Expansion connector, wind turbine assembly, and method
Patent Information
- Application Number
- AU2025237236
- Authority / Receiving Office
- AU · AU
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-03-15
- Filing Date
- 2025-03-14
- Publication Date
- 2026-10-01
AI Technical Summary
Existing wind turbine assembly connections using large bolts and flanges are labor-intensive, time-consuming, and suffer from unpredictable preload, poor fatigue resistance, and inadequate load distribution, leading to maintenance challenges and reduced assembly accuracy.
An expansion connector with an actuator and wedge portions that expand perpendicularly to the actuating direction, allowing for even load distribution and controlled preload, featuring overlapping wedge portions for stable and accurate connection.
Enhances load distribution, improves assembly accuracy, reduces maintenance needs, and increases fatigue resistance, resulting in a more efficient and reliable wind turbine assembly process.
Smart Images
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Abstract
Description
[0001] EXPANSION CONNECTOR, WIND TURBINE ASSEMBLY, AND METHOD
[0002] TECHNICAL FIELD
[0003] The present disclosure relates to an expansion connector for interconnecting a first member and a second member of a wind turbine assembly. The disclosure further relates to a wind turbine assembly and a method of assembling a wind turbine assembly.
[0004] The present disclosure is particularly useful for onshore and offshore applications, e.g., for connecting a wind turbine to a monopile, a wind turbine to a transition piece, a transition piece to a monopile, as well as between members, e.g., tower segments, of a monopile or wind turbine, and jacket connections. The present disclosure may also be used for a connection between the tower of a monopile and a nacelle, for connecting rotor blades to the nacelle, and for connecting rotor blade segments to each other.
[0005] BACKGROUND
[0006] Traditionally, the members of wind turbine assemblies are traditionally provided with flanges which are connected using bolts of significant size. Currently M72, M80 or even M90 bolts are used for connecting a wind turbine tower to a monopile or transition piece. In a first step, these bolts are electrically tightened with 8.000 Nm. In a second step, the preload is increased with hydraulic tools to 22.000 Nm. The bolts themselves are heavy and the tools for tightening the bolts are also heavy and hard to handle.
[0007] It appears that the actual preload on the bolts after some settling time is hard to predict and control, and may vary significantly. Although it is not exactly clear which factors influence the torquetension relationship of the bolts, it may be concluded that installing the bolts using a “constant torque” method does not achieve satisfying results. Similar issues occur with tensioning systems for bolting. The preload on the bolts must be regularly checked and adjusted, periodically requiring significant maintenance work.
[0008] Furthermore, the bolts are arranged all around the circumference of the flanges, leaving only a very limited gap between adjacent bolts. A connection using flanges with bolts is insufficiently scalable to meet the ever-increasing demands resulting from even larger wind turbines and greater depths as sea where they are installed.
[0009] International patent application WO 2020 / 035770 Al of the same inventor proposed an improved assembly using a connector that is inserted in a channel through a first and second member followed by a further step of consecutively expanding said connector radially relative to said channel, to thereby connect the first and second member relative to each other. In this way, the connector may be accurately and easily placed in the channel by a user with very limited hassle or force. Only when the connector is placed in its desired end position, it is expanded in the channel to connect the first and second member relative to each other.
[0010] Benefits of using such expandable connector are, for instance, that the members of the assembly do not need to be adapted for accommodating large bolts (e.g., M72 bolts, or even larger sizes that are being considered such as M90). Accordingly, less material is needed, such that the assembly may be more compact and lighter.
[0011] A further advantage of such assembly as compared to traditional bolted flanges, is the absence of these flanges, that would provide a significant mass outside the path where forces travel whilst driving the assembly into a ground using a hammer. The mass of conventional flanges may result in bending of the neck of the flanges. These bending stresses currently result in significantly reduced lifetime of the welds of these flanges when installed with a conventional impact hammer. Furthermore, the large inward protruding body of a conventional L-flange connection limits the access of installation tools, such a drilling rigs, and forms an obstruction for secondary steel and platforms that slide into the tubulars.
[0012] The successively tightening the bolts of a bolted flange - which are typically tightened in multiple steps, as mentioned above - is very time consuming and labour-intensive. The assembly proposed in WO 2020 / 035770 Al is less labour-intensive and time consuming than a connection having bolted flanges. Furthermore, such expandable connectors will show a superior fatigue resistance which is less sensitive to preload loss than typical bolted L-flanges, even under reduced preload levels relative to the initial torque, or initial tension, upon instalment. In bolted L-flanges the pretension is vital to prevent significant load fluctuations from occurring in the bolts or studs which have a poor fatigue resistance due to the presence of the threads. The connection provided by the proposed assembly proposed in WO 2020 / 035770 Al does not experience these issues since the bolt only keeps the wedges in place but is, due to its orientation, not subjected to large load fluctuations. The main / dominant load fluctuations are experienced in the first member.
[0013] Whilst WO 2020 / 035770 Al of the same inventor already proposed a large number of significant improvements relative to the older prior art of bolted flanges, there is an ongoing need to further improve such assemblies. One such improvement was proposed in WO 2023 / 059200 Al of the same inventor. Aiming to mitigate forces on the elongate actuator of the expansion connector, the upper expansion block and the wedges between both expansion blocks were designed such that forces applied on the upper expansion block were transferred around the actuator, instead of through the actuator. However, as the practical width of the connector is limited and the elongate actuator is required to have a certain width, the contact surfaces through which these forces must be transferred are relatively small, leading to higher peak stresses at the contact surfaces of the connector.
[0014] Furthermore, due to tolerances and misalignment in the channel in which the expansion connector is utilized, there is a need for a certain range in the amount of expansion of the connector. Accordingly, the distance between the wedges of the connector may differ leading to different load distributions in each case. Also, no loads can be transferred between the expansion blocks through the gap between the wedges, but such gap needs to be present. This further leads to bending loads on the upper expansion block, and high contact loads at the outer ends of the blocks and the wedges that are positioned between the blocks that are in contact with those outer ends. In turn, this leads to high plasticity and coating damage. Coating damage additionally leads to non-constant friction coefficients along the contact surfaces, which in turn leads to less predicable and therefore less accurate actuation of the connector. As a result, the pre-tensioning of the structural assembly is also performed less accurately. Furthermore, coating damage can lead to corrosion and limits reusability of the connector and its parts.
[0015] Accordingly, there is a need for improved load distribution within an expansion connector. The present disclosure aims to provide such improved expansion connector.
[0016] SUMMARY
[0017] According to a first aspect of the disclosure, an expansion connector for interconnecting a first member and a second member of a wind turbine assembly is provided. The expansion connector has an actuating direction, and is configured to expand in an expansion direction substantially perpendicular to the actuating direction. The expansion connector comprises an actuator, having an elongate portion with engaging means. The elongate portion extends in the actuating direction. The actuator further comprises a primary wedge portion extending from the elongate portion in the actuating direction. The primary wedge portion has a first inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the primary wedge portion tapers towards the elongate portion. The expansion connector further comprises an actuation wedge, having a base portion configured to receive the elongate portion of the actuator, such that the base portion is movable along the elongate portion in the actuating direction, and a secondary wedge portion extending from the base portion in the actuating direction, towards the primary wedge portion in an assembled state of the expansion connector. The secondary wedge portion has a second inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the secondary wedge portion tapers away from the base portion. The secondary wedge portion is offset with respect to the primary wedge portion in a lateral direction that is substantially perpendicular to the actuating direction and the expansion direction, such that, as seen in the lateral direction, the primary and secondary wedge portions are allowed to overlap. The expansion connector further comprises a first expansion block comprising at least a first complementary inclined surface and a second complementary inclined surface. In an assembled state of the expansion connector, the first and second complementary inclined surfaces contact, respectively, the first and second inclined surfaces of the actuator and the actuation wedge. Accordingly, actuation of the actuator in the actuating direction leads to displacement of the first expansion block in the expansion direction. Thereby the connector is expanded in the expansion direction. Expanding the expansion connector preferably does not lead to any expansion in the lateral direction.
[0018] By incorporating the primary wedge portion used for expanding the connector, i.e., for moving the expansion block, as an integral part of the actuator, the forces acting upon the expansion block can be transferred directly through the actuator, instead of around the actuator as proposed in the prior art, thus achieving better load transfer distribution throughout the connector, whilst still mitigating bending of the elongate part of the actuator. Furthermore, as the primary wedge portion and the secondary wedge portion are allowed to overlap as seen in the lateral direction, the contact area between the wedge portions and the first expansion block is maximized and kept constant over the full practical actuation range (i.e., from unexpanded to fully expanded state) of the expansion connector. In other words, no gap exists between the wedges over the practical expansion range of the connector, such that loads can be transferred through the middle part of the connector, even with limited expansion of the connector. Accordingly, the loads transferred through the connector can be transferred along virtually the full length and width of the connector, regardless of amount of expansion, thus resulting in a more evenly distributed load (and thus stresses) throughout the connector. Moreover, the centers of gravity of the components of the presently proposed connector are better balanced than in the prior art, making them more stable during assembly which favors ease of use.
[0019] Preferably, the actuation wedge further comprises a tertiary wedge portion extending from the base portion in the actuating direction, towards the primary wedge portion in an assembled state of the expansion connector, the tertiary wedge portion having a third inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the tertiary wedge portion tapers away from the base portion, wherein the tertiary wedge portion is offset with respect to the secondary wedge portion in the lateral direction, such that the base portion, secondary wedge portion, and tertiary wedge portion form a fork-shaped actuation wedge. Such fork-shaped actuation wedge prevents the induction of a torque on the actuation wedge when actuating (i.e., expanding) the expansion connector, thereby preventing separation between the actuation wedge and the actuator. Accordingly, the expansion of the connector, and thus the application of a pretension to an assembly utilizing the expansion connector, can be controlled more effectively and accurately.
[0020] Preferably, the offset between the secondary and tertiary wedge portions corresponds approximately to a width, in the lateral direction, of the primary wedge portion, such that the primary wedge portion can be accommodated between the secondary and tertiary wedge portions. Accordingly, the primary wedge portion, and the secondary and tertiary wedge portions provide lateral guidance to each other, further improving actuation accuracy. In addition, the lack of significant gaps between the wedge portions prevents lateral movement of the wedge portions relative to each other.
[0021] Preferably, the first expansion block further comprises a third complementary inclined surface wherein, in an assembled state of the expansion connector, the third complementary inclined surface contacts the third inclined surface of the actuation wedge. Thereby forces applied on the first expansion block can effectively be transferred through the connector, particularly through the first, second and third (and optional further) wedge portions.
[0022] Preferably, the base portion of the actuation wedge comprises a through-hole through which the elongate portion of the actuator can be received. The elongate portion may have a round crosssection, or another non-round cross-section. The through-hole is preferably shaped in accordance with a largest cross-section of the elongate portion.
[0023] Preferably, the primary, secondary, and / or tertiary wedge portions comprise, respectively, an additional first, second, and / or third inclined surface opposite to, respectively, the first, second, and / or third inclined surfaces in the expansion direction. Further preferably, the expansion connector comprises a second expansion block comprising a first complementary inclined surface, a second complementary inclined surface, and / or a third complementary inclined surface, wherein, in an assembled state of the expansion connector, the first, second, and / or third complementary inclined surfaces contact, respectively, the additional first, second, and / or third inclined surfaces. Preferably, the primary, secondary, and / or tertiary wedge portions are mirror-symmetric, with a plane of symmetry that extends in the lateral and actuating directions. By using both a first and a second expansion block (which can also be referred to as, respectively, an upper and a lower expansion block) the actuation wedge and the actuator do not directly slide against the assembly in which the expansion connector is used. As the sliding only occurs between the actuator and actuation wedge, and the first and second expansion blocks, the friction coefficient can be controlled accurately to thereby achieve predicable actuating behavior for the expansion connector.
[0024] Preferably, the expansion connector further comprises an adjustment means configured to engage with the engaging means of the actuator. Further preferably, the engaging means of the actuator are formed by external threading and the adjustment means comprise internal threading, preferably wherein the adjustment means comprise a nut. Preferably, in an assembled state of the expansion connector, the engaging means protrude through a through-hole through the base portion of the actuation wedge, and the adjustment means, preferably a nut, has an bearing surface that may be positioned against the base portion at a side facing outwardly from the connector, such that tightening the adjustment means against the bearing face pulls the actuator and its primary wedge portion towards the actuation wedge, thereby expanding the expansion connector by pushing the expansion blocks through engagement of the inclined surfaces and complementary inclined surfaces. When using a nut as adjustment means, tightening the nut thus expands the connector, whilst loosening the nut contracts the connector.
[0025] Preferably, the primary, secondary, and / or tertiary wedge portions, at either side in the lateral direction, comprise flat side surfaces. The flat side surfaces aid in guidance of the components, and ensures smooth movement whilst having tight tolerances between the components.
[0026] Preferably, a normal of each of the first, second, and / or third inclined surfaces, and / or the additional first, second, and / or third inclined surfaces has a component in the actuating direction and the expansion direction. Preferably, the normal of the first inclined surfaces has a component in the actuating direction that is positive, and the second and third inclined surfaces have a component in the actuating direction that is negative, or vice versa, i.e., the first, and second and third inclined surfaces are oriented partially towards each other. Preferably, the normal of the first, second and third inclined surfaces each have a component in the expansion direction that is either positive or negative, i.e., facing in the same direction.
[0027] In a second aspect of the present disclosure, a wind turbine assembly is provided, comprising a first structural member and a second structural member, wherein the second member has a fork-shaped cross section with a main body arranged between two substantially parallel walls that each comprise at least one passage and the first member is arranged between the two walls of the second member in abutting contact with a face of the main body of the second member, the first member comprising a passage, wherein said passage of the first member and the passages of the second member define a channel, wherein, preferably, said channel has an elongate cross section extending in a longitudinal direction of at least one of said first and said second member, the assembly further comprising an expansion connector according to the first aspect of the disclosure, that is axially insertable into said channel to an end position and consecutively expandable radially relative to said channel, in the expansion direction of the expansion connector, by actuating the actuator in the actuating direction of the expansion connector, to connect the first and second member relative to each other by pushing, in an expanded state of the connector, the first member in a radial direction relative to said channel against the face of the main body of the second member to define a clamping contact and thereby a pre-tensioned connection in said radial direction relative to said channel between the face of the main body of the second member and faces defined by the passages in the substantially parallel walls of the second member.
[0028] In a third aspect of the present disclosure, a method of assembling a wind turbine assembly according to the second aspect of the disclosure is provided, the method comprising: arranging the first member between the two walls of the second member; positioning the passages of the first and the second member to define a channel, wherein, preferably, said channel has an elongate cross section extending in a longitudinal direction of at least one of said first and said second member; providing the expansion connector and inserting the expansion connector into the channel to an end position; consecutively expanding said connector radially relative to said channel, in the expansion direction of the connector, by actuating the actuator in the actuating direction of the connector, to thereby connect the first and second member relative to each other; and the expanded expansion connector pushing the first member in a radial direction relative to said channel against a face of the main body of the second member to define a clamping contact and thereby a pre-tensioned connection in a radial direction relative to said channel between the face of the main body of the second member and faces defined by the passages in the substantially parallel walls of the second member.
[0029] BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The present disclosure will further be elucidated with reference to the appended drawings, wherein: FIG. 1 shows a schematic view of an offshore wind turbine tower supported by a monopile;
[0031] FIG. 2 shows a perspective view of an assembly according to the second aspect of the disclosure;
[0032] FIG. 3 shows a detailed perspective view of the assembly of FIG. 2, showing an expansion connector positioned in a channel of the assembly;
[0033] FIG. 4 shows a perspective front view of an expansion connector according to the first aspect of the disclosure;
[0034] FIG. 5 shows a perspective rear view of the expansion connector;
[0035] FIG. 6 shows a schematic side view of the expansion connector;
[0036] FIG. 7 shows a schematic cross-sectional side view of the expansion connector;
[0037] FIG. 8 shows a perspective exploded view of the expansion connector;
[0038] FIG. 9 shows a perspective exploded view of the expansion connector, wherein a crosssection of the expansion blocks and actuation wedge are shown;
[0039] FIGS. 10 - 12 show schematic cross-sectional views of successive steps of assembling an assembly with an expansion connector; and
[0040] FIG. 13 shows an enlarged view of FIG. 12.
[0041] DETAILED DESCRIPTION
[0042] In FIG. 1, an example of an offshore construction is depicted, comprising multiple connections C where an assembly according to the present disclosure may be applied. An offshore wind turbine tower 1 is supported by a supporting base structure 2 which is embodied as a monopile 3 with a transition piece 4 in the present example. The skilled person will understand that similar connections are present for alternative supporting base structures 2, such as (not shown) jackets.
[0043] The connections C may be applied between separate members 8 of the monopile 3, between the monopile 3 and the transition piece 4, between the transition piece 4 and the turbine tower 1, between members 9 of the turbine tower 1, and between segments of a rotor blade 6 and between a rotor blade 6 and a hub of a rotor.
[0044] During use, a wind turbine 5 will be oriented such that the rotor blades 6 are optimally driven by the available wind power. The rotor blades 6 drive a (not shown) generator in the nacelle 7, wherein the generator generates electricity. The wind turbine 5 causes alternating loads on any connection C in the construction, and dependent on the wind direction, specific parts of the connection C have to absorb most of the loads. FIGS. 2 and 3 show an expansion connector 18 that is axially inserted in a channel 17 of the assembly formed by the first member 10 and second member 11. The connector 18 is inserted in the channel 17 to an end position and consecutively expandable radially relative to said channel 17, to connect the first member 10 and the second member 11 relative to each other by pushing, in an expanded state of the connector 18, the first member 10 in a radial direction relative to said channel 17 against the face 15 of the main body 12 of the second member 11. Due to this pushing action, a clamping contact is defined, which results in a pre-tensioned connection in said radial direction relative to said channel 17 between the face 15 of the main body 12 of the second member 11 and faces 19 that are defined by the passages 14 (see FIGS. 10 and 11) in the substantially parallel walls 13 of the second member 11.
[0045] The expansion connector 18, in particular defined by the lengths of the first and second expansion blocks 20, 21 (also referred to as upper expansion block 20 and lower expansion block 21), exhibits a length L extending in a longitudinal direction of the channel 17 and comprises a first (or upper) expansion block 20 that is configured to push the first member 10 against the face 15 of the main body 12 of the second member 11, and a lower expansion block 21 that is configured to contact the faces defined 19 by the passages 14 in the substantially parallel walls 13 of the second member 11. The connector 18 further comprises an actuator 31 and an actuation wedge 22 that are explained in more detail below with reference to FIGS. 4 - 9.
[0046] The expansion connector 18 for interconnecting the first member 10 and the second member 11 of a wind turbine assembly has an actuating direction X, and is configured to expand in an expansion direction Z substantially perpendicular to the actuating direction X. In the expanded state of the expansion connector 18, it pushes against faces 19 of the passages 14 of the second member 11 that are directed away from the main body 12 thereof to define the pre-tensioned connection between the first member 10 and the second member 11. In the expanded state of the expansion connector 18, wherein the connection between the first member 10 and the second member 11 is pretensioned, the passage 16 of the first member 10 is arranged at an offset relative to the passages 14 in the second member 11. This offset is arranged in the radial direction relative to the channel 17.
[0047] The expansion connector 18 comprises a compacted state, wherein the expansion connector 18 has a size that is freely insertable into and out of the channel 17 (see, e.g., FIG. 11), and a connecting state, wherein the expansion connector 18 is radially expanded in the channel 17 to connect the first 10 and second member 11 relative to each other.
[0048] Hereinafter the connector 18 is exemplified in more detail with reference to FIGS. 4 - 9. For actuation of the connector 18, it comprises an actuator 31. The actuator 31 has an elongate portion 33 that has engaging means 331 and extends in the actuating direction X in the assembled state of the connector 18. The engaging means 331 are in this example formed by external threading 331.
[0049] The actuator 31 comprises a primary wedge portion 310 that extends from the elongate portion 33 in the actuating direction X. Preferably, the primary wedge portion 310 and the elongate portion 33 are formed integrally, such as from a single piece of steel. The primary wedge portion 310 has a first inclined surface 310A that extends along the actuating direction X and is inclined with respect thereto, such that the primary wedge portion 310 tapers towards the elongate portion 33. The primary wedge portion 310 further has an additional first inclined surface 310B opposite to the first inclined surface 310A in the expansion direction Z. Accordingly, in the present example, the primary wedge portion 310 is mirror-symmetric, with a plane of symmetry that extends in the lateral Y and actuating directions Z. Preferably, the first inclined surface 310A is inclined at an inclination angle y with respect to the actuating direction X. Preferably, the additional first inclined surface 310B is inclined at an inclination angle 5 with respect to the actuating direction X. More preferably, inclination angle y is equal to inclination angle 5.
[0050] The connector 18 further comprises an actuation wedge 22. The actuation wedge 22 has a base portion 41 configured to receive the elongate portion 33 of the actuator 31 through a through-hole 42 therein. The base portion 41 is movable along the elongate portion 33 in the actuating direction X. The actuation wedge 22 in the present example is forked-shaped, and has a secondary wedge portion 43 and a tertiary wedge portion 44 that extend from the base portion 41 in the actuating direction X, towards the primary wedge portion 310 in an assembled state of the expansion connector 18. The secondary wedge portion 43 has a second inclined surface 43 A that extends along the actuating direction X and is inclined with respect thereto, such that the secondary wedge portion 43 tapers away from the base portion 41. Similarly, the tertiary wedge portion 44 has a third inclined surface 44A that extends along the actuating direction X and is inclined with respect thereto, such that the tertiary wedge portion 44 tapers away from the base portion 41. The secondary and tertiary wedge portions 43, 44 further have, respectively, an additional second inclined surface 43B and an additional third inclined surface 44B, that are opposite, respectively, to the second and third inclined surfaces 43 A, 44A in the expansion direction Z. Preferably, the second and third inclined surfaces 43A, 44A are inclined at the same inclination angle a with respect to the actuating direction X. Preferably, the additional second and third inclined surfaces 43B, 44B are inclined at the same inclination angle with respect to the actuating direction X. More preferably, the inclination angles of the second and third inclined surfaces 43 A, 44A and the additional second and third inclined surfaces 43B, 44B are inclined at the same inclination angle with respect to the actuating direction X. In other words, preferably inclination angle a is equal to inclination angle p.
[0051] It is preferred that the sum of inclination angle a and inclination angle is equal to the sum of inclination angle y and inclination angle 5. The sum of inclination angle a and inclination angle P preferably lies in the range of 5 - 30 degrees, and more preferably in the range of 10 - 20 degrees. The sum of inclination angle y and inclination angle 5 preferably lies in the range of 5 - 30 degrees, and more preferably in the range of 10 - 20 degrees. Even further preferably, inclination angle a, inclination angle P, inclination angle y, and inclination angle 5 are all equal.
[0052] The secondary wedge portion 43 and tertiary wedge portion 44 are both offset with respect to the primary wedge portion 310 in the lateral direction Y that is substantially perpendicular to the actuating direction X and the expansion direction Z. Accordingly, as seen in the lateral direction Y, the primary wedge portion 310, and secondary and tertiary wedge portions 43, 44 are allowed to overlap. In other words, the primary wedge portion 310 can be accommodated between the secondary and tertiary wedge portions 43, 44.
[0053] The connector 18 further comprises a first expansion block 20 (or upper expansion block 20), and a second expansion block 21 (or lower expansion block 21). The upper expansion block 20 has a first complementary inclined surface 201 that contacts, in an assembled state of the connector 18, the first inclined surface 310A of the actuator 31. The upper expansion block 20 also has second and third complementary inclined surfaces 202, 203 that contact, respectively, in an assembled state of the connector 18, the second inclined surface 43A and third inclined surface 44A of the actuation wedge 22. Likewise, the lower expansion block 21 has a first complementary inclined surface 211 that contacts, in an assembled state of the connector 18, the additional first inclined surface 310B of the actuator 31. The lower expansion block 21 also has second and third complementary inclined surfaces 212, 213 that contact, respectively, in an assembled state of the connector 18, the additional second inclined surface 43B and additional third inclined surface 44B of the actuation wedge 22.
[0054] When the actuator 31 is actuated in the actuation direction X, the inclined surfaces of the actuator 31, actuation wedge 22, and upper and lower expansion blocks 20, 21 slide with respect to each other to push the expansion blocks 20, 21 in the expansion direction Z. The connector 18 is actuated from its compacted state to its expanded state by tightening the nut 32, which effects pulling of the primary wedge portion 310 between the secondary and tertiary wedge portions 43, 44.
[0055] FIGS. 10 - 13 illustrate a method of assembling the first member 10 and the second member 11.
[0056] In FIG. 10 the step of arranging the first member 10 between the two walls 13 of the second member 11 is shown.
[0057] In FIG. 11 shows a step comprising the positioning the passages 14, 16 of the first 10 and the second member 11 to define a channel 17, and the step of providing a connector 18. The first expansion block 20 is configured to push the first member 10 against the face 15 of the main body 12 of the second member 11, and the second expansion block 21 is configured to contact faces 19 defined by the passages 14 in the substantially parallel walls 13 of the second member 11. The connector 18 is a connector according to, e.g., FIGS. 4 - 9.
[0058] In FIGS. 12 and 13 show the step of inserting the connector 18 into the channel 17 to an end position. The next steps comprise the step of consecutively expanding said connector 18 radially relative to said channel 17, to thereby connect the first member 10 and the second member 11 relative to each other, and the expanded connector 18 pushing the first member 10 in a radial direction relative to said channel 17 against the face 15 of the main body 12 of the second member 11 to define a clamping contact and thereby a pre-tensioned connection in a radial direction relative to said channel 17 between the face 15 of the main body 12 of the second member 11 and the faces 19 defined by the passages 14 in the substantially parallel walls 13 of the second member 11.
[0059] The figures and the description thereof presented herein are not to be construed as limiting the scope of the disclosure, particularly the claims, to any extent, but merely as illustrative examples used to elucidate the present disclosure and invention(s) described therein.
[0060] The disclosure further comprises the following clauses:
[0061] CLAUSES
[0062] 1. Expansion connector for interconnecting a first member and a second member of a wind turbine assembly, the expansion connector having an actuating direction, and being configured to expand in an expansion direction substantially perpendicular to the actuating direction, comprising: an actuator, having: an elongate portion with engaging means, the elongate portion extending in the actuating direction, and a primary wedge portion extending from the elongate portion in the actuating direction, the primary wedge portion having a first inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the primary wedge portion tapers towards the elongate portion; an actuation wedge, having: a base portion configured to receive the elongate portion of the actuator, such that the base portion is movable along the elongate portion in the actuating direction, and a secondary wedge portion extending from the base portion in the actuating direction, towards the primary wedge portion in an assembled state of the expansion connector, the secondary wedge portion having a second inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the secondary wedge portion tapers away from the base portion, wherein the secondary wedge portion is offset with respect to the primary wedge portion in a lateral direction that is substantially perpendicular to the actuating direction and the expansion direction, such that, as seen in the lateral direction, the primary and secondary wedge portions are allowed to overlap; and a first expansion block comprising at least a first complementary inclined surface and a second complementary inclined surface wherein, in an assembled state of the expansion connector, the first and second complementary inclined surfaces contact, respectively, the first and second inclined surfaces of the actuator and the actuation wedge, such that actuation of the actuator in the actuating direction leads to displacement of the first expansion block in the expansion direction, thereby expanding the connector in the expansion direction. Expansion connector according to clause 1, wherein the actuation wedge further comprises a tertiary wedge portion extending from the base portion in the actuating direction, towards the primary wedge portion in an assembled state of the expansion connector, the tertiary wedge portion having a third inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the tertiary wedge portion tapers away from the base portion, wherein: the tertiary wedge portion is offset with respect to the secondary wedge portion in the lateral direction, such that the base portion, secondary wedge portion, and tertiary wedge portion form a fork-shaped actuation wedge. Expansion connector according to clause 2, wherein the offset between the secondary and tertiary wedge portions corresponds approximately to a width, in the lateral direction, of the primary wedge portion, such that the primary wedge portion can be accommodated between the secondary and tertiary wedge portions. Expansion connector according to clause 2 or 3, wherein the first expansion block further comprises a third complementary inclined surface wherein, in an assembled state of the expansion connector, the third complementary inclined surface contacts the third inclined surface of the actuation wedge. Expansion connector according to any of the preceding clauses, wherein the base portion of the actuation wedge comprises a through-hole through which the elongate portion of the actuator can be received. Expansion connector according to any of the preceding clauses, wherein the primary, secondary, and / or tertiary wedge portions comprise, respectively, an additional first, second, and / or third inclined surface opposite to, respectively, the first, second, and / or third inclined surfaces in the expansion direction. Expansion connector according to clause 6, further comprising a second expansion block comprising a first complementary inclined surface, a second complementary inclined surface, and / or a third complementary inclined surface, wherein, in an assembled state of the expansion connector, the first, second, and / or third complementary inclined surfaces contact, respectively, the additional first, second, and / or third inclined surfaces. Expansion connector according to any of the preceding clauses, further comprising an adjustment means configured to engage with the engaging means of the actuator. Expansion connector according to clause 8, wherein the engaging means of the actuator are formed by external threading and the adjustment means comprise internal threading, preferably wherein the adjustment means comprise a nut. Expansion connector according to any of the preceding clauses, wherein the primary, secondary, and / or tertiary wedge portions, at either side in the lateral direction, comprise flat side surfaces. Expansion connector according to any of the preceding clauses, wherein a normal of each of the first, second, and / or third inclined surfaces, and / or the additional first, second, and / or third inclined surfaces has a component in the actuating direction and the expansion direction. Wind turbine assembly, comprising a first structural member and a second structural member, wherein the second member has a fork-shaped cross section with a main body arranged between two substantially parallel walls that each comprise at least one passage and the first member is arranged between the two walls of the second member in abutting contact with a face of the main body of the second member, the first member comprising a passage, wherein said passage of the first member and the passages of the second member define a channel, wherein, preferably, said channel has an elongate cross section extending in a longitudinal direction of at least one of said first and said second member, the assembly further comprising an expansion connector according to any one of the preceding clauses, that is axially insertable into said channel to an end position and consecutively expandable radially relative to said channel, in the expansion direction of the expansion connector, by actuating the actuator in the actuating direction of the expansion connector, to connect the first and second member relative to each other by pushing, in an expanded state of the connector, the first member in a radial direction relative to said channel against the face of the main body of the second member to define a clamping contact and thereby a pre-tensioned connection in said radial direction relative to said channel between the face of the main body of the second member and faces defined by the passages in the substantially parallel walls of the second member. Method of assembling a wind turbine assembly according to clause 12, the method comprising:
[0063] - arranging the first member between the two walls of the second member;
[0064] - positioning the passages of the first and the second member to define a channel, wherein, preferably, said channel has an elongate cross section extending in a longitudinal direction of at least one of said first and said second member;
[0065] - providing the expansion connector and inserting the expansion connector into the channel to an end position;
[0066] - consecutively expanding said connector radially relative to said channel, in the expansion direction of the connector, by actuating the actuator in the actuating direction of the connector, to thereby connect the first and second member relative to each other; and - the expanded expansion connector pushing the first member in a radial direction relative to said channel against a face of the main body of the second member to define a clamping contact and thereby a pre-tensioned connection in a radial direction relative to said channel between the face of the main body of the second member and faces defined by the passages in the substantially parallel walls of the second member.
Claims
CLAIMS1. Expansion connector for interconnecting a first member and a second member of a wind turbine assembly, the expansion connector having an actuating direction, and being configured to expand in an expansion direction substantially perpendicular to the actuating direction, comprising: an actuator, having: an elongate portion with engaging means, the elongate portion extending in the actuating direction, and a primary wedge portion extending from the elongate portion in the actuating direction, the primary wedge portion having a first inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the primary wedge portion tapers towards the elongate portion; an actuation wedge, having: a base portion configured to receive the elongate portion of the actuator, such that the base portion is movable along the elongate portion in the actuating direction, and a secondary wedge portion extending from the base portion in the actuating direction, towards the primary wedge portion in an assembled state of the expansion connector, the secondary wedge portion having a second inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the secondary wedge portion tapers away from the base portion, wherein the secondary wedge portion is offset with respect to the primary wedge portion in a lateral direction that is substantially perpendicular to the actuating direction and the expansion direction, such that, as seen in the lateral direction, the primary and secondary wedge portions are allowed to overlap; and a first expansion block comprising at least a first complementary inclined surface and a second complementary inclined surface wherein, in an assembled state of the expansion connector, the first and second complementary inclined surfaces contact, respectively, the first and second inclined surfaces of the actuator and the actuation wedge, such that actuation of the actuator in the actuating direction leads to displacement of the first expansion block in the expansion direction, thereby expanding the connector in the expansion direction.
2. Expansion connector according to claim 1, wherein the actuation wedge further comprises a tertiary wedge portion extending from the base portion in the actuating direction, towards the primary wedge portion in an assembled state of the expansion connector, the tertiarywedge portion having a third inclined surface that extends along the actuating direction and is inclined with respect thereto, such that the tertiary wedge portion tapers away from the base portion, wherein: the tertiary wedge portion is offset with respect to the secondary wedge portion in the lateral direction, such that the base portion, secondary wedge portion, and tertiary wedge portion form a fork-shaped actuation wedge.
3. Expansion connector according to claim 2, wherein the offset between the secondary and tertiary wedge portions corresponds approximately to a width, in the lateral direction, of the primary wedge portion, such that the primary wedge portion can be accommodated between the secondary and tertiary wedge portions.
4. Expansion connector according to claim 2 or 3, wherein the first expansion block further comprises a third complementary inclined surface wherein, in an assembled state of the expansion connector, the third complementary inclined surface contacts the third inclined surface of the actuation wedge.
5. Expansion connector according to any of the preceding claims, wherein the base portion of the actuation wedge comprises a through-hole through which the elongate portion of the actuator can be received.
6. Expansion connector according to any of the preceding claims, wherein the primary, secondary, and / or tertiary wedge portions comprise, respectively, an additional first, second, and / or third inclined surface opposite to, respectively, the first, second, and / or third inclined surfaces in the expansion direction.
7. Expansion connector according to claim 6, further comprising a second expansion block comprising a first complementary inclined surface, a second complementary inclined surface, and / or a third complementary inclined surface, wherein, in an assembled state of the expansion connector, the first, second, and / or third complementary inclined surfaces contact, respectively, the additional first, second, and / or third inclined surfaces.
8. Expansion connector according to any of the preceding claims, further comprising an adjustment means configured to engage with the engaging means of the actuator.
9. Expansion connector according to claim 8, wherein the engaging means of the actuator are formed by external threading and the adjustment means comprise internal threading, preferably wherein the adjustment means comprise a nut.
10. Expansion connector according to any of the preceding claims, wherein the primary, secondary, and / or tertiary wedge portions, at either side in the lateral direction, comprise flat side surfaces.
11. Expansion connector according to any of the preceding claims, wherein a normal of each of the first, second, and / or third inclined surfaces, and / or the additional first, second, and / or third inclined surfaces has a component in the actuating direction and the expansion direction.
12. Wind turbine assembly, comprising a first structural member and a second structural member, wherein the second member has a fork-shaped cross section with a main body arranged between two substantially parallel walls that each comprise at least one passage and the first member is arranged between the two walls of the second member in abutting contact with a face of the main body of the second member, the first member comprising a passage, wherein said passage of the first member and the passages of the second member define a channel, wherein, preferably, said channel has an elongate cross section extending in a longitudinal direction of at least one of said first and said second member, the assembly further comprising an expansion connector according to any one of the preceding claims, that is axially insertable into said channel to an end position and consecutively expandable radially relative to said channel, in the expansion direction of the expansion connector, by actuating the actuator in the actuating direction of the expansion connector, to connect the first and second member relative to each other by pushing, in an expanded state of the connector, the first member in a radial direction relative to said channel against the face of the main body of the second member to define a clamping contact and thereby a pre-tensioned connection in said radial direction relative to said channel between the face of the main body of the second member and faces defined by the passages in the substantially parallel walls of the second member.
13. Method of assembling a wind turbine assembly according to claim 12, the method comprising:- arranging the first member between the two walls of the second member;- positioning the passages of the first and the second member to define a channel, wherein, preferably, said channel has an elongate cross section extending in a longitudinal direction ofat least one of said first and said second member;- providing the expansion connector and inserting the expansion connector into the channel to an end position;- consecutively expanding said connector radially relative to said channel, in the expansion direction of the connector, by actuating the actuator in the actuating direction of the connector, to thereby connect the first and second member relative to each other; and- the expanded expansion connector pushing the first member in a radial direction relative to said channel against a face of the main body of the second member to define a clamping contact and thereby a pre-tensioned connection in a radial direction relative to said channel between the face of the main body of the second member and faces defined by the passages in the substantially parallel walls of the second member.