Aeroclimb

Due to non-existent or inappropriate and also very expensive access systems for the implementation of "unforeseeable major repairs" on rotor blades of wind turbines with assembled rotors Aeroconcept GmbH developed a cable-based, self-climbing work platform called Aeroclimb TW / EW / GE 1.5 i / s / sl / s offshore in 2002.

Due to a long-term cooperation agreement with GE Wind Energy GmbH in the field of rotor blade maintenance, the focus was initially on the unrestricted use of Aeroclimb for all 1.5 megawatts facilities of the cooperating partner. Besides different diameters and blade geometries a variety of equipment rental options in development had to be considered.

Based on a detailed knowledge of the requirements of a "floating workshop" with many years of practical experience, the main claim was on a perfect access to the rotor blade. Optimum grip ranges should be adjusted at any time simply by service personnel. This requirement should be coupled with the ability to rotate the rotor even when the working platform is assembled.

Out of a pool of different drafts the "rhombus"-solution was favored.
Besides the realization of a relatively simple basic design Aaeroclimb succeed in an outstanding manner the demand for adaptability in order to achieve optimum range at all times to the rotor blade for the service personnel as well as it's ability to rotate the rotor when stage is suspended.

This were enough reasons to sign the draft in February 2003 for a patent. Machines such as Aeroclimb have a special risk potential under the EU Machinery Directive and may therefore not be used within the European Union unless an EC type-examination can be authenticate that the design and their calculation in the DIN EN 1808 fits to the "safety requirements on suspended access equipment".

In an iterative process, therefore, design and calculation were customised until both, the constructive as well as the static demands, could be met.

The construction was done entirely with the help of 3D CAD. All calculations were performed using the method of finite elements. After examination and approval of the design, strength and securitycalculations by an independent office for static testing in May 2003 the first prototype was produced. In August 2003 test engineers of the Technical Committee of Construction Testing and Certification Body were able to examine the Aeroclimb the first time on a wind turbine of the type EW 1.5 sl 85m hub height and a rotor diameter of 77m.

In a subsequent two-year field testing Aeroclimb was tested on different 1.5MW facilities of the GE Wind Energy GmbH in different wind conditions. With a host of major repairs carried out, partly with wind speeds of up to 14 m / s, it could be demonstrated impressively that Aeroclimb fulfilled the expectations.

The conclusion of the EC type-examination for unrestricted use in Europe was released in August 2005. In February 2007 the German Patent 103 11 674 was granted to the platform Aeroclimb. Since then Aeroclimb was used for maintaining several hundred wind turbines, without interference or accidents with high quality and reduced costs. Undoubtedly can be said that worldwide is no other platform with comparable horizontal stability and a payload of 400kg.

Due to the recent, very positive experience we work on a Aeroclimb successor for 2.5MW facilities.