风能起重解决方案现在必须能够处理更大的部件、更重的负载以及更苛刻的制造和维护操作。
在中国实现碳中和和碳排放目标的推动下,风电产业持续扩张。到2025年底,中国累计并网风电装机容量将超过400吉瓦,海上风电装机容量仍居世界第一。中国国家能源局的官方数据显示,风电总装机容量约为640吉瓦。
与此同时,风力涡轮机的尺寸也在不断增大。更长的叶片、更高的塔筒和更重的机舱对制造、物流和风电场维护都提出了新的起重要求。
Nucleon 拥有 20 多年的起重机制造经验和 299 项专利,开发了一系列协调的风能起重解决方案,涵盖从组件生产到现场维护的整个过程。
五大核心应用风能提升解决方案
Nucleon 的方法并非简单地将几种起重机产品组合在一起。每一种解决方案都是根据风电行业特定阶段的起重需求进行配置的。
1. 风力涡轮机叶片制造
刀片制造需要大面积作业空间、同步升降和受控运动,才能打开、关闭、旋转和释放刀片模具。
Nucleon公司为双梁桥式起重机配置了以下部件：
- 起重能力从50吨到200吨
- 跨度从 30 米到 60 米
- 矢量变频控制
- 双小车同步提升
- 防摇摆控制
- 根据模具重心定制的吊梁
这些系统旨在支持稳定的模具搬运,同时降低复合材料叶片结构受损的风险。
2. 风力涡轮机塔筒制造
塔架生产包括钢板轧制、焊接、法兰组装、截面校准和户外搬运。
Nucleon 将双梁桥式起重机和龙门起重机相结合,起重能力从 10 吨到 350 吨不等。多台起重机同步起重可用于在法兰连接过程中搬运和对齐塔段。
A7-A8 型起重机配置可支持频繁的重载作业。室外龙门起重机采用抗风结构,适用于堆场和预装配区域。
3. 机舱和发电机组件
齿轮箱、发电机、主轴和其他机舱部件需要进行重型吊装并进行精确定位。
起重能力从 5 吨到 320 吨的卷扬式双梁桥式起重机可用于这些装配作业。可用功能包括：
- 变频升降和行驶
- 防摇摆控制
- 实时负载监测
- Brake-status monitoring
- Remote diagnostics
- Fault warnings and maintenance support
- Modular lifting attachments
These functions help coordinate the lifting and positioning of heavy nacelle components during assembly.
4. Outdoor Storage and Wind Component Logistics
Wind turbine blades, tower sections and nacelles must be stored, transferred and loaded for transportation.
Nucleon combines gantry cranes, rubber-tired gantry cranes and customized transport equipment with capacities from 35 to 200 t.
Its multifunctional blade straddle carrier uses PLC control and hydraulic drive to support lifting, traveling and turning operations. Configurations are available for handling blades between 40 and 120 m long.
Electric and hybrid drive options can also be selected according to the operating area and energy requirements.
5. Wind Farm Maintenance
As more wind turbines enter regular maintenance cycles, gearboxes, generators and blades increasingly require inspection, repair and replacement.
Nucleon's patented self-climbing wind turbine maintenance crane provides an alternative to deploying a large crawler crane for certain maintenance tasks.
The system combines a self-climbing hydraulic platform with a high-lift articulated crane. Published configurations include:
- Rated capacities of 8 or 12 t
- Lifting heights of 80 or 100 m
- Applications on turbines with tower heights from 60 to 85 m
- Electro-hydraulic drive
- Safety monitoring and protection
- Hydraulic and mechanical interlocking
The NHC electric chain hoist is also available for maintenance inside confined nacelle spaces. Nucleon lists capacities from 80 kg to 20 t, M5+ duty capability, IP55 protection and a wide operating-temperature range.
Wind Energy Crane Product Matrix
| Product range | Dung tích | Typical wind power application |
|---|---|---|
| Electric hoists | 0.5–32 t | Small components, mold assistance and equipment maintenance |
| Double-girder overhead cranes | 3–80 t | Blade production, tower assembly and component transfer |
| Winch-type double-girder cranes | 5–320 t | Nacelle, gearbox and generator assembly |
| Gantry and semi-gantry cranes | 10–600 t | Outdoor yards, tower preassembly and heavy-component transfer |
| Wind turbine maintenance cranes | 8–12 t | Generator, gearbox and blade maintenance |
| Blade straddle carriers | Customized | Blade transfer, turning, storage and loading |
| NHC electric chain hoists | 80 kg–20 t | Confined nacelle maintenance and small-component lifting |
| Automated cranes | Customized | Unmanned lifting and automated production lines |
This product range allows Nucleon to address lifting tasks from small maintenance components to wind turbine structures weighing hundreds of tonnes.
Technologies Supporting Wind Energy Lifting Solutions
Intelligent Control and Anti-Sway Functions
Nucleon combines vector variable-frequency drive technology with anti-sway and positioning control.
Depending on the crane configuration, the control system can monitor lifting loads, traveling speeds, brake status, voltage and current. It can also record operating and fault data for later analysis.
Low-Noise Drive Systems
Nucleon 的模块化驱动系统旨在降低运行噪音和维护需求。
该公司表示,部分驱动配置的运行噪音低于70分贝。硬化齿轮减速器和模块化电机组合可支持不同的起重能力和运行工况。
模块化起重机设计
标准化的主梁、端梁、驱动装置和起升机构使起重机的配置能够适应车间布局、生产过程和负载特性。
PLM系统和3D仿真技术应用于产品开发和工程设计过程中。
轻型结构
Nucleon公司在其起重机设计中应用了结构优化和有限元分析。
根据该公司公布的技术资料,选定的轻型起重机配置可以降低起重机的重量、整体高度和运行能耗,同时保持应用所需的结构性能。
基于数据的维护
Nucleon 集成了 SAP-ERP、PLM、MES 和 CRM 系统,以连接设计、制造、产品和服务信息。
远程状态监测可以支持历史数据分析、故障诊断、维护计划和备件交付。
为风电项目提供全生命周期支持
Nucleon 提供涵盖风能提升项目主要阶段的服务。
咨询和解决方案设计：工程师在推荐设备、安装位置和基础布置之前,会评估车间布局、生产流程和起重要求。
制造和交付： Nucleon 运营着一个占地 43 万平方米的智能制造基地,拥有 3000 多个生产和检测单元。
安装和调试：安装团队在项目现场完成设备安装、调试和操作人员培训。
售后支持：服务网络、远程设备监控、维护计划和原厂备件供应,确保长期稳定运行。Nucleon承诺,服务请求将在48小时内得到响应。
从制造到维护,为风力发电提供支持
风力发电在未来能源系统中正扮演着越来越重要的角色。其持续发展需要能够搬运更大部件并适应更特殊操作条件的起重设备。
无论客户是制造叶片、生产塔筒段、组装机舱还是维护风力涡轮机,Nucleon 都能提供涵盖设计、制造、安装和维护的风能提升解决方案。
Nucleon 致力于持续开发智能、高效、低能耗的起重机系统,以支持风电行业的长期发展。
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