described with reference to FIG. 2. The preferred method of incrementally moving theadjustable carriage assembly90, and an associated load, along the first and second carriage tracks20a,20btowards thesteel tower72 is to use the slidingblocks106 in combination with multiple extensions of thetransverse rods184a,184b.First, eachcarriage beam104 is attached to a slidingblock106 at the slidingblock receiving hole108 closest to thesteel tower72. Thetransverse rods184a,184bare extended causing theadjustable carriage assembly90 to move approximately 4 feet to the right, as viewed in FIG. 2.
• Then, workers remove the pin from one of the sliding[0070]blocks106 from acarriage beam104, retract the associatedtransverse rod184aor184binto the associatedhydraulic cylinder182aor182b,and re-pin the slidingblock106 to a slidingblock receiving hole108 that is next closest to the associatedhydraulic cylinder184aor184b.Afterwards, the above procedure is repeated for the slidingblock106 that has not been adjusted. It is preferable to only detach one sliding block at a time to maintain stability of thecarriage assembly90, and its associated load, on the first and second carriage tracks20a,20b.Once both of the slidingblocks106 have been re-positioned, thetransverse rods184a,184bare again extended causing theadjustable carriage assembly90 to move another 4 feet to the right. This process is repeated until the adjustable carriage assembly is properly aligned over thesteel tower72.
• It is understood by those of ordinary skill in the art that other methods could be used to move the[0071]tower segment84, along with thecarriage assembly90, over the top of thesteel tower72 without departing from the spirit and scope of the present invention. For instance, an alternative method to incrementally moving theadjustable carriage assembly90 along the first and second carriage tracks20a,20bis to successive re-bolt and re-position thehydraulic cylinders182a,182balong the length of the first and second carriage tracks20a,20b(not shown).
• Referring to FIGS. 8 and 9, the[0072]adjustable carriage assembly90 is shown supporting thetower segment84 having the smallest diameter. The platform engagingcarriage beams104 remain positioned to be appropriately aligned over the first and second carriage tracks20a,20b.However, both the carriage cross beams98 and the lateral carriage beams96 have been adjusted to account for the small diameter of thetower segment84. As discussed above, thetower segment84 has bolt onbrackets94 attached about its circumference to allow the lateral carriage beams96 and the carriage cross beams98 to vertically support thetower segment84. Thecarriage cross beam98 that is shown on the right side of both FIGS. 8 and 9 is bolted to bolt receivingholes102 that are located towards the midpoint of the platform engaging carriage beams104. Additionally, the lateral carriage beams96 are bolted to bolt receivingholes102 that are located closer to the center of the carriage cross beams98. Thus, theadjustable carriage assembly90 can accommodatetower segments84 having various diameters. This facilitates the modular construction of towers, as the design of many towers calls for a narrowing peak, as shown in FIG. 1. The range of sizes that can be accommodated by theadjustable carriage assembly90 can be altered depending on the applications for which theadjustable carriage assembly90 is used.
• Referring now to FIGS. 5, 7 and[0073]9, thebottom surface94aof the bolt-on brackets94 ( i.e. the surface of the bolt-onbrackets94 that contacts the adjustable carriage assembly90) that are attached to thetower segment84 have a bearingsurface94athat allows thetower segment84 to be slightly rotated to align the bolt holes74 in theinner flange86 at the bottom of theadditional tower segment84 with the bolt holes at the top of the existingtower72, as shown in FIG. 5. The use of bearing-type bolt-onbrackets94 allows thetower segment84 to be rotated approximately 5-10 degrees to align the guide rails40 of thetower segment84 with the guide rails40 of thesteel tower72.
• Often, it is desirable to mount a permanent structure to the top of a tower. The preferred embodiment of the[0074]steel tower72 shown in FIGS.1-13 is a wind turbine tubular tower. As such, it is desirable to mount a wind turbine generator (not shown) to the top of the wind turbine tubular tower once thesteel tower72 is completed.
• Referring now to FIGS.[0075]11-13 and18-21, one method of attaching the wind turbine generator to the wind turbine tubular tower is to place anacelle120 over the wind turbine generator (not shown). Then, the wind turbine generator and thenacelle120 are attached to ashort tower segment122. Thenacelle120 is an enclosure for the wind turbine generator that reduces the wind resistance experienced by the wind turbine generator. The wind turbine generator and thenacelle120 are mounted to theshort tower segment122, as shown in FIG. 11, prior to lifting the wind turbine generator to the top of thesteel tower72 with theplatform assembly10. Theshort tower segment122 may, for example, have a length of approximately 3 to 5 feet.
• The nacelle (and the enclosed wind turbine generator)[0076]120 are attached to theshort tower segment122 so that thenacelle120 and the wind turbine generator can rotate 360 degrees on top of theshort tower segment122. This allows thenacelle120 to be facing the side of theplatform assembly10 during the lifting operation, as shown in FIG. 12. This reduces the moment force that theplatform assembly10 is subject to during the lifting process.
• Once the[0077]nacelle120 and theshort tower segment122 are located at the top of the steel tower72 (as shown in FIG. 13), it is necessary to align the bolt holes74 in theinner flanges86 of both the upper end of thetower72 and the lower end of theshort tower segment122. FIG. 12 shows theplatform assembly10 supporting theshort tower segment122 and the attachednacelle120, at both the base of thesteel tower72 and at the top of thesteel tower72. FIG. 13 illustrates, in phantom line, the protrusion of theshort tower segment122 below theadjustable carriage assembly90.
• When loading either a[0078]tower segment84, ashort tower segment122, or a wind turbine generator onto a partially constructedsteel tower72, it is first necessary to bring the platform apparatus to the top of thesteel tower72, as shown in FIGS. 1, 10,12, and13. Afterwards, as shown in FIG. 2, thetransverse cylinders182a,182bare used to extend thetransverse rods184a,184bto move thecarriage assembly90 over thecenter line73 of thesteel tower72, as discussed above. Once thetower segment84, theshort tower segment122, or thenacelle120 is aligned over thecenter line73 of thesteel tower72, the bolt-on bearingbrackets94 are used to rotate the additional tower component into the appropriate alignment with theuppermost tower segment84 of thesteel tower72, as shown in FIGS. 19 and 21. This is necessary to both properly align the guide rails40 and the bolt holes74. The additional tower component (e.g. any one of atower segment84, ashort tower segment122, anacelle120 and any other machinery supported by the platform assembly) is engaged with the upper end of thesteel tower72 by lowering theplatform assembly10 until the bottom end of the additional tower component engages the top end of thesteel tower72.
• Once the additional tower component is engaged with the top end of the[0079]steel tower72, the additional component is bolted to the end of thesteel tower72 by workers that are positioned inside of thesteel tower72. To facilitate the movement of workers inside of thesteel tower72 an internal stairwell (not shown) can be formed inside of eachtower segment84 to allow a worker to climb up inside of thesteel tower72.
• Once the[0080]nacelle120, and the enclosed wind turbine generator, are mounted on the top of thesteel tower72, thenacelle120 and the wind turbine generator are rotated so that the front of the nacelle120 (i.e. the side onto which therotor126 androtor blades124 are attached) faces the front of theplatform assembly10, as shown in FIGS. 19 and 21.
• After the[0081]nacelle120 has been rotated 90 degrees, the platform assembly is used to lift therotor126, and the attachedrotor blades124 to the top of the steel tower as shown in FIG. 18. Once therotor126 and therotor blades124 are aligned properly with thenacelle120, the rotor assembly is attached to the wind turbine generator as shown in FIG. 19.
• Referring now to FIGS.[0082]14-17, a hydraulic circuit illustrates the control of the first and second latch pins46, the first and second slide pins48a,48b,the first andsecond lift cylinders42a,42b,and the first and secondtransverse cylinders182a,182b.A diesel powered pumpingunit50, also shown on theequipment deck16 in FIG. 3, drives a variabledisplacement piston pump152. In the preferred embodiment, the diesel power pumping unit is a three cylinder air cooled pumping unit that is rated at29 horsepower at 1800 rpm and the variabledisplacement piston pump152 is pressure and flow compensated with a horse power limiter. The variabledisplacement piston pump152 pumps fluid from a hundred gallon reservoir160 past athird check valve174cto apressure filter156. Afterwards the fluid flows into a simplified load sense sectional valve, generally designated132. The simplified load sensesectional valve132 contains five hydraulic switches that control the various hydraulic cylinders. Additionally, fluid is returned from the simplified load sensesectional valve132 to the reservoir160 after passing through thereturn filter158. Preferably both thereturn filter158 and thepressure filter156 are ten micron filters. In addition, a systempressure relief valve154 is also capable of passing fluid through thereturn filter158 to the reservoir160.
• The hydraulic switches inside the simplified load sense[0083]sectional valve132 are standard spool valves which allow fluid to be pumped along different paths to the various hydraulic cylinders. All of the hydraulic switches can be positioned to use either afirst flow path144 or asecond flow path146. Additionally, the hydraulic switches controlling the first andsecond lift cylinders42a,42band hydraulic switches controlling the first and secondtransverse cylinders182a,182bcan also be positioned to use athird flow path148. The details of the individual hydraulic switches will be discussed along with the corresponding hydraulic components below.
• The first and second latch pins[0084]46a,46bare controlled by the latch pinhydraulic switch140. The latch pinhydraulic switch140 is capable of switching between positions using afirst flow path144 and asecond flow path146. In addition, the latch pinhydraulic switch140 is biased by a fourth hydraulicswitch biasing element150d,such as a spring, into a position using thesecond flow path146. In the preferred embodiment, the first and second latch pin cylinders162a,162bhave a 2 inch bore, a 1.375 inch diameter rod, and an 8 inch stroke.
• When the latch pin[0085]hydraulic switch140 is in a position that uses thesecond flow path146, fluid is pumped into the first and second latch pin cylinders162a,162bto force the first and second latch pins46a,46bto extend outward (thus, engaging the guide rail and vertically stabilizing the platform assembly10).
• When the latch pin[0086]hydraulic switch140 is positioned to use thefirst flow path144, fluid is pumped into the first and second latch pin cylinders162a,162bto force the first and second latch pins46a,46bto retract into the first and second latch pin cylinders162a,162b(thus disengaging the latch pins46a,46bfrom the guide rails40). The latch pinhydraulic switch140 is moved to thefirst flow path144 by a solenoid140awhich is remotely controlled by an operator located at the operating panel described below.
• The biasing of the latch pin[0087]hydraulic switch140 into a position using thesecond flow path146 is a safety feature that causes the latch pins46a,46bto have, as a default position, the extended position. In addition, a second safety is designed into the system by using a first and a second latchpin biasing element164a,164bto bias the first and second latch pins46a,46binto an extended position in the event of a loss of fluid. Thus, to retract the first and second latch pins46a,46bit is necessary to both have proper fluid flow and to override the bias of the latch pinhydraulic switch140.
• The slide pin[0088]hydraulic switch138 controls the first and second slide pins48a,48b.The slide pinhydraulic switch138 is movable between a position using afirst flow path144 and a position using asecond flow path146. The slide pinhydraulic switch138 is biased into a position using thesecond flow path146 by a third hydraulicswitch biasing element150c.In the preferred embodiment, the first and secondslide pin cylinders166a,166bhave a 2 inch bore, a 1.375 inch diameter rod, and an 8 inch stroke.
• When the slide pin[0089]hydraulic switch138 is in a position using thesecond flow path146, fluid is pumped to the first and secondslide pin cylinders166a,166bto extend the first and second slide pins48a,48boutward from the first and secondslide pin cylinders166a,166b.When the slide pinhydraulic switch138 is in a position using thefirst flow path144, fluid is pumped to the first and secondslide pin cylinders166a,166bto retract the first and second slide pins48a,48binto the first and secondslide pin cylinders166a,166b.The slide pinhydraulic switch138 is moved to thefirst flow path144 by asolenoid138awhich is remotely controlled by an operator located at the operating panel described below.
• As a safety feature, the slide pin[0090]hydraulic switch138 is biased by the third hydraulicswitch biasing element150c,such as a spring, into a position using thesecond flow path146. This causes the first and second slide pins48a,48bto, by default, extend from the first and secondslide pin cylinders166a,166band engage the guide rails40. An additional safety is built into the first and second slide pins48a,48bby inserting a first and a second slide pin biasing element168a,168binto the first and secondslide pin cylinders166a,166b.The first and second slide pin biasing elements168a,168bbias the first and second slide pins48a,48binto the extended position in the event of a lack of fluid flow. Thus, the first and second slide pins48a,48bare only retracted into the first and second slide pinscylinders166a,166bwhen there is proper fluid flow in the conduits and the slide pinhydraulic switch138 is moved out of its biased position.
• Additionally, in the preferred embodiment of the guide rail climbing lifting platform additional safe guards are built into the operating panel that controls the hydraulic cylinders of the[0091]platform assembly10. The hydraulic cylinders are controlled from an operating panel that is located close to the ground level proximate to the base of thesteel tower72. From a remote point on the ground, or from a position in the tower, a controller operates the operating panel (not shown) to manipulate the hydraulic switches and control the hydraulic cylinders of theplatform assembly10. The operating panel includes appropriate electronic lock outs well understood by those of ordinary skill in the art that will not allow the operator to disengage the first and second latch pins46a,46bwhen the first and second slides pins48a,48bare not engaged with the guide rails40. Similarly, the operating panel will not allow an operator to disengage the first and second slide pins48a,48bwhen the first and second latch pins46a,46bare disengaged from the guide rails40.
• While in the preferred embodiment people are not transported on the[0092]platform assembly10 as it traverses thesteel tower72 and theplatform assembly10 is controlled by an operator positioned on the ground, it is understood by those of skill in the art that the present invention is not limited to a lifting platform that does not transport people. For instance, with the addition of further safeguards (that are well known to those of skill in the art), it is possible to have workers and operators transported by the platform while controlling the platform operations. The advantage of not transporting people on theplatform assembly10 is that the cost of manufacturing theplatform assembly10 is significantly reduced due to not having to design the guide railclimbing lifting platform10 to comply with OSHA (Occupational Safety and Health Act) regulations.
• The first and second lift cylinder[0093]hydraulic switches134,136 are used to control the first andsecond lift rods43a,43b.Two hydraulic switches are used to control the first andsecond lift cylinders42a,42bto increase the fluid flow provided to the first andsecond lift cylinders42a,42b.The first and second lift cylinderhydraulic switches134,136 are adjustable into a position using either of afirst flow path144, asecond flow path146, and athird flow path148. Both the first and second lift cylinderhydraulic switches134,136 are biased into a position using the third flow path. The first lift cylinderhydraulic switch134 is biased into position by a first and a sixth hydraulicswitch biasing element150a,150f,such as a spring, and the second lift cylinderhydraulic switch136 is biased into position by a second and a seventh hydraulicswitch biasing element150b,150g,such as a spring. In the preferred embodiment, the first andsecond lift cylinders42a,42bare double acting and have a 6 inch bore, a 3 inch diameter rod, and a stroke of 10 feet.
• The[0094]pressure equalizing connection176 synchronizes the movement of the first andsecond lift rods43a,43b.The control orifice used as thepressure equalizing connection176 is preferably 0.040 inches. The control orifice used at thepressure equalizing connection176 remains small so that, in the event of conduit breakage, fluid will not escape faster through thepressure equalizing connection176 than the variabledisplacement piston pump152 can pump replacement fluid into the first andsecond lift cylinders42a,42b.
• When the first and second lift cylinder[0095]hydraulic switches134,136 are in position to use thefirst flow path144, fluid is pumped so as to retract the first andsecond lift rods43a,43binto the first andsecond lift cylinders42a,42b.When the first and second lift cylinderhydraulic switches134,136 are in position to use thesecond flow path146, fluid is pumped so as to extend the first andsecond lift rods43a,43bfrom the first andsecond lift cylinders42a,42b.When the first and second lift cylinder hydraulic switches are in position to use thethird flow path148, the fluid in the conduits is vented to the reservoir160. This results in both the first andsecond lift rods43a,43bstaying in their current position. The first and second lift cylinderhydraulic switches134,136 are each moved between the first, second andthird flow paths144,146,148 bysolenoids134a,136a,respectively, which are remotely controlled by an operator located at the operating panel described above.
• The[0096]first lift rod43aremains in its current position when fluid in the conduits connecting thefirst lift cylinder42ato the variabledisplacement piston pump152 is vented back to the reservoir (i.e. when the first and second lift cylinderhydraulic switches134,136 are using the third flow path148), because of the combination effect of the firstcounter balance valve170aand the first check valve174a.As viewed in FIG. 14, fluid in the upper portion of thefirst lifting cylinder42ais prevented from leaving by the first check valve174aand by the firstcounter balance valve170a.The first check valve174aonly allows fluid to pass from the right side towards the left side of the first check valve174a.The firstcounter balance valve170adoes not allow fluid to pass from the left of the firstcounter balance valve170ato the right side of the firstcounter balance valve170a.In the preferred embodiment the first through the sixth counter balance valves170a-170fare designed to have a 4.5:1 ratio.
• A[0097]first pilot line172aconnects the conduit attached to the lower end of thefirst lifting cylinder42a,as viewed in FIG. 14, to the firstcounter balance valve170a.Thefirst pilot line172acauses the firstcounter balance valve170ato release fluid when the load induced pressure exceeds a predetermined amount.
• Additionally, the[0098]pressure equalizing connection176 does not allow fluid to leave thefirst lifting cylinder42aand return to the reservoir160. Thepressure equalizing connection176 retains fluid because the fluid in thepressure equalizing connection176 is blocked on each side by the combination of both acounter balance valve170a,170band a check valve174a,174b.
• The operation of the second lift cylinder[0099]42bwhen the first and second lift cylinderhydraulic switches134,136 are positioned to use thethird flow path148 is the same as that described above for thefirst lift cylinder42a.Moreover, the second counter balance valve170b,the second check valve174b,and the second pilot line172b,serve the same function for the second lift cylinder42bthat their counterparts serve for thefirst lift cylinder42a.
• The transverse[0100]hydraulic cylinder switch142 controls the operation of the first and secondtransverse cylinders182a,182b.The transversehydraulic cylinder switch142 is adjustable into a position using either of afirst flow path144, asecond flow path146, and athird flow path148. The transversehydraulic cylinder switch142 is biased into a position using thethird flow path148. The transversehydraulic cylinder switch142 is biased into position by a fifth and an eighth hydraulicswitch biasing element150e,150h,such as a spring. In the preferred embodiment, the first and secondtransverse cylinders182a,182bhave a 4 inch bore, a 2.5 inch diameter rod, and a stroke of 4 feet.
• When the transverse[0101]hydraulic cylinder switch142 is in a position that uses thefirst flow path144, fluid is pumped into the first and secondtransverse cylinders182a,182bto extend the first and secondtransverse rods184a,184bfrom the first and secondtransverse cylinders182a,182b.In addition, the fluid pumped to the left sides of the first and secondtransverse cylinders182a,182b,as viewed in FIGS. 14 and 17, is passed through arotary flow divider178 that preferably uses a 50:50 split. A first andsecond relief valve180a,180bare positioned inside of therotary flow divider178. When the transversehydraulic cylinder switch142 is in a position using thesecond flow path146, fluid is pumped to the first and secondtransverse cylinders182a,182bto retract the first and secondtransverse rods184a,184binto the first and secondtransverse cylinders182a,182b.When the transversehydraulic cylinder switch142 is in a position using thethird flow path148, fluid that is in the conduits between the variabledisplacement piston pump152 and the first and secondtransverse cylinders182a,182bis vented to the reservoir160. This results in both the first and secondtransverse rods184a,184bstaying in their current position. The position of the transversehydraulic cylinder switch142 is controlled by adouble acting solenoid142awhich is remotely controlled by an operator located at the operating panel described above.
• The first[0102]transverse cylinder182aremains in its current position when fluid in the conduits connecting the firsttransverse cylinder182ato the variabledisplacement piston pump152 is vented back to the reservoir (i.e. when transversehydraulic cylinder switch142 is using the third flow path148), because of the combination effect of the fifth and the sixthcounter balance valves170e,170f,with the sixth and theseventh check valves174f,174g.Thus, a combination check valve and counterbalance valve on each end of the firsttransverse cylinder182aprevents fluid from leaving the firsttransverse cylinder182a.
• As viewed in FIG. 14, fluid in the left portion of the first[0103]transverse cylinder182ais prevented from leaving by the combination effect of the seventh check valve174gand by the fifthcounter balance valve170e.The seventh check valve174gonly allows fluid to pass from the top side towards the bottom side of the seventh check valve174g,as viewed in FIGS. 14 and 17. The fifthcounter balance valve170edoes not allow fluid to pass from the bottom side of the fifthcounter balance valve170eto the top side of the fifthcounter balance valve170e.The sixthcounter balance valve170fand thesixth check valve174foperate in a manner similar to their counterparts attached to the left side of the firsttransverse cylinder182a,as viewed in FIG. 14.
• The use of counter balance valves in a dual counter balance arrangement prevents the first[0104]transverse rod184afrom being displaced due to pressures exerted on theadjustable carriage assembly90. This is necessary to prevent wind forces from causing the firsttransverse rod184ato extend or retract without commands from the operator.
• The fifth and the[0105]sixth pilot lines172eand172fare attached to the fifth and the sixthcounter balance valves170e,170f.The fifth andsixth pilot lines172e,172fcause the fifth and the sixthcounter balance valves170e,170fto allow fluid to pass when the load induced pressure exceeds a predetermined level.
• The operation of the second transverse cylinder[0106]182bwhen the transversehydraulic cylinder switch142 is positioned to use thethird flow path148 is the same as that described above for the firsttransverse cylinder182a.Moreover, the third and the fourthcounter balance valves170c,170d,the fourth andfifth check valves174d,174e,and the third and the fourth pilot lines172c,172d,serve the same function for the second transverse cylinder182bas their counterparts serve for the firsttransverse cylinder182a.
• While a currently preferred embodiment of a possible hydraulic circuit for controlling the operation of the guide rail[0107]climbing lifting platform10 has been described, it is understood by those of skill in the art from this disclosure that the present invention is not limited to any specific hydraulic circuit or control system. Nor is the invention limited to components having the specifications detailed above. For example, different numbers of hydraulic switches can be used, flow paths can be changed, counterbalance valve ratios can be varied, a flow divider can be omitted, a PLC could be added for enhanced control, other components can be added, etc. In addition, the size of the hydraulic cylinders can also be varied depending on the particular application for which theplatform assembly10 is being designed.
• The[0108]platform assembly10 also simplifies the maintenance of wind turbine tubular towers72 and their associated wind turbine generators. Wind turbine generators are often struck by lightning that can result in damage to either thesteel tower72, thenacelle120, the wind turbine generator, or therotor blades124. Thus, necessitating the repair or replacement of various components of thesteel tower72, the wind turbine generator, or therotor blades124. Theplatform assembly10 is capable of performing repairs more economically than repairs performed by a large industrial crane. FIG. 20 illustrates areplacement rotor blade124 being transported upwards along a windturbine tubular tower72. Therotor124 is connected to theplatform assembly10 using a saddle structure, or a swing structure,116. Thissaddle structure116 supports the lower end of therotor blade124 as viewed in FIG. 20. The portion of therotor blade124 that passes through theplatform assembly10 has at least one guide (not shown) attached to theplatform assembly10 and placed around a cross-section of therotor blade124. Thus, the lower end of therotor blade124 is able to be rotated about a pivot point formed by the guide (not shown). Additionally, the position of therotor blade124 can be adjusted vertically relative to theplatform assembly10 by adjusting the length of the sides of thesaddle structure116. Thus, once therotor blade124 is positioned proximate to therotor126, the top end of therotor blade124 can have its position adjusted to facilitate the attachment of therotor blade124 to therotor126. While in the preferred embodiment asaddle structure116 and at least one guide are used to attach arotor blade124 to theplatform assembly10, it is understood from this disclosure by those of skill in the art that the present invention is not limited to any particular method of securing therotor blade124 to the platform assembly.
• Thus, to replace a damaged[0109]rotor blade124, theplatform assembly10 is brought to the base of the windturbine tubular tower72 and attached to the guide rails40 that remained attached to the windturbine tubular tower72.
• After the[0110]platform assembly10 is secured to the guide rails40, therotor126 is rotated so that the damagedrotor blade124 points towards the ground. After the damagedrotor blade124 has been properly positioned, as shown in FIG. 21, therotor126 is locked in position. This prevents the remainingrotor blades124 from swinging downwards after the damagedrotor blade124 is removed. Afterwards, an operator raises theplatform assembly10 to the top of the wind turbine tubular tower.
• Then, workers secure the damaged[0111]rotor blade124 to theplatform assembly10 and detach therotor blade124 from the rotor126 (FIG. 21 illustrates arotor blade124 secured to theplatform assembly10 and ready for either attaching to or detaching from the rotor126).
• After the[0112]rotor blade124 is detached from therotor126, an operator lowers theplatform assembly10 to the base of the windturbine tubular tower72. Then, workers remove the damagedrotor blade124 and attach areplacement rotor blade124 to theplatform assembly10.
• Once the replacement blade is attached to the[0113]platform assembly10, as described above, an operator again raises theplatform assembly10 to the top of the windturbine tubular tower72, as shown in FIG. 20. After theplatform assembly10 has reached the top of thetower72, workers attach thereplacement rotor blade124 to therotor126 as shown in FIG. 21. Then, therotor blade124 is detached from theplatform assembly10 and the platform assembly is again lowered to the base of the wind turbine tubular tower.
• Referring to FIGS.[0114]1-21, the guide railclimbing lifting platform10 operates as follows. Initially, a small crane (not shown) is used to place thelowermost tower segment84 on the ground. The guide rails40 are already installed on the lowermost tower segment. Next, theplatform assembly10 is attached to the guide rails40 and positioned proximate to the base of the partially assembledsteel tower72, as shown in FIG. 1. The first and second latch pins46a,46bare engaged with the guide rails40. The first and second slide pins48a,48bare also engaged with the guide rails40 while the first andsecond lifting rods43a,43bare fully extended, as shown in FIG. 3.
• Before the next or second from the[0115]ground tower segment84 is positioned on theadjustable carriage assembly90, the first and secondtransverse rods184a,184bare attached to thecarriage assembly90 using slidingblocks106. The slidingblocks106 are attached to the slidingblock receiving holes108 closest to thetower72. This causes the adjustable carriage assembly to be securely positioned on theplatform assembly10.
• Then, a small crane places the next tower segment[0116]84 (or another additional tower component) onto theadjustable carriage assembly90. Thetower segment84 has bolt-onbrackets94 that engage theadjustable carriage assembly90 to vertically support thetower segment84.
• Afterwards, the latch pin[0117]hydraulic switch140 is moved out of its biased position and into a position using afirst flow path144. The causes fluid to be pumped to the first and second latch pin cylinders162a,162bto force the first and second latch pins46a,46bto retract inside of the first and second latch pin cylinders162a,162b,thereby compressing the first and second latchpin biasing elements164a,164b.Thus, the first and second latch pins46a,46bare disengaged from the guide rails40.
• Then, the first and second lift cylinder[0118]hydraulic switches134,136 are moved out of their biased positions and into positions using thefirst flow path144. This causes fluid to be pumped to the first andsecond lift cylinders42a,42bto cause the first andsecond lift rods43a,43bto retract inside of the first andsecond lift cylinder142a,142b.As the first andsecond lift rods43a,43bare retracted, theplatform assembly10 is moved upwards.
• The[0119]platform assembly10 continues to move upwards until the first andsecond lift rods43a,43bare retracted. Once the platform assembly has moved upwards approximately 10 feet, the first andsecond lift rods43a,43bare fully retracted and theplatform assembly10 stops moving upward.
• Next, the latch pin[0120]hydraulic switch140 is returned to its biased position that uses thesecond flow path146. This causes fluid to be pumped to the first and second latch pin cylinders162a,162bto force the first and second latch pins46a,46bto extend outwards from the first and second latch pin cylinders162a,162band engage the guide rails40.
• Once the first and second latch pins[0121]46a,46bare engaged with thepin receiving holes70 in the guide rails40, the slide pinhydraulic switch138 is moved out of its biased position and into a position that uses thefirst flow path144. This causes fluid to be pumped to the first and secondslide pin cylinders166a,166bcausing the first and second slide pins48a,48bto retract into the first and secondslide pin cylinders166a,166band to disengage from the guide rails40.
• Then, the first and second lift cylinder[0122]hydraulic switches134,136 are moved into a position using thesecond flow path146. This causes fluid to be pumped into the first andsecond lift cylinders42a,42bpushing the first andsecond lifting rods43a,43bupwards and causing theslide assembly55 to move upwards along the guide rails40. Once theslide assembly55 has been moved upwards along the guide rails40 approximately 10 feet, the first and second slide pins48a,48bare aligned with the next set ofpin receiving holes70 in the guide rails40.
• Then, the slide pin[0123]hydraulic switch138 is moved into its biased position that uses thesecond flow path146 to cause the first and second slide pins48a,48bto engage the guide rails40. The above process is repeated until the guide rail climbing lifting platform reaches the top of the partially constructedsteel tower72, as shown in FIG. 1.
• Once the guide rail climbing lifting platform reaches the top of the partially constructed[0124]steel tower72, the transverse cylinderhydraulic switch142 is moved out of its biased position and into a position that uses thefirst flow path144 to pump fluid into the first and secondtransverse cylinders182a,182b.This causes the first and secondtransverse rods184a,184bto extend outward from the first and secondtransverse cylinders182a,182bto force theadjustable carriage assembly90, as shown in FIG. 2, to move to the right. Once the first and secondtransverse rods184a,184bare fully extended, a worker repositions one of the slidingblocks106 to engage a slidingblock receiving hole108 that is closer to the firsttransverse cylinder182a.
• Once one of the transverse rods has had its sliding[0125]block106 adjusted to engage a slidingblock receiving hole108 that is closer to the transverse cylinder, the same procedure is repeated for the other transverse rod. After both the first and secondtransverse rods184a,184bare adjusted to engage a closer slidingblock receiving hole108 via their respective slidingblocks106, the first and secondtransverse rods184a,184bare again extended to push theadjustable carriage assembly90 further to the right, as viewed in FIG. 2. This procedure is continued until thecenter line73 of thetower segment84 is aligned with thecenter line73 of the partially constructedsteel tower72.
• After the[0126]additional tower segment84 is properly positioned over the partially constructedsteel tower72, the bearingcontacts94aon the bottom of the bolt-onbrackets94 allow thetower segment84 to be rotated approximately 5-10 degrees in order to align the bolt holes74 in theinner flange86 of thetower segment84 with the bolt holes74 in theinner flange86 of the top portion of the partially constructedtower72.
• When the[0127]tower segment84 is properly aligned with the partially constructedsteel tower72, using the liftingrods43a,43b,theplatform assembly90 is lowered to bring thetower segment84 into contact with thesteel tower72. Then, workers secure theadditional tower segment84 to thesteel tower72 using bolts and the guide rails40 are secured in alignment with each other. Thelifting platform10 is then lowered to the ground using the same procedure described above whereupon thenext tower segment84 is loaded on thecarriage assembly90 by the small crane. Thenext tower segment84 is then raised to the top of partially constructedtower72 and put in place as the next tower segment, using the same procedure described above. This process is repeated until all of thetower segments84 are in place to make up thesteel tower72. Lastly thenacelle120 and other elements of the wind turbine, such as the rotor and rotor blades124 (shown in FIGS.18-21), are raised to the top of thesteel tower72 and installed.
• As described above, the guide rail[0128]climbing lifting platform10 greatly simplifies the erecting of modular towers for use as wind turbine tubular towers. Furthermore, the guide railclimbing lifting platform10 is ideal for the lifting of the wind turbine generators including thenacelle120,rotor126,rotor blades124, replacement parts, and repair parts to the top of the wind turbine tubular towers and is capable of further simplifying later repairs to the wind turbine generators.
• The guide rail and climbing lifting platform as described may be used in connection with tower construction, repair and maintenance generally and is not limited to wind turbine towers. The use of the term “tubular towers” herein is intended to refer to towers which have a hollow interior and includes cross-sectional tubes that may be of any configuration, including but not limited to square and round cross-sections. Of course, it is generally contemplated that the tower may be smaller in diameter as it increases in height such that “tubular tower” also encompasses straight walled and tapering walled towers. The term “tubular towers” as used herein also includes open towers made of girders so long as guide wires are not in the way. In fact, the benefits of the invention may be achieved with any free standing structure where guide wires would not interfere with the platform movement.[0129]
• The invention is also suited for off-shore wind towers since the system would only require a conventional work barge and standard crane rather than an extremely expensive ocean going vessel with a permanently mounted large crane.[0130]
• It should be noted that the system can be used to lay down its own rails or to remove the rails after completion of the erection if aesthetics dictate removal. The rails may be reinstalled later for maintenance if required.[0131]
• While this invention may be embodied in many different forms, there are shown in the drawings and described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.[0132]
• This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.[0133]

Claims (14)

1. A tower comprising in combination:

a) a plurality of generally tubular sections each having a top and a bottom, including a lower tubular section to be anchored to the ground and at least one higher tubular section constructed and arranged to be securable on top of a lower section;

b) each said tubular section including a guide rail extending from said bottom to said top and being constructed and arranged such that stacked and secured tubular sections may be arranged such that the guide rail is continuous from the bottom to the top of the tower thus formed; and

c) a guide rail climbing lifting platform attachable to said guide rails with a carriage track system, said platform including a climbing mechanism for raising and lowering said platform on said guide rails and for securing said carriage track system to said guide rails, said platform further including a carriage assembly for carrying items up and down said tower.

2. The tower ofclaim 1 further including a wind turbine generator connected atop the highest tubular section.

3. The tower ofclaim 1 wherein said guide rail climbing lifting platform includes apparatus for moving said carriage assembly horizontally over said tower and for raising and lowering said carriage assembly when positioned over said tower.

4. The tower ofclaim 1 wherein said climbing mechanism includes a lower pair of latch pins on said platform which engage with pin receiving holes in said rails and a pair of lift cylinders having lower and upper ends, the lower ends of said lift cylinders being mounted to said lift platform and said upper end of said lift cylinders being slidably connected to said guide rail, said upper end of said lift cylinders being securable to said guide rail pin receiving holes via an upper pair of latch pins.

5. The tower ofclaim 4 wherein said lift cylinders are controlled by a hydraulic control mechanism that causes said lift cylinders to extend and retract and said upper and lower pins to engage and disengage alternatively such that said platform may be driven up and down said guide rails with one set of latch pins always being latched to said guide rail pin receiving holes.

6. The tower ofclaim 1 wherein said climbing mechanism includes a plurality of latch pins constructed and arranged to engage with said guide rail, said latch pins being controlled by a hydraulic control mechanism which lifts and lowers said platform on said rail with at least one latch pin always being secured to said guide rail.

7. The tower ofclaim 1 wherein a payload on said platform is carried by said guide rails to a base on which said tower is erected by mounting the lowermost rails against said base.

8. A vertically oriented tower having a series of interconnected modular tubular sections along a vertical height connected by joints, each said tubular section including a guide rail aligned with a guide rail from an adjacent tubular section such that a continuous guide rail extends from the bottom to the top of said tower, said tower including a guide rail climbing lifting platform attachable to said guide rail and including a mechanism for moving along said guide rail, said platform defining a carriage assembly to which items may be placed for delivery up or down said tower.

9. A kit for adapting structures to include a guide rail and guide rail lifting platform system comprising:

a) a plurality of guide rail sections each having mechanisms for attaching the guide rail sections to a structure;

b) a guide rail climbing lifting platform attachable to said guide rail and including a mechanism for moving along said guide rail, said platform defining a carriage assembly to which items may be placed for delivery up or down said structure.

10. The kit ofclaim 9 wherein said structure is a tower.

11. A method for building towers comprising the steps of:

a) preparing a base;

b) erecting a first generally tubular section on said base, said tubular section including a guide rail along its length;

c) attaching a guide rail climbing lifting platform to said guide rail, said platform including a mechanism for moving along said guide rail, said platform defining a carriage assembly to which items may be placed for delivery up or down said tower;

d) placing another tubular section onto said carriage assembly and lifting said platform on said guide rails and sliding said another tubular section over the top of said first tubular section and securing said sections together; and

e) lowering said platform to receive another tubular section and repeating said process until the desired tower height is achieved.

12. A method for servicing wind generating towers comprising the steps of:

a) attaching a guide rail to the outside of the tower;

b) attaching a guide rail climbing lifting platform to said guide rail, said platform including a a mechanism for moving along said guide rail, said platform defining a carriage assembly to which items may be placed for delivery up or down said tower; and

c) utilizing said platform to raise and lower repair or replacement components on said tower.

13. A method for constructing wind generating towers comprising the steps of:

a) preparing a base;

b) erecting a first generally tubular section on said base, said tubular section including a guide rail along its length;

c) attaching a guide rail climbing lifting platform to said guide rail, said platform including a a mechanism for moving along said guide rail, said platform defining a carriage assembly to which items may be placed for delivery up or down said tower;

d) placing another tubular section onto said carriage assembly and lifting said platform on said guide rails;

e) sliding said another tubular section over the top of said first tubular section and securing said sections together;

e) lowering said platform to receive another tubular section and repeating said process until the desired tower height is achieved; and

f) lowering said platform to receive wind generating turbine components and raising each of said wind generating turbine components on said platform to the top of said tower until all components are assembled.

14. A tower comprising in combination:

a) a plurality of generally tubular sections each having a top and a bottom, including a lower tubular section to be anchored to the ground and at least one higher tubular section constructed and arranged to be securable on top of a lower section;

b) each said tubular section including a guide rail extending from said bottom to said top and being constructed and arranged such that stacked and secured tubular sections may be arranged such that the guide rail is continuous from the bottom to the top of the tower thus formed; and

c) a guide rail climbing lifting platform attachable to said guide rails with a carriage track system, said platform including a climbing mechanism for raising and lowering said platform on said guide rails and for securing said carriage track system to said guide rails, said platform further including a carriage assembly for carrying items up and down said tower, said carriage assembly including apparatus for moving said carriage assembly horizontally over said tower and for raising and lowering said carriage assembly when positioned over said tower.

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