U.S. patent application number 16/669729 was filed with the patent office on 2021-05-06 for universal root end support fixture for wind turbine blade.
This patent application is currently assigned to BNSF Logistics, LLC. The applicant listed for this patent is Billy R. Goodwin, James H. Jones, III, Andrew J. Sullivan. Invention is credited to Billy R. Goodwin, James H. Jones, III, Andrew J. Sullivan.
Application Number | 20210131401 16/669729 |
Document ID | / |
Family ID | 1000005535230 |
Filed Date | 2021-05-06 |
United States Patent
Application |
20210131401 |
Kind Code |
A1 |
Sullivan; Andrew J. ; et
al. |
May 6, 2021 |
Universal Root End Support Fixture for Wind Turbine Blade
Abstract
A support fixture for a wind turbine blades transported by rail.
A main frame pivots about a first vertical axis and a first lateral
axis, and has a frame arm extending from it. The main frame
supports the wind turbine blade on a blade cradle. A root end stand
is pivotally supported from the frame arm about a second vertical
axis. A mounting flange adapter, coupled to the wind turbine blade,
pivots about a second lateral axis and a longitudinal axis, and is
supported by the root end stand. Fixture has universal adaptability
by virtue of the plural axes of pivot.
Inventors: |
Sullivan; Andrew J.;
(Bedford, TX) ; Jones, III; James H.; (Arlington,
TX) ; Goodwin; Billy R.; (Richland Hills,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sullivan; Andrew J.
Jones, III; James H.
Goodwin; Billy R. |
Bedford
Arlington
Richland Hills |
TX
TX
TX |
US
US
US |
|
|
Assignee: |
BNSF Logistics, LLC
Springdale
AR
|
Family ID: |
1000005535230 |
Appl. No.: |
16/669729 |
Filed: |
October 31, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F05B 2260/02 20130101;
F03D 13/40 20160501 |
International
Class: |
F03D 13/40 20060101
F03D013/40 |
Claims
1. A fixture for supporting a root end of a wind turbine blade upon
a railcar, the root end having a flange with an elongated blade
extending therefrom along a first longitudinal axis toward a tip
end thereof, said fixture suitable for use in conjunction with a
rotatable tip end support fixture, the fixture comprising: a main
frame supported from the railcar by a main pivot assembly, operable
to pivot about both of a first vertical axis and a first lateral
axis; a blade cradle fixed to said main frame, configured to
supportively engage the elongated blade adjacent the root end
thereof; a blade strap for connection to said blade cradle and for
disposition about the elongated blade to thereby retain the wind
turbine blade in position upon said blade cradle; a frame arm that
extends from said main frame; a root stand supported from said
frame arm and having a stand pivot assembly, operable to pivot
about a second vertical axis; a mounting flange adapter for fixed
attachment to the flange of the wind turbine blade, said mounting
flange adapter supported from said root stand by a flange pivot
assembly, operable to pivot about a second lateral axis and a
second longitudinal axis, wherein said second longitudinal axis is
substantially aligned with the first longitudinal axis; a
counterweight fixed to said main frame, and having a mass selected
to balance the combined mass of the foregoing elements at a balance
point adjacent to said first lateral axis, and wherein rotational
orientation of the wind turbine blade about the first longitudinal
axis is selectable according to the angular position between said
mounting flange adaptor and said root stand about said second
longitudinal axis, and wherein a longitudinal position of the wind
turbine blade with respect to the railcar is controlled by said
root stand.
2. The fixture of claim 1, and wherein: said frame arm extends in a
horizontal direction, substantially in parallel with said second
longitudinal axis, to said stand pivot assembly.
3. (canceled)
4. The fixture of claim 1, and further comprising: a conformal
inset disposed upon said blade cradle, having a support surface
conformed to a profile of the elongated blade at a position of
support.
5. The fixture of claim 1, and wherein said main pivot assembly
further comprises: a rail car deck plate coupled to a main pivot
plate about said first lateral axis by plural main lateral pivot
bearings and a main lateral pivot shaft.
6. The fixture of claim 5, and wherein said main pivot assembly
further comprises: a main vertical pivot lower center plate fixed
to said main pivot plate, and rotatably engaged with a main
vertical pivot upper center plate fixed to said main frame, and
having a main vertical pivot center pin disposed therebetween.
7. The fixture of claim 6, and wherein said main vertical pivot
lower center plate and said main vertical pivot upper center plate
are selected from railroad industry standard center plates as are
employed in the engagement of railcar truck assembly bolsters to
railcar frames.
8. The fixture of claim 1, and wherein said stand pivot assembly
further comprises: a stand vertical pivot lower center plate fixed
to said frame arm, and pivotally engaged with a stand vertical
pivot upper center plate fixed to said root stand, and having a
stand vertical pivot center pin disposed therebetween.
9. The fixture of claim 8, and wherein said stand pivot assembly
further comprises: plural side bearings plates disposed between a
lower surface of said root stand and and an upper surface of said
frame extension, and disposed about said second vertical axis, to
thereby stabilize said root stand.
10. The fixture of claim 1, and wherein said stand pivot assembly
further comprises: a vertically oriented bearing tube disposed
within said root stand, which is fixed to said frame arm; a bearing
shaft for insertion into said bearing tube; a flange bracket fixed
to an upper end of said bearing shaft, which supports said flange
pivot assembly and enables pivotal movement about said second
vertical axis.
11. The fixture of claim 1, and wherein said mounting flange
adapter further comprises: a hub having plural radially oriented
spokes extending therefrom, each having a flange attachment member
at a distal end thereof for fixedly engaging the flange at the root
end of the wind turbine blade, and having a spindle extending from
said hub about said second longitudinal axis.
12. The fixture of claim 11, and wherein said flange pivot assembly
further comprises: a bearing mounting plate coupled to said root
stand about said second lateral axis by plural flange lateral pivot
bearings and a flange lateral pivot shaft, and a spindle cradle
bearing fixed to said bearing mounting plate for pivotally
supporting said spindle about said second longitudinal axis.
13. The fixture of claim 12, and further comprising: an alignment
plate disposed between said hub and said bearing mounting plate,
having plural alignment holes for receiving at least a first bolt
for fixedly aligning said angular position between said mounting
flange adapter and said root stand.
14. The fixture of claim 13, further comprising: a railroad
industry standard center bowl liner disposed between said main
vertical pivot lower center plate and said main vertical pivot
upper center plate.
15. A support fixture for use on a railcar to transport a wind
turbine blade having a mounting flange, comprising: a main frame
supported from the railcar by a main pivot, which pivots about a
first vertical axis and a first lateral axis, said main frame
having a frame arm extending therefrom, and wherein said main frame
supports the wind turbine blade a distance away from the mounting
flange; a root stand supported from said frame arm; a mounting
flange adapter supported from said root stand by a flange pivot,
which pivots about a second lateral axis and a longitudinal axis,
said mounting flange adapter configured for fixed attachment to the
mounting flange, and wherein said mounting flange further includes
a hub having plural radially oriented spokes extending therefrom,
each having a flange attachment member at a distal end thereof for
fixedly engaging the mounting flange of the wind turbine blade, and
having a spindle extending from said hub about said longitudinal
axis; a counterweight disposed upon said main frame, and having a
mass selected to balance the combined mass of said main frame, said
frame arm, said root stand, and said mounting flange adapter at a
balance point adjacent to said first lateral axis, and wherein
rotational orientation of the wind turbine blade about the
longitudinal axis is selectable according to the angular position
between said mounting flange adaptor and said root stand, and
wherein the wind turbine blade longitudinal position with respect
to the railcar is located by said root stand.
16. The support fixture of claim 15, and further comprising: a
blade cradle disposed between said main frame and the wind turbine
blade, and having a conformal inset disposed upon said blade
cradle, having a support surface conformed to a profile of the wind
turbine blade at a position of support.
17. The support fixture of claim 15, further comprising: a stand
pivot assembly disposed between said frame arm and said root stand,
which pivots about a second vertical axis.
18. (canceled)
19. The fixture of claim 18, and wherein said flange pivot assembly
further comprises: a bearing mounting plate coupled to said root
stand about said second lateral axis, and a spindle cradle bearing
fixed to said bearing mounting plate for pivotally supporting said
spindle about said longitudinal axis.
20. The fixture of claim 19, and further comprising: an alignment
plate disposed between said hub and said bearing mounting plate,
having plural alignment holes for receiving at least a first bolt
for fixedly aligning said angular position between said mounting
flange adapter and said root stand.
Description
BACKGROUND OF THE INVENTION
Related Applications
[0001] None.
Field of the Invention
[0002] The present invention relates to support fixtures for the
transportation of wind turbine blades. More particularly, the
present invention relates to universally adaptable wind turbine
blade blade root end support fixtures having multiple axes of
pivotal rotation and compatibility with intermodal transport
fixture systems.
Description of the Related Art
[0003] The continued growth of wind power utilization has led to
increasingly larger wind turbine structures. This has presented a
number of challenges in the field of logistics for transporting
wind turbine components from the points of manufacturer to the
points of utilization. Since the distances involved are of a global
scale, various modes of transportation are routinely employed,
including ocean vessels, barges, railroads and trucks. In the
particular case of wind turbine blades, which are very long and
relatively fragile, various support fixtures have been developed to
facilitate efficient and economical transportation, including
inter-modal systems of transportation.
[0004] The assignee of the present disclosure holds a range of US
patents that are germane to the logistics of wind turbine blade
transportation. These patents are listed below, and the entire
contents and teachings of all of these patents are hereby
incorporated by reference, and in their entirety, for all purposes.
[0005] A) U.S. Pat. No. 7,591,621 issued on Sep. 22, 2009 to
Landrum et al. for Wind Turbine Blade Transportation System and
Method. [0006] B) U.S. Pat. No. 7,670,090 issued on Mar. 2, 2010 to
Landrum et al. for Wind Turbine Blade Transportation System and
Method. [0007] C) U.S. Pat. No. 8,708,625 issued on Apr. 29, 2014
to Landrum et al. for Wind Turbine Blade Railroad Transportation
System and Method. [0008] D) U.S. Pat. No. 8,834,082 issued on Sep.
16, 2014 to Landrum et al. for Wind Turbine Blade Railroad
Transportation System and Method. [0009] E) U.S. Pat. No. 9,315,200
issued on Apr. 19, 2016 to Landrum et al. for Wind Turbine Blade
Railroad Transportation With Two Axis Translation. [0010] F) U.S.
Pat. No. 9,347,426 issued on May 24, 2016 to Landrum et al. for
Wind Turbine Blade Railroad Transportation System and Method.
[0011] G) U.S. Pat. No. 9,494,140 issued on Nov. 15, 2016 to
Sigurdsson for Frame Support Assembly For Transporting Wind Turbine
Blades. [0012] H) U.S. Pat. No. 9,567,969 issued on Feb. 14, 2017
to Sigurdsson for Systems and Methods For Transporting Wind Turbine
Blades. [0013] I) U.S. Pat. No. 9,790,927 issued on Oct. 17, 2017
to Landrum et al. for Wind Turbine Blade Double Pivot
Transportation System and Method. [0014] J) U.S. Pat. No.
10,030,633 issued Jul. 24, 2018 to Sigurdsson for System and Method
for Transporting Wind Turbine Blades.
[0015] It should be noted that the fixtures, stands, bolsters, and
other attachment equipment used to transport wind turbine blades
represent a substantial investment and cost factor, so that fixture
design considerations present opportunities for streamlining
logistics of wind turbine blade transportation, as well as
controlling the costs of doing so. It is desirable to use these
structures across various modes of transportation where possible,
as this saves on fixture cost and reduces the amount of handling
required during intermodal operations. As the scale of wind turbine
blades continues to grow in length and capacity, suppliers of
logistics fixtures and services continue to address the challenges
by developing new fixtures sets to support and transport these
blades. Such ongoing fixture development and deployment processes
represent a substantial cost in the logistics of wind turbine blade
storage and transport. Thus it can be appreciated that there is a
need in the art for improved fixtures having a more universal
applicability to various, and increasingly larger, sizes of wind
turbine blades.
SUMMARY OF THE INVENTION
[0016] The need in the art is addressed by the apparatuses of the
present invention. The present disclosure teaches a fixture for
supporting the root end of a wind turbine blade on a railcar, where
the root end has a flange with an elongated blade extending
therefrom along a first longitudinal axis toward a tip end. The
fixture is suitable for use in conjunction with a rotatable tip end
support fixture, to thereby facilitate rotation of the blade upon
the fixtures. The fixture includes a main frame supported from the
railcar by a main pivot assembly, which can pivot about both of a
first vertical axis and a first lateral axis. A blade cradle is
fixed to the main frame, and supportively engages the elongated
blade adjacent to the root end of the blade. A frame arm extends
away from the main frame. A root stand is supported from the frame
arm by a stand pivot assembly, which pivots about a second vertical
axis. A mounting flange adapter is fixed to the flange of the wind
turbine blade, which is supported from the root stand by a flange
pivot assembly that pivots about both a second lateral axis and a
second longitudinal axis. The second longitudinal axis is
substantially aligned with the first longitudinal axis. A
counterweight is fixed to the main frame, and has a mass selected
to balance the combined mass of the fixture components at a balance
point adjacent to the first lateral axis, so as to balance the
fixture about the main pivot assembly. The rotational orientation
of the wind turbine blade about the first longitudinal axis is
selectable according to the angular position between the mounting
flange adaptor and the root stand about the second longitudinal
axis. And, the longitudinal position of the wind turbine blade with
respect to the railcar is controlled by the root stand.
[0017] In a specific embodiment of the foregoing fixture, the frame
arm extends in a horizontal direction, substantially in parallel
with the second longitudinal axis, to the stand pivot assembly.
[0018] In a specific embodiment, the foregoing fixture further
includes a blade strap connected to the blade cradle and wrapped
about the elongated blade to thereby retain the wind turbine blade
in position upon the blade cradle.
[0019] In a specific embodiment, the foregoing fixture further
includes a conformal inset disposed upon the blade cradle, which
has a support surface conformed to a profile of the blade at point
of support.
[0020] In a specific embodiment of the foregoing fixture, the main
pivot assembly includes a rail car deck plate coupled to a main
pivot plate about the first lateral axis by plural main lateral
pivot bearings and a main lateral pivot shaft. In a refinement to
this embodiment, the main pivot assembly further includes a main
vertical pivot lower center plate fixed to the main pivot plate,
which rotatably engages a main vertical pivot upper center plate
fixed to the main frame, with a main vertical pivot center pin
disposed between them.
[0021] In a specific embodiment of the foregoing fixture, the stand
pivot assembly further includes a stand vertical pivot lower center
plate fixed to the frame arm, that is pivotally engaged with a
stand vertical pivot upper center plate fixed to the root stand,
and having a stand vertical pivot center pin disposed between
them.
[0022] In a specific embodiment of the foregoing fixture, the stand
pivot assembly further includes plural side bearings plates
disposed between a lower surface of the root stand and and an upper
surface of the frame arm, and disposed about the second vertical
axis, to thereby stabilize the root stand.
[0023] In a specific embodiment of the foregoing fixture, the
mounting flange adapter further includes a hub with plural radially
oriented spokes extending therefrom, each having a flange
attachment member at a distal end for attachment to the blade root
end flange, and also has a spindle extending from the hub about the
second longitudinal axis. In a refinement of this embodiment, the
flange pivot assembly further includes a bearing mounting plate
coupled to the root stand about the second lateral axis by plural
flange lateral pivot bearings and a flange lateral pivot shaft, and
a spindle cradle bearing fixed to the bearing mounting plate for
pivotally supporting the spindle about the second longitudinal
axis.
[0024] In a specific embodiment, the foregoing fixture further
includes an alignment plate disposed between the hub and the
bearing mounting plate, having plural alignment holes for receiving
at least a first bolt to fixedly align the angular position between
the mounting flange adapter and the root stand.
[0025] In a refinement to the foregoing fixture, the main vertical
pivot lower center plate and the main vertical pivot upper center
plate are selected from railroad industry standard center plates as
are employed in the engagement of railcar truck assembly bolsters
to railcar frames. In a refinement to this embodiment, the fixture
further includes a railroad industry standard center bowl liner
disposed between the main vertical pivot lower center plate and the
main vertical pivot upper center plate.
[0026] In a refinement to the foregoing fixture, the stand vertical
pivot lower center plate and the a stand vertical pivot upper
center plate are selected from railroad industry standard center
plates as are employed in the engagement of railcar truck assembly
bolsters to railcar frames.
[0027] The present disclosure teaches a support fixture for use on
a railcar to transport a wind turbine blade that has a mounting
flange. The support fixture includes a main frame supported from
the railcar by a main pivot, which pivots about a first vertical
axis and a first lateral axis, and the main frame has a frame arm
extending from it. The main frame supports the wind turbine blade
at a distance away from the mounting flange. The support fixture
also includes a root stand supported from the frame arm, and a
mounting flange adapter supported from the root stand by a flange
pivot, which pivots about a second lateral axis and a longitudinal
axis. The mounting flange adapter is configured for fixed
attachment to the mounting flange. A counterweight is disposed upon
the main frame, and has a mass selected to balance the combined
mass of the main frame, the frame arm, the root stand, and the
mounting flange adapter at a balance point adjacent to the first
lateral axis. The rotational orientation of the wind turbine blade
about the longitudinal axis is selectable according to the angular
position between the mounting flange adaptor and the root stand. In
addition, the wind turbine blade longitudinal position with respect
to the railcar is located by the root stand.
[0028] In a specific embodiment, the foregoing support fixture
further includes a blade cradle disposed between the main frame and
the wind turbine blade, which has a conformal inset disposed upon
the blade cradle that has a support surface conformed to a profile
of the wind turbine blade at the position of support.
[0029] In a specific embodiment, the foregoing support fixture
includes a stand pivot assembly disposed between the frame arm and
the root stand, which pivots about a second vertical axis.
[0030] In s specific embodiment of the foregoing support fixture,
the mounting flange adapter further includes a hub with plural
radially oriented spokes extending therefrom, where each spoke has
a flange attachment member at its distal end for attachment to the
mounting flange of the wind turbine blade, and the mounting flange
adapter also has a spindle extending from the hub along the
longitudinal axis. In a refinement to this embodiment, the flange
pivot assembly further includes a bearing mounting plate coupled to
the root stand along the second lateral axis, and also, a spindle
cradle bearing attached to the bearing mounting plate that
pivotally supports the spindle along the longitudinal axis. In a
further refinement, an alignment plate is disposed between the hub
and the bearing mounting plate, and it has plural alignment holes
for receiving at least a first bolt for fixedly aligning the
angular position between the mounting flange adapter and the root
stand.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a schematic diagram of a universal root end
support fixture supporting a wind turbine blade on a railcar
according to an illustrative embodiment of the present
invention.
[0032] FIG. 2 is a plan view drawing of plural railcars supporting
a wind turbine blade on support fixtures according to an
illustrative embodiment of the present invention.
[0033] FIG. 3 is a side view drawing of plural railcars supporting
a wind turbine blade on support fixtures according to an
illustrative embodiment of the present invention.
[0034] FIG. 4 is a perspective view drawing of a root end fixture
supporting a wind turbine blade above a pair of railcars according
to an illustrative embodiment of the present invention.
[0035] FIG. 5 is a perspective view drawing of a root end fixture
disposed above a pair of railcars according to an illustrative
embodiment of the present invention.
[0036] FIG. 6 is a side view drawing of a root end fixture
supporting a wind turbine blade above a pair of railcars according
to an illustrative embodiment of the present invention.
[0037] FIG. 7 is a perspective view drawing of a main pivot
assembly according to an illustrative embodiment of the present
invention.
[0038] FIG. 8 is a section view drawing of a main pivot assembly
according to an illustrative embodiment of the present
invention.
[0039] FIG. 9 is a plan view drawing of a root end frame assembly
according to an illustrative embodiment of the present
invention.
[0040] FIG. 10 is a side view drawing of a root end frame assembly
according to an illustrative embodiment of the present
invention.
[0041] FIG. 11 is a perspective view drawing of a flange adapter
assembly according to an illustrative embodiment of the present
invention.
[0042] FIG. 12 is a side view drawing of a root stand assembly
according to an illustrative embodiment of the present
invention.
[0043] FIG. 13 is an end view drawing of a root stand assembly
according to an illustrative embodiment of the present
invention.
[0044] FIG. 14 is a section view drawing of the upper portion of a
stand pivot assembly according to an illustrative embodiment of the
present invention.
[0045] FIG. 15 is a top view drawing of the lower portion of a
stand pivot assembly according to an illustrative embodiment of the
present invention.
[0046] FIG. 16 is a section view drawing of the lower portion of a
stand pivot assembly according to an illustrative embodiment of the
present invention.
[0047] FIG. 17 is a perspective view drawing of a root end fixture
supporting a wind turbine blade above a pair of railcars according
to an illustrative embodiment of the present invention.
[0048] FIG. 18 is a plan view drawing of a root end frame assembly
according to an illustrative embodiment of the present
invention.
[0049] FIG. 19 is a side view drawing of a root end frame assembly
according to an illustrative embodiment of the present
invention.
[0050] FIG. 20 is a side view drawing of a vertical pivot shaft and
flange pivot assembly according to an illustrative embodiment of
the present invention.
[0051] FIG. 21 is an end view drawing of a vertical pivot shaft and
flange pivot assembly according to an illustrative embodiment of
the present invention.
DESCRIPTION OF THE INVENTION
[0052] Illustrative embodiments and exemplary applications will now
be described with reference to the accompanying drawings to
disclose the advantageous teachings of the present invention.
[0053] While the present invention is described herein with
reference to illustrative embodiments for particular applications,
it should be understood that the invention is not limited thereto.
Those having ordinary skill in the art and access to the teachings
provided herein will recognize additional modifications,
applications, and embodiments within the scope hereof and
additional fields in which the present invention would be of
significant utility.
[0054] In considering the detailed embodiments of the present
invention, it will be observed that the present invention resides
primarily in combinations of steps to accomplish various methods or
components to form various apparatus and systems. Accordingly, the
apparatus and system components, and method steps, have been
represented where appropriate by conventional symbols in the
drawings, showing only those specific details that are pertinent to
understanding the present invention so as not to obscure the
disclosure with details that will be readily apparent to those of
ordinary skill in the art having the benefit of the disclosures
contained herein.
[0055] In this disclosure, relational terms such as first and
second, top and bottom, upper and lower, and the like may be used
solely to distinguish one entity or action from another entity or
action without necessarily requiring or implying any actual such
relationship or order between such entities or actions. The terms
"comprises," "comprising," or any other variation thereof, are
intended to cover a non-exclusive inclusion, such that a process,
method, article, or apparatus that comprises a list of elements
does not include only those elements but may include other elements
not expressly listed or inherent to such process, method, article,
or apparatus. An element proceeded by "comprises a" does not,
without more constraints, preclude the existence of additional
identical elements in the process, method, article, or apparatus
that comprises the element.
[0056] Those skilled in the art of wind turbine blade logistics,
particularly with regard to railroad transport, will be aware of
the challenges in loading, securing, and transporting long
structures, such as wind turbine blades (also referred to herein as
a "blade"). At the time of this writing, commercial wind turbine
blades range in length from approximately 48 meters to 71 meters,
and longer blades are envisioned by suppliers. As such, these
blades are much longer than the typical railcar. For example, the
common rail flatcar is about 27 meters in length. Therefore,
multiple railcars must be coupled together to provide adequate
length to carry a single wind turbine blade, which may require two,
three, or even four railcars joined together. The coupling of
plural railcars to provide adequate length may hereinafter be
referred to as a "consist" of railcars. The blade must be supported
on at least two support fixtures and aligned along the longitudinal
axis of the consist of railcars. As a side note for this
disclosure, an axis generally aligned with the length of a consist
of railcars will be referred to as a "longitudinal" axis. An axis
that is generally transverse to a longitudinal axis, such as
side-to-side of a railcar, will be referred to as a "lateral" axis.
And, vertically aligned axes will be referred to as "vertical"
axes. For example, the longitudinal axis of a wind turbine blade is
generally aligned with the longitudinal axis of a consist of
railcars. Although, there may be several angular degrees of
misalignment with respect to these reference directions, as will be
appreciated by those skilled in the art.
[0057] Since two support fixtures, minimum, are required to support
a wind turbine blade, and since a consist may include more than two
railcars, some of the railcars in a consist may be load bearing
cars, referred to as "load" cars, and some railcars may be non load
bearing cars, referred to a "idler" cars. It will be appreciated by
those skilled in the art that the total mass borne by a railcar
must result in a center of mass that is close to the longitudinal
axis of the railcars and consist so as to avoid excessive tipping
forces. Sometimes it is necessary to add counterweights to a
railcar where the actual load cannot be so aligned. This is
sometime the case for long, curved, wind turbine blades. It will
also be appreciated that concentrated loads are preferably located
directly above a railcar truck assembly so as to limit bending
stresses along the railcar frame.
[0058] Longer wind turbine blades are commonly designed with a
curved airfoil design, the `flattens` out under wind loading.
However, during transport, the curved shape, sometimes referred to
as a "hockey stick" shape, must be addressed with respect to
railway clearances. The logistics of wind turbine blade rail
transport are facing increasing clearance issues as the blades
become longer, and this challenge is exacerbated where the blade is
curved. Considering the curvature of railroad tracks, and the
undulations over hills and valleys, and the differences between how
a consist of railcars traverse a curved section of rail, as
compared to the relatively fixed shape of wind turbine blades, and
it can be appreciated that clearance logistics is a major
consideration in support fixture design and placement. With a
two-point support system as discussed above, and the consist of
railcars following a curved track, it can be appreciated that the
blade axis generally defines a geometric chord along the curved
track, where the ends and center portions of the blade overhang the
clearance profile more so than where the track section is
straight.
[0059] To address the foregoing issues, logistics engineers have
designed specialized support fixtures base on particular blade
sizes and shapes that provide axes of pivot, both vertically and
laterally, and fixtures the provide lateral translation of the
support point as a consist rounds a curved section of track, so as
to address clearance issues. Reference is directed to the patents
listed in the Background section of this disclosure for such
examples. Each of these fixture sets are designed to provide the
narrowest clearance profile so that the consist can be routed
through the greatest number of acceptable railroad routings.
Another aspect of the transport of wind turbine blades is the
height of the railcar, support fixtures and blade, particularly,
the broadest blade section, which is generally adjacent the root
end of the blade where would be attached to a wind generator. By
rotating the blade along its longitudinal axis, the height can be
limited, however, such rotation may also increase lateral clearance
issues. Each blade design and each consist arrangement requires
considered engineering attention with respect to these clearance
issues.
[0060] As can be appreciated from the foregoing discussion, the use
of custom and specific designed fixtures for each blade type has
been commonly employed in the field of wind turbine blade
logistics. This is a relatively expensive approach and results in
fixture sets that become obsolete as wind turbine blade designs
evolve over time. The present disclosure teaches an improved
support fixture for use adjacent the root end of a wind turbine
blades, which enables a more universal applicability for wind
turbine blades of various lengths, curvatures, and blade depths.
This fixture provides, among other features, adjustable rotational
orientation about the longitudinal axis of the blade, and is thus
appropriate for use with a blade tip end fixture that also enables
such rotation.
[0061] Reference is directed to FIG. 1, which is a schematic
diagram of a universal root end support fixture assembly for
supporting a wind turbine blade 2 on a railcar 6 according to an
illustrative embodiment of the present invention. This embodiment
employs plural pivot axes, which are depicted schematically in this
drawing figure. A Pivot Axes Legend is provided as a convenient
reference. Lateral axes 32 are depicted in the drawing using a
circle, as illustrated. Vertical axes 34 are depicted as elongated
ovals, as illustrated. And, longitudinal axes 36 are depicted as
overlapped rectangles, as illustrated. Now, returning to the
substance of FIG. 1, two rail flatcars 6, 8 are joined by a
couplers 7 into a consist, where flatcar 6 is a load car and
flatcar 8 is an idler car. A main pivot assembly 16 rests upon the
load car 6 directly above the truck assembly 9, so as to transfer
the weight directly through the truck assembly 9. Main pivot
assembly 16 provides both a vertical pivot axis and a lateral pivot
axis. The vertical axis enables the blade 2 to rotate and align
with a tip end fixture (not shown), which also provides its own
vertical pivot axis. In this way, the blade 2 can align as a
geometric chord of the curved track section as the consist rounds a
curve in the railway (not shown). The lateral pivot axis of main
pivot assembly 16 enables the blade 2 to incline and decline as the
consist traverses a railway having hills and valleys.
[0062] The main pivot assembly 16 of FIG. 1 supports a main frame
10, which is comprised of suitable structural steel members in the
illustrative embodiment. A blade cradle 20 rest on top of the main
frame 10, and supports the blade at a suitable distance from the
blade 2 root end flange 4. This distance is selected to optimize
the clearance profile of the loaded consist. In order to provide a
more universal adaptability of the assembly, the blade cradle is
shaped to accommodate the largest blade 2 required for the scope of
design of the system. Smaller blades are accommodated by providing
a conformal insert 22, which is placed on the larger blade cradle
20, and has a smaller surface that is conformed to a profile of the
blade 2 at the actual location of support.
[0063] A frame arm 12 extends horizontally away from the main frame
10, in the direction of the root end flange 4 of the blade 2. In
this embodiment, the frame arm 12 extends past the end of the load
car 6 and over the idler car 8. This is useful for arranging the
blade over plural railcars, keeping in mind the overhang effect on
the clearance profile in doing so. Toward the distal end of the
frame arm 12 is a root stand 24 that is pivotally supported by a
stand pivot assembly 26. The stand pivot assembly 26 enables
pivotal movement about a second vertical axis. The purpose of the
root stand 24 is to support a mounting flange adapter 28 that is
connected to the root end flange 4 of the blade 2. The combination
of these components hold the blade 2 against longitudinal movement
with respect to the load car 6. Even though straps or other
logistics components could be employed to provide added
longitudinal securement, AAR (American Association of Railroads)
open top loading rule required a structural fixture to achieve this
objective, and the root stand 24 and it associated elements satisfy
this requirement. Note that the mounting flange adapter 28 is
connected to the root stand 24 using a flange pivot assembly 30,
which enables pivotal movement about a second lateral axis and
along the longitudinal axes 3 of the blade 2.
[0064] The pivotal movement about the longitudinal axis 3 enabled
by the flange pivot assembly 30 provides for selective control of
the rotational angle between the blade 2 and the root stand 24.
With this degree of control, engineers are able to select and
control the height profile of the blade 2 on the consist of
railcars 6, 8. Note also that the vertical pivot of stand pivot
assembly 26 and the lateral pivot of flange pivot 30 enables the
universality of the fixture set for a wide range of blade loading
configurations, as there will be a need for small angular
adjustments to achieve proper rail car loading, and management of
the overhang and clearance profile issues discussed hereinbefore.
These degrees of adjustment enable the universality of the fixture
assembly as a whole. Also note that the centerline of the
longitudinal axis of the flange pivot assembly 30 and longitudinal
axis 3 of the blade 2 do not necessarily have to be precisely
aligned. In fact, some misalignment and/or eccentricity between
these axes can be beneficial in controlling and tailoring the
railcar loading and the railway clearance requirements of the
system as whole across a range of blade sizes, weights, and
lengths.
[0065] Another significant aspect of the root end fixture design in
FIG. 1 is how the fixture components balance prior to resting the
blade 2 thereupon. Since the frame arm 12 and root stand 24 extend
away from the primary point of support, at the main pivot assembly
16, and since this pivot assembly can tip about its lateral axis, a
counterweight 14 is provided on the opposing end of the main frame
10 to position a center of gravity 18 that is directly adjacent to
the main pivot assembly 16, so the fixture is somewhat balanced as
the blade 2 is loaded thereupon.
[0066] Reference is directed to FIG. 2 and FIG. 3, which are a plan
view drawing and a side view drawing, respectively, of plural
railcars supporting a wind turbine blade 50 on support fixtures 56,
48 according to an illustrative embodiment of the present
invention. In this embodiment, a seventy-one meter long blade 50 is
supported on a consist of railcars, including four eight-nine foot
flatcars 40, 42, 44, and 46. Note that flatcar 40 is a load car
carrying the weight of the wind turbine blade 50 through root end
fixture assembly 56. Flatcar 44 is an idler car, providing
clearance for blade 50 overhang at its root end 52. Similarly,
flatcar 42 is a load car carrying the weight of the wind turbine
blade 50 through tip end fixture assembly 48, while flatcar 46 is
an idler car providing clearance for blade 50 tip end 54 overhang.
Note that both of the support fixtures 56 and 48 are located
directly above corresponding railcar truck assemblies. Note the
orientation of the blade 50 in the plan view of FIG. 2. The blade
50 is offset from the centerline (not shown) of the consist for the
purposes of both balance and overhang clearance, as discussed
hereinbefore. The tip end support fixture 48 enables pivotal
movement about all of the vertical, lateral, and longitudinal axis.
The design of the tip end fixture 48 is beyond the scope of this
disclosure, however, one example of such a fixture is the subject
of co-pending U.S. patent application Ser. No. 16/552,625 filed on
Aug. 8, 2019 for Rotatable Support Fixture for Wind Turbine
Blade.
[0067] Reference is directed to FIG. 4, which is a perspective view
drawing of a root end fixture assembly 56 supporting a wind turbine
blade 50 above a pair of railcars 40, 44 according to an
illustrative embodiment of the present invention. Flatcar 40 is the
load bearing car and flatcar 44 is an idler car that provides
clearance for the frame arm 66 and root end 52 of the wind turbine
blade 50. The bulk of the weight of blade 50 is supported by
conformal insert 62, which has an upper surface that conforms to
the shape of the blade 50 at the point of support. The conformal
insert 62 correspondingly rests upon blade cradle 60. Blade cradle
60 rests upon main frame 58 that is supported from load car 40 by a
main pivot assembly 64, which is slightly visible on this drawing
view. The main frame 58 is fabricated from mild steel structural
components, and has counterweights 78 disposed thereupon for the
purpose of balance, as described hereinbefore.
[0068] Continuing in FIG. 4, a frame arm 66 extends horizontally
from main frame 58 in the direction of the root end 52 of wind
turbine blade 50. The frame arm 66 is also fabricated from mild
steel structural components, and is rigidly attached to the main
frame 58. A root stand 70 is supported upon the frame arm 66 by a
stand pivot assembly 68, which is only slightly visible in this
drawing view. The root stand 70 is fabricated from mild steel
structural sections and has flange pivot assembly 72 attached to an
upper portion adjacent the rood end flange 52 of the wind turbine
blade 50. The flange pivot assembly 72 supports a flange adaptor
63, comprising plural radially oriented spoke 74 having
corresponding flange attachment members 76 positioned at the distal
ends thereof, for attachment to the root flange 52 of the wind
turbine blade 50. Further details of the stand pivot assembly 68
and flange pivot assembly 72 will be described hereinafter.
[0069] Reference is directed to FIG. 5, which is a perspective view
drawing of a root end fixture 56 disposed above a pair of railcars
40, 44 according to an illustrative embodiment of the present
invention. With the wind turbine blade removed from this drawing
view, the conformal insert 62 and its upper surface that conforms
to the shape of the blade 50 (not shown) at the point of support is
clearly visible. The conformal insert 62 rests upon a larger
arcuate shape of blade cradle 60. Blade cradle 60 rests upon main
frame 58 that is supported from load car 40 by a main pivot
assembly 64, which is slightly visible on this drawing view. The
main frame 58 has counterweights 78 disposed thereupon for the
purpose of balance, as described hereinbefore. The frame arm 66
extends horizontally from main frame 58. The root stand 70 is
supported upon the frame arm 66 by a stand pivot assembly 68, which
is only slightly visible in this drawing view. The root stand 70
has flange pivot assembly 72 attached to an upper portion thereof,
which supports the flange adaptor 63, comprising the plural
radially oriented spokes 74 and corresponding flange attachment
members 76 at the distal ends thereof, for attachment to the root
flange 52 (not shown) of the wind turbine blade 50 (not shown).
[0070] Reference is directed to FIG. 6, which is a side view
drawing of a root end fixture supporting a wind turbine blade 50
above a pair of railcars 40, 44 according to an illustrative
embodiment of the present invention. This FIG. 6 corresponds to
FIGS. 4 and 5. The two flatcars 40, 44 are joined by couplers 41.
The main pivot assembly 64 is disposed upon flatcar 40 and supports
main frame 58, and pivots about a first lateral axis and a first
vertical axis. The main frame 58 has frame arm 66 extending
therefrom over flatcar 44, and also has counter weights 78 disposed
thereupon. The blade cradle 60 and conformal insert 62 are visible.
Note that a webbing strap 82 is fixed to the blade cradle 60 and is
routed over blade 50 and is tightened to secure the blade 50 in
place upon the conformal insert 62.
[0071] The blade stand 70 is supported about a second vertical
pivot axis by stand pivot assembly 68. In addition, plural side
bearing plates 69 are disposed between the frame extension 66 and
the root stand 70 to stabilize the root frame 70 against any
tipping movement. The flange pivot assembly 72 is fixed to the root
stand 70, and engaged a hub 80 that is connected to the radial
spokes 74 with flange attachment members 76. The root flange 52 of
the wind turbine blade 50 is bolted to the plural flange attachment
members 76.
[0072] Reference is directed to FIG. 7, which is a perspective view
drawing of a main pivot assembly 64 according to an illustrative
embodiment of the present invention. The assembly 64 includes a
rail car deck plate 90, which is a steel plate that is attached to
the host railcar deck (not shown), typically by welding. A main
pivot plate 92 is pivotally supported from the rail car deck plate
90 by plural main lateral pivot bearings 98 engaged by a main
lateral pivot shaft 102, which defines the first lateral pivot axis
of the present disclosure. The plural main lateral pivot bearings
98 are pillow block bearings of suitable load capacity. On the
upper surface of the main pivot plate 92, there is disposed a main
vertical pivot center plate 94 with a main vertical pivot center
pin 96. The main pivot bearing assembly 64 advantageously utilizes
railroad industry standard center plate bearing assemblies commonly
utilized in railcars between the railcar truck assembly bolster and
the railcar frame. These vertical axis bearing assemblies are well
known in the art, they are suitable to carry the entire load rating
of such railcars, and are know to have sufficient load carrying
capacity and wear characteristics that easily surpass the
requirements of the present main bearing pivot assembly loading
requirements.
[0073] Reference is directed to FIG. 8, which is a section view
drawing of a main pivot assembly 64 according to an illustrative
embodiment of the present invention. This FIG. 8 corresponds to
FIG. 7. The assembly 64 includes the rail car deck plate 90 and the
main pivot plate 92. In this section view, it can be seen that the
plural main lateral pivot bearings include both lower bearings 98
that are fixed to the railcar deck plate 90, and upper bearings 96
that are connected to the main pivot plate 92, and these are
pivotally joined by the main lateral pivot shaft 102, which defines
the first lateral pivot axis of the present disclosure.
[0074] In FIG. 8, a portion of the main frame 58 is presented, so
as to reveal how the main vertical pivot axis is arranged by use of
a main vertical pivot lower center plate 94 that is fixed to the
main pivot plate 92, and which is pivotally engaged with a main
vertical pivot upper center plate 84, which is fixed to the main
frame 58. The lower 94 and upper 84 center plates are aligned with
a main vertical pivot center pin 96. Also note that a center bowl
liner 95 is disposed between center plates 84 and 94, which reduces
friction and reduces wear, and which is also a railroad industry
standard component, as will be appreciated by those skilled in the
art.
[0075] Reference is directed to FIG. 9 and FIG. 10, which are a
plan view drawing and a side view drawing, respectively, of a root
end frame assembly comprising a main frame portion 58 and a frame
arm portion 66, according to an illustrative embodiment of the
present invention. Both of these portions are fabricated form mild
steel structural components, such as I-beans, C-channel, angle
irons, and fabricated plates. They are rigidly fixed to one another
about a horizontal form factor, and certain structural members may
be contiguous between the two portions 58, 66. The counterweights
78, which are steel plates in the illustrative embodiment, are
attached to the main frame portion 58, and serve to balance the
fixture, as was described hereinbefore. Other materials could also
be employed as counterweights. The main vertical pivot upper center
plate 84 is attached to the main frame 58, such as by welding or
other suitable fastening arrangement, as will be appreciated by
those skilled in the art.
[0076] The frame arm 66 in FIGS. 9 and 10 extend laterally from the
main frame 58, and, at its distal end, a portion of the root stand
pivot assembly is presented, which includes the stand vertical
pivot lower center plate 86 and stand vertical pivot center pin 87.
This defines the vertical axis about which the root stand (not
shown) pivots. Note that stand pivot assembly also include plural
side lower bearing plates 69, which engage corresponding side upper
plates on the root stand (not shown), and which slideably engage
one another to limit any tipping movement of the root stand (not
shown).
[0077] Reference is directed to FIG. 11, which is a perspective
view drawing of a mounting flange adapter 63 according to an
illustrative embodiment of the present invention. A circular hub 75
has plural radial spokes 74 extending therefrom, which are
fabricated from structural tubing or other suitable material. At
the distal end of each spoke 74 is a flange attachment member 76,
which are bolted to the root end flange of the wind turbine blade
(not shown). The attachment members 76 may be a flat plate with
holes formed therethrough, or may be a boxed section as
illustrated. The central hub 75 has a spindle 79 extending
therefrom, which rotatably engages a cradle bearing (not shown) in
the flange pivot assembly (not shown), along the longitudinal axis
of the stand pivot assembly. Note that a circular alignment plate
77 is disposed along the spindle 79, which has plural holes and/or
grooves formed through it. This plate 77 is useful for aligning the
longitudinal rotational position orientation of the wind turbine
blade (not shown) with respect to the root stand (not shown).
[0078] Reference is directed to FIG. 12 and FIG. 13, which are a
side view drawing and an end view drawing, respectively, of a root
stand assembly according to an illustrative embodiment of the
present invention. The root stand 70 is fabricated from mild steel
structural components. On a lower surface thereof, a stand vertical
pivot upper center plate 85 is attached, which rotatably engages
the stand vertical pivot lower center plate 86 (not shown) that is
attached to the frame arm 66 (not shown). Thusly, the root stand 70
is enabled to pivot about the vertical axis defined by those center
plates. The root stand 70 has has a portion of the stand pivot
assembly, namely the plural side upper bearing plates 67 attached
to its lower surface, which slideably engage corresponding side
lower plates on the frame arm 66 (not shown), which serve to limit
any tipping movement of the root stand 70.
[0079] Continuing with regard to FIGS. 12 and 13, the flange pivot
assembly 73 is also illustrated. This assembly 73 comprises plural
flange lateral pivot bearings 71, 73 pivotally coupled by a flange
lateral pivot shaft 75. These are pillow block type bearings of
suitable load bearing capacity. Note that a portion of the plural
flange lateral pivot bearings 73 are fixed to the root stand 70,
and the other portion of the plural flange lateral pivot bearings
71 are fixed to a bearing mounting plate 81. In this manner, the
bearing mounting plate is enable to pivot about the flange lateral
pivot shaft 75. The bearing mounting plate 81 has a cradle bearing
83 disposed about a suitable opening for receiving and engaging the
mounting flange adapter (not shown) spindle (not shown), to thereby
rotate about a longitudinal axis, as described hereinbefore.
[0080] Reference is directed to FIG. 14, FIG. 15, and FIG. 16,
which are a section view drawing of the upper portion of a stand
pivot assembly, a top view drawing of the lower portion of a stand
pivot assembly, and a section view drawing of the lower portion of
a stand pivot assembly, respectively, according to an illustrative
embodiment of the present invention. This assembly also
advantageously utilizes railroad industry standard center plate
bearing assemblies commonly utilized in railcars between the
railcar truck assembly bolster and the railcar frame. These
vertical axis bearing assemblies are well known in the art. In
these Figures, the frame arm 66 is illustrate with the stand
vertical pivot lower center plate 86 fixed thereto, and the stand
vertical pivot center pin extending upwardly therefrom. In FIG. 14,
a portion of the root stand 70 is illustrated with the stand
vertical pivot upper center plate 85 fixed thereto. The center
plates 85, 86 rotatably engage one another, as described
hereinbefore.
[0081] Reference is directed to FIG. 17, which is a perspective
view drawing of a root end fixture supporting a wind turbine blade
104 above a pair of railcars 100, 102 according to an illustrative
embodiment of the present invention. This embodiment presents
another root stand configuration. The main frame 106 is supported
above a load railcar 100. A blade cradle 108 supports the wind
turbine blade 104, and includes a retention strap 118 to retain the
blade 104 in place. A frame arm 110 extends therefrom over an idler
railcar 102. A root stand 112 is fixed to the frame arm 110, and
supports a flange bracket 114, which is pivotally engaged with the
root stand 112 about a vertical axis of pivot. A flange pivot
assembly 116 pivotally supports a flange adapter 117, which is
fixed to the root flange 105 of the wind turbine blade 104. Note in
this embodiment that two additional straps 120 are connected to the
frame arm 110 and wrapped about the root end of the wind turbine
blade 104. The primary difference between this illustrative
embodiment and the prior illustrative embodiment is the structure
of the rood stand 112 and the location of the stand pivot, which
will be more fully described below.
[0082] Reference is directed to FIG. 18 and FIG. 19, which are a
plan view drawing and a side view drawing, respectively, of a root
end frame assembly according to an illustrative embodiment of the
present invention. This drawing corresponds to FIG. 17. FIG. 18
illustrated a main frame 106 with frame arm 110 extending
therefrom. The main pivot assembly upper center plate 122 is fixed
to the main frame 106, as in the prior embodiments. At the distal
end of the frame arm 110, a root stand 112 that is fixed to its
upper side. The root stand 112 is configured with a vertically
oriented bearing tube 113, which has a flange 115 at its upper end.
The purpose of the bearing tube 113 is to receive a bearing shaft
(not shown) that is coupled to the flange bracket (not shown), to
thereby enable pivotal movement about a vertical axis.
[0083] Reference is directed to FIG. 20 and FIG. 21, which are a
side view drawing and an end view drawing, respectively, of a
vertical pivot bearing shaft 126, flange bracket 114, and flange
pivot assembly 132 according to an illustrative embodiment of the
present invention. The bearing shaft 126 is sized for insertion
into the bearing tube (item 113 in FIGS. 18 and 19) to enable a
vertical pivot axis for the root end support structure. A pair of
brass sleeves 128 are disposed about the bearing shaft to provide
suitable bearing surfaces against the loads involved. A flange
bracket 114 is fixed to the upper end of the bearing shaft 126. A
stand pivot assembly 132 is fixed to a face of the flange bracket
114. The stand pivot assembly 132 is similar in configuration to
the stand pivot assembly described hereinbefore. The stand pivot
assembly 132 supports a bearing plate 134 having a cradle bearing
136 for receiving the spindle of the flange adapter, also as
detailed hereinbefore. A flange 130 is disposed about the bearing
shaft 126, which serves to engage the flange (item 113 in FIGS. 18
and 19) on the bearing tube (item 115 in FIGS. 118 and 119). A wear
plate Not shown) may be inserted between the flanges to reduce
friction and wear.
[0084] Thus, the present invention has been described herein with
reference to a particular embodiment for a particular application.
Those having ordinary skill in the art and access to the present
teachings will recognize additional modifications, applications and
embodiments within the scope thereof.
[0085] It is therefore intended by the appended claims to cover any
and all such applications, modifications and embodiments within the
scope of the present invention.
* * * * *