Patent Description:
Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades capture kinetic energy from wind using known foil principles and transmit the kinetic energy through rotational energy to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.

Installing, repairing or replacing a component of a wind turbine, such as a drivetrain, a drivetrain component and/or a transformer, requires cranes to lift the components and sections of the nacelle to or from a tower of the wind turbine. <CIT> relates to a method of mounting a nacelle component. A drivetrain is lifted with a roof of a housing. <CIT> relates to a method of assembling a wind energy installation, wherein a partially assembled nacelle is mounted on an already erected supporting structure, and a cover segment and at least one component of the drive train are jointly attached to a single load handling means and are raised in a single lifting operation by a hoisting gear connected to the load handling means up to the nacelle.

However, the use of cranes with a sufficient lifting capacity in the aforementioned installation, repair or replacement procedures can be cumbersome. Moreover, very low thresholds for the wind speed may apply, making the whole process even more time-consuming, even in case of the presence of merely low wind speeds.

Accordingly, the present disclosure is directed to a method of mounting a nacelle of a wind turbine and at least one component of the wind turbine on a tower of the wind turbine in installation, repair or replacement procedures.

In one aspect, the present disclosure is directed to a method according to independent claim <NUM>. A method of mounting a nacelle of a wind turbine and at least one component of the wind turbine on a tower of the wind turbine includes hooking a roof of the nacelle to a crane hook of a crane, hooking the at least one component to the crane hook of the crane, and lifting the roof of the nacelle together with the at least one component using the crane. It should be understood that the method may further include any of the additional steps and/or features as described herein.

The present disclosure further describes a method of carrying a roof of a nacelle of a wind turbine and at least one component of the wind turbine to or from a base of the nacelle on a tower of the wind turbine, the method including connecting the at least one component to a lifting device, connecting the roof of the nacelle to a lifting device, and lifting the roof of the nacelle together with the at least one component using the lifting device.

In yet another aspect, the present disclosure is directed to an assembling set of parts of a wind turbine according to independent claim <NUM>. An assembling set of parts of a wind turbine is to be hooked together on a crane hook of a crane, the assembling set including at least one component of the wind turbine; a roof of a nacelle of the wind turbine, the roof including an opening; a first connecting device for connecting the at least one component to the crane hook; and a second connecting device for connecting the roof to the crane hook; wherein the opening in the roof is positioned to allow the first connecting device to reach from the at least one component through the roof to the crane hook. It should be understood that the assembling set of parts may further include any of the additional features as described herein.

These and other features, aspects and advantages of the present invention will be further supported and described with reference to the following description and appended claims.

Referring now to the drawings, <FIG> illustrates a perspective view of a wind turbine <NUM>. As shown, the wind turbine <NUM> generally includes a tower <NUM> extending from a support surface <NUM>, a nacelle <NUM> mounted on the tower <NUM>, and a rotor <NUM> coupled to the nacelle <NUM>. Thus, the nacelle <NUM> corresponds to the overall housing structure and has a bottom wall, opposing side walls, a front wall, a rear wall, and a top wall. Further, the front wall may have a main shaft opening configured to receive a main shaft <NUM> (<FIG>) there through that is connectable to the rotor <NUM>.

As shown in <FIG>, the rotor <NUM> includes a rotatable hub <NUM> and at least one rotor blade <NUM> coupled to and extending outwardly from the hub <NUM>. For example, in <FIG>, the rotor <NUM> includes three rotor blades <NUM>. However, in an alternative wind turbines, the rotor <NUM> may include more or less than three rotor blades <NUM>. Each rotor blade <NUM> may be spaced about the hub <NUM> to facilitate rotating the rotor <NUM> to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy. For instance, the hub <NUM> may be rotatably coupled to an electric generator <NUM> (<FIG>) positioned within the nacelle <NUM> to permit electrical energy to be produced.

The wind turbine <NUM> may also include a wind turbine controller <NUM> centralized within the nacelle <NUM>. However, in other wind turbines, the controller <NUM> may be located within any other component of the wind turbine <NUM> or at a location outside the wind turbine <NUM>. Further, the controller <NUM> may be communicatively coupled to any number of the components of the wind turbine <NUM> in order to control the components. As such, the controller <NUM> may include a computer or other suitable processing unit. Thus, in several wind turbines, the controller <NUM> may include suitable computer-readable instructions that, when implemented, configure the controller <NUM> to perform various different functions, such as receiving, transmitting and/or executing wind turbine control signals.

Referring now to <FIG>, a simplified, internal view of an exemplary nacelle <NUM> of the wind turbine <NUM> shown in <FIG>, particularly illustrating the drivetrain components thereof, is illustrated. More specifically, as shown, the generator <NUM> may be coupled to the rotor <NUM> for producing electrical power from the rotational energy generated by the rotor <NUM>. The rotor <NUM> may be coupled to the main shaft <NUM>, which is rotatable via a main bearing (not shown). The main shaft <NUM> may, in turn, be rotatably coupled to a gearbox output shaft <NUM> of the generator <NUM> through a gearbox <NUM>. The gearbox <NUM> may include a gearbox housing <NUM> that is connected to the bedplate <NUM> by one or more torque arms <NUM>. More specifically, in certain wind turbines, the bedplate <NUM> may be a forged component in which the main bearing (not shown) is seated and through which the main shaft <NUM> extends. As is generally understood, the main shaft <NUM> provides a low speed, high torque input to the gearbox <NUM> in response to rotation of the rotor blades <NUM> and the hub <NUM>. Thus, the gearbox <NUM> thus converts the low speed, high torque input to a high speed, low torque output to drive the gearbox output shaft <NUM> and, thus, the generator <NUM>.

Each rotor blade <NUM> may also include a pitch adjustment mechanism <NUM> configured to rotate each rotor blade <NUM> about its pitch axis <NUM> via a pitch bearing <NUM>. Similarly, the wind turbine <NUM> may include one or more yaw drive mechanisms <NUM> communicatively coupled to the controller <NUM>, with each yaw drive mechanism(s)<NUM> being configured to change the angle of the nacelle <NUM> relative to the wind (e.g., by engaging a yaw bearing <NUM> of the wind turbine <NUM>).

In some embodiments according to the present disclosure, a nacelle and wind turbine components positioned within the nacelle, including the drivetrain, can have a combined mass of more than <NUM> (metric) tonnes, particularly of more than <NUM> tonnes or <NUM> tonnes. In typical embodiments, the drivetrain of the wind turbine exceeds <NUM> (metric) tonnes, particularly of more than <NUM> tonnes or <NUM> tonnes.

In some embodiments, the wind turbine may be an onshore wind turbine. In several embodiments, the wind turbine may be an offshore wind turbine.

<FIG> show a wind turbine, or an assembling set of parts of a wind turbine during mounting of a nacelle, or during carrying at least one component and a roof of a nacelle, according to embodiments described herein.

In several embodiments, a component of a wind turbine and a roof of a nacelle of the wind may be connected to, for example, hooked to or fixed at, a lifting device, particularly to a crane, such as a mobile crane, an offshore crane, especially to a crane hook of a crane. In some embodiments, the component and the roof may be lifted together using the lifting device.

For example, as shown in <FIG>, a roof <NUM> of a nacelle <NUM> and at least one component <NUM> of a wind turbine <NUM> are hooked to a crane hook <NUM> of a crane <NUM> and lifted using the crane <NUM>.

In some embodiments, a component of a wind turbine can include a mechanical, electrical or electromechanical device, in particular associated with energy production or conversion. In embodiments, a component includes at least one of a drivetrain, a drivetrain component and a transformer. In particular, a drivetrain component may include a gearbox, a main shaft, a main bearing and/or a generator. In exemplary embodiments, a component can be heavier than <NUM> (metric) tonnes, in particular, heavier than <NUM> tonnes or heavier than <NUM> tonnes, and/or the component can be heavier than the roof.

In embodiments according to the present disclosure, a roof of a nacelle can form at least a part of a top wall of the nacelle. The roof may include at least one of: at least a part of a side wall, at least a part of a front wall, at least a part of a rear wall and at least a part of a bottom wall of the nacelle. The roof can have a weight of more than <NUM> tonnes, in particular, more than <NUM> tonnes or <NUM> tonnes, and/or less than <NUM> tonnes, particularly less than <NUM> tonnes or <NUM> tonnes. Lifting a roof together with a component might reduce the sensitivity of the lifting process to wind loading as compared to lifting the roof alone. With some embodiments, it might be possible to have more favorable wind speed thresholds for lifting.

In some embodiments, a nacelle may include a base coupled to a tower of the wind turbine. The base can include a bedplate and/or at least a part of the bottom wall of the nacelle. In some embodiments, the roof can be configured for mounting to a base of the nacelle, in particular using a releasable connecting device, e. by positive locking of the roof and the base or via a fastener such as a bolt.

In <FIG>, the crane <NUM> may be any crane with a sufficient lifting capacity to lift the component <NUM> and the roof <NUM> to the top of a tower <NUM> of the wind turbine <NUM>. The crane <NUM> may be positioned on a support surface <NUM> near the tower <NUM> or may be coupled to the tower <NUM>. <FIG> shows the roof <NUM> and the component <NUM> lifted above a tower <NUM> of the wind turbine <NUM> and above a base <NUM> of the nacelle <NUM>.

The crane hook includes a lifting tool of the crane, the lifting tool including a beam. In embodiments, the crane hook may further include a single hook as shown in <FIG>. The lifting tool of the crane may further include e. one or more hooks or shackles and/or a device for stabilizing or balancing the crane hook.

<FIG> shows a component <NUM> and a roof <NUM> hooked to a crane hook <NUM>. The component <NUM> is connected to the crane hook <NUM> using a first connecting device <NUM>. The roof <NUM> includes an opening <NUM>, which allows the first connecting device <NUM> to reach from the component <NUM> through the roof <NUM> to the crane hook <NUM>. In particular, <FIG> shows an assembling set of parts of a wind turbine according to embodiments described herein in a hooked state.

In some embodiments, the roof can include at least two openings or at least three openings allowing, for example, a first connecting device to reach from the component through the roof to the crane hook. The openings may have a diameter of at least <NUM>, for example of at least <NUM> or of at least <NUM>. The opening might have a maximum diameter or maximum elongation of <NUM> or of <NUM>. The roof may be connected to the crane hook using a second connecting device.

<FIG> show a component <NUM> and a roof <NUM> hooked to a crane hook <NUM> in two exemplary configurations, wherein the roof <NUM> is connected to the component <NUM> using a third connecting device <NUM>. The invention is not restricted to these two exemplary configurations.

In embodiments, the first connecting device, the second connecting device and/or the third connecting device may include a sling, a rope and/or a chain.

In several embodiments, the roof can include a fastening site on the inside of the roof. The fastening site on the inside of the roof can be configured as a fixation device, for a third connecting device, for connecting the roof to the at least one component. For instance, the fastening site may include a loop, a hook and/or a shackle. In particular, the roof may include at least two fastening sites or at least three fastening sites on the inside of the roof. In exemplary embodiments, the third connecting device might help to stabilize the roof and/or the component, e.g. during occurrence of wind. In further embodiments, no third connecting device is used or necessary.

In some embodiments, the roof is not fixedly mounted to the component during lifting. The connecting devices are flexible and do not provide a fixed connection. On the other hand, in a mounted nacelle ready for normal service, the roof is fixedly connected with components, e.g. by screws or bolts.

For example, <FIG> each show the roof <NUM> with a fastening site <NUM> on the inside of the roof <NUM>, wherein the fastening site <NUM> is configured and is used as a fixation device for the third connecting device <NUM>.

In exemplary embodiments, the roof might include a further fastening site on the outside of the roof as a fixation device for the second connecting device.

In particular, <FIG> shows the roof <NUM> with two further fastening sites <NUM> connected to the crane hook <NUM> using two second connecting devices <NUM>, whereas in <FIG> the roof <NUM> includes a single further fastening site <NUM> located centrally on the roof <NUM> and connected to the crane hook <NUM> using a single second connecting device <NUM>.

It should be understood that the number and configuration of connecting devices including the first connecting device, the second connecting device and/or the third connecting device is not limited to the embodiments shown in FIGS. For instance, in some embodiments the number and configuration of connecting devices may be adapted depending on the loading capacity of the connecting devices or on the sensitivity of the roof to wind loading. Also, more than one first connecting device may reach through one opening.

<FIG> shows an exemplary embodiment with a component <NUM> and a roof <NUM> hooked to a crane hook <NUM> and lifted to the top of a tower <NUM> with a base <NUM> coupled to the tower <NUM>. In a hooked state, as shown in <FIG>, the load of the component and of the roof can be carried by the crane hook <NUM>. In the hooked state shown in <FIG>, the component may be positioned and fixed in the base <NUM>. After fixing the component <NUM>, the crane hook <NUM> and the roof <NUM> may be lowered, as illustrated in <FIG>. In <FIG>, the crane hook may carry only the load of the roof <NUM>. The first connecting device <NUM> and the third connecting device <NUM> may be in a relaxed state or might be removed. The roof <NUM> may further be positioned and fixed on the base <NUM> of the nacelle <NUM>. After positioning and fixing, the component <NUM> and the roof <NUM> may be in a mounted state and positioned at a mounting distance.

In some embodiments, a first length of a first connecting device and a second length of a second connecting device may be configured such that in a hooked state, particularly in a hooked state of an assembling set according to embodiments described herein, at least one component and a roof are hooked together on a crane hook at a hooking distance. In such embodiments, the hooking distance can be at least <NUM>, particularly at least <NUM> or at least <NUM>, or at most <NUM>, or at most <NUM>, or at most <NUM> larger than a mounting distance between the at least one component and the roof in a mounted state, particularly of an assembling set, wherein in the mounted state the component and the roof are fixed to a base of a nacelle.

In several embodiments, a third length of a third connecting device may be configured such that, in a hooked state of at least one component and a roof with the component and the roof connected by the third connecting device, the component and the roof cannot swing or move relative to the other. Preventing the swinging of a component and a roof relative to the other in a hooked state might prevent the component and the roof from colliding or becoming damaged. For instance, swinging of a component and a roof relative to the other in a hooked state might occur due to different sensitivities of the roof and the component to wind loading.

Referring now to the exemplary embodiment of <FIG>, a component <NUM>, in particular a transformer of a wind turbine <NUM>, and a roof <NUM> are lifted for mounting to a base <NUM> of a nacelle <NUM>, in particular to a rear side of the nacelle <NUM>. As shown in <FIG>, a further component <NUM> of the wind turbine <NUM> may already be fixed to the base <NUM>. The roof <NUM> may include a part of a rear wall of the nacelle <NUM> and/or a part of a bottom wall of the nacelle <NUM>.

Referring to <FIG>, a flow diagram of a typical embodiment of a method <NUM> of mounting a nacelle of a wind turbine, such as the wind turbine <NUM> of <FIG>, and at least one component of the wind turbine on a tower of the wind turbine is illustrated. The method <NUM> includes hooking (block <NUM>) a roof of the nacelle to a crane hook of a crane, and hooking (block <NUM>) the at least one component to the crane hook of the crane. The method <NUM> further includes lifting (block <NUM>) the roof of the nacelle together with the at least one component using the crane.

Referring now to <FIG>, a flow diagram of an exemplary embodiment of a method <NUM> of mounting a nacelle of a wind turbine is illustrated. The method <NUM> includes hooking (block <NUM>) a roof of the nacelle to a crane hook of a crane, and hooking (block <NUM>) a component to the crane hook of the crane.

In some embodiments, hooking a roof to a crane hook can include connecting the roof of the nacelle to the crane hook using a second connecting device, particularly by connecting the second connecting device to a further fastening site on the outside of the roof.

In embodiments, hooking a component to a crane hook can include connecting the component to the crane hook using a first connecting device, wherein the first connecting device reaches through an opening in the roof of the nacelle. Hooking the component to the crane hook can include connecting the roof of the nacelle to the component using a third connecting device, particularly by connecting the third connecting device to a fastening site on the inside of the roof.

In exemplary embodiments, hooking a component to a crane hook can include stabilizing the roof of the nacelle and the component at a hooking distance, wherein the hooking distance is at least <NUM>, in particular at least <NUM> or at least <NUM>, larger than a mounting distance between the roof and the component in the mounted nacelle. In particular, the roof can be stabilized above the component.

In some embodiments, hooking a component to a crane hook can include stabilizing the roof of the nacelle and the component at a hooking distance, wherein the hooking distance is maximum <NUM>, in particular maximum <NUM> or maximum <NUM>, larger than a mounting distance between the roof and the component in the mounted nacelle. "Mounted nacelle" might typically refer to a mounting status in which the nacelle and the wind turbine are ready for normal service.

The method <NUM> includes lifting (block <NUM>) the roof of the nacelle together with the component using the crane.

In some embodiments, after hooking a component to a crane hook and during lifting, the component and the roof may be in a hooked state, for example as described in conjunction with the exemplary embodiments shown in <FIG>, <FIG>, <FIG>. In several embodiments, the roof and the component may be lifted from a support surface, e. from ground or from a ship, to a base of a nacelle on a tower of a wind turbine. In some embodiments, the roof and the component may be lifted from a base to a support surface.

In some embodiments, the roof may be mounted non-fixedly to the component during at least one of hooking the roof to the crane hook, hooking the at least one component to the crane hook and lifting. In particular, the roof may be mounted non-fixedly to the component in a hooked state. Non-fixedly typically refers to a mounting, using flexible connecting devices such as ropes or slings.

The method <NUM> can include positioning (block <NUM>) and fixing the component in a base of the nacelle.

In some embodiments, during positioning of a component in a base, the component may be lowered to its designated position in the base and may then be fixed to the base. In particular, the component and the roof may still be separated by the hooking distance or by a distance larger than the mounting distance.

After positioning (block <NUM>) and fixing the component in the base of the nacelle, the method <NUM> may proceed with positioning (block <NUM>) and fixing the roof on the base.

In exemplary embodiments, during positioning of the roof, the roof may be lowered onto the base, as described e. in conjunction with <FIG>, and may then be fixed to the base, in particular using a releasable connecting device. A releasable connecting device might allow a roof to be easily removed, for example to repair or to replace a component or a further component of a wind turbine. A releasable connecting device may include a device for positive locking of the roof and the base, or releasable fasteners such as bolts.

The method <NUM> may include disconnecting (block <NUM>) the component and the roof from the crane hook, in particular disconnecting the first connecting device from the component or from the crane hook and/or disconnecting the second connecting device from the roof or from the crane hook.

The method <NUM> may include closing (block <NUM>) the opening, particularly using a lid.

In several embodiments of a method according to the present disclosure, in particular, in embodiments directed to the repair or replacement of a damaged component located in a nacelle of a wind turbine, the method can include hooking a roof of the nacelle to a crane hook of a crane and hooking the damaged component to the crane hook. The method may include lifting the roof together with the damaged component from a base of the nacelle on a tower of the wind turbine to a support surface. The method may proceed with further steps of embodiments of the method as described herein, in particular in conjunction with <FIG>, wherein in the further steps the component may be the damaged component after repair or a replacement component.

In embodiments of the method according to the present disclosure, hooking the roof to the crane hook may be performed before hooking the component to the crane hook. In exemplary embodiments, hooking the roof to the crane hook may be performed after hooking the component to the crane hook. In some embodiments, hooking the roof to the crane hook may be performed simultaneously with hooking the component to the crane hook. The order of mentioning the hooking of the roof and the component does not necessarily describe the order of the hooking in described exemplary embodiments. In typical embodiments, the roof and the component are placed under the crane hook, e.g. with spacers or in a mounting distance using a fixation device, before hooking them.

The various embodiments of the method and the assembling set of parts of a wind turbine may advantageously reduce the number of lifting steps required for lifting a component of a wind turbine and a roof of a nacelle to and/or from a tower or base of the wind turbine, in particular to half the number of lifting steps. Furthermore, lifting the component and the roof together can decrease the sensitivity of lifting to wind loading as compared to lifting the roof alone. In particular, decreasing the sensitivity to wind loading can reduce the time and costs associated with lifting the component and the roof, since lifting is less dependent on wind conditions. Decreasing the sensitivity to wind loading can reduce the risk of damaging the roof during lifting.

Claim 1:
A method (<NUM>, <NUM>) of mounting a nacelle of a wind turbine and at least one component of the wind turbine on a tower of the wind turbine, the method comprising:
- hooking (<NUM>, <NUM>) a roof of the nacelle to a crane hook of a crane, wherein the crane hook includes a lifting tool of the crane, the lifting tool including a beam;
- hooking (<NUM>, <NUM>) the at least one component to the crane hook of the crane, wherein the at least one component comprises a drivetrain, a drivetrain component and/or a transformer; and
- lifting (<NUM>, <NUM>) the roof of the nacelle together with the at least one component using the crane;
wherein hooking (<NUM>, <NUM>) the at least one component to the crane hook comprises connecting the at least one component to the crane hook using a first connecting device, wherein the first connecting device reaches through an opening in the roof of the nacelle;
wherein hooking (<NUM>, <NUM>) the roof to the crane hook comprises connecting the roof to the crane hook using a second connecting device; and
wherein the first connecting device and the second connecting device are flexible connecting devices.