Wind Turbines Tower Construction: This Elevator for Wind Turbines Grows Along With Them

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Taiwan Machine Tool & Accessory Builders' Association (TMBA)

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A new rack-and-pinion system makes it possible to use battery-powered elevators in wind turbines as early as the tower installation phase—starting from the very first meters. A patented process solves a key challenge related to tolerances and transitions. The concept is particularly well-suited for tall towers.

With the battery-powered SH 250 W lift, Geda has developed a new elevator system for wind turbines that improves the safe transport of people and materials to the turbine and to intermediate levels. Every modern wind turbine requires a transport system in the tower. The new lift operates on lithium-ion batteries, is designed for travel heights of up to 210 meters (689 feet), and features a state-of-the-art remote maintenance system as well as numerous safety features. The lift can accommodate two people and materials. 

Start Using the Elevator as Early as the Installation Phase

The new battery-powered rack-and-pinion lift can be used right from the first meter: This is made possible by ladder sections with a rack-and-pinion system, whose guide profiles start at the ground and extend upward as the tower is erected. As a result, in many cases, the time-consuming and physically demanding task of climbing is eliminated during the installation phase. This makes the work considerably easier, reduces risks, and supports more efficient workflows on the construction site.

Conventional rope hoists, on the other hand, cannot be used until the tower is fully erected and the ropes for the traveling winch have been attached at the top. In addition, they often cannot be used until the entire system has been inspected and approved. 

The Lift is Easy to Transport, Install, and Replace

Once the circuit path has been installed, the lift can be easily moved into the tower. A special transport frame allows for both upright and horizontal transport. Inside the tower, the machine can be set up horizontally using a collapsible tubular frame. Service and replacement were taken into account from the very beginning: The machine can be rolled onto the transport frame, detached from the guide system, and removed ergonomically. This also makes it possible to remove the machine later, even after more than 25 years, with minimal effort.

Challenges with Taller Wind Turbines

As modern wind turbines grow taller, the demands placed on transportation systems increase. Taller towers are economically attractive because airflows at higher altitudes are more uniform and laminar (i.e., less turbulent). At the same time, however, tower deflections and mechanical stresses increase. At a tower height of around 200 meters (656 feet), the deflection can be approximately two meters in both directions.

Conventional rope elevators are increasingly reaching their technical limits in this regard: Tower vibrations can cause ropes to strike internal structures, become damaged, or become tangled. Replacement intervals and maintenance work also lead to downtime. Furthermore, the safety cable for personnel cannot be fully inspected before reaching the upper section of the tower. The battery-powered rack-and-pinion lift avoids these system-related drawbacks. For taller towers, this solution becomes increasingly attractive from both an economic and technical standpoint.

Remote Maintenance and Image-Based Fault Diagnosis Increase Availability

The elevator system features various digital functions that help prevent unplanned downtime. These include online remote maintenance, a touchscreen display in the elevator car, and image-based fault diagnosis. Operators and service teams can remotely check the elevator’s operational status even before a service call. Visual instructions help less experienced users with operation and troubleshooting. 

Elevator with a Modular Overall Design

The product’s strength lies not in any single component, but in the combination of numerous coordinated solutions. These include the resource-efficient guidance system: The manufacturer does not use traditional cross-bracing here; instead, it achieves the required stiffness through the connections to the exterior wall that are necessary anyway.

The car has also been redesigned: An H-shaped layout allows passengers to step into the elevator from below, all the way into the car and beyond. The entry guard can be opened ergonomically with a light kick when boarding from above and automatically swings upward out of the way. Special components were developed for the central charge controller for bidirectional charging and discharging, as well as for the drive system, since suitable solutions were not available in this performance class.

Wind Turbines

Compact Despite High Performance Thanks to Plain Bearings

The battery-powered rack-and-pinion lift enhances safety, availability, and efficiency in the operation of modern wind turbines. It improves transportation within the tower, from the installation phase through to long-term service operations.