A new cast steel pipe node lattice wind power support structure

Abstract

The application relates to a novel wind power supporting structure. A novel cast steel pipe node lattice wind power supporting structure comprises a pile foundation, a cast steel pipe node lattice tower, a tower conversion node and a steel tower drum which are sequentially connected in the height direction; the cast steel pipe node lattice tower is composed of a top layer tower section, a plurality of middle tower sections and a bottom layer tower section; the top layer tower section, the plurality of middle tower sections and the bottom layer tower section are respectively composed of lattice units with the same structure; the lattice unit comprises a plurality of support columns and column interconnecting rods; each support column is composed of a TT type node and a tower column; the column interconnecting rod comprises a diagonal rod and a horizontal rod; adjacent TT type nodes are connected through the horizontal rod; the upper end and the lower end of adjacent support columns are cross-connected through the diagonal rod. The cast steel pipe node lattice wind power supporting structure has high strength and bending stiffness, can effectively exert the mechanical properties of the material, reduce the construction difficulty on site, greatly shorten the construction period and reduce the cost.

Description

Technical Field

[0001] This invention belongs to the field of wind power equipment technology, and specifically relates to a novel wind power support structure. Background Technology

[0002] Wind energy, as a clean and renewable energy source, has attracted much attention due to its wide distribution, abundant reserves, and safety and reliability. Wind power generation is one of the most mature new energy technologies. As the supporting structure of wind turbine units, the tower is responsible for safely and reliably transferring the load of the wind turbine to the foundation. Once damaged, it will threaten the safety of the entire unit and related equipment. After wind power is connected to the grid, a single tower accident may even threaten the safe and stable operation of the entire power grid.

[0003] As single-tube towers continue to increase in size, their diameter has approached or even exceeded the maximum height limit of 4.5m for highway transportation in my country, posing significant challenges to the transportation, processing, and manufacturing of large tower sections. If the outer diameter of the bottom section of the tower is kept constant and the wall thickness is increased to resist the load effect, the aforementioned reduction in structural efficiency will nearly double the volume of tower material, leading to a significant increase in construction costs.

[0004] Lattice-type spatial structure systems possess advantages such as wide cross-sections, high bending stiffness, and light weight. Under the action of large bending moments and lateral forces, the mechanical properties of the materials can be better utilized. Modular lattice-type wind turbine towers, as a highly integrated assembly form, are easy to control in terms of construction quality, facilitate mechanized construction and industrialized production, and are structurally safe and stable, thus gaining widespread application and attention.

[0005] Wind turbine structures are subjected to complex alternating stresses throughout their service life. The ultimate strength and fatigue strength of pipe joints are key control criteria in structural design, making connection nodes crucial in lattice-type spatial structure systems. Traditional connection nodes mainly include bolted connections, welded connections, and prestressed connections. With the diversification of structural types and the increasing complexity of connection methods and mechanical properties between components, traditional steel structure connection methods can no longer guarantee the safety of complex stress systems in terms of manufacturing processes and structural requirements, and are no longer suitable for the development needs of modern structures. Summary of the Invention

[0006] The purpose of this invention is to solve the problems existing in the wind power support structure and provide a new type of cast steel pipe node lattice wind power support structure. The cast steel node lattice wind power support structure can effectively reduce stress concentration between nodes, facilitate road transportation, facilitate construction and economy, and has superior mechanical properties. It can meet the requirements of high hub size, large diameter and large size of wind turbine units, and is easy to manufacture and construct, which can effectively reduce construction costs.

[0007] To achieve the above objectives, the technical solution adopted in this invention is: a novel cast steel pipe node lattice wind power support structure, comprising pile foundations, cast steel pipe node lattice towers, tower transition nodes, and steel tower sections connected sequentially along the height direction; the cast steel pipe node lattice towers consist of a top-level tower section, several intermediate tower sections, and a bottom-level tower section; the top-level tower section, several intermediate tower sections, and the bottom-level tower section are each composed of lattice units with identical structures; each lattice unit includes several support columns and inter-column connecting rods; each support column consists of TT-type cast steel nodes and a tower column; the inter-column connecting rods include diagonal rods and horizontal rods; adjacent TT-type cast steel nodes are connected by horizontal rods; the upper and lower ends of adjacent support columns are cross-connected by diagonal rods.

[0008] Preferably, the top tower section and the tower conversion node are connected by a tree-shaped node; the tree-shaped node consists of a steel pipe and six connecting columns installed on the steel pipe; the six connecting columns include one inclined upper connecting column, two horizontal connecting columns, one inclined lower connecting column and two downward inclined connecting columns; the inclined upper connecting column and the inclined lower connecting column are located between the two horizontal connecting columns.

[0009] Preferably, the top tower section is connected to the middle tower section, and the middle tower section is connected to the bottom tower section via KK-type nodes. The KK-type node consists of a steel pipe and two inclined upward connecting columns and two inclined downward connecting columns installed on the steel pipe. The inclined upward connecting columns and the inclined downward connecting columns are at equal angles with the steel pipe. The inclined upward connecting columns and the inclined downward connecting columns are connected to the inclined rods respectively.

[0010] Preferably, the bottom tower section is connected to the pile foundation via a YY-shaped node, which consists of a steel pipe and two inclined connecting columns installed on the steel pipe; the inclined connecting columns are connected to the inclined rod.

[0011] Preferably, the TT-type cast steel node is a TT-type node, which consists of a steel pipe and two horizontal connecting columns installed on the steel pipe; the horizontal connecting columns are connected to the crossbar.

[0012] Preferably, the diagonal and horizontal members between adjacent supporting tower columns are connected by a star-shaped node.

[0013] Preferably, the conversion node consists of a cast steel node tower, an upper diagonal brace, a lower diagonal brace, and a horizontal brace; wherein the cast steel node tower consists of a steel pipe and a lower diagonal connecting column and an upper diagonal connecting column installed on the steel pipe; the lower diagonal connecting column and the upper diagonal connecting column are evenly arranged along the circumference of the steel pipe; the lower diagonal connecting column is located above the upper diagonal connecting column; the upper diagonal brace is connected to the lower diagonal connecting column; the lower diagonal brace is connected to the upper diagonal connecting column.

[0014] Preferably, the cast steel pipe node lattice tower adopts an upright form with equal diameter at the top and bottom or a segmented variable diameter truncated cone form along the height direction; wherein the diameter of the segmented variable diameter truncated cone form gradually decreases from bottom to top.

[0015] Preferably, the pile foundation adopts a single pile or a pile group form.

[0016] Compared with the prior art, the beneficial effects of this invention are reflected in:

[0017] 1. Compared with existing steel towers and ordinary lattice wind turbine towers, this invention provides a novel cast steel pipe node lattice wind turbine support structure. The tower components and nodes are all prefabricated in the factory, requiring only assembly on site. Modular production and assembly effectively improve construction efficiency and reduce construction costs.

[0018] 2. This invention uses integral forged cast steel nodes as the main connection nodes, replaces intersecting welds with butt welds, and eliminates tube sheet welds. Therefore, the welds are dispersed and the amount of welding can be reduced, thereby reducing stress concentration at the nodes, improving the fatigue resistance of the structure, and solving the difficulty of fatigue design of tube nodes in current engineering.

[0019] 3. The cast steel pipe node lattice wind power support structure adopted in this invention has high strength and bending stiffness, which can effectively utilize the mechanical properties of the material, reduce the difficulty of on-site construction, significantly shorten the construction period and reduce costs.

[0020] 4. The lower part adopts a steel pipe node lattice wind power support structure, and the upper part adopts a steel tower. Under the premise of ensuring the safe and stable operation of the wind turbine, the hub height of the wind turbine can be greatly increased to 160 meters or more, which meets the requirements of high hub and large diameter in low wind speed areas, effectively utilizes wind resources in low wind speed areas, and provides a new structural form for the development of ultra-high towers in low wind speed areas. Attached Figure Description

[0021] Figure 1 This is an overall three-dimensional view of an embodiment of a novel cast steel pipe node lattice wind power support structure according to the present invention;

[0022] Figure 2 This is an overall front elevation view of an embodiment of a novel cast steel pipe node lattice wind power support structure according to the present invention;

[0023] Figure 3 This is a schematic diagram of the tower conversion node in an embodiment of the present invention;

[0024] Figure 4 This is a schematic diagram of the cast steel node tower in an embodiment of the present invention;

[0025] Figure 5 This is a schematic diagram of a tree-shaped cast steel node in an embodiment of the present invention;

[0026] Figure 6 This is a schematic diagram of the top tower section in an embodiment of the present invention;

[0027] Figure 7 This is a schematic diagram of a TT-type cast steel node in an embodiment of the present invention;

[0028] Figure 8 This is a schematic diagram of a KK-type cast steel node in an embodiment of the present invention;

[0029] Figure 9 This is a schematic diagram of the star-shaped cast steel node in an embodiment of the present invention;

[0030] Figure 10 This is a schematic diagram of the intermediate tower section in an embodiment of the present invention;

[0031] Figure 11 This is a schematic diagram of the bottom tower section in an embodiment of the present invention;

[0032] Figure 12 This is a schematic diagram of a YY-type cast steel node in an embodiment of the present invention;

[0033] Figure 13 This is a schematic diagram of a pile foundation in an embodiment of the present invention;

[0034] Figure 14 This is a schematic diagram of the steel tower and wind turbine blades in an embodiment of the present invention;

[0035] In the diagram: 1-Tower conversion node; 2-Cast steel node tower; 3-Tree-shaped cast steel node; 4-Upper diagonal brace; 5-Lower diagonal brace; 6-Horizontal brace; 7-Top tower section; 8-TT type cast steel node; 9-Tower column; 10-Horizontal bar; 11-Diagonal bar; 12-KK type cast steel node; 13-M-shaped cast steel node; 14-Middle tower section; 15-Bottom tower section; 16-YY type cast steel node; 17-Pile foundation; 18-Wind turbine blade; 19-Steel tower; 21-First lower diagonal connecting column; 22-First upper diagonal connecting column; 31-Second upper diagonal connecting column; 32-Second lower diagonal connecting column; 33-First horizontal connecting column; 34-First lower diagonal connecting column; 81-Second horizontal connecting column; 121-First upper diagonal connecting column; 122-Second lower diagonal connecting column; 161-Second upper diagonal connecting column. Detailed Implementation

[0036] To facilitate understanding of the present invention, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the present invention.

[0037] The embodiment takes an ultra-high tower with a hub height of 180 meters and a rotor diameter of 180 meters as an example. The novel cast steel pipe node lattice wind power support structure provided in this embodiment is as follows: Figure 1 and Figure 2 As shown, it is supported by four legs, with the upper part consisting of a 90-meter conventional steel tower 19 and wind turbine blades 18, as... Figure 14 As shown, the middle 6 meters is the tower conversion node 1, and the lower part is a cast steel pipe node lattice tower, which consists of a top tower section 7 with a height of 12 meters, a middle tower section 14 with a height of 12 meters, and a bottom tower section 15 with a height of 12 meters. Each section is assembled using modular prefabrication.

[0038] like Figure 3 As shown, the tower transition node 1 consists of a cast steel node tower 2, a tree-shaped cast steel node 3, an upper diagonal brace 4, a lower diagonal brace 5, and a horizontal brace 6. The upper part of the tower transition node 1 is connected to the upper steel tower 19 at the top of the cast steel node tower 2 via a flange, and the lower part is connected to the top tower section 7 via the tree-shaped cast steel node 3. The connection method can be welding or flange connection.

[0039] like Figure 4 As shown, the cast steel node tower 2 includes a first inclined downward connecting column 21 and a first inclined upward connecting column 22 arranged circumferentially along the steel pipe. Figure 5 As shown, the tree-shaped cast steel node 3 contains six connecting posts, namely: one second diagonal upper connecting post 31, one second diagonal lower connecting post 32; two first horizontal connecting posts 33, and two first lower diagonal connecting posts 34.

[0040] In this embodiment, the cast steel node tower 2 is connected to four tree-shaped cast steel nodes 3 through four upper diagonal braces 4, four lower diagonal braces 5, and four horizontal braces 6. Specifically, one end of the upper diagonal brace 4 is connected to the first lower diagonal connecting column 21 on the cast steel node tower 2, and the other end is connected to the second upper diagonal connecting column 31 on the tree-shaped cast steel node 3; one end of the lower diagonal brace 5 is connected to the first upper diagonal connecting column 22 on the cast steel node tower 2, and the other end is connected to the second lower diagonal connecting column 32 on the tree-shaped cast steel node 3; and both ends of the horizontal brace 6 are connected to the first horizontal connecting columns 33 on the two adjacent tree-shaped cast steel nodes 3.

[0041] like Figure 6 , Figure 7 , Figure 8 and Figure 9 As shown, the top-level tower section 7 includes four supporting columns. Each pair of adjacent supporting columns is connected by diagonal braces 11, horizontal braces 10, and star-shaped nodes 13, forming a planar grid structure between the columns. Each supporting column consists of two tower columns 9 and a TT-type cast steel node 8 connected axially. The top of the supporting column is connected to the tower transition node 1 via a tree-shaped cast steel node 3, and the bottom of the supporting column is connected to the intermediate tower section 14 via a KK-type cast steel node 12.

[0042] Two adjacent TT-type cast steel nodes 8 are connected by two horizontal bars 10. The tree-shaped cast steel node 3 at the top of a support column is cross-connected to the KK-type cast steel node 12 at the bottom of the adjacent support column by two diagonal bars 11. Specifically, one end of one diagonal bar is connected to the first lower diagonal connecting column 34 on the tree-shaped cast steel node 3, and one end of the other diagonal bar is connected to the first upper diagonal connecting column 121 on the KK-type cast steel node 12. The near ends of the two diagonal bars are connected by a star-shaped node 13. One end of one horizontal bar is connected to the second horizontal connecting column 81 on one of the TT-type cast steel nodes 8. The other end of the other horizontal bar is connected to the second horizontal connecting column 81 on the adjacent TT-type cast steel node. The near ends of the two horizontal bars are connected by a star-shaped node 13. The two diagonal bars, the two horizontal bars, and the star-shaped node 13 together form a planar grid structure between the two support columns.

[0043] The intermediate tower section 14 consists of five identical tower sections. The structure of each intermediate tower section is similar to that of the top tower section 7, such as... Figure 10 As shown, it also includes four supporting columns. Each pair of adjacent supporting columns is connected by diagonal braces 11, horizontal braces 10, and star-shaped nodes 13, forming a planar grid structure between the columns. Each supporting column consists of two tower columns 9 and a TT-type cast steel node 8 connected axially. Two adjacent TT-type cast steel nodes 8 in the circumferential direction are connected by two horizontal braces 10.

[0044] The intermediate tower section differs from the top tower section 7 in that the top and bottom of each intermediate tower section are connected by KK-type cast steel nodes 12. Specifically, the first upward-sloping connecting column 121 on the KK-type cast steel node 12 is connected to the second downward-sloping connecting column 122 on another adjacent KK-type cast steel node 12 in the height direction via a diagonal brace, and so on. It should be noted that the two adjacent KK-type cast steel nodes 12 in the height direction refer to two KK-type cast steel nodes located on opposite diagonals, and not two KK-type cast steel nodes 12 located on the same axis.

[0045] like Figure 11 and Figure 12 As shown, the structure of the bottom tower section 15 is similar to that of the middle tower section 14 or the top tower section 7, also including four supporting columns. Each pair of adjacent supporting columns is connected by diagonal braces 11, horizontal braces 10, and star-shaped nodes 13, forming a planar grid structure between the columns. Each supporting column consists of two tower columns 9 and a TT-type cast steel node 8 connected axially. Two adjacent TT-type cast steel nodes 8 in the circumferential direction are connected by two horizontal braces 10.

[0046] The bottom tower section 15 differs from the middle or top tower section 7 in that its top is connected to the lowest section of the middle tower section via a KK-type cast steel node 12, and its bottom is connected to the pile foundation 17 via a YY-type cast steel node 16. Figure 13 As shown, specifically: one end of one of the diagonal rods is connected to the second lower diagonal connecting column 122 on the KK-type cast steel node 12 at the top of the bottom tower section 15, and one end of the other diagonal rod is connected to the second upper diagonal connecting column 161 on the YY-type cast steel node 16 at the bottom of the bottom tower section 15.

[0047] In this embodiment, the cast steel node tower 2, tree-shaped cast steel node 3, TT-type cast steel node 8, KK-type cast steel node 12, and YY-type cast steel node 16 are all integral forged structures. They are all prefabricated in batches in the factory and only need to be assembled on site. The connection method can be welding or flange connection.

[0048] In this embodiment, the cast steel pipe node lattice tower, composed of the top tower section 7, the middle tower section 14, and the bottom tower section 15, adopts the form of an upright quadrangular prism with equal diameter at the top and bottom along the height direction. In other embodiments of the present invention, a segmented frustum-shaped form with the diameter gradually decreasing from bottom to top can also be adopted. The cross-sectional shape of the cast steel pipe node lattice tower can also be circular, polygonal, etc., which can be achieved by slightly adjusting the corresponding structure without departing from the inventive concept of the present invention. For example, a polygon can be achieved by adjusting the included angle between the connecting columns on various cast steel nodes; a circular shape can be achieved by changing the crossbar from a straight line to an arc.

[0049] Before construction, various types of cast steel nodes and connecting members are prefabricated in the factory according to the design drawings. When selecting materials for cast steel nodes, factors such as the load characteristics of the structure, the type of node, and the casting process should be considered to select reasonable and reliable cast steel materials. Static strength analysis of the cast steel nodes under various unfavorable working conditions should also be performed to ensure that the nodes meet the safety requirements for load bearing.

[0050] During construction, each section of the tower is assembled in sections and then grouped together for final assembly. When conditions permit, multiple tower sections can be assembled in sections to make full use of the working surface on the construction site. During final assembly, the construction is carried out in a horizontal assembly method using two slides on the construction base.

[0051] The assembly method for the bottom tower section is as follows:

[0052] The first step is to fix the four YY-shaped cast steel nodes 16 onto the four pile foundations 17.

[0053] The second step is to assemble and weld the four tower columns 9 to the four YY-shaped cast steel nodes 16 by hoisting.

[0054] The third step is to assemble and weld the four TT-type cast steel nodes 8 to the four tower columns 9 respectively.

[0055] The fourth step is to assemble and weld the KK-type cast steel nodes 8 to the four tower columns 9 respectively.

[0056] The fifth step is to assemble and weld together a set of diagonal bars 11, horizontal bars 10, and star-shaped cast steel nodes 13.

[0057] The sixth step is to assemble and weld the four sets of cross-shaped diagonal web members that were assembled and welded in the fifth step, and the four sets of tower column nodes from the first to the fourth step.

[0058] The same method can be used to complete the on-site assembly and welding of the intermediate tower section 14, the top tower section 7, and the tower conversion node 1, which will not be described in detail here. Both the intermediate tower section 14 and the top tower section 7 are assembled in sections, and then hoisted and welded section by section using a crawler crane, ultimately assembling all tower sections into a single unit. After the bottom tower is assembled, the tower conversion node 1 is hoisted and welded to the bottom tower structure to form a single unit, completing the construction of the bottom tower. Finally, the steel tower 19 with the assembled wind turbine blades 18 is connected and installed to the tower.

[0059] It is important to note that before welding, the assembly quality must be checked to ensure accurate positioning and alignment with the centroids of the round holes in the members and nodes. Welding should only proceed after these requirements are met. Strict control must be exercised over all procedures, including specimen assembly, specimen correction, allowance for welding shrinkage, welding positioning, pre-weld protection, cleaning, preheating, welding, heat preservation, and inspection.

[0060] To ensure welding quality, facilitate stress release, and reduce welding constraints, welding should be performed in the following order: from the center outwards, from bottom to top, and from thicker members to thinner members. The weld strength should be equal to or higher than that of the original structural material. Non-destructive testing should be performed after welding; if weld defects exceed acceptable limits, immediate repair is required.

[0061] The above implementation methods all use the X-shaped diagonal web members as examples. The connection method can also be flange connection, where flanges are welded onto the nodes and connecting members during factory prefabrication, and then bolted together on site. This method requires regular maintenance of the bolts. In addition, cast steel pipe node lattice towers can also use different combinations of cast steel node forms (such as X-shaped, A-shaped, and N-shaped) depending on the different compositions of the diagonal web members, all of which are within the scope of this patent.

[0062] Although the invention has been specifically shown and described with reference to exemplary examples, those skilled in the art should understand that various changes in form and detail thereof without departing from the spirit and scope of the invention as defined by the claims are within the scope of protection of the invention.

Claims

1. A novel cast steel pipe node lattice wind power support structure, comprising pile foundations, cast steel pipe node lattice towers, tower transition nodes, and steel tower cylinders connected sequentially along the height direction; characterized in that: The cast steel pipe node lattice tower structure consists of a top-level tower section, several intermediate tower sections, and a bottom-level tower section. Each of these sections is composed of identical lattice units. Each lattice unit includes several support columns and inter-column connecting rods. Each support column consists of a TT-type cast steel node and a tower column. The inter-column connecting rods include diagonal and horizontal members. Adjacent TT-type cast steel nodes are connected by horizontal members. The upper and lower ends of adjacent support columns are cross-connected by diagonal members. The diagonal and horizontal members between adjacent support columns form a cross-grid structure. The top-level tower section is connected to the tower transition node via a tree-shaped cast steel node. The tree-shaped cast steel node consists of a steel pipe and six connecting columns installed on the pipe, and is an integral forged structure. The six connecting columns include one upward-sloping connecting column, two horizontal connecting columns, one downward-sloping connecting column, and two downward-sloping connecting columns. The tree-shaped cast steel node's upward-sloping connecting column... The connecting column and the inclined lower connecting column are located between the two horizontal connecting columns of the tree-shaped cast steel node; the tower conversion node consists of a cast steel node tower, an upper inclined brace, a lower inclined brace, and a horizontal brace; wherein the cast steel node tower is composed of a steel pipe and inclined lower connecting columns and inclined upper connecting columns installed on the steel pipe; the inclined lower connecting columns and inclined upper connecting columns of the cast steel node tower are evenly arranged along the circumference of the steel pipe and are integral forged structures; the inclined lower connecting column of the cast steel node tower is located above the inclined upper connecting column of the cast steel node tower; one end of the upper inclined brace is connected to the inclined lower connecting column on the cast steel node tower, and the other end is connected to the inclined upper connecting column on the tree-shaped cast steel node; one end of the lower inclined brace is connected to the inclined upper connecting column on the cast steel node tower, and the other end is connected to the inclined lower connecting column on the tree-shaped cast steel node; both ends of the horizontal brace are connected to the horizontal connecting columns on the two connected tree-shaped cast steel nodes respectively; the lower inclined connecting column on the tree-shaped cast steel node is connected to the diagonal bar.

2. The novel cast steel pipe node lattice wind power support structure according to claim 1, characterized in that: The top tower section and the middle tower section are connected by KK-type nodes, as are the sections inside the middle tower section and the sections between the middle tower section and the bottom tower section. The KK-type node consists of a steel pipe and two inclined upper connecting columns and two inclined lower connecting columns installed on the steel pipe. The angles between the inclined upper connecting columns and the inclined lower connecting columns of the KK-type node and the steel pipe are equal. The inclined upper connecting columns and the inclined lower connecting columns of the KK-type node are connected to the inclined rods respectively.

3. The novel cast steel pipe node lattice wind power support structure according to claim 1, characterized in that: The bottom tower section is connected to the pile foundation through a YY-shaped node, which consists of a steel pipe and two inclined connecting columns installed on the steel pipe; the inclined connecting columns of the YY-shaped node are connected to the inclined rod.

4. The novel cast steel pipe node lattice wind power support structure according to claim 1, characterized in that: The TT-type cast steel node consists of a steel pipe and two horizontal connecting columns installed on the steel pipe; the horizontal connecting columns of the TT-type cast steel node are connected to the crossbar.

5. The novel cast steel pipe node lattice wind power support structure according to claim 1, characterized in that: The diagonal and horizontal bars between adjacent support columns are connected by a star-shaped joint.

6. The novel cast steel pipe node lattice wind power support structure according to claim 1, characterized in that: The cast steel pipe node lattice tower adopts either an upright form with equal diameter at the top and bottom or a segmented variable diameter truncated cone form along the height direction; wherein the diameter of the segmented variable diameter truncated cone form gradually decreases from bottom to top.

7. The novel cast steel pipe node lattice wind power support structure according to claim 1, characterized in that: The pile foundation can be in the form of a single pile or a group of piles.

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