A method of manufacturing a segmented tower section

Abstract

The application provides a manufacturing method of a split tower drum, characterized by comprising the following steps: S1. An integral drum body is manufactured by a conventional method, and the drum body is horizontally arranged on a rotating trolley; S2. An annular flange is welded at each end of the drum body, each annular flange is formed by splicing three arc-shaped blocks with the same size through connecting plates and bolts, thereby forming three splicing seams, and when the drum body is welded, the splicing seams of the annular flanges at the two ends are ensured to be completely aligned; S3. Three axial cutting lines are drawn on the inner wall of the drum body based on the connecting line of the splicing seams between the two annular flanges, the drum body is divided into three arc-shaped plates according to the three cutting lines, and a longitudinal flange with a threaded through hole in a strip shape is welded at both sides of each arc-shaped plate; and S4. The bolts and the connecting plates on the annular flanges are removed, and the whole tower drum is divided into three tower drum pieces. The split tower drum manufactured by the method has the advantages of high precision and easy assembly.

Description

Technical Field

[0001] This invention belongs to the field of wind power tower technology, specifically relating to a method for manufacturing a segmented tower. Background Technology

[0002] In wind turbine generators, the tower supports the generator set. The larger the generator set's power, the larger the tower diameter. However, when the tower diameter is too large, it becomes subject to limitations imposed by road width, bridge arch height, and height restriction barriers during transportation. To address this issue, existing technology has developed segmented tower designs. Each tower section is transported in three or four pieces, assembled on-site into a complete tower section, and then multiple tower sections are stacked upwards to form a single unit.

[0003] While this segmented tower design solves the problem of tower transportation, it presents new challenges in ensuring the strength and stability of the tower.

[0004] The existing manufacturing method for segmented wind turbine towers requires welding several connectors along the dividing line to the inner wall of the tower, and then cutting the tower into multiple longitudinal tower sections along the dividing line. Since the connectors are welded first and then the tower is cut, a certain gap must be maintained between the symmetrically welded connectors on both sides of the dividing line to allow for subsequent cutting. This manufacturing method is actually the most readily conceived by those skilled in the art, and it is relatively simple to operate, allowing for quick cutting of the tower into multiple longitudinal tower sections. However, reassembling these multiple longitudinal tower sections into a complete tower at the installation site is quite troublesome. This is because the total perimeter of any position on the multiple longitudinal tower sections after cutting will inevitably be slightly smaller than the perimeter of the corresponding position on the tower before cutting, making it difficult to ensure a tight fit between adjacent longitudinal tower sections. Furthermore, the existence of a certain gap between the symmetrically welded connectors on both sides of the dividing line makes it difficult to ensure that the bolt holes on the two connectors are perfectly aligned, and it is also easy for the symmetrical connectors to be stretched and deformed after the bolts are tightened. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a method for manufacturing a segmented tower, which has the advantages of high precision and easy assembly.

[0006] To solve the above-mentioned technical problems, the technical solution of the present invention is: a method for manufacturing a segmented tower, comprising the following steps:

[0007] S1. Making the cylinder: Make a complete cylinder using conventional methods, and then place the cylinder horizontally on a rotating trolley;

[0008] S2. Installing the ring flanges: Weld a ring flange to each end of the cylinder to obtain a complete tower. Each ring flange is made of three arc-shaped blocks of the same size spliced ​​together by connecting plates and bolts, thus having three splicing seams. When welding to the cylinder, ensure that the splicing seams of the ring flanges at both ends are completely aligned.

[0009] S3. Cutting the cylinder and welding the longitudinal flange: Using the splice seam line between the two annular flanges as a reference, draw three axial cutting lines on the inner wall of the cylinder. Then, according to these three cutting lines, divide the cylinder into three arc-shaped plates, and weld a long strip longitudinal flange with threaded through holes on each side of each arc-shaped plate.

[0010] S4. Tower disassembly: Remove the bolts and connecting plates on the annular flange and disassemble the entire tower into three tower sections.

[0011] In the above technical solution, since the annular flanges welded to both ends of the cylinder are all made of three arc-shaped blocks of the same size spliced ​​together by connecting plates and bolts, each annular flange has three splicing seams. When welding with the cylinder, it is necessary to ensure that the splicing seams of the annular flanges at both ends are completely aligned. Then, the entire cylinder is cut and welded with long strip longitudinal flanges based on the splicing seam line between the two annular flanges. This makes the relative dimensions between the various components of the tower more accurate, making it easier to reassemble the disassembled tower sections.

[0012] As a further technical solution, step S3 can be divided into the following steps:

[0013] 1) Divide the six long strip-shaped longitudinal flanges with threaded through holes into three groups, so that each pair of longitudinal flanges is fitted together and fixed by positioning pins and bolts;

[0014] 2) Using the three cutting lines as a reference, cut three axial long strip openings on the cylinder. The length of each of the three long strip openings is less than the length of the cylinder, so that both ends of the cylinder temporarily maintain a complete circular structure. After each long strip opening is cut, a set of longitudinal flanges must be immediately inserted into the long strip opening and welded to fix it.

[0015] 3) After all three sets of longitudinal flanges have been welded, cut the annular structure at both ends of the cylinder into three sections along the three cutting lines;

[0016] 4) Remove all locating pins and bolts from the three sets of longitudinal flanges.

[0017] Furthermore, in step 2), the method for cutting three long strip openings on the cylinder is as follows:

[0018] ① Cut multiple non-connected strip-shaped through holes at intervals along each cutting line of the cylinder, so that an isolation zone of no more than 50mm is formed between every two strip-shaped through holes, and the length of each strip-shaped through hole does not exceed 5m;

[0019] ② When the longitudinal flange is about to be embedded, cut off the multiple isolation strips one by one, so that the multiple strip-shaped through holes are connected into a long strip opening.

[0020] This method avoids deformation of the cylinder caused by cutting three long strips at once, because the presence of multiple isolation strips can keep the cylinder as a whole.

[0021] Furthermore, in step 2), before cutting three long strip openings on the cylinder, multiple U-shaped fixing fixtures need to be installed at intervals along the cutting line on the outer wall of the cylinder with the part to be cut facing downwards, using bolts or welding. The lower part of the fixing fixtures is equipped with a support column that supports downwards to the ground. This can prevent stress release and local sinking due to gravity after the cylinder is cut.

[0022] Preferably, in step 2), the two ends of the three elongated openings are kept at a distance of not less than 300 mm from the two end faces of the cylinder, so that the two ends of the cylinder temporarily maintain a complete circular structure.

[0023] Preferably, the width of each long strip opening is 55mm, and the thickness of each set of longitudinal flanges is 52mm.

[0024] Preferably, in step 2), when the three sets of longitudinal flanges are respectively embedded into the three long openings of the cylinder, the longitudinal flanges need to protrude 15mm toward the outer wall of the cylinder, and then the gap between the longitudinal flanges and the cylinder is welded from the inner and outer sides of the cylinder.

[0025] Preferably, when cutting three long strip openings, a dual-head flame cutter that can move automatically is used.

[0026] Preferably, step S4 can be divided into the following steps:

[0027] 1) Install a tie rod between any two arc-shaped blocks of the annular flange, and keep the tie rod positions on both ends of the annular flange consistent;

[0028] 2) Remove the bolts and connecting plates from the arc-shaped block without the tie rod installed, and remove the first tower section;

[0029] 3) Remove all the tie rods, bolts and connecting plates from the remaining two arc-shaped blocks, and remove the second and third tower sections.

[0030] By installing tie rods, it is possible to prevent the second and third tower sections from becoming difficult to disassemble due to stress release after the first tower section has been removed. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the tower and strip-shaped through-hole structure in an embodiment of the present invention;

[0032] Figure 2 This is a schematic diagram of the tower and elongated opening structure in an embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of the structure of the tower when welding the longitudinal flange in an embodiment of the present invention;

[0034] Figure 4 This is a schematic diagram of the longitudinal flange structure in an embodiment of the present invention;

[0035] Figure 5 This is a schematic diagram of the annular flange structure in an embodiment of the present invention;

[0036] Figure 6 This is a schematic diagram of the tower plate structure in an embodiment of the present invention;

[0037] The attached figures are labeled as follows:

[0038] 10 – Tower; 11 – Shell; 12 – Annular Flange

[0039] 12a – Arc-shaped block; 12b – Joint; 13 – Longitudinal flange

[0040] 14 – Long strip opening; 14a – Strip-shaped through hole; 15 – Separation strip

[0041] 16 – Tie rod; 20 – Rotating trolley; 30 – Fixed fixture

[0042] 31—Pillar. Detailed Implementation

[0043] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to embodiments and accompanying drawings. The content mentioned in the embodiments is not intended to limit the present invention.

[0044] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0045] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly defined. It should be noted that, unless otherwise specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, internal connections between two components, direct connections, or indirect connections via an intermediate medium. Those skilled in the art can understand the specific meaning of these terms based on the specific circumstances.

[0046] like Figures 1 to 6 As shown, a method for manufacturing a segmented tower includes the following steps:

[0047] S1. Making the cylinder: Make a complete cylinder 11 using conventional methods, and then place the tower cylinder horizontally on the rotating trolley 20;

[0048] S2. Installing the annular flanges: Weld an annular flange 12 to each end of the cylinder 11 to obtain a complete tower 10. Each annular flange 12 is made of three arc-shaped blocks 12a of the same size spliced ​​together by connecting plates and bolts, thus having three splice seams 12b (the connecting plates and bolts are omitted in the attached figure for easy display of the splice seams). When welding to the cylinder 11, ensure that the splice seams 12b of the annular flanges 12 at both ends are completely aligned.

[0049] S3. Cutting the cylinder and welding the longitudinal flange:

[0050] 1) Using the splice seam line between the two annular flanges 12 as a reference, draw three axial cutting lines on the inner and outer walls of the cylinder 11.

[0051] 2) In order to avoid stress deformation and local sinking due to gravity after the cylinder 11 is cut, before cutting, the part to be cut should be facing down and multiple U-shaped fixing fixtures 30 should be installed at intervals along the cutting line on the outer wall of the cylinder 11 by bolts or welding. The lower part of the fixing fixture 30 is provided with a support column 31 that supports downward to the ground.

[0052] 3) Divide the six elongated longitudinal flanges 13 with threaded through holes into three groups, with each pair of longitudinal flanges 13 fitted together and secured with locating pins and bolts; the thickness of each group of longitudinal flanges 13 is 52mm; the overall structure of each group of longitudinal flanges 13 is described in [reference needed]. Figure 3 ;

[0053] 4) Using the three cutting lines as a reference, use an automatically moving dual-head flame cutter to cut three axial elongated openings 14 on the cylinder. Each elongated opening 14 is 55mm wide, and the length of each opening 14 is less than the length of the cylinder 11. A distance of at least 300mm is maintained between the two ends of each opening 14 and the two end faces of the cylinder 11, temporarily maintaining a complete circular structure at both ends of the cylinder 11. It is important to note that the longitudinal flanges 13 should not be welded after all three elongated openings 14 have been cut. Instead, after each elongated opening 14 has been cut, a set of longitudinal flanges 13 must be immediately inserted into that opening 14 and welded in place. The method for cutting the three elongated openings 14 is as follows:

[0054] ① Multiple non-connected strip-shaped through holes 14a are cut at intervals along each cutting line of the cylinder 11, so that an isolation zone 15 with a diameter of no more than 50 mm is formed between every two strip-shaped through holes 14a. The length of each strip-shaped through hole 14a does not exceed 5 m. See the relevant structure as follows. Figure 1 The presence of multiple isolation strips 15 can continue to keep the cylinder 11 as a whole, preventing the cylinder 11 from deforming due to a long strip opening 14 being cut out at once;

[0055] ② When the longitudinal flange 13 is about to be embedded, cut off the multiple isolation strips 15 one by one, so that the multiple strip-shaped through holes 14a are connected into a long strip opening 14, see [link to relevant documentation]. Figure 2 ;

[0056] 5) Embed each set of longitudinal flanges 13 into the long strip opening 14 of the cylinder 11 and protrude 15mm from the outer wall of the cylinder 11. Then weld the gap between the longitudinal flanges 13 and the cylinder 11 from the inner and outer sides of the cylinder 11 respectively.

[0057] 6) Cut the annular structure at both ends of the cylinder 11 into three sections along the three cutting lines;

[0058] 7) Remove all locating pins and bolts from the three sets of longitudinal flanges 12;

[0059] S4. Tower disassembly:

[0060] 1) Install a tie rod 16 between any two arc-shaped blocks 12a of the annular flange 12, and keep the tie rod 16 on both ends of the annular flange 12 in the same position;

[0061] 2) Remove the bolts and connecting plates on the arc-shaped block where tie rod 16 is not installed, and remove the first tower section; at this time, due to the pulling effect of tie rod 16, the second and third tower sections will not spring outward due to stress release;

[0062] 3) Remove all tie rods 16, bolts, and connecting plates from the remaining two arc-shaped blocks, and then remove the second and third tower sections. The structure of the disassembled tower sections is shown in the image below. Figure 5 .

[0063] In this embodiment, since the annular flanges welded to both ends of the cylinder are made of three arc-shaped blocks of the same size spliced ​​together by connecting plates and bolts, each annular flange has three splicing seams. When welding to the cylinder, it is necessary to ensure that the splicing seams of the annular flanges at both ends are completely aligned. Then, the entire cylinder is cut and welded with long strip-shaped longitudinal flanges based on the splicing seam line between the two annular flanges. In addition, various measures to prevent cylinder deformation are adopted during the cutting and disassembly of the cylinder and tower. This makes the relative dimensions between the various components of the tower more accurate, which makes it easier to reassemble the disassembled tower sections and makes the roundness of the reassembled tower closer to the state of the tower before cutting, thereby ensuring that the stability and support strength of the tower are not affected.

[0064] The above embodiments are preferred implementations of the present invention. In addition, the present invention can be implemented in other ways. Any obvious substitutions without departing from the concept of the present technical solution are within the protection scope of the present invention.

[0065] To facilitate understanding by those skilled in the art of the improvements of this invention over the prior art, some of the accompanying drawings and descriptions have been simplified, and for clarity, some other elements have been omitted from this application. Those skilled in the art should realize that these omitted elements may also constitute the content of this invention.

Claims

1. A method for manufacturing a segmented tower, characterized in that, Includes the following steps: S1. Making the cylinder: Make a complete cylinder (11), and then place the cylinder (11) horizontally on the rotating trolley (20); S2. Installing the annular flanges: Weld an annular flange (12) to each end of the cylinder (11) to obtain a complete tower (10). Each annular flange (12) is made of three arc-shaped blocks (12a) of the same size spliced ​​together by connecting plates and bolts, thus having three splicing seams (12b). When welding to the cylinder (11), ensure that the splicing seams (12b) of the annular flanges at both ends are completely aligned. S3. Cutting the cylinder and welding the longitudinal flange: 1) Using the splice seam line between the two annular flanges (12) as a reference, draw three axial cutting lines on the inner wall of the cylinder (11); 2) Divide the six long strip-shaped longitudinal flanges (13) with threaded through holes into three groups, so that each pair of longitudinal flanges (13) are attached together and fixed by positioning pins and bolts; 3) Before cutting three long strip openings on the cylinder (11), the part to be cut is facing down and multiple U-shaped fixing fixtures (30) are installed at intervals on the outer wall of the cylinder (11) by bolts or welding along the cutting line. The lower part of the fixing fixture (30) is provided with a support column (31) that supports downward to the ground. 4) Using the three cutting lines as a reference, cut three axial long strip openings (14) on the cylinder (11). The length of each of the three long strip openings (14) is less than the length of the cylinder (11), so that both ends of the cylinder (11) temporarily maintain a complete circular structure. After each long strip opening is cut, a set of longitudinal flanges (13) must be immediately inserted into the long strip opening (14) and welded to fix it. 5) After the three sets of longitudinal flanges (13) are welded, the annular structure at both ends of the cylinder (11) is cut into three sections along the three cutting lines; 6) Remove all locating pins and bolts from the three sets of longitudinal flanges (13); S4. Tower disassembly: 1) Install a tie rod (16) between any two arc blocks (12a) of the annular flange (12), and keep the tie rod (16) on both ends of the annular flange (12) in the same position; 2) Remove the bolts and connecting plates from the arc-shaped block (12a) without the tie rod installed, and remove the first tower section; 3) Remove all the tie rods (16), bolts and connecting plates on the remaining two arc blocks (12a), and remove the second and third tower sections.

2. The manufacturing method of the segmented tower according to claim 1, characterized in that: In step S3, step 4), the method for cutting three long strip openings (14) on the cylinder (11) is as follows: ① Cut multiple non-connected strip through holes (14a) at intervals on each cutting line of the cylinder (11), so that an isolation band (15) of no more than 50mm is formed between every two strip through holes (14a), and the length of each strip through hole (14a) does not exceed 5m; ② When the longitudinal flange (13) is about to be embedded, cut the multiple isolation bands (15) one by one, so that the multiple strip through holes (14a) are connected to form a long strip opening (14).

3. The method for manufacturing a segmented tower according to claim 1 or 2, characterized in that: In step S3, step 4), the two ends of the three long strip openings (14) are kept at a distance of not less than 300 mm from the two ends of the cylinder (11), so that the two ends of the cylinder (11) temporarily maintain a complete circular structure.

4. The method for manufacturing a segmented tower according to claim 1 or 2, characterized in that: The width of each long strip opening (14) is 55mm, and the thickness of each set of longitudinal flanges (13) is 52mm.

5. The method for manufacturing a segmented tower according to claim 1 or 2, characterized in that: In step S3, step 4), when the three sets of longitudinal flanges (13) are respectively inserted into the three long openings (14) of the cylinder (11), the longitudinal flanges (13) need to protrude 15mm from the outer wall of the cylinder (11), and then weld the gap between the longitudinal flanges (13) and the cylinder (11) from the inner and outer sides of the cylinder (11).

6. The method for manufacturing a segmented tower according to claim 1 or 2, characterized in that: When cutting three long strip openings (14), a double-headed flame cutter that can move automatically is used.

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