Abstract:
A wind energy tower erection device is disclosed together with the method of assembling the same and the method of utilizing the device to erect a wind energy tower. The tower erection device successively places tower sections one upon the other until the tower is erected.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to a method and means for erecting a tower and more particularly to a method and means for erecting a wind energy tower wherein tower sections are successively placed upon one another. 
   2. Description of the Related Art 
   Wind turbines or wind energy devices are becoming more popular in the production of electrical energy. The wind turbine or wind energy device normally comprises a rotor-driven generator mounted atop a tower which may reach heights of 70 meters or more. The tower is usually comprised of a plurality of tapered or cylindrical tower sections which are secured together in an end-to-end relationship. The tower is normally erected by the use of a large crane. When the tower has been erected, the large crane lifts the turbine onto the top of the tower. The customary method of erecting the tower is quite expensive due to the requirement that the large crane must be present on the job site. Further, in some windy conditions, the lifting of the tower sections by the large crane is hazardous. 
   SUMMARY OF THE INVENTION 
   A wind energy tower erecting device is provided for successively erecting tower sections upon a base tower section which extends upwardly from a foundation and which is secured thereto. Normally, the base tower section will be positioned upon the foundation with a small crane. The tower erecting device comprises a skid or skid module upon which is positioned a power source such as an engine, a main winch having a hoisting cable extending therefrom, and a tower section staging platform upon which individual tower sections are successively positioned for erection on the base tower section. The skid module is positioned adjacent the base tower section and is anchored to the foundation by a plurality of bolts. 
   A jack stand is placed adjacent the base tower section and extends partially therearound. A lower cage is initially positioned on the upper end of the jack stand and extends at least partially around the base tower section. A lower block is secured to the lower cage. The lower cage includes roll bank assemblies mounted thereon which are adapted to engage rails on opposite sides of the tower sections to enable the lower cage and associated structure to be selectively vertically moved on the tower sections. An upper cage is spaced above the lower cage and is interconnected thereto by a supporting frame structure which is comprised of spaced-apart side panels and spaced-apart side trusses. 
   An upper block is initially removably attached to the base tower section adjacent the upper end thereof and is adapted to be successively attached to the upper ends of the tower sections as they are placed upon the base tower section. The hoisting cable from the main winch extends around the upper and lower blocks in a multi-parted fashion with the free end thereof being secured to the lower block. A bridge assembly is positioned on the upper end of the upper cage and comprises a bridge, trolley and Z-slide. The bridge is a trapezoidal-shaped beam which straddles or bridges the upper end of the upper cage and moves in the Y direction (front to back). The trolley moves with respect to the bridge in the X direction (side to side). The Z-slide is mounted on the trolley and moves in the Z direction (vertical). A tower section connector or load toggle is connected to the Z-slide at the lower end thereof and is comprised of a double gimble-type joint and a load spider. The load spider includes four rotating load arms which are selectively attached to the flange on the upper end of the tower section being transported. An auxiliary power unit is mounted on the bridge assembly for providing power for the bridge assembly and miscellaneous electrical equipment. An auxiliary winch is also positioned on the Z-slide. 
   The wind energy tower is erected as follows: (1) a small crane is utilized to place the base tower section on the foundation and is bolted into place; (2) the jack stand is positioned around the base tower section; (3) the skid module is moved into place and bolted to the foundation; (4) the roll bank assemblies on the lower cage are opened; (5) the lower cage is lifted onto the jack stand; (6) the roll bank assemblies are moved into an operative engagement position with respect to the rails on the opposite sides of the base tower section; (7) the side panels and side trusses are assembled; (8) one side panel-side truss is secured to one side of the lower cage so as to extend upwardly therefrom; (9) the other side panel-side truss is secured to the other side of the lower cage so as to extend upwardly therefrom; (10) the upper cage is mounted on the upper ends of the side panels by means of a small crane; (11) the upper block is secured to the side of the base tower section at the upper end thereof; (12) the hoisting cable is extended from the main winch on the skid module and connected to the lower block on the lower cage and upper block on the upper end of the base tower section whereby movement of the hoisting cable by the main winch causes the lower cage and the structure supported thereby to be moved vertically with respect to the base tower section; (13) another tower section is placed or staged on the staging platform provided on the skid module; (14) the bridge assembly is manipulated on the upper cage to position the load toggle on the Z-slide within the upper end of the tower section on the staging platform; (15) the load toggle is secured to the flange on the staged tower section; (16) the main winch is operated to cause the hoisting cable to raise the lower cage, upper cage, interconnecting supporting frame structure, bridge assembly and the staged tower section upwardly with respect to the base tower section; (17) when the staged tower section is raised sufficiently, the lower cage is pinned to the rails on the base tower section; (18) the bridge assembly is manipulated so that the staged tower section is positioned over the base tower section and then lowered onto the base tower section; (19) the flange on the lower end of the staged tower section is bolted to the flange on the upper end of the base tower section; (20) the auxiliary winch on the bridge assembly is operated to raise the upper block from the upper end of the base tower section, after it has been disconnected from the base tower section, to the upper end of the staged tower section mounted thereon; (21) the upper block is secured to the staged tower section mounted on the base tower section; (22) the lower cage is unpinned from the rails and is moved downwardly until the lower cage rests upon the jack stand; (23) the bridge assembly is manipulated to position the load toggle within the upper end of another tower section on the staging platform; (24) repeating the necessary steps described above until the wind energy tower is completely erected; (25) using the auxiliary winch to lower the upper block to the ground after it has been removed from the erected tower; (26) removing the bridge assembly, upper cage, side panels and side trusses, lower cage and jack stand from the erected tower; and (27) removing the skid module from the foundation. 
   It is therefore a principal object of the invention to provide an improved wind energy tower erection device. 
   A further object of the invention is to provide an improved wind energy tower erection device which eliminates the need for a large crane such as is customarily required. 
   Yet another object of the invention is to provide an improved wind energy tower erection device which may be used to erect towers having a height which exceeds the reach of even a very large crane. 
   Still another object of the invention is to provide an improved wind energy tower erection device which is safe to use in practically all weather conditions. 
   Still another object of the invention is to provide an improved wind energy tower erection device which is durable and reliable. 
   These and other objects will be apparent to those skilled in the art. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the apparatus for erecting a wind energy tower; 
       FIG. 2  is a perspective view of the skid module portion of the apparatus; 
       FIG. 3  is a partial perspective view of the lower end of the apparatus; 
       FIG. 4  is a partial perspective view of the upper end of the apparatus illustrating the upper cage and bridge assembly; 
       FIG. 5  is a side view of the apparatus illustrating the lower cage, etc., its uppermost position with respect to the tower base section; 
       FIG. 6  is a side view of the apparatus illustrating the lower cage, etc., in its lowermost position supported upon the jack stand; 
       FIG. 7  is a side view of the apparatus illustrating the lower cage, etc., in its uppermost position with a tower section having been lifted from the staging platform for positioning on the base tower section; 
       FIG. 8  is a view similar to  FIG. 7  except that the bridge assembly has moved the staged tower section to a position over the base tower section; 
       FIG. 9  is a side view similar to  FIG. 8  which illustrates another tower section having been raised from the staging platform; 
       FIG. 10  is a top view of the apparatus; 
       FIG. 11  is a top view illustrating the relationship of the lower cage with respect to the rails of a tower section; 
       FIG. 12  is a top view of the upper block attachment hanger and upper block; 
       FIG. 13  is a side view of the upper block attachment hanger and upper block; 
       FIG. 14  is a front view of the upper block attachment hanger and upper block; 
       FIG. 15  is a bottom view of the upper block attachment hanger and upper block; 
       FIG. 16  is a perspective view of the Z-slide and load toggle and their relationship to the top flange on a tower section; 
       FIG. 17  is a front view of the Z-slide and load toggle and their relationship to the top flange on a tower section; 
       FIG. 18  is a side view of the Z-slide and load toggle and their relationship to the top flange on a tower section; 
       FIG. 19  is a perspective view similar to  FIG. 16  except that the Z-slide is shown mounted on the trolley; 
       FIG. 20  is a top view of the Z-slide, trolley and load toggle of  FIG. 19 ; 
       FIG. 21  is a bottom view of the Z-slide, trolley and load toggle of  FIG. 19 ; 
       FIG. 22  is a side view of the Z-slide, trolley and load toggle of  FIG. 19 ; 
       FIG. 23  is a front view of the Z-slide, trolley and load toggle of  FIG. 19 ; 
       FIG. 24  is a top perspective view of the load toggle; 
       FIG. 25  is a bottom perspective view of the load toggle; 
       FIG. 26  is a top view of the load toggle; 
       FIG. 27  is a side view of the load toggle; 
       FIG. 28  is a side view of the load toggle; and 
       FIG. 29  is a bottom view of the load toggle. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring to the drawings, the numeral  10  refers to a base tower section of the wind energy tower to be erected. The base tower section  10  will normally be positioned on a concrete foundation  12  by a small crane (not shown). The base tower section  10  is bolted to the foundation  12  in a conventional fashion. The base tower section  10  includes a pair of longitudinally extending rails  14  and  16  secured to the opposite sides thereof with each of the rails having vertically spaced-apart openings  18  formed therein, each of which is adapted to receive a pin  20  therein as will be described in more detail hereinafter. 
   Normally, the small crane will be used to mount a single base tower section on the foundation, but one or more tower sections of the tower could be mounted on the base tower section through the use of the small crane. The invention herein will be described as if a single base tower section is erected through the use of the small crane with the other tower sections of the tower being erected through the use of the apparatus of this invention. 
   The numeral  22  refers to a skid or skid module which is comprised of a tubular framework which is bolted to the foundation  12 . Skid  22  includes a power unit  24  and a main winch  26  having a hoisting cable  28  extending therefrom. If desired, an auxiliary winch may be mounted on the skid  22  for lowering a top block to the ground at the end of a work day. Preferably, the main winch is hydraulically driven by a suitable hydraulic pump on the skid  22  which is driven by the power unit. However, the main winch  26  could be mechanically driven by the power unit if so desired. Power unit  24  is preferably a diesel engine but could be a gas engine or an electric motor. Preferably, the main winch, and associated equipment, are remotely controllable. A tower staging platform  29  is provided on skid  22  for successively supporting the tower sections thereon. 
   For ease of description, the numeral  30  will refer to the apparatus which is actually movably mounted on the tower. Apparatus  30  is initially positioned on a jack stand assembly  32  which is comprised of four upstanding jack stands  34 , the lower ends of which are positioned on the foundation. The upper ends of the jack stands  34  are preferably positioned approximately sixty inches above the foundation  12 . It is recommended that the jack stands  34  be chained together to prevent the tipping thereof. 
   Apparatus  30  includes a lower cage  36  which is three-sided to enable the lower cage  36  to be positioned around the base tower section  30 , and the other tower sections as well. For purposes of description, lower cage  36  will be described as including sides  38 ,  40  and  42 , each of which are comprised of a tubular framework welded together. Lower cage  36  includes four hollow, vertically disposed corner posts or legs  44 . The lower end of lower cage  36  is normally supported upon the jack stand assembly  32 . The lower end of lower block  46  is pivotally secured to lower cage  36  by a clevis and pin structure  48 . Lower cage  36  includes a pair of roll bank assemblies  49  mounted thereon on opposite sides thereof for engagement with the rails  14  and  16  on the opposite sides of the tower section. 
   An interconnecting frame assembly or frame structure  50  is selectively secured to lower cage  36  and extends upwardly therefrom. Frame assembly  50  includes side panel  52  which has the lower ends of posts or legs  54  and  56  received within the upper ends of a pair of corner posts  44  and secured thereto by pins  58  (FIG.  3 ). Frame assembly  50  also includes side panel  52 ′ which is identical to side panel  52  and which extends upwardly from side  42  of lower cage  36 . Interconnecting frame assembly  50  also includes side trusses  60  and  62  which are removably secured to lower cage  36  and side panel  52  to add strength and stability to the assembly  50 . Side trusses  60 ′ and  62 ′, which are identical to side trusses  60  and  62 , are removably secured to lower cage  36  and side panel  52 ′ to add strength and stability to the assembly  50 . 
   Upper cage  64  is selectively removably mounted on the upper end of side panels  52  and  52 ′ of interconnecting frame assembly  50 . As seen in the drawings, one end of upper cage  64  protrudes laterally of the frame assembly  50 . The laterally protruding portion of upper cage  64  is supported by a pair of support arms  66  and  68 , the lower ends of which are connected to side panels  52  and  52 ′, respectively. 
   The numeral  70  refers to a bridge assembly mounted on rails  72  and  74  of upper cage  64 . Bridge assembly  70  includes a bridge  76  which comprises a pair of spaced-apart trapezoidal-shaped beams that straddle or bridge and rides atop the rails  72  and  74  of upper cage  64  and moves in the Y direction (front to back). Bridge  76  includes four rollers  78  which roll upon the rails  72  and  74 . A pair of hydraulic cylinders (not shown) are secured to and extend between upper cage  64  and bridge  76  for moving bridge  76  in the Y direction. Upper power unit  80  preferably consists of a 24 kw diesel generator set and a  15  hp electric pressure-compensated hydraulic pump. Unit  80  provides power for the bridge assembly  70  and can power miscellaneous electrical equipment. An auxiliary winch  82  is mounted on bridge  76  and has a cable  83  extending therefrom. 
   A trolley  84  is movably mounted upon the upper ends of the beams of bridge  76  by means of four rollers  86  and moves in the X direction (side to side). As seen in  FIG. 19 , trolley  84  includes a pair of spaced-apart frame members  88  and  90  having a pair of frame members  92  and  94  secured to the ends thereof which extend therebetween. A pair of spaced-apart yokes  96  and  98  extend downwardly from frame members  88  and  90  at the ends thereof. A hydraulic cylinder (not shown) is secured to and extends between the bridge  76  and trolley  84  for moving trolley  84  with respect to bridge  76 . 
   A Z-slide assembly  100  is selectively vertically movably mounted on trolley  84  for movement therewith. As seen in  FIG. 19 , Z-slide assembly  100  is positioned between frame members  88 - 90  and  92 - 94  for movement in the Z direction (vertical). Slide assembly  100  includes four vertically disposed posts or frame members  102 ,  104 ,  106  and  108  interconnected by braces  110 . An arcuate brace  112  is secured to the upper ends of posts  102  and  104  and extends therebetween. Similarly, an arcuate brace  114  is secured to the upper ends of posts  106  and  108  and extends therebetween. Roller assemblies  116 ,  118 ,  120  and  122  are provided on trolley  84  which engage the posts  102 ,  104 ,  106  and  108 , respectively. Trolley  84  is also provided with roller assemblies  124 ,  126 ,  128  and  130  which are also in engagement with posts  102 ,  104 ,  106  and  108 , respectively. A hydraulic cylinder  132  has its base end (upper) connected to plates  134  and  136  at one end thereof by pin  138 . Similarly, hydraulic cylinder  140  has its base end (upper) connected to plates  134  and  136  at the other end thereby by pin  142 . The rod ends of hydraulic cylinders  132  and  140  are connected to yokes  96  and  98 , respectively. Thus, extension of the cylinder rods of the cylinders  132  and  140  causes the Z-slide assembly to be moved upwardly with respect to bridge  76 . Retraction of the cylinder rods within cylinders  132  and  140  causes the Z-slide assembly to move downwardly with respect to bridge  76 . Preferably, the movement of the bridge, trolley and Z-slide assembly are remotely operated and controlled from ground level or from the tower by workers erecting the tower. 
   A load toggle or tower connection member  144  is secured to the lower end of Z-slide assembly  100  and includes a double gimble-type joint  146  at its upper end and a load spider  148  at its lower end. The joint  146  has four posts  150 ,  152 ,  154  and  156  extending upwardly therefrom which are received by and secured to the posts  102 ,  104 ,  106  and  108 , respectively. Joint  146  includes a first gimble joint defined by pivot pins  158  and  160  and a second gimble joint defined by pivot pins  162  and  164 . Load spider  148  includes vertically spaced plates  166  and  168  having four load arms  170 ,  172 ,  174  and  176  pivotally secured thereto and therebetween. The load arms  170 ,  172 ,  174  and  176  each have an elongated opening  178  formed therein for connection to the flange  180  which is secured to the upper end of the tower sections. The diameter of the plates  166  and  168  is less than the diameter of the opening  182  in flange  180  so that the load spider may pass through opening  182  when load arms  170 ,  172 ,  174  and  176  are folded inwardly. When the load spider  148  has been lowered through the opening  182  by the Z-slide assembly  100 , the load arms  170 ,  172 ,  174  and  176  are pivoted outwardly beneath the lower surface of flange  180 . The load arms are then bolted to the flange  180  to enable the bridge assembly to lift and transport the tower section as will be described hereinafter. 
   The numeral  184  refers to an attachment hanger which is used to selectively attach the upper block  186  to a tower section adjacent the upper end thereof. Attachment hanger  184  includes an angled support plate  188  which conforms to the exterior surface of the tower sections. Attachment pin  190  extends from the inner surface of plate  188  and is adapted to be received within an opening formed in each of the tower sections adjacent the upper end thereof. Bracket  192  is mounted on the exterior surface of plate  188  and has support arm  194  of block  186  pivotally secured thereto by pivot pin  196 . The hoisting cable  28  of main winch  26  is threaded around upper block  186  and lower block  46  with the free end thereof being tied to the frame of the lower block  46  as previously described. 
   The method of assembly the tower erection device of this invention and the method of erecting the wind turbine tower or wind energy tower will now be described. A small crane is utilized to place the base tower section  10  on the foundation  12  with the base tower section being bolted to the foundation. The jack stands  34  of the jack stand assembly  32  are placed around the lower end of the base tower section  10  and are preferably chained together to prevent the tipping thereof. The skid or skid module  22  is then moved into place and bolted to the foundation so that the main winch  26  is in close proximity to the base tower section  10 . The roll bank assemblies  49  on the lower cage  36  are opened and the lower cage  36  is lifted onto the jack stand by means of a small crane. The roll bank assemblies  49  on the lower cage  36  are moved into an operative engagement position with respect to the rails  14  and  16  on the opposite sides of the base tower section  10 . 
   Side trusses  60  and  62  are secured to side panel  52  and side trusses  60 ′ and  62 ′ are secured to side panel  52 ′. One side panel-side truss assembly is secured to one side of the lower cage  36  so as to extend upwardly therefrom. The other side panel-side truss assembly is secured to the other side of the lower cage  36  so as to extend upwardly therefrom. The upper cage  64  is mounted on the upper ends of the side panels by means of a small crane and secured thereto. The attachment hanger  184  having the upper block  186  secured thereto is secured to the side of the base tower section  10  at the upper end thereof by inserting the connector pin  190  into the hole or opening provided in the upper end of the side wall of the base tower section  10 . The hoisting cable  28  from the main winch  26  is threaded around the lower block  46  and the upper block  186  with the free end of the hoisting cable  28  attached to the frame of the lower block  46  so that movement of the hoisting cable  28  by the main winch  26  causes the lower cage  36  and the structure supported thereby to be moved vertically with respect to the base tower section  10 . 
   Another tower section  10   a  is placed or staged on the staging platform  29  provided on the skid  22 . The bridge assembly  70  is manipulated or moved on the upper cage  64  to position the load toggle  144  on the Z-slide assembly  100  so that the load arms  170 ,  172 ,  174  and  176  are positioned below the bottom surface of the upper flange  180  on the upper end of the base tower section  10 . The load arms  170 ,  172 ,  174  and  176  are then pivotally moved outwardly and are connected to the flange  180  by bolts or the like. The main winch  26  is then operated to cause the hoisting cable  28  to raise the lower cage  36 , upper cage  64 , interconnecting frame assembly or structure  50  and bridge assembly  70  and the staged tower section  10   a  upwardly with respect to the base tower section  10 . When the staged tower section  10   a  is raised sufficiently, the lower cage is pinned to the rails  14  and  16 . The bridge assembly  70  is manipulated so that the staged tower section  10   a  is positioned over the base tower section  10  and is then lowered onto the base tower section  10 . The lower end of the staged tower section  10   a  is bolted to the upper end of the base tower section  10 . The auxiliary winch  82  on the bridge assembly  70  is operated to raise the attachment hanger  184  and upper block  186  from the upper end of the base tower section  10 , after it has been disconnected from the base tower section  10 , to the upper end of the staged tower section  10   a  mounted thereon. The attachment hanger  184  is then secured to the staged tower section  10   a  mounted on the base tower section  10 . The lower cage  36  is unpinned from the rails  14  and  16  and is moved downwardly by the hoisting cable  28  of the main winch  26  until the lower cage  36  rests upon the jack stand assembly  32 . 
   The bridge assembly is then again manipulated to position the load spider  148  of load toggle  144  within the open upper end of another tower section  10   b  on the staging platform. The necessary steps described above are repeated until the wind energy tower is completely erected. The auxiliary winch is then used to lower the upper block  186  to the ground after it has been removed from the erected tower. The bridge assembly, upper cage, side panels and side trusses, lower cage and jack stand are then removed from the erected tower. The skid module is then removed from the foundation  12 . 
   The tower erection device may then be moved to another location for use in erecting another tower. It can be seen that the tower erection device of this invention is convenient and safe to use and permits the erection of a wind energy tower without the use of a large crane which is expensive and which is hazardous in certain weather conditions. 
   Thus it can be seen that the invention accomplishes at least all of its stated objectives.