Arcuate Segment Alignment Tool for Annular Structure Assembly
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Solution Overview
Problem
Existing methods for fabricating and transporting large annular structures, such as anode cages for offshore wind turbines, are impractical due to size and/or weight limitations, particularly for offshore applications, and require significant improvements in alignment and assembly, especially for offshore wind turbine monopiles.
Innovation Solution
A transport and assembly alignment tool that includes alignment fixtures and bracing members that are used to align and secure arcuate segments during fabrication and transport, ensuring circularity and structural integrity without external support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the annular structure is fabricated in one piece, then structural integrity is improved, but transportability deteriorates due to size and weight limitations
Solution Approach 1:
The annular structure is divided into multiple arcuate segments that can be transported separately on road vehicles. Each segment maintains sufficient structural integrity on its own, and the segments are designed to be reassembled at the installation site to form the complete annular structure, thus resolving the contradiction between structural integrity and transportability.
Solution Approach 2:
The arcuate segments are pre-assembled into a complete annular structure at the fabrication site using alignment tools and bracing members before transport. This preliminary assembly allows the structure to be disassembled into transportable segments while maintaining the ability to be reassembled with proper alignment, addressing both structural integrity requirements and transport constraints.
2Length of moving object
If the annular structure is segmented for transport, then transportability is improved, but alignment precision deteriorates during reassembly
Solution Approach 1:
Alignment tools serve as intermediary devices during the reassembly process. These tools include alignment members that fit into corresponding features on the arcuate segments, providing precise guidance for positioning. The bracing members act as additional intermediaries that maintain structural rigidity and circularity during assembly, ensuring that segments align accurately without requiring external support.
Solution Approach 2:
The alignment process occurs in periodic stages: first, alignment tools are positioned on the segments; second, the segments are brought together using the alignment members as guides; third, bracing members are installed to maintain alignment; and fourth, permanent connections are made. This staged periodic approach ensures precise alignment is achieved and maintained throughout the reassembly process.
3Manufacturing precision
If alignment tools are used during assembly, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The alignment tools are designed with multi-functionality to reduce overall system complexity. The alignment members serve multiple purposes: they guide segment positioning, maintain circularity during assembly, and provide reference features for bracing member installation. The bracing members themselves serve dual functions of maintaining structural rigidity and facilitating alignment, thereby reducing the need for separate specialized tools for each function.
Data Source
AI summary
A transport and assembly alignment tool, for prefabrication, transport and/or erection/assembly of a plurality of arcuate segments or near identical modules into a large annular or toroidal structure includes one or more alignment fixtures that have a matched pair of mating alignment members. The alignment members each have a first circularity and/or axial alignment member which aligns to a second circularity and/or axial alignment member. The first circularity and/or axial alignment member is held in alignment with the second circularity and/or axial alignment member by a radially extending alignment feature to establish circumferential alignment thereof and are locked together by locking means. The first axial alignment member is rigidly secured to a first one of the arcuate segments proximate to one circumferential end thereof and the second axial alignment member rigidly secured to a second one of the arcuate segments proximate to one circumferential end thereof.