Apparatus and method for transporting and aligning wind turbine rotor blade

An apparatus and method to facilitate transporting and aligning a multiple piece wind turbine rotor blade including a root piece and a tip piece. The apparatus includes a first portion configured to support a first end portion of the root piece and a second portion pivotally coupled to the first portion. The second portion is configured to support a first end portion of the tip piece.

BACKGROUND OF THE INVENTION

The subject matter described herein relates generally to wind turbine blades and, more particularly, to transporting two piece wind turbine blades to a wind farm site and assembling the wind turbine blades at the wind farm site.

Many conventional wind turbine generators include a plurality of single piece or unitary rotor blades that may have a length of about 30 meters (m) to about 47 m or more. Transporting the single piece rotor blades to a wind farm site has become increasingly difficult, particularly over rough terrain or through narrow passageways, as the length of these single piece rotor blades increases.

As a result, two piece rotor blades are being made that are easier to transport than the conventional single piece rotor blades. Further, the two piece rotor blades when assembled may exceed the length of conventional one piece blades.

Once transported to the wind farm site, the two piece rotor blades are assembled and coupled to the rotor hub of the wind turbine generator. One approach for assembling the two piece rotor blades includes coupling a small base or root piece to the wind turbine hub and then coupling a larger tip piece to the root piece. A second approach includes coupling the two pieces together on the ground and then coupling the assembled rotor blades to the rotor hub using a suitable crane or hoisting apparatus.

However, using either of the two approaches described, the two pieces of the rotor blade are difficult to align while assembling the pieces together and coupling the assembled rotor blade to the rotor hub requires multiple crane operations to complete, which may be undesirable.

It is desirable to provide an apparatus and method that facilitates easy transportation of a two piece rotor blade to a wind farm site and/or easy alignment of the two pieces while assembling the rotor blade at the wind farm site.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, an apparatus is provided to facilitate transporting and aligning a two piece wind turbine rotor blade including a root piece and a tip piece. The apparatus includes a first portion configured to support a first end portion of the root piece. A second portion is pivotally coupled to the first portion, and configured to support a first end portion of the tip piece.

In another aspect, a method is provided for transporting and aligning a two piece wind turbine rotor blade having a root piece and a tip piece. The method includes supporting a first end of the root piece within a first portion of an apparatus and supporting a first end of the tip piece within a second portion of the apparatus pivotally coupled to the first portion. The tip piece is aligned with the root piece.

In another aspect, a method is provided for transporting a two piece wind turbine rotor blade having a root piece and a tip piece. The method includes supporting a first end of the root piece within a first portion of an apparatus and supporting a first end of the tip piece within a second portion of the apparatus pivotally coupled to the first portion. The second portion is positioned with respect to the first portion in a transport configuration to facilitate transporting the rotor blade. The rotor blade is transported to a desired location, such as a wind turbine installation site.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments described herein relate to an apparatus and a method for transporting a multiple piece rotor blade for a wind turbine and aligning and coupling the rotor blade pieces at a wind turbine installation site, such as at a wind farm. In one embodiment, a reusable apparatus is supported by a suitable platform, such as a flat bed trailer. The apparatus includes a first portion configured to support and/or retain an end of a first or root piece of the rotor blade and a second portion movably coupled to the first portion and configured to support and/or retain a cooperating end of a second or tip piece of the rotor blade. The second portion of the apparatus is pivotally movable with respect to the first portion to facilitate alignment of the cooperating ends of the rotor blade. The apparatus provides a stable support structure to facilitate coupling the two pieces together at the wind turbine installation site. In a further embodiment, a third portion of the apparatus facilitates adjusting a height of a portion, such as a blade tip end, of the second piece with respect to a ground plane. For example, in one embodiment, the third portion includes a height adjustable blade tip support structure that supports a blade tip end of the second piece as the second piece is swung or pivotally moved with respect to the first piece to align the second piece with the first piece of the rotor blade. The third portion further facilitates proper alignment of the second piece with the first piece in a direction along an x-axis, a direction along a y-axis, and a direction along a z-axis defined with respect to a centerline of the rotor blade.

Referring toFIG. 1, a two piece rotor blade10includes a first piece12, such as a base or root piece, that is configured to couple to a rotor hub of the wind turbine and a second piece14, such as a tip piece that is configured to couple to first piece12. First piece12and second piece14are arranged and aligned with respect to a centerline16of rotor blade10. More specifically, second piece14is properly aligned with first piece12in a direction along an x-axis18, a direction along a y-axis19, and a direction along a z-axis20defined with respect to centerline16and shown inFIG. 1.

A first connecting element22and a cooperating second connecting element24bridge a partition line26between first piece12and second piece14. In a coupled configuration, first connecting element22and second connecting element24are positioned within a recess28of first piece12and a recess30of second piece14. As shown inFIG. 1, recess28is formed by a diminution of an end of first piece12at partition line26and recess30is formed by a diminution of an end of second piece14at partition line26. In the embodiment shown inFIG. 1, recesses28and30are defined to surround centerline16of rotor blade10. Connecting element22and connecting element24have suitable dimensions to match dimensions of recesses28and30such that connecting elements22and24, when in flush alignment with a respective outer delimitation surface32of first piece12and an outer delimitation surface34of second piece14, still leave a hollow space between the outer delimitation surfaces of recess28and recess30and the inner delimitation surfaces of connecting element22and connecting element24.

For assembly of rotor blade10, connecting element22and connecting element24are brought into a desired flush alignment with first piece12and second piece14. Then, the hollow space formed between the outer delimitation surfaces of recesses28and30and the inner delimitation surfaces of connecting elements22and24is flooded with an adhesive, which is subsequently hardened.

The embodiment as described above with reference toFIG. 1is one suitable approach for coupling rotor blade pieces to assemble a multiple piece rotor blade. It should be apparent to those skilled in the art that other suitable coupling or attachment mechanisms and methods may be incorporated to facilitate coupling the rotor blade pieces. For example, rotor blade pieces may be coupled together using suitable mechanical fasteners, such as bolts and/or screws. Regardless of the mechanisms and methods used to couple rotor blade pieces together, the apparatus and method as described below facilitate transporting a multiple piece wind turbine blade to a wind turbine installation site, as well as provide a suitable support structure and alignment mechanism to facilitate coupling the rotor blade pieces together at the wind turbine installation site to minimize a number of crane operations needed to assemble the wind turbine.

Referring toFIGS. 2-6, an apparatus40is configured to facilitate transporting pieces of a multiple piece rotor blade to a desired location, such as a wind turbine installation site, and aligning the pieces to assemble rotor blade10on site. In one embodiment as shown inFIGS. 2-6, apparatus40is configured to facilitate transporting and assembling two piece rotor blade10including first or root piece12and second or tip piece14of rotor blade10.FIG. 2is a perspective view of apparatus40andFIG. 3is a side view of apparatus40in a transport configuration to facilitate transporting rotor blade10to the desired location.FIG. 4is a perspective view of apparatus40in an intermediate configuration between the transport configuration and an alignment configuration during assembly of rotor blade10.FIG. 5is a side view of apparatus40in the alignment configuration to facilitate assembling rotor blade10.FIG. 6is a front plan view of a second portion of apparatus40including an alignment system.

In the embodiment shown inFIGS. 2-6, apparatus40is mounted on and/or coupled to a suitable support surface or platform41, such as a flat bed trailer42that is coupled to a truck cab44, shown inFIG. 3, to transport rotor blade10to the desired location. In certain embodiments, apparatus40is mounted on and/or coupled to platform41, which is loaded onto a suitable surface or platform of a transport vehicle for transporting rotor blade10to the desired location. Although apparatus40is shown inFIGS. 3-5as mounted on flat bed trailer42, other forms or modes of transportation may be used to transport rotor blade10to the desired location.

Apparatus40includes a first portion50configured to support and retain an end portion52of first piece12. A second portion54of apparatus40is movably coupled, such as pivotally coupled, to first portion50and configured to support and retain an end portion56of second piece14. In one embodiment, a hinge60pivotally couples second portion54to first portion50to facilitate pivotal movement of second portion54with respect to first portion50. More specifically, in one embodiment, second portion54is movable with respect to first portion50between a first or transport position to facilitate transporting rotor blade10and a second or alignment position to facilitate aligning and coupling second piece14to first piece12to assemble rotor blade10.

Referring further toFIGS. 3-5, in one embodiment, apparatus40includes in a third or tip support portion62configured to support a second or tip end portion64of second piece14opposing first end portion56. With second portion54pivotally coupled to first portion50in the alignment configuration shown inFIG. 5, for example, third portion62is movable with respect to second portion54to facilitate aligning second piece14with first piece12. With second piece14properly aligned with first piece12in the x-axis direction, the y-axis direction, and the z-axis direction defined with respect to centerline16, second piece14is coupled or attached to first piece12to assemble rotor blade10. In one embodiment, third portion62is coupled to second portion54with a suitable support member, such as a rigid member65shown inFIGS. 3-5, to facilitate moving third portion62with second portion54as second portion54is pivotally moved with respect to first portion50and preventing or limiting misalignment of third portion62with second portion54during such movement.

In one embodiment, third portion62includes a mechanism, such as retractable roller mechanism66, as shown inFIG. 4, configured to facilitate moving third portion62with respect to second portion54. Roller mechanism66includes an adjustment mechanism68, shown inFIG. 5, configured to adjust a height70of second end portion64of second piece14with respect to a ground plane72to facilitate aligning second piece14with first piece12in the y-axis direction. Further, adjustment mechanism68is configured to provide a rotational adjustment, for example with flat bed trailer42and/or apparatus40positioned on an uneven ground plane72, to align second piece14with first piece12in the x-axis direction, the y-axis direction, and the z-axis direction. Adjustment mechanism68provides for a rotational adjustment or twist adjustment to compensate for an unevenness of ground plane72. In a particular embodiment, adjustment mechanism68allows a freedom of movement to twist or rotate second piece14with respect to first piece12to facilitate aligning second piece14with first piece12in the x-axis direction, the y-axis direction, and the z-axis direction. In a further embodiment, first portion50and/or second portion54includes a suitable mechanism, such as a retractable roller mechanism and/or a suitable adjustment mechanism to facilitate aligning second piece14with first piece12in the x-axis direction, the y-axis direction, and the z-axis direction.

In one embodiment, first portion50and second portion54include at least one section or wall that is movable between a closed position in the transport configuration and an open position in the alignment configuration to facilitate removing rotor blade10from within apparatus40after assembly. For example, as shown inFIG. 4, first portion50includes a top wall80that is pivotally and/or removably coupled to a side wall81of first portion50and, similarly, second portion54includes a top wall82that is pivotally and/or removably coupled to a side wall83of second portion54. With second piece14coupled to first piece12, top wall80and top wall82are movable to an open position as shown in phantom lines inFIG. 5or, alternatively, removed to facilitate removing rotor blade10from apparatus40.

In embodiments wherein third portion62includes a top wall84, top wall84of third portion62is similarly pivotally and/or removably coupled to a side wall85of third portion62such that, with second piece14coupled to first piece12, top wall84is movable to an open position as shown in phantom lines inFIG. 5or, alternatively, removed to facilitate removing rotor blade10from apparatus40. In an alternative embodiment, first portion50, second portion54, and/or third portion62form an opening sized to allow removal of rotor blade10through the respective openings.

In further embodiments, apparatus40may include a fourth portion or root support portion92configured to support a second end portion94of first piece12opposing first end portion52, as shown inFIG. 2. In one embodiment, fourth portion92is securely mounted to platform41of flat bed trailer42to facilitate properly positioning first piece12on flat bed trailer42and moving rotor blade10between the transport configuration and the alignment configuration.

Referring further toFIG. 6, second portion54includes an alignment system100to facilitate aligning second piece14with first piece12. Although only second portion54is shown as including alignment system100, in the exemplary embodiment, at least one of first portion50, second portion54, third portion62and fourth portion92of apparatus40includes alignment system100to facilitate aligning second piece14with first piece12. Alignment system100includes an inner support102that is movably positionable within an outer support104. In one embodiment, one or more tracks106are positioned between inner support102and outer support104to facilitate movement of inner support102with respect to outer support104in a direction along z-axis20. In a particular embodiment, tracks106also facilitate movement of inner support102with respect to outer support104in a direction along x-axis18and/or a direction along y-axis19.

Alignment system100includes a first blade support110configured to receive and support a first side112of second piece14positioned within second portion54and a cooperating second blade support114configured to receive and support an opposing second side116of second piece14. An x-axis alignment mechanism118is operatively coupled to first blade support110and configured to position and/or align first blade support110at a desired x-axis orientation to facilitate properly positioning second piece14with respect to x-axis18. In one embodiment, x-axis alignment mechanism118includes one or more bases120coupled to inner support102and a corresponding arm122movably coupled between corresponding base120and first blade support110to facilitate moving first blade support110in a direction along x-axis18. Similarly, x-axis alignment mechanism118is operatively coupled to second blade support114and configured to position and/or align second blade support114at a desired x-axis orientation to facilitate properly positioning second piece14with respect to x-axis18. In one embodiment, x-axis alignment mechanism118includes one or more bases124coupled to inner support102and a corresponding arm126movably coupled between corresponding base124and second blade support114to facilitate moving second blade support114in a direction along x-axis18.

A y-axis alignment mechanism130is operatively coupled to first blade support110and configured to position and/or align first blade support110at a desired y-axis orientation to facilitate properly positioning second piece14with respect to y-axis19. In one embodiment, y-axis alignment mechanism130includes a base132coupled to inner support102and a corresponding arm134coupled to base132and movably coupled between corresponding arms122of x-axis alignment mechanism118to facilitate moving first blade support110in a direction along y-axis19. Similarly, y-axis alignment mechanism130is operatively coupled to second blade support114and configured to position and/or align second blade support114at a desired y-axis orientation to facilitate properly positioning second piece14with respect to y-axis19. In one embodiment, y-axis alignment mechanism130includes a base136coupled to inner support102and a corresponding arm138coupled to base136and movably coupled between corresponding arms126of x-axis alignment mechanism118to facilitate moving second blade support114in a direction along y-axis19.

In one embodiment, inner support102includes a top panel140pivotally coupled to an adjacent side panel142using a suitable coupling component, such as a hinge144. Top panel140is movable between a closed position, as shown inFIG. 6, and an open position to facilitate removing the assembled rotor blade from within apparatus40, and specifically from within second portion54. Similarly, outer support104includes a top panel146pivotally coupled to an adjacent side panel148using a suitable coupling component, such as a hinge150. Top panel146is movable with top panel140between a closed position, as shown inFIG. 6, and an open position to facilitate removing the assembled rotor blade from within apparatus40, and specifically from within second portion54.

FIG. 7is a flow diagram illustrating an exemplary method200for assembling a wind turbine rotor blade, such as two piece rotor blade10. In one embodiment, second piece14is aligned with first piece12of rotor blade10. In one embodiment, second piece14is moved with respect to first piece12in at least one of the x-axis direction, the y-axis direction, and the z-axis direction to facilitate aligning second piece14with first piece12.

To facilitate transporting and assembling rotor blade10, a first end52of first piece12is supported by and retained within202first portion50of apparatus40and a first end portion56of second piece14is supported by and retained within204second portion54of apparatus40, which is pivotally coupled to first portion50. In one embodiment, second portion54is hingedly coupled to first portion50and is pivotally moved206with respect to first portion50of apparatus40to facilitate aligning second piece14with first piece12. As second portion54is pivotally moved with respect to first portion50, third portion62, supporting second end portion64, also moves in an arcuate direction with respect to first portion50to facilitate aligning and/or coupling second piece14to first piece12. Further, third portion62of apparatus40is moved208with respect to second portion54to facilitate aligning second piece14with first piece12, for example with first portion50coupled to second portion54in the installation configuration.

Third portion62is configured to support second end portion64of second piece14with respect to second portion54. Third portion62includes roller mechanism66that is extendable to facilitate moving third portion62with respect to second portion54. A height of second end portion64of second piece14with respect to a ground plane is adjusted to facilitate aligning second piece14with first piece12in the y-axis direction. With second piece14aligned210with first piece12, second piece14is coupled212to first piece12. More specifically, first end portion56of second piece14is coupled to first end portion52of first piece12.

In a further embodiment, the assembled rotor blade10is removed214from within apparatus40. In a particular embodiment, first portion50, second portion54, and/or third portion62includes a wall, such as a top wall, having one or more panels that are movable to an open position or, alternatively, removed to facilitate removing assembled rotor blade10from within apparatus40. In an alternative embodiment, first portion50, second portion54, and/or third portion62form an opening at a top end that is sized to allow removal of rotor blade10through the respective openings.

FIG. 8is a flow diagram illustrating an exemplary method300for transporting a wind turbine rotor blade, such as two piece rotor blade10having a first or root piece and a second or tip piece. To facilitate transporting rotor blade10, a first end portion52of first piece12is supported by and retained within302first portion50of apparatus40and a first end56of second piece14is supported by and retained within304second portion54of apparatus40, which is pivotally coupled to first portion50. In one embodiment, second portion54is hingedly coupled to first portion50and is positioned with respect to first portion50of apparatus40in a transport configuration to facilitate transporting rotor blade10. With rotor blade10in the transport configuration, rotor blade10is transported306to a desired location, such as the wind turbine installation site.

The above-described apparatus and method provide for easy transportation of a multiple piece wind turbine blade and a support structure and an alignment mechanism to facilitate aligning and coupling the two pieces together at a wind turbine installation site to assemble the rotor blade and minimize a number of crane operations needed to assemble the rotor blade to the wind turbine rotor hub.