Wind power tower cylinder recess repair and reinforcement structure and construction method thereof

Abstract

This invention relates to the field of wind power equipment operation and maintenance technology, and in particular provides a wind turbine tower dent repair and reinforcement structure and its construction method. The reinforcement structure includes a lifting device for jacking out and repositioning the dented area of ​​the wind turbine tower until the inner diameter deviation meets the standard requirements; an inner reinforcing layer bonded to the inner wall of the wind turbine tower repair area; and an outer insulation layer disposed on the outer wall of the wind turbine tower repair area. This invention uses a lifting device to jack out and reposition the wind turbine tower repair area until the inner diameter of the wind turbine tower meets the standard requirements; maintains the pressure of the lifting device to bond the inner reinforcing layer to the inner wall of the wind turbine tower repair area, improving the out-of-plane stability of the wind turbine tower and preventing further denting; and coats the wind turbine tower repair area with an outer insulation layer to reduce the impact of thermal expansion and contraction by isolating external temperature differences, preventing the internally bonded inner reinforcing layer from detaching due to rapid temperature changes.

Description

Technical Field

[0001] This invention relates to the field of wind power equipment operation and maintenance technology, and in particular provides a wind turbine tower dent repair and reinforcement structure and its construction method. Background Technology

[0002] As a tall, thin-walled steel structure supporting the nacelle and blades, the wind turbine tower is subjected to the combined effects of alternating loads transmitted by the wind turbine, its own weight, and gust loads in an outdoor environment for up to 20 years of service.

[0003] During wind turbine operation, when encountering typhoons, strong gusts, or extreme wind shear speeds, the compressive stress in localized areas of the tower may momentarily exceed a critical value, causing nonlinear instability in the thin-walled shell and forming localized depressions. This depression deformation disrupts the ideal geometry of the tower, leading to severe stress concentration. Under the continuous vibration and alternating stress generated by the wind turbine's operation, microcracks in the depressions are prone to propagate, significantly reducing the fatigue life of the tower and, in severe cases, potentially causing overall tower instability and collapse.

[0004] In existing technologies, the repair techniques for towers during operation typically include mechanical jacking, welding reinforcement, and bolt connection.

[0005] While mechanical jacking can cold-correct dents using hydraulic jacking, for towers with large defects or low design redundancy, once the external force is removed, the dent often rebounds, making it difficult to maintain the corrected shape. Furthermore, the stiffness of the corrected area has been lost, and without auxiliary reinforcement, it is very easy for the dent to reappear in the original position.

[0006] The welding reinforcement method uses welded reinforcing ribs or patched steel plates, but welding inside an already operating tower poses a significant fire hazard. Furthermore, on-site welding quality is difficult to control, and the heat-affected zone generated by the welding heat input will change the metallographic structure of the steel and generate residual tensile stress at the weld, which will further reduce the fatigue resistance of the tower.

[0007] The bolted connection method requires drilling holes in the tower wall to fix the stiffening steel plate with bolts. This not only damages the integrity of the tower, but also easily damages the original anti-corrosion layer, causing rainwater leakage and rust problems.

[0008] Therefore, how to provide an online repair and reinforcement structure for wind turbine towers that can effectively strengthen the tower without welding or drilling, and its construction method, is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0009] To address the aforementioned problems, this invention provides a wind turbine tower dent repair and reinforcement structure to solve at least one of the problems mentioned above in the prior art.

[0010] To achieve the above objectives, the present invention adopts the following technical solution: This invention provides a wind turbine tower dent repair and reinforcement structure, comprising: The lifting device is used to push out and reposition the recessed area of ​​the wind turbine tower repair area and maintain pressure until the inner diameter deviation meets the standard requirements. An inner reinforcing layer is bonded to the inner wall of the repair area of ​​the wind turbine tower. An external insulation layer is installed on the outer wall of the wind turbine tower repair area.

[0011] According to the present invention, a wind turbine tower dent repair and reinforcement structure is provided, wherein the inner reinforcing layer comprises: Precast fiberglass blocks are installed on the inner wall of the wind turbine tower repair area; An adhesive layer is disposed on the side of the precast fiberglass block facing the wind turbine tower repair area, and the adhesive layer is used to fix the precast fiberglass block to the wind turbine tower repair area; A fiber-reinforced material layer is disposed on the side of the precast fiberglass block facing away from the wind turbine tower repair area.

[0012] According to the present invention, a wind turbine tower dent repair and reinforcement structure is provided, wherein the prefabricated fiberglass block extends along the axial direction of the wind turbine tower, the prefabricated fiberglass block includes multiple fiberglass units, and adjacent columns of fiberglass units are staggered and spliced ​​along the axial direction.

[0013] According to the present invention, a wind turbine tower dent repair and reinforcement structure is provided, wherein the prefabricated fiberglass block has chamfered edges on all four sides.

[0014] According to the present invention, a wind turbine tower dent repair and reinforcement structure is provided, wherein the fiber-reinforced material layer comprises at least two layers of fiber cloth.

[0015] According to the present invention, a wind turbine tower dent repair and reinforcement structure is provided, wherein the external insulation layer comprises an aerogel insulation coating.

[0016] According to the present invention, a dent repair and reinforcement structure for wind turbine towers is provided, wherein the lifting device includes a hydraulic jack.

[0017] This invention provides a construction method for repairing and reinforcing a dented wind turbine tower structure, comprising: Identify the repair area for wind turbine towers; The repaired area of ​​the wind turbine tower is pushed out and reset until the inner diameter of the wind turbine tower meets the standard requirements; Maintain the pressure of the lifting device and bond the inner reinforcing layer to the inner wall of the wind turbine tower repair area; An external insulation layer is applied to the repair area of ​​the wind turbine tower.

[0018] According to the present invention, a construction method for repairing and reinforcing a dented wind turbine tower includes maintaining the pressure of the jacking device and bonding an inner reinforcing layer to the inner wall of the repair area of ​​the wind turbine tower, comprising: Clean and polish the inner wall around the lifting point of the lifting device; An adhesive layer is applied to the repair area of ​​the wind turbine tower. Adhere precast fiberglass blocks; A resin-impregnated fiberglass cloth is laid on the surface of the precast fiberglass block and heated to cure. After curing, the lifting device is removed.

[0019] According to the present invention, a construction method for repairing and reinforcing a dented wind turbine tower includes setting an external insulation layer in the repair area of ​​the wind turbine tower, comprising: Grinding and applying aerogel insulation coating to the corresponding area on the outer wall of the wind turbine tower.

[0020] As can be seen from the above technical solution, compared with the prior art, the present invention provides a wind turbine tower dent repair and reinforcement structure and its construction method, which has the following beneficial effects: The repaired area of ​​the wind turbine tower is jacked up and reset using a jacking device until the inner diameter of the wind turbine tower meets the standard requirements. Maintaining the pressure of the jacking device, an inner reinforcing layer is bonded to the inner wall of the repaired area to improve the out-of-plane stability of the wind turbine tower and effectively prevent further denting. An outer insulation layer is applied to the repaired area to reduce the effects of thermal expansion and contraction by isolating it from external temperature differences, preventing the internally bonded reinforcing layer from detaching due to rapid temperature changes. Furthermore, the entire process is cold-worked to avoid the adverse effects of welding on the fatigue strength of the tower.

[0021] More specifically, prefabricated fiberglass blocks and fiberglass cloth are used to reinforce the tower, improving the out-of-plane stability of the tower and effectively curbing the problem of tower re-diving.

[0022] By using precast fiberglass blocks reinforced with bonded fiberglass cloth, they can fit the tower well, preventing them from falling off, while avoiding the weakening of the tower and the risk of water leakage caused by traditional bolt connections.

[0023] Aerogel insulation coating is applied to the outer wall of the wind turbine tower repair area to reduce the effects of thermal expansion and contraction by isolating it from external temperature differences, and to prevent the internal reinforcement materials from falling off due to rapid temperature changes.

[0024] In addition, the wind power tower dent repair and reinforcement structure and its construction method provided by the present invention can not only locally reinforce the dented part of the tower, but also reinforce the entire circle of weak sections.

[0025] Therefore, the present invention adopts a non-destructive process during the repair process to avoid damaging the tower, while effectively reinforcing the tower to prevent it from sinking again, thus ensuring the reliability and long-term effectiveness of the overall repair effect. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0027] Figure 1 An exploded view of the overall structure of the wind turbine tower dent repair and reinforcement structure provided by the present invention. Figure 2 This is a diagram showing the arrangement of prefabricated fiberglass block arrays in the wind turbine tower dent repair and reinforcement structure provided by the present invention. Figure 3 This is a schematic diagram of the wind turbine tower dent repair and reinforcement structure provided by the present invention for reinforcing dented towers.

[0028] Figure 4 This is a schematic diagram of the wind turbine tower dent repair and reinforcement structure provided by the present invention used for the reinforcement of weak towers.

[0029] In the figure: 1. Inner reinforcement layer; 2. Outer insulation layer; 11. Adhesive layer; 12. Precast fiberglass block; 13. Fiber reinforced material layer. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] like Figures 1-4 As shown, the present invention provides a wind turbine tower dent repair and reinforcement structure, including a lifting device, an inner reinforcing layer 1 and an outer insulation layer 2.

[0032] The jacking device is used to push out and reset the dented areas in the wind turbine tower repair area until the inner diameter deviation meets the standard requirements, while maintaining pressure on the jacking device. This precise and controllable jacking and reset method allows for in-situ correction of deformed parts without cutting, welding, or damaging the tower's base material, protecting the original structural strength and material integrity of the tower. Simultaneously, continuous pressure maintenance ensures the stable solidification of the reset shape, providing a neat and fitting working foundation for subsequent reinforcement construction.

[0033] The inner reinforcing layer 1 is bonded to the inner wall of the wind turbine tower repair area, which improves the structural stiffness and out-of-plane stability of the wind turbine tower repair area, forms a reliable internal support system, effectively curbs the re-dentation problem caused by load and deformation of the wind turbine tower, and extends the service life of the repaired part.

[0034] The outer insulation layer 2 is installed on the outer wall of the wind turbine tower repair area, and isolates the external environment from temperature differences. This reduces the thermal expansion and contraction effect of the tower wall caused by day and night and seasonal changes, and avoids problems such as debonding, cracking and failure of the internally bonded reinforcing layer 1 due to temperature stress, thus ensuring the long-term stability and reliability of the internal reinforcing layer 1.

[0035] The wind turbine tower dent repair and reinforcement structure provided by this invention uses a jacking device to push out and reset the dented area of ​​the wind turbine tower until the inner diameter meets the standard requirements. The pressure of the jacking device is maintained, achieving non-destructive in-situ correction without damaging the base material or leaving permanent damage. The correction accuracy is high, and the shape remains stable. The inner reinforcing layer 1 improves the out-of-plane stability of the wind turbine tower, forming rigid reinforcement and stress dispersion, enhancing the structural load-bearing capacity and effectively preventing the wind turbine tower from re-denting. The outer insulation layer 2 isolates external temperature differences to reduce the impact of thermal expansion and contraction, eliminates the damage of temperature stress to the internal bonding section, prevents the failure of the internally bonded inner reinforcing layer 1, and ensures the long-term stability of the overall structure.

[0036] Therefore, the present invention adopts a non-destructive process throughout the repair process to avoid damage to the tower, while effectively reinforcing the wind turbine tower to prevent it from sinking again, thus ensuring the reliability and long-term effectiveness of the overall repair.

[0037] It should be noted that the lifting pressure of the jacking device is not specifically limited here, as long as it can ensure the repair of the dent.

[0038] In a feasible embodiment of the present invention, the inner reinforcing layer 1 includes a precast fiberglass block 12, an adhesive layer 11, and a fiber-reinforced material layer 13.

[0039] The precast fiberglass block 12 is disposed on the inner wall of the wind turbine tower repair area, and has high rigidity and strength. An adhesive layer 11 is disposed on the side of the precast fiberglass block 12 facing the wind turbine tower repair area, and is used to fix the precast fiberglass block 12 to the wind turbine tower repair area. Typically, the adhesive layer 11 can be epoxy resin, or other types of adhesive, as long as it can achieve bonding between the precast fiberglass block 12 and the wind turbine tower.

[0040] A fiber-reinforced material layer is placed on the side of the precast fiberglass block 12 facing away from the wind turbine tower repair area and is heated and cured. After curing, the lifting device is removed.

[0041] More specifically, the fiber reinforcement layer uses fiberglass cloth, which has the characteristics of high strength, light weight, temperature resistance, flame retardancy, durability and anti-aging, and is suitable for fiberglass reinforcement, building reinforcement, and waterproof and anti-corrosion lining.

[0042] In one feasible embodiment of the present invention, the prefabricated fiberglass block 12 extends axially along the wind turbine tower, conforming to the vertical stress characteristics of the tower, fully covering the recessed and damaged areas, and reinforcing weak stress points as much as possible. The prefabricated fiberglass block 12 comprises multiple fiberglass units, and its modular disassembly structure facilitates flexible on-site assembly and construction, adapts to the arc-shaped internal shape of the tower, reduces the difficulty of installation and fitting, and facilitates the convenient inspection and replacement of individual units. Adjacent rows of fiberglass units are staggered along the axial direction. This staggered splicing avoids stress concentration gaps, evenly distributes the load stress generated by the tower operation, and improves the overall integrity and deformation resistance of the spliced ​​structure.

[0043] It is understandable that the prefabricated fiberglass blocks 12 are distributed in an array. The regular array arrangement can form a uniform and continuous internal reinforcing skeleton, improve the structural strength of the inner wall of the tower, and stabilize the shape of the repair area.

[0044] In a feasible embodiment of the present invention, the precast fiberglass block 12 has chamfers on all four edges. The chamfer structure can effectively reduce the sharp stress points at the corners of the components, thereby alleviating the stress concentration at the edges and preventing cracking and breakage at the edges of the plate. At the same time, it can also improve the adhesion between the plate and the inner wall of the tower, further ensuring the stability of the reinforced structure.

[0045] In a feasible embodiment of the present invention, the fiber-reinforced material layer includes at least two layers of fiber cloth. The superposition and composite of multiple layers of fiber cloth can form a continuous and dense reinforcement network, which improves the overall interlayer bonding and structural toughness, and can better reinforce the fiberglass, improve its tensile, shear and fatigue resistance, make the reinforcement layer more uniformly stressed and less prone to delamination and cracking, and further improve the structural stability and durability of the wind turbine tower repair area.

[0046] In a feasible embodiment of the present invention, the outer insulation layer 2 is formed by applying an aerogel insulation coating. The aerogel insulation coating has a low thermal conductivity and excellent weather resistance, and can form a continuous and dense insulation and protective coating, which can effectively isolate the tower from external temperature, moisture and corrosive media, reduce the temperature difference between the inside and outside of the tower and the thermal expansion and contraction stress, protect the internal bonding structure from being damaged by temperature changes, and improve the long-term stability of the repair system.

[0047] In one feasible embodiment of the present invention, the lifting device includes a hydraulic jack. The lifting device may also include other equipment, as long as it can achieve a large lifting force, such as an electric push rod, a hydraulic cylinder and a pneumatic pusher.

[0048] like Figure 4 As shown, the wind turbine tower dent repair and reinforcement structure provided by the present invention can not only locally reinforce the dented part of the tower, but also reinforce the entire circumference of the weak tower section.

[0049] In one specific embodiment, the present invention provides a wind turbine tower dent repair and reinforcement structure, including a lifting device, an inner reinforcing layer 1, and an outer insulation layer 2. The lifting device is used to push out and reset the dented position in the wind turbine tower repair area until the inner diameter deviation meets the standard requirements. The inner reinforcing layer 1 is disposed inside the wind turbine tower repair area, and includes an adhesive layer 11, a prefabricated fiberglass block 12, and fiberglass cloth from one side closest to the wind turbine tower to the other side. The outer insulation layer 2 is disposed on the outer wall corresponding to the dent repair area of ​​the tower and is formed by applying an aerogel insulation coating.

[0050] A second aspect of the present invention provides a construction method for repairing and reinforcing a dented wind turbine tower structure, comprising: S1. Perform dent correction. Specifically, the repaired area of ​​the wind turbine tower can be lifted and reset using a jacking device until the inner diameter of the wind turbine tower meets the standard requirements.

[0051] Before step S1, the location of the maximum deformation of the tower dent can be determined by the inner curvature template, that is, the repair area of ​​the wind turbine tower can be determined.

[0052] S2. Maintain the pressure of the jacking device and bond the inner reinforcing layer 1 to the inner wall of the wind turbine tower repair area.

[0053] In step S2 above, the out-of-plane stability of the tower is improved through the inner reinforcing layer 1, effectively curbing the problem of tower re-diving. In addition, the adhesive bonding process ensures that the inner reinforcing layer 1 adheres well to the tower, preventing detachment, while avoiding the weakening of the tower and the risk of water leakage caused by traditional bolted connections.

[0054] S3. Apply an external insulation layer 2 to the repair area of ​​the wind turbine tower.

[0055] In step S3 above, the external temperature difference is isolated by the outer insulation layer 2 to reduce the impact of thermal expansion and contraction, and to prevent the internally pasted reinforcement material from falling off due to rapid temperature changes.

[0056] In a feasible embodiment of the present invention, step S2 includes: S21. Maintain the pressure of the lifting device and clean and polish the inner wall around the lifting point of the lifting device.

[0057] S22. Apply adhesive layer 11 to the repair area of ​​the wind turbine tower.

[0058] S23, Attach precast fiberglass blocks 12.

[0059] In step S23, during the process of pasting the precast fiberglass blocks 12, they are spliced ​​together with staggered joints along the axial direction.

[0060] S24. Lay resin-impregnated fiberglass cloth on the surface of the precast fiberglass block 12 and heat it to cure. After curing, remove the lifting device.

[0061] In step S24 above, after the internal reinforcement layer has completely cured, the jacking device is removed, and the outer wall area of ​​the wind turbine tower repair area is polished and coated with aerogel insulation coating.

[0062] In step S24, while the lifting device is in the lifting state, a fiberglass cloth reinforcement layer impregnated with hand lay-up resin is laid on the surface of the precast fiberglass block 12, and the repair area is heated by heating equipment until the structural adhesive and fiberglass cloth are completely cured.

[0063] In one feasible embodiment of the present invention, step S3 includes: S31. Grind and apply aerogel insulation coating to the corresponding area on the outer wall of the wind turbine tower.

[0064] The construction method for repairing and reinforcing dented wind turbine towers provided by this invention has the following advantages compared with existing technologies: (1) The tower is reinforced with precast fiberglass blocks 12 and fiberglass cloth to improve the out-of-plane stability of the tower and effectively curb the problem of tower re-diving.

[0065] (2) The entire repair process is cold-worked to avoid the adverse effects of welding on the fatigue strength of the tower. (3) The precast fiberglass blocks 12 are reinforced with glued fiberglass cloth, which can fit the tower well and prevent them from falling off. At the same time, it avoids the weakening of the tower and the risk of water seepage caused by traditional bolt connection.

[0066] (4) Apply aerogel insulation coating to the outer wall of the repair area to reduce the impact of thermal expansion and contraction by isolating the external temperature difference, and prevent the internal reinforcement material from falling off due to rapid temperature changes.

[0067] (5) It can be used to reinforce the recessed parts of the wind turbine tower locally, and to reinforce the entire circle of the weak section.

[0068] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0069] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A structure for repairing and reinforcing dents in wind turbine towers, characterized in that, include: The lifting device is used to push out and reposition the recessed area of ​​the wind turbine tower repair area and maintain pressure until the inner diameter deviation meets the standard requirements. An inner reinforcing layer (1) is bonded to the inner wall of the wind turbine tower repair area; An external insulation layer (2) is provided on the outer wall of the wind turbine tower repair area.

2. The wind turbine tower dent repair and reinforcement structure according to claim 1, characterized in that, The inner reinforcement layer (1) includes: Precast fiberglass blocks (12) are placed on the inner wall of the wind turbine tower repair area; An adhesive layer (11) is provided on the side of the precast fiberglass block (12) facing the wind turbine tower repair area. The adhesive layer (11) is used to fix the precast fiberglass block (12) to the wind turbine tower repair area. A fiber-reinforced material layer (13) is disposed on the side of the precast fiberglass block (12) facing away from the wind turbine tower repair area.

3. The wind turbine tower dent repair and reinforcement structure according to claim 2, characterized in that, The prefabricated fiberglass block (12) extends along the axial direction of the wind turbine tower. The prefabricated fiberglass block (12) includes multiple fiberglass units, and adjacent columns of fiberglass units are staggered and spliced ​​along the axial direction.

4. The wind turbine tower dent repair and reinforcement structure according to claim 2, characterized in that, The precast fiberglass block (12) has chamfered edges on all four sides.

5. The wind turbine tower dent repair and reinforcement structure according to claim 2, characterized in that, The fiber-reinforced material layer (13) comprises at least two layers of fiber cloth.

6. The wind turbine tower dent repair and reinforcement structure according to any one of claims 1-5, characterized in that, The outer insulation layer (2) includes an aerogel insulation coating.

7. The wind turbine tower dent repair and reinforcement structure according to any one of claims 1-5, characterized in that, The lifting device includes a hydraulic jack.

8. A construction method for repairing and reinforcing a dented wind turbine tower structure, characterized in that, include: Identify the repair area for wind turbine towers; The repaired area of ​​the wind turbine tower is pushed out and reset until the inner diameter of the wind turbine tower meets the standard requirements; Maintain the pressure of the lifting device and bond the inner reinforcing layer (1) to the inner wall of the wind turbine tower repair area; An external insulation layer (2) is applied to the repair area of ​​the wind turbine tower.

9. The construction method for repairing and reinforcing the dented structure of a wind turbine tower according to claim 8, characterized in that, Maintaining the pressure of the lifting device, the inner reinforcing layer (1) is bonded to the inner wall of the wind turbine tower repair area, comprising: Clean and polish the inner wall around the lifting point of the lifting device; An adhesive layer (11) is applied to the repair area of ​​the wind turbine tower; Adhere the precast fiberglass blocks (12); A resin-impregnated fiberglass cloth is laid on the surface of the precast fiberglass block (12) and heated to cure. After curing, the lifting device is removed.

10. The construction method for repairing and reinforcing the dented wind turbine tower structure according to claim 8, characterized in that, The installation of an external insulation layer (2) in the wind turbine tower repair area includes: The corresponding area on the outer wall of the wind turbine tower is polished and coated with aerogel insulation material.

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