Suction Caisson Foundation Self-Supporting Assembly
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Solution Overview
Problem
The manufacturing of suction caisson foundations for offshore wind turbines is costly and inflexible due to the need for heavy cranes and strict design tolerances, which increases costs and reduces design flexibility.
Innovation Solution
A method and apparatus that uses a center support and peripheral supports to allow a suction caisson foundation to become self-supporting during manufacture, enabling the removal of the center support without cranes and reducing tolerance stack-ups by attaching skirt panels to radial frame members before attaching them to the thumb section, allowing for horizontal movement and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heavy cranes are used to lift and assemble foundation parts, then assembly is possible, but cost increases and design flexibility is reduced
Solution Approach 1:
The foundation is divided into modular components (thumb section, skirt panels, frame members) that can be assembled in a sequential self-supporting manner. Each module is designed to bear its own weight once installed, eliminating the need for heavy cranes to hold the entire structure during assembly.
Solution Approach 2:
The thumb section and initial frame members are pre-assembled to create a self-supporting structure before attaching the skirt panels. This preliminary assembly creates a stable framework that supports subsequent components without requiring external lifting equipment.
2Manufacturing precision
If strict design tolerances are enforced for piece assembly, then proper fit is achieved, but manufacturing cost increases
Solution Approach 1:
The assembly process is designed to be progressive and adaptive, where each component is installed and becomes self-supporting before the next is added. This dynamic approach allows for minor tolerance variations without compromising the final assembly, as each stage stabilizes the structure before the next load is applied.
Solution Approach 2:
Each foundation component is designed to be self-supporting once installed, with the structure progressively bearing its own weight. The thumb section supports the frame members, which in turn support the skirt panels, creating a self-sustaining assembly process that reduces the need for precision matching and expensive manufacturing tolerances.
3Adaptability or versatility
If the foundation is designed to be self-supporting during manufacture, then crane reliance is reduced, but assembly complexity increases
Solution Approach 1:
The foundation structure is segmented into distinct functional modules (thumb section with initial frame members, skirt panels, lid) that can be manufactured separately and assembled in a logical sequence. Each segment is designed to be self-supporting once installed, simplifying the overall assembly process despite the modular complexity.
Solution Approach 2:
The thumb section and initial frame members are pre-assembled into a stable, self-supporting configuration before skirt panel installation. This preliminary structuring creates a stable platform that simplifies subsequent assembly steps, as each component has a defined support path rather than requiring simultaneous multi-point lifting.
Data Source
AI summary
A method and fixturing apparatus for manufacturing a suction caisson foundation includes providing an elevated center support and peripheral supports, elevating the foundation's prefabricated thumb section atop the center support, and temporarily securing radial frame members about the circumference of the prefabricated thumb section with the each frame member resting atop a respective peripheral support. The skirt panels are then affixed to the frame members, and the frame members to the prefabricated thumb section to thereby become self-supporting. The center support is removed from the interior of the resulting bucket, as by raising the peripheral supports to unload the center support, and lowering and dismantling the center support, whereupon additional panels are affixed to the frame members to define the foundation's lid, and further shaft sections added atop the prefabricated thumb section to complete the foundation. Temporary beams bridging preselected framing members advantageously allow use of transportation crawlers.