The sky is the limit for new crane technology
As the wind energy sector aims to reduce the cost of energy production, large turbines that generate at least 4 MW of power and stand at heights taller than 140 m are an efficient solution. However, as wind turbines become larger and heavier, their construction becomes limited by the availability and capability of cranes and related equipment. The EU-funded AIRCRANE(opens in new window) project set out to decrease the levelised cost of produced energy for wind turbines by designing a brand new crane technology. AIRCRANE is an external self-climbing crane that rises as the tower does, and then lifts the nacelle and blades to complete the wind turbine. “The coordinating company HWS Concrete Towers(opens in new window) has patented and developed the AirCRANE, a self-climbing crane that defies the limitations of existing cranes for the wind energy sector,” says project coordinator Mariano Abadía. “It is a versatile and cost-effective self-climbing crane for installation of ‘unlimited height’ wind turbines.”
AIRCRANE advantages and capabilities
The AIRCRANE system can assemble a concrete tower with no limits in height, which is important for building larger and heavier wind turbines that operate in faster and steadier wind speeds found above 140 m. It has the advantage of being low cost compared to alternative cranes and crawlers that are not as capable and as versatile as AIRCRANE. AIRCRANE is designed to be easy to transport, with only 12 trucks required to move a unit versus the 30-70 trucks needed to move conventional cranes and crawlers. No special platforms or soils are required at the base of the tower to support AIRCRANE as the system supports itself with the wind turbine tower being constructed. Project researchers designed AIRCRANE to be capable of lifting 165 tonnes to install wind turbines. They started by designing and manufacturing a 30-tonne capacity demonstrator to show to potential customers. The team was in constant contact with customers that included turbine manufacturers, tower manufacturers, construction firms and various other companies. TÜV Rheinland(opens in new window), a compliance organisation, certified AIRCRANE as compliant with the Conformity Assessment according to Directive 2006/42/EC(opens in new window). This certification assures potential clients that the AIRCRANE system has been designed and manufactured in a manner that complies with all the health and safety standards of European directives. “With this certificate, all the doubts about the correct design of the AIRCRANE are eliminated and trust is gained,” says Abadía.
Plans to commercialise AIRCRANE
The researchers have contacted potential customers to move forward with future collaborations. AIRCRANE teamed up with a structural engineering and an intellectual property protection firm to improve efficiency and creativity and to have a more streamlined project structure. Now that the project has finished, AIRCRANE has worked on signing an agreement to produce the first commercial AIRCRANE unit. The team is exploring opportunities in various markets, such as for installing concrete towers and wind turbines, operating wind turbines and constructing high-rise buildings. The team expects significant gains once AIRCRANE goes commercial. Predictions include revenues of up to EUR 58.5 million in 5-7 years and creating from 98 to 167 direct jobs and between 176 and 307 indirect jobs.
