Detachable Tower Base Rings for Wind Turbines
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Solution Overview
Problem
The high costs associated with wind turbine tower base adapter and door section components, including welding certification and transportation limitations, necessitate a more cost-effective and efficient interface between the tower base and foundation.
Innovation Solution
A detachable tower base ring assembly comprising two or three rings (top, middle, and bottom) that secure the L-flange of the tower base section to the foundation, eliminating the need for a welded T-flange and extra L-flanges, allowing for easier access and maintenance by incorporating troughs and apertures for installation and maintenance access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a tower base adapter with welded T-flange is used to secure the tower base to the foundation, then the connection strength and stability are improved, but the manufacturing cost and transportation cost increase significantly
Solution Approach 1:
The tower base adapter is divided into multiple detachable segments: a tower base section with L-flange, a ring section with troughs, and a foundation section. These segments can be manufactured separately and assembled on-site using bolting instead of welding, eliminating the need for expensive welded T-flanges and welding certification while maintaining connection strength.
Solution Approach 2:
The connection method transitions from static welded joints to dynamic bolted connections. The detachable ring assembly with multiple bolt holes allows for flexible assembly and disassembly, enabling transportation of smaller components and simplifying manufacturing while maintaining structural integrity through proper bolting patterns.
2Stability of the object's composition
If a tower base adapter with T-flange is used to secure the tower base to the foundation, then the connection stability is improved, but the transportation cost and logistics complexity increase due to exceeding size limits
Solution Approach 1:
The adapter is segmented into transportable components including a tower base section, a ring section with troughs, and a foundation section. Each segment fits within standard transportation dimensions, allowing separate shipping and on-site assembly, thereby eliminating logistics constraints while preserving overall structural stability through proper connection design.
3Strength
If a tower base adapter with extra L-flanges is used to secure the tower base to the foundation, then the structural integrity is improved, but the manufacturing cost increases due to additional components
Solution Approach 1:
Multiple structural functions are merged into the detachable ring assembly. The ring section with integrated troughs combines support, alignment, and connection functions that would otherwise require separate components like additional L-flanges. This consolidation reduces the total number of parts while maintaining structural integrity through the integrated design.
Solution Approach 2:
The detachable ring assembly serves multiple functions simultaneously: it provides structural support, enables alignment through tapered surfaces, facilitates connection through bolt holes, and allows maintenance access through troughs. This multi-functionality eliminates the need for separate specialized components, reducing overall component quantity while preserving structural integrity.
4Ease of manufacture
If the tower entry door is located at higher height to accommodate the tower base adapter, then the adapter installation is facilitated, but the cost of external stairs and structures increases
Solution Approach 1:
Instead of positioning the tower base adapter at a height that facilitates its installation, the design inverts the approach by enabling ground-level or low-height assembly. The detachable ring components can be assembled on the ground and then lifted into position, or the tower base section can be assembled with the ring at lower heights, eliminating the need for elevated installation platforms and reducing tower height requirements.
5Reliability
If the tower base adapter is used to secure the tower base to the foundation, then the connection reliability is improved, but the maintenance access and equipment accessibility deteriorate
Solution Approach 1:
The ring section incorporates localized troughs at specific positions where maintenance access is needed. These troughs create localized openings in the ring structure, allowing technicians to access bolts and connection points without compromising the overall structural integrity or connection reliability of the adapter assembly.
Solution Approach 2:
The troughs act as intermediary access channels that mediate between the need for reliable enclosed connection and the need for maintenance access. These localized openings provide passage for tools and hands while maintaining the structural continuity and reliability of the tower base adapter connection through proper reinforcement and bolt placement.
Data Source
AI summary
A tower base ring assembly is provided for securing a wind turbine tower to a foundation. A top ring is configured for securing to a wind turbine tower. A bottom ring has an open center and a plurality of radially oriented troughs spaced circumferentially about the open center, with each trough having an outer end. The top ring and the bottom ring are detachable from one another, and the tower base ring assembly is connectable to the foundation.