New tools for the safe installation of wind turbines – from super-heavy to ultra-light
With the construction of ever more powerful and larger wind turbines and the call for shorter set-up times, the demands on load handling equipment for assembly are also increasing. Safe gripping and lifting therefore requires further technical developments, which SpanSet Axzion GmbH, Langenfeld, is implementing together with testing institutes.
Upending Tool – giant gripper for offshore projects
One of the products frequently used in this environment is the “upending tool” for lifting and erecting monopiles. With its six grippers, the three-arm grab can carry flangeless monopiles weighing up to 1,800 tons. The basic design of the tool is always the same; Axzion makes project-specific adaptations according to the customer’s order. The maximum configuration enables the lifting of monopiles with flanges weighing up to 2,100 tons. The Neustrelitz site in Mecklenburg-Western Pomerania is certified by DNV Norway for offshore use.
The upending tool with a dead weight of approx. 95 to 105 tons depending on the configuration and a maximum load capacity of 2,100 tons has been developed for lifting and erecting piles and is operated by Axzion Rental Services GmbH, Neustrelitz. It has three giant grippers and thus reliably prevents the piles from deforming during gripping and erecting. The grabs bite into the monopiles with a maximum unit weight of 1,000 tons and a gripping force of more than 3,000 tons. The “star” can be pivoted hydraulically so that piles can be gripped and erected from the front.
SBI-Light Traverse 2.0 – also for high wind speeds
The new SBI-Light Traverse 2.0 for single blade installation on wind turbines is more flexible, more robust and lighter than its predecessors. Despite its low weight of just 13 tons, the SBI-Light enables controlled lifting even at wind speeds of up to 12 meters per second.
“With the SBI Light 2.0, we are responding to the current challenges facing our customers, who are faced with ever larger wind turbines and ever shorter set-up times. The new SBI Light 2.0 is quick and easy to assemble and can still work at high wind speeds of up to 12 meters per second. This is a considerable advantage when assembling rotor blades, as it increases operating times,” says Managing Director Andreas Höltkemeier.
Compatible with different rotor blade types
The flexible hold-down device and the supports adapted to the respective rotor blade type grip the rotor blade optimally and protect the sensitive structure of the rotor blade from damage. To make it even easier to adapt to different rotor blade types, Axzion also offers the traverse as a telescopic version. In addition to the operating length of 20 meters, there are also adjustment options to 14, 16 and 18 meters. The two supports follow the adjustment, i.e. the points of application are shifted further outwards when telescoping, the pressure on the rotor blade is better distributed and blade deflection is avoided. This increases process reliability, prevents blade deformation and prevents the blade tip from dropping. This is a significant cost saving when erecting wind farms with a high number of repetitions.
With an optional self-adapting support system, the SBI-Light 2.0 adapts even more easily to the different shapes of the rotor blades to be assembled. The new lifting beam can therefore safely accommodate and handle a wide variety of blade shapes with a blade weight of up to 30 tons. The high level of flexibility and short set-up times when changing the rotor blade type make this variant particularly attractive for use in the service sector with changing turbine types.
The closed C-frame ensures the best possible stability. It prevents the rotor blade from falling out sideways and protects it from damage during robust handling on everyday construction sites. Axzion has shortened the hook height of the lifting beam by 5 to 6 meters. This gives the user more freedom when using the crane class.
Axzion has also taken another look at logistics. “We have a large international customer base. With a transport length of just 12 meters, the SBI-Light can be easily transported in 40-foot containers – an efficient solution for land and, above all, sea transport,” explains Höltkemeier.
Environmentally friendly and maintenance-free
The SBI-Light 2.0 is equipped with a battery-powered electric motor for particularly environmentally friendly installation. It is maintenance-free compared to conventional systems. Even at temperatures of minus 10 degrees Celsius, the battery can operate for up to 16 hours. No diesel generator is required and the traverse is independent of an external power supply. For 24-hour operation, a charging case with replacement batteries can be connected in just a few minutes.
