Prestressed ribbed concrete filled steel tube cage type tower structure

Abstract

The utility model relates to a prestressed ribbed concrete filled steel tube cage type tower structure which comprises a plurality of sections of connected steel tube cages, and each section of steel tube cage comprises prestressed concrete steel tubes, metal rings, crossed steel tubes and transverse steel tubes. The prestressed concrete steel pipes are annularly arranged and are composed of steel pipes, stiffeners bonded to the inner side walls of the steel pipes, prestressed steel strand bundles penetrating through the axial directions of the steel pipes and self-compacting high-strength concrete. The multiple layers of metal rings are welded to the outer side of the prestressed concrete steel pipe, and vertical connecting flanges are arranged at the ends of the metal rings. The plurality of prestressed concrete steel pipes are connected into a cage-shaped structure by the crossed steel pipes and the transverse steel pipes through the connecting plates and the welding lug plates; wherein the steel pipe cage is formed by splicing at least two semi-arc-shaped prefabricated sections on site, splicing surfaces are fixed through vertical connecting flanges and connecting plates by bolts, and the bolt connecting positions are covered with welding layers to form a maintenance-free structure. The fatigue life of the whole tower is remarkably prolonged, and the tower is suitable for land high-wind-speed draught fans and offshore wind power scenes.

Description

Technical Field

[0001] This utility model relates to the field of wind power generation equipment technology, and in particular to a prestressed ribbed steel pipe concrete cage tower structure, which is suitable for the support structure of large onshore and offshore wind turbine generators. Background Technology

[0002] With the rapid upgrading of wind power installations, existing wind turbine steel towers are facing problems such as insufficient structural strength and low material utilization efficiency. Therefore, it is particularly important to study a new wind turbine steel tower with sufficient structural strength and high material utilization efficiency.

[0003] In recent years, concrete-steel pipe truss structures have received widespread attention and been widely used due to their high structural strength. However, some problems still need to be solved during operation: such as uneven stress distribution between the internal concrete and steel pipe contact surfaces under high-frequency vibration, excessive number of steel pipe connecting bolts, long tower installation cycle, and no reduction in steel consumption compared to steel towers. Utility Model Content

[0004] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a prestressed ribbed steel pipe concrete cage tower structure, which significantly improves the fatigue life of the entire tower, is suitable for onshore high wind speed wind turbines and offshore wind power scenarios, and has promotional value.

[0005] The above-mentioned utility model objective is achieved through the following technical solution:

[0006] A prestressed ribbed steel tube concrete cage tower structure includes several connected steel tube cages, each of which contains a prestressed concrete steel tube, a metal ring, intersecting steel tubes, and transverse steel tubes.

[0007] Multiple prestressed concrete steel pipes are arranged in a ring and consist of steel pipes, ribs bonded to the inner wall of the steel pipes, prestressed steel strand bundles passing through the axial direction of the steel pipes, and self-compacting high-strength concrete.

[0008] The multi-layered metal rings are welded to the outside of the prestressed concrete steel pipe, and the ends of the metal rings are provided with vertical connecting flanges.

[0009] The intersecting steel pipes and the transverse steel pipes are connected to form a cage structure by connecting plates and welded ear plates.

[0010] The steel pipe cage is assembled on site from at least two semi-circular prefabricated sections. The assembly surface is fixed with bolts through vertical connecting flanges and connecting plates, and the bolted joints are covered with a welded layer to form a maintenance-free structure.

[0011] As a further technical solution of this utility model: the ribs are one of the following: ribbed threaded steel bars, round bars, steel bars, angle steel, and reinforced steel pipes. The ribs are distributed at equal intervals of 4 or 8 along the axial direction of the steel pipe and are bonded to the inner wall of the steel pipe by epoxy adhesive.

[0012] As a further technical solution of this utility model: the metal ring includes an upper metal ring, a middle metal ring and a lower metal ring, the inner side of the upper metal ring is provided with an upper flange, the inner side of the lower metal ring is provided with a lower flange, and the upper flange and the lower flange are respectively used to connect adjacent steel pipe cage sections.

[0013] As a further technical solution of this utility model: the arrangement of the metal ring corresponds to that of the steel pipe cage. When a straight steel pipe cage is used, the metal ring has a constant diameter; when a tapered steel pipe cage is used, the metal ring has a tapered shape, and the tapered shape corresponds to the tapered shape of the steel pipe cage.

[0014] As a further technical solution of this utility model: the two ends of the prestressed concrete steel pipe are respectively provided with a lower flange and an upper flange, and the flange end faces of the lower flange and the upper flange are provided with bolt holes for longitudinal flange connection between sections.

[0015] As a further technical solution of this utility model: the cross steel pipe and the transverse steel pipe are connected on the assembly surface by a connecting plate with bolt holes, and the non-assembly surface is directly welded and fixed by welding ear plates.

[0016] As a further technical solution of this utility model: the connecting plate is welded to the outer wall of the prestressed concrete steel pipe, and the plate surface extends to the assembly end face to form a bolt connection interface.

[0017] As a further technical solution of this utility model: the prestressed steel strand bundle is provided with a PVC sleeve, and the space between the inner wall of the steel pipe and the PVC sleeve is filled with C80 grout.

[0018] As a further technical solution of this utility model: the arc of the semi-circular prefabricated section is 120°-180°.

[0019] As a further technical solution of this utility model: the welding layer covering the connection of the bolt completely covers the bolt head and nut, forming a permanent closed structure.

[0020] In summary, this utility model has at least one of the following beneficial technical effects:

[0021] 1. This utility model discloses a prestressed reinforced steel pipe concrete cage tower structure. Its main load-bearing structure is a prestressed concrete steel pipe, with several large-diameter threaded steel reinforcement bars inside the pipe. Typically, prestressed steel strands are tensioned first, followed by pouring self-compacting high-strength concrete. This method significantly improves the various properties of the main load-bearing steel pipe concrete. The main load-bearing steel pipe concrete is arranged in a ring, with large-diameter metal rings welded together on the inner side. Several slender steel pipes are welded together to form a cage between the main load-bearing steel pipes. Due to transportation limitations, each steel pipe cage is fabricated in two semi-circular sections. Vertical connecting flanges are installed at the ends of the metal rings on the connecting surfaces. Connecting plates on the connecting surfaces are used to connect intersecting and transverse steel pipes. The connecting surfaces are bolted on-site, while non-connecting surfaces are welded in the factory. Each steel pipe cage section is connected by steel pipe flanges and metal ring flanges to form a complete wind turbine tower. The synergistic effect of reinforcing ribs and prestressed concrete significantly improves the bending stiffness of the main load-bearing steel pipe and increases material utilization efficiency. Simultaneously, this design allows for a reduction in the wall thickness or diameter of the main load-bearing steel pipe, reducing steel weight and significantly lowering costs. Semi-circular fabrication eliminates transportation limitations, reduces the number of on-site bolt connections, and significantly improves the fatigue life of the entire tower. Suitable for onshore high-wind-speed wind turbines and offshore wind power applications, this design has significant potential for widespread adoption.

[0022] 2. This utility model employs a composite steel pipe with reinforced ribs, prestressing, and self-compacting high-strength concrete. This enhances the synergistic stress distribution between the high-frequency vibrating concrete and the steel pipe, significantly improving the bending resistance of the main load-bearing steel pipe and increasing material utilization efficiency. Simultaneously, it optimizes the design of the steel pipe's diameter, wall thickness, and quantity, thereby reducing costs. Through semi-arc factory welding, the number of on-site connection bolts and installation steps is reduced, improving the fatigue life of the entire tower and shortening the construction cycle. It has broad application prospects in the development of large-capacity wind turbines. Attached Figure Description

[0023] Figure 1 This is a front view of the structural connection surface of this utility model.

[0024] Figure 2 This is a front view of the non-connected surface of the structure of this utility model.

[0025] Figure 3 for Figure 1 Cross-sectional view along the middle AA'.

[0026] Figure 4 for Figure 1 Cross-sectional view along the middle BB'.

[0027] Figure 5 for Figure 3 Cross-sectional view of the steel pipe.

[0028] Reference numerals: 100, prestressed concrete steel pipe; 101, steel pipe; 102, reinforced bar; 103, prestressed steel strand; 104, self-compacting high-strength concrete; 110, lower flange of steel pipe; 120, upper flange of steel pipe; 200, metal ring; 210, lower metal ring; 220, upper metal ring; 230, vertical connecting flange; 300, intersecting steel pipe; 310, transverse steel pipe; 320, connecting plate; 330, welded lug plate. Detailed Implementation

[0029] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0030] In the description of this application, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application 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, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0031] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0032] Example 1:

[0033] Reference Figure 1 and Figure 2 This utility model discloses a prestressed ribbed steel pipe concrete cage tower structure, which includes several connected steel pipe cages. Each steel pipe cage includes a prestressed concrete steel pipe 100, a metal ring 200, a cross steel pipe 300, and a transverse steel pipe 310.

[0034] The prestressed concrete steel pipe 100 is the main load-bearing structure of the steel pipe cage, arranged in a ring. The number of pipes is preferred. Depending on the project requirements, it can be designed as a straight cylindrical steel pipe cage tower or a tapered steel pipe cage tower.

[0035] Reference Figure 5 The prestressed concrete steel pipe 100 consists of a steel pipe 101, reinforcing bars 102, prestressed steel strands 103, and self-compacting high-strength concrete 104. It has connecting flanges at both ends, namely a lower flange 110 and an upper flange 120, for connecting the upper and lower main load-bearing steel pipes 101. The steel pipe 101 is a large-diameter steel pipe, with optimized material, diameter, and wall thickness.

[0036] The reinforcing rib 102 refers to a slender, rigid metal material, a reinforcing material whose cross-sectional size and shape are not limited, including but not limited to ribbed threaded steel bars, round bars, steel bars, angle steel, reinforced steel pipes, and other rigid materials. The reinforcing rib 102 is connected to the inside of the steel pipe 101, primarily using self-flowing epoxy adhesive. The preferred quantity is a multiple of 4 or 8. The reinforcing rib 102 must be connected to the steel pipe 101 one by one; the next reinforcing rib 102 can only be bonded after the previous reinforcing rib 102 has cured with the epoxy adhesive on the inside of the steel pipe 101.

[0037] The prestressed steel strand 103 consists of several steel strands and anchorages. The load meets design requirements and runs through the entire main load-bearing steel pipe 101 during on-site installation. After installation, it is tensioned and secured as required. Self-compacting high-strength concrete 104 is filled inside the steel pipe 101 after the steel pipe 101 is connected and the prestressed steel strand 103 is tensioned correctly. It serves to anchor the steel strands and enhance the bending strength of the steel pipe 101. Alternatively, the prestressed steel strand 103 can be tensioned post-planned. PVC pipes are pre-inserted into the steel strands, and after the self-compacting high-strength concrete 104 in each section of the steel pipe cage is poured and reaches its strength, the entire structure is post-tensioned. Finally, C80 grout is poured inside the PVC pipes.

[0038] The metal ring 200 is manufactured using the same process as the wind turbine tower, employing mature manufacturing techniques, including cylinder joining and rolling, longitudinal seam welding, and circumferential seam assembly, with optimized cross-sectional dimensions and wall thickness. In this embodiment, three large-diameter metal rings 200 are temporarily arranged in the upper, middle, and lower sections of the steel pipe cage.

[0039] Reference Figure 3 and Figure 4 The upper metal ring 220 has an inner connecting flange for connecting to the lower metal ring 210 connecting flange of the upper section of the steel pipe cage. The outer side of the upper metal ring 220 is welded to the main load-bearing steel pipe 101 arranged in a ring. The outer side of the middle metal ring is welded to the main load-bearing steel pipe 101 arranged in a ring. The lower metal ring 210 has an inner connecting flange for connecting to the upper metal ring 220 connecting flange of the lower section of the steel pipe cage. The outer side of the lower metal ring 210 is welded to the main load-bearing steel pipe 101 arranged in a ring.

[0040] The metal ring 200 corresponds to the arrangement of the steel pipe cage. When a straight steel pipe cage is used, the metal ring 200 has a constant diameter; when a tapered steel pipe cage is used, the metal ring 200 is tapered, and the taper corresponds to the taper of the steel pipe cage. The intersecting steel pipes 300 and the transverse steel pipes 310 are made of thin-walled steel pipes, mainly used to connect the steel pipes 101 into a cage. Their length, diameter, and wall thickness are selected based on the stress. Connecting plates 320 are installed on-site with bolts at the connection surfaces, while welding lugs 330 are used for factory welding at non-connection surfaces.

[0041] Each steel pipe cage segment is fabricated in two (or three, or four) semi-circular shapes. Each semi-circular steel pipe cage segment is welded together from steel pipe 101, semi-metallic rings, intersecting steel pipes 300, and transverse steel pipes 310. The semi-metallic rings are equipped with vertical connecting flanges 230, which, when connected, form a complete metal ring 200.

[0042] The intersecting steel pipes 300 and the transverse steel pipes 310 are bolted together with the connecting plates 320 set on the steel pipes 101 at the connection surfaces, forming a complete steel pipe cage section. The connecting bolts are then welded in place using methods such as welding, achieving maintenance-free bolt installation. Several steel pipe cage sections are connected by the connecting flanges of the steel pipes 101 and the connecting flanges of the metal rings 200 to form a complete prestressed ribbed steel pipe 101 concrete cage tower. The top metal ring 200 is used to connect to the top section of the wind turbine steel tower, where the wind turbine hub, blades, turbine, and other equipment are installed.

[0043] To facilitate understanding of this utility model, a construction method for a prestressed ribbed steel tube concrete cage tower structure is as follows:

[0044] Step 1: Determine the main parameters of all components, such as model, quantity, size, wall thickness, and distribution, based on the project capacity.

[0045] Step 2: Complete the connection between the reinforcing ribs 102 and the steel pipe 101, using epoxy adhesive to connect them one by one; complete the welding of the steel pipe 101 to the corresponding connecting flange; complete the welding of the metal ring 200 to the corresponding connecting flange.

[0046] Step 3: Position the semi-circular main load-bearing steel pipe 101 using a large operating platform, then weld the semi-metallic ring and the intersecting steel pipe 300 and transverse steel pipe 310. Weld a flange to the end of the semi-metallic ring, and install a connecting plate 320 on the outside of the connecting steel pipe 101. After welding, perform anti-corrosion treatment on the entire component.

[0047] Step 4: Transport the finished semi-circular steel pipe cage to the project site. Use transport supports to install the formed semi-circular steel pipe cage, ensuring that the metal ring 200 and the intersecting steel pipes 300 and the transverse steel pipes 310 are not subjected to stress during transportation.

[0048] Step 5: Assembly. Using metal ring 200 flanges and connecting plate 320, multiple semi-circular steel pipe cages are assembled into a complete steel pipe cage segment. Finally, the connecting bolts are welded in place by welding or other methods to achieve maintenance-free operation.

[0049] Step 6: Lifting. The lifting point is the main load-bearing steel pipe 101. The upper and lower steel pipe cage sections are installed using the flange of steel pipe 101 and the metal ring 200 flange. Finally, the end wind turbine tower is installed.

[0050] Step 7: Assemble the wind turbine equipment on site according to the design requirements, install the upper blades, hub and other structures step by step, and finally put it into operation.

[0051] The implementation principle of this utility model is as follows: This utility model discloses a prestressed ribbed steel pipe concrete cage tower structure. Its main load-bearing structure is a prestressed concrete steel pipe 100. Several large-diameter threaded steel bars 102 are set on the inner side of the steel pipe 101. Usually, prestressed steel strands 103 are tensioned first, and self-compacting high-strength concrete 104 is poured. This method can greatly improve the various properties of the main load-bearing steel pipe 101 concrete. The main load-bearing steel pipe 101 concrete is arranged in a ring, and the inner side is connected by welding with large-diameter metal rings 200. Several slender steel pipes 101 are welded together to form a cage between the main load-bearing steel pipes 101. Due to transportation restrictions, each section of steel pipe cage is processed and manufactured in two semi-circles. A vertical connecting flange 230 is set at the end of the metal ring 200 on the connecting surface. The steel pipe 101 on the connecting surface is equipped with a connecting plate 320 for connecting the intersecting steel pipes 300 and the transverse steel pipes 310. The connecting surface is connected by bolts on site, and the non-connecting surface is welded in the factory. Each section of the steel pipe cage is connected to form a complete wind turbine tower using steel pipe 101 flanges and metal ring 200 flanges. Through the synergistic effect of the reinforcing ribs 102 and prestressed concrete, the bending stiffness of the main load-bearing steel pipe 101 is significantly improved, increasing material utilization efficiency. Simultaneously, this design allows for a reduction in the wall thickness or diameter of the main load-bearing steel pipe 101, reducing the weight of the steel material and significantly lowering costs. The semi-circular manufacturing process eliminates transportation limitations, reduces the number of on-site bolt connections, and significantly improves the fatigue life of the entire tower. Suitable for onshore high-wind-speed wind turbines and offshore wind power applications, it has significant potential for widespread adoption.

[0052] The embodiments described herein are preferred embodiments of this utility model and are not intended to limit the scope of protection of this utility model. Therefore, all equivalent changes made to the structure, shape, and principle of this utility model should be included within the scope of protection of this utility model.

Claims

1. A prestressed ribbed steel tube concrete cage tower structure, characterized in that, It includes several connected steel pipe cages, each of which comprises a prestressed concrete steel pipe (100), a metal ring (200), a cross steel pipe (300), and a transverse steel pipe (310); Multiple prestressed concrete steel pipes (100) are arranged in a ring and consist of a steel pipe (101), a reinforcing bar (102) bonded to the inner wall of the steel pipe (101), a bundle of prestressed steel strands (103) passing through the axial direction of the steel pipe (101), and self-compacting high-strength concrete (104). The multi-layered metal rings (200) are welded to the outside of the prestressed concrete steel pipe (100), and the ends of the metal rings (200) are provided with vertical connecting flanges (230); The cross steel pipe (300) and the transverse steel pipe (310) are connected to form a cage structure by connecting plate (320) and welded ear plate (330) for multiple prestressed concrete steel pipes (100); The steel pipe cage is assembled on site from at least two semi-circular prefabricated sections. The assembly surface is fixed with bolts through vertical connecting flanges (230) and connecting plates (320), and the bolt connection is covered with a welding layer to form a maintenance-free structure.

2. The prestressed ribbed steel tube concrete cage tower structure according to claim 1, characterized in that, The ribs (102) are one of the following: ribbed threaded steel bars, round bars, steel bars, angle steel, and reinforced steel pipes. The ribs (102) are distributed at equal intervals of 4 or 8 along the axial direction of the steel pipe (101) and are bonded to the inner wall of the steel pipe (101) by epoxy adhesive.

3. The prestressed ribbed steel tube concrete cage tower structure according to claim 1, characterized in that, The metal ring (200) includes an upper metal ring (220), a middle metal ring and a lower metal ring (210). The upper metal ring (220) has an upper flange on its inner side and the lower metal ring (210) has a lower flange on its inner side. The upper flange and the lower flange are used to connect adjacent steel pipe cage sections.

4. The prestressed ribbed steel tube concrete cage tower structure according to claim 1, characterized in that, The metal ring (200) corresponds to the arrangement of the steel pipe cage. When a straight steel pipe cage is used, the metal ring (200) is of equal diameter. When a tapered steel pipe cage is used, the metal ring (200) is tapered, and the tapering corresponds to the tapering of the steel pipe cage.

5. A prestressed ribbed steel tube concrete cage tower structure according to claim 1, characterized in that, The prestressed concrete steel pipe (100) is provided with a lower flange and an upper flange at both ends. The flange end faces of the lower flange and the upper flange are provided with bolt holes for longitudinal flange connection between sections.

6. A prestressed ribbed steel tube concrete cage tower structure according to claim 1, characterized in that, The cross steel pipe (300) and the transverse steel pipe (310) are connected to the steel pipe (101) on the assembly surface by a connecting plate (320) with bolt holes, and the non-assembly surface is directly welded and fixed by welding ear plates (330).

7. A prestressed ribbed steel tube concrete cage tower structure according to claim 6, characterized in that, The connecting plate (320) is welded to the outer wall of the prestressed concrete steel pipe (100), and the plate surface extends to the assembly end face to form a bolt connection interface.

8. A prestressed ribbed steel tube concrete cage tower structure according to claim 1, characterized in that, The prestressed steel strand (103) bundle is surrounded by a PVC sleeve, and the space between the inner wall of the steel pipe (101) and the PVC sleeve is filled with C80 grout.

9. A prestressed ribbed steel tube concrete cage tower structure according to claim 1, characterized in that, The arc of the semi-circular prefabricated section is 120°-180°.

10. A prestressed ribbed steel tube concrete cage tower structure according to claim 1, characterized in that, The weld layer covering the connection of the bolts completely covers the bolt head and nut, forming a permanent closed structure.

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