Systems and methods for transporting and assembling segmented wind turbine blades

Abstract

Systems and methods for transporting and assembling segmented wind turbine blades are disclosed. A system in accordance with a particular embodiment includes multiple transport devices that are each moveable as a unit from a blade fabrication site to a blade assembly site, and that have corresponding carriers positioned to carry corresponding spanwise segments of a wind turbine blade. The system can still further include a guide structure carried by at least one of the transport devices and coupled to a corresponding one of the carriers, with a motion path aligned with a corresponding blade axis. The guide structure can be positioned to guide the corresponding carrier along the motion path toward the other transport devices, e.g., to facilitate assembly of the blade segments.

1 . A system for assembling spanwise segments of a wind turbine blade, comprising:
 a first transport device being movable as a unit from a blade fabrication site to a blade assembly site, the first transport device having a first carrier positioned to carry a first spanwise segment of a wind turbine blade with the first segment aligned along a first blade axis;   a second transport device being movable as a unit from a blade fabrication site to the blade assembly site, the second transport device having a second carrier positioned to carry a second spanwise segment of a wind turbine blade with the second segment aligned along a second blade axis; and   a guide structure carried by at least one of the first and second transport devices, the guide structure being coupled between the at least one transport device and a corresponding one of the carriers, the guide structure having a motion path aligned with a corresponding one of the first and second blade axes, the guide structure being positioned to guide the corresponding carrier along the motion path toward the other of the first and second transport devices.   
     
     
         2 . The system of  claim 1  wherein the guide structure is positioned to guide the corresponding carrier in a linear manner. 
     
     
         3 . The system of  claim 1  wherein the first and second transport devices are wheeled. 
     
     
         4 . The system of  claim 3  wherein the first and second transport devices include corresponding highway truck trailers. 
     
     
         5 . The system of  claim 1 , further comprising a drive mechanism carried by at least one of the first and second transport devices, the drive mechanism being positioned to drive at least one of the first and second carriers relative to the other along the guide path. 
     
     
         6 . The system of  claim 1  wherein the guide structure includes a base portion carried by the first transport device, a first portion carried by the base portion and movable relative to the base portion along a restricted first motion path, and a second portion carried by the first portion and movable relative to the first portion along a restricted second motion path, transverse to the first motion path. 
     
     
         7 . The system of  claim 6  wherein the second portion includes a roller assembly that is movable relative to the first portion and that is releasably engaged with the first carrier. 
     
     
         8 . The system of  claim 6  wherein the first portion includes a first roller assembly that is engaged with the base and rollable relative to the base along the first motion path, and wherein the second portion includes a second roller assembly that is engaged with the first portion and rollable relative to the first portion along the second motion path. 
     
     
         9 . The system of  claim 6 , further comprising:
 a first driver operatively coupled between the base and the first portion to move the first portion relative to the base; and   a second driver operatively coupled between the first portion and the second portion to move the second portion relative to the first portion.   
     
     
         10 . The system of  claim 6  wherein the base includes an axial guide, and wherein the first portion includes a roller assembly, and wherein the roller assembly include a first, load-bearing roller positioned to rotate about a generally horizontal axis, and a second, guide roller positioned to rotate about a non-horizontal axis. 
     
     
         11 . The system of  claim 1  wherein the guide structure is a first guide structure positioned between the first transport device and the first carrier, the first carrier being movable along the first blade axis, and wherein the system further comprises a second guide structure positioned between the second transport device and the second carrier, the second carrier being movable along the second blade axis. 
     
     
         12 . The system of  claim 1 , further comprising:
 a driver device operatively coupled to the guide structure to move the corresponding carrier along the motion path;   a sensor positioned to sense a location of the carrier; and   a controller operatively coupled to the driver device and the sensor, the controller being programmed with instructions that, when executed, automatically activate the driver to move the carrier in response to a signal received from the sensor.   
     
     
         13 . A system for assembling spanwise segments of a wind turbine blade, comprising:
 a transport device;   an all-terrain positioning unit depending from the transport device and activatable to move the transport device along a first axis;   a carrier supported by the transport device, the carrier being positioned to support a spanwise-extending wind turbine blade segment; and   multiple engagement members depending from the carrier, with individual engagement members releasably connectable to the blade segment, and movable relative to the carrier to adjust a vertical position of the blade segment, a first rotation angle of the blade segment relative to the first axis, and a second rotation angle of the blade relative to a second axis transverse to the first axis.   
     
     
         14 . The system of  claim 13  wherein the positioning unit includes four all-terrain tires. 
     
     
         15 . The system of  claim 13  wherein the multiple engagement members include four engagement members, and wherein individual engagement members include a flexible tension member. 
     
     
         16 . The system of  claim 13  wherein the carrier includes multiple upright support members, and wherein the multiple engagement members include four engagement members, and wherein each engagement member includes a flexible strap having an adjustable length portion between the carrier and the blade segment. 
     
     
         17 . A method for assembling spanwise segments of a wind turbine blade, comprising:
 transporting a first assembled spanwise segment of a wind turbine blade as a unit from a blade fabrication site to a blade assembly site while the first blade segment is carried by a first transport device;   transporting a second assembled spanwise segment of a wind turbine blade as a unit from a blade fabrication site to the blade assembly site while the second blade segment is carried by a second transport device;   at the blade assembly site, moving at least one of the first and second blade segments relative to the other along a restricted guide path, while the first blade segment is carried by the first transport device and the second blade segment is carried by the second transport device;   connecting the first and second blade segments to each other while the first blade segment is carried by the first transport device and the segment blade section is carried by the second transport device;   separating the connected first and second blade segments from the first and second transport devices; and   mounting the first and second blade segments as a unit to a wind turbine.   
     
     
         18 . The method of  claim 17  wherein separating the first and second blade segments from the first and second transport devices includes:
 disengaging the second blade segment from the second transport device while the connected first and second blade segments are carried by the first transport device; 
 carrying the connected first and second blade segments from the assembly site to the wind turbine with the first transport device; and 
 removing the connected first and second blade segments as a unit from the first transport device. 
 
     
     
         19 . The method of  claim 17  wherein transporting the first assembled spanwise segment of the wind turbine blade includes transporting the first segment via a first over-the-road truck-drawn trailer, and wherein transporting the second assembled spanwise segment of the wind turbine blade includes transporting the second segment via a second over-the-road truck-drawn trailer. 
     
     
         20 . The method of  claim 17 , further comprising moving at least one of the first and second blade segments relative to the corresponding transport device and relative to the other blade segment at the assembly site prior to connecting the first and second blade segments. 
     
     
         21 . The method of  claim 20  wherein moving at least one of the first and second blade segments relative to the other includes moving the at least one blade segment along a linear axis while restricting or preventing motion of the at least one blade segment transverse to the linear axis. 
     
     
         22 . The method of  claim 20  wherein moving at least one of the first and second blade segments relative to the other includes moving the at least one blade segment along motion path that includes components in two orthogonal directions. 
     
     
         23 . The method of  claim 20  wherein moving at least one of the first and second blade segments relative to the other includes connecting a pulling device between the first and second blade segments and drawing the at least one blade segment toward the other with the pulling device. 
     
     
         24 . The method of  claim 17  wherein transporting the first assembled spanwise segment includes transporting the first assembled spanwise segment with a carrier while the carrier has a fixed position relative to the first transport device, and wherein the method further comprises removably positioning a guide structure between the carrier and the first transport device prior to moving the first blade segment, and wherein moving at least one of the first and second blade segments relative to the other along a restricted guide path includes moving the first blade segment along a restricted guide path established by the guide structure. 
     
     
         25 . The method of  claim 17  wherein carrying the first blade segment includes carrying multiple assembled blade segments with the first transport device. 
     
     
         26 . The method of  claim 17  wherein transporting a first assembled spanwise segment of a wind turbine blade includes transporting the first segment from a first fabrication site, and wherein transporting a second assembled spanwise segment of a wind turbine blade includes transporting the second segment from a second fabrication site. 
     
     
         27 . A method for assembling spanwise segments of a wind turbine blade, comprising:
 transporting a first assembled spanwise segment of a wind turbine blade as a unit on a surface road from a blade fabrication site to a blade assembly site while the first blade segment is supported by a first carrier that is in turn supported by a first truck-drawn trailer;   transporting a second assembled spanwise segment of a wind turbine blade as a unit on a surface road from a blade fabrication site to the blade assembly site while the second blade segment is supported by a second carrier that is in turn supported by a second truck-drawn trailer;   transporting a third assembled spanwise segment of a wind turbine blade as a unit on a surface road from a blade fabrication site to the blade assembly site while the third blade segment is supported by a third carrier that is in turn supported by a third truck-drawn trailer;   at the assembly site, aligning the first and second truck-drawn trailers relative to each other, while the first blade section is carried by the first truck-drawn trailer and the second blade section is carried by the second truck-drawn trailer;   at the assembly site, aligning the first and second carriers relative to each other, while the first blade section is carried by the first truck-drawn trailer and the second blade section is carried by the second truck-drawn trailer;   moving at least one of the first and second carriers relative to the other along a restricted motion path to position the first and second spanwise segments adjacent to each other;   connecting the first and second blade segments to each other while the first blade segment is carried by the first truck-drawn trailer and the second blade segment is carried by the second truck-drawn trailer;   moving at least one of the second and third carriers relative to the other along a restricted motion path to position the second and third spanwise segments adjacent to each other;   connecting the second and third blade segments to each other while the second blade segment is carried by the second truck-drawn trailer and the third blade segment is carried by the third truck-drawn trailer;   removing the first, second and third blade segments from the first, second and third truck-drawn trailers; and   mounting the first, second and third blade segments as a unit to a wind turbine.   
     
     
         28 . The method of  claim 27  wherein connecting the first and second blade segments includes:
 aligning a first spar end portion of the first blade segment with a second spar end portion of the second blade segment; 
 aligning a third spar end portion of the first blade segment with a fourth spar end portion of the second blade segment; and 
 moving the first spar end portion toward the second spar end portion and the third spar end portion toward the fourth spar end portion to connect the first spar end portion to the second spar end portion and connect the third spar end portion to the fourth spar end portion. 
 
     
     
         29 . The method of  claim 28  wherein the first and second end spar portions include staggered layers of material that form a non-monotonically varying bond line when the two end spar portions are connected. 
     
     
         30 . The method of  claim 28 , further comprising temporarily coupling a compressing device between the first spanwise segment and the second spanwise segment, wherein moving the first spar end portion toward the second spar end portion and the third spar end portion toward the fourth spar end portion includes acuating the compressing device to draw the first spanwise segment and the second spanwise segment together. 
     
     
         31 . A method for assembling spanwise segments of a wind turbine blade, comprising:
 transporting a first assembled spanwise segment of a wind turbine blade as a unit to a blade assembly site;   transporting a second assembled spanwise segment of a wind turbine blade as a unit to the blade assembly site;   at the assembly site, connecting the first and second segments to each other;   carrying the first and second segments with a transport device;   transporting the connected first and second segments as a unit from the assembly site to a wind turbine, with the transport device;   removing the connected first and second segments, as a unit, from the transport device; and   installing the connected first and second segments, as a unit, to the wind turbine.   
     
     
         32 . The method of  claim 31  wherein transporting a first segment includes transporting the first segment while the first segment is carried by a first transport device, and wherein transporting a second segment includes transporting the second segment while the second segment is carried by a second transport device, and wherein connecting the first and second segments includes connecting the first and second segments while the first segment is carried by the first transport device and the second segment is carried by the second transport device, and wherein transporting the connected first and second segments includes transporting the connected first and second segments with the first transport device and not the second transport device. 
     
     
         33 . The method of  claim 31  wherein transporting a first segment includes transporting the first segment over a first distance and at a first average rate, and wherein transporting the second segment includes transporting the second segment over a second distance and at a second average rate, and wherein transporting the connected first and second segments includes transporting the connected first and second segments over a third distance less than each of the first and second distances, and at a third average rate less than each of the first and second average rates. 
     
     
         34 . The method of  claim 31  wherein the connected first and second segments have a connected segment length, and wherein transporting the connected first and second segments as a unit includes transporting the connected first and second segments with at least 50% of the connected segment length cantilevered relative to the first transport device. 
     
     
         35 . A method for assembling spanwise segments of a wind turbine blade, comprising:
 transporting a first assembled spanwise segment of a wind turbine blade as a unit to a blade assembly site;   transporting a second assembled spanwise segment of the wind turbine blade as a unit to the blade assembly site;   carrying at least the second segment with a transport device at the assembly site;   rolling the transport device over rough terrain at the assembly site to position the second segment adjacent to the first segment;   connecting the first and second segments to each other at the assembly site;   installing the connected first and second segments, as a unit, on a wind turbine.   
     
     
         36 . The method of  claim 35 , further comprising transporting the connected first and second segments as a unit from the assembly site to the wind turbine. 
     
     
         37 . The method of  claim 35 :
 wherein carrying the second segment includes supporting the second segment at four different locations with four independently adjustable engagement members;   wherein rolling the transport device includes rolling the transport device over unpaved terrain to adjust an axial position, lateral position, and yaw angle of the second segment; and   wherein the method further comprises:
 adjusting the engagement members to adjust a height of the second segment; 
 adjusting the engagement members to adjust a pitch angle of the second segment relative to the ground; and 
 adjusting the engagement members to adjust a roll angle of the second segment relative to the ground. 
   
     
     
         38 . The method of  claim 35  wherein carrying the second blade segment includes suspending the second blade segment from four independently adjustable engagement members.