Bolt Elongation Coupling Unit for Low-Friction Thread Engagement
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Solution Overview
Problem
Existing bolt elongation tools for wind turbine tower assembly are labor-intensive, prone to errors, and risk damage due to high friction and load during thread engagement.
Innovation Solution
A coupling unit that includes a lowering unit, a rotation unit, and a height compensation unit to automatically match the thread engagement means with the bolt threads, reducing friction and the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the thread engagement means is manually screwed onto the bolt, then the stretching force can be applied to the bolt, but the process is time-consuming and prone to errors due to high friction forces and loads on the first few threads
Solution Approach 1:
The patent replaces the manual mechanical screwing operation with an automated coupling unit that uses a lowering unit to vertically lower the thread engagement means onto the bolt while a rotation unit simultaneously rotates it. This automated mechanical system eliminates manual operation errors and ensures precise control over the thread engagement process, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The coupling unit performs preliminary positioning and alignment of the thread engagement means with the bolt before actual thread engagement occurs. The lowering unit positions the thread engagement means at the correct height and the rotation unit pre-rotates it to match the thread pitch, ensuring smooth engagement from the first thread and preventing the high friction and damage issues that occur with manual screwing.
2Ease of manufacture
If the thread engagement means is manually screwed onto the bolt, then the stretching force can be applied, but damage to the bolt and/or thread engagement means may occur due to high friction forces and loads
Solution Approach 1:
The patent replaces the manual screwing mechanism with an automated coupling unit comprising a lowering unit and rotation unit. This system controls the engagement process precisely, lowering the thread engagement means vertically onto the bolt while simultaneously rotating it at the correct speed to match the thread pitch. This eliminates the high friction forces and impact loads that occur during manual screwing, preventing damage to both the bolt and thread engagement means while maintaining ease of operation.
3Strength
If the thread engagement means is heavy, then it can provide sufficient strength for elongation, but the first few threads have to resist high friction forces and loads during screwing on
Solution Approach 1:
The patent segments the thread engagement means into two functional parts: a heavy-duty expansion device for applying the stretching force, and a lighter coupling unit with lowering and rotation mechanisms for the engagement process. The coupling unit handles the positioning and threading operations with minimal friction, while the expansion device provides the necessary strength for elongation. This segmentation resolves the contradiction by allowing the strength function and operation ease function to be performed by differently optimized components.
Solution Approach 2:
The patent replaces the manual mechanical screwing operation with an automated coupling unit that uses controlled vertical lowering and simultaneous rotation. This automated system eliminates the high friction forces that occur when manually screwing on heavy thread engagement means, making the operation easier while maintaining the strength integrity of the components through controlled engagement.
4Reliability
If manual torquing is performed with torque wrenches, then the necessary clamping forces can be achieved, but the process is labor-intensive and the tools are expensive and prone to errors
Solution Approach 1:
The patent merges multiple functions into a single integrated bolt elongation tool: the thread engagement means, the expansion device for applying stretching force, and the coupling unit with lowering and rotation mechanisms. This unified system eliminates the need for separate torque wrenches and manual operations, achieving reliable clamping forces through controlled bolt elongation while reducing overall device complexity and eliminating the errors prone to manual torquing processes.
5Device complexity
If the thread engagement means is screwed onto the bolt manually, then the process can be performed with simple tools, but it is time-consuming and may require unscrewing and restarting
Solution Approach 1:
The patent replaces simple manual screwing tools with an automated coupling unit that uses a lowering unit to vertically lower the thread engagement means onto the bolt while a rotation unit simultaneously rotates it at the correct speed. This automated mechanical system ensures continuous successful engagement without the need to unscrew and restart, dramatically improving productivity while maintaining relatively simple tooling architecture.
Solution Approach 2:
The coupling unit performs preliminary positioning and alignment of the thread engagement means with the bolt before actual thread engagement. The lowering unit positions the thread engagement means at the correct height and the rotation unit pre-rotates it to match the thread pitch, ensuring smooth engagement from the first thread. This preliminary action prevents the need to unscrew and restart, improving productivity while keeping the device structure relatively simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coupling unit enables efficient, precise, and automated thread engagement, reducing the risk of errors and damage, and allowing for consistent, high-clamping forces in wind turbine tower assembly.
Implementation Method 1
By matching the rotational speed of the thread engagement means with the lowering speed of the lowering unit and the thread feed of the bolt, an automatic matching of the thread engagement means, and the threads of the bolt can be achieved. Hereby the friction between the thread engagement means and the threads of the bolt are reduced
Implementation Method 2
The coupling unit comprises a lowering unit configured to lower the thread engagement means onto the bolt and towards the flange connection
Implementation Method 3
an expansion device connected to the thread engagement means configured to exert a force essentially perpendicular to and away from the flange connection onto the thread engagement means
Implementation Method 4
Once this lock nut has been fastened, the stretching force is released, and the bolt returns to its original length, thereby clamping the lock nut
Data Source
AI summary
A coupling unit configured to couple a rotatable thread engagement device of a bolt elongation tool for elongating a bolt of a flange connection with the bolt, wherein the bolt elongation tool includes the thread engagement device and an expansion device connected to the thread engagement device, where the coupling unit includes a lowering unit configured to lower the thread engagement device onto the bolt and towards the flange connection, and a rotation unit configured to rotate the thread engagement device when the thread engagement device is lowered, with a rotational speed corresponding to a thread feed of the bolt.