Radially Expanding Connector Assembly for Preloaded Structural Joints
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Solution Overview
Problem
Current offshore wind turbine connections using large bolts and flanges are cumbersome, difficult to maintain, and lack scalability, with unpredictable preload and high maintenance requirements, and are not suitable for increasing demands from larger turbines and deeper sea installations.
Innovation Solution
A connector system featuring a fork-shaped second member with parallel walls and a first member forming a channel, where a connector is axially inserted and radially expanded to create a pre-tensioned connection, reducing the need for bulky flanges and allowing for more compact, lightweight, and scalable assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flanges with bolts are used to connect members, then the connection provides structural strength, but the assembly becomes heavy and difficult to handle
Solution Approach 1:
The connector is divided into multiple segments (first connector part and second connector part) that can be assembled separately and then joined together. This segmentation allows for easier handling and installation while maintaining the structural strength of the connection, directly addressing the contradiction between connection strength and assembly weight.
2Force
If large bolts are used for connecting wind turbine to monopile, then the connection can withstand high loads, but the tightening tools become heavy and hard to handle
Solution Approach 1:
The connector design transitions from a traditional bolted connection (requiring axial tightening force) to a radially expanding connection. The connector parts are joined by radial expansion rather than axial bolt tightening, eliminating the need for heavy hydraulic tightening tools while maintaining high preload capacity through the radial expansion mechanism.
3Reliability
If flanges with bolts are used, then the connection is structurally sound, but the preload control becomes unpredictable and requires frequent maintenance
Solution Approach 1:
The connector design incorporates a self-locking mechanism where the radial expansion of the connector parts creates friction and mechanical interlocking that maintains the preload without requiring external adjustment. This self-service feature eliminates the need for periodic preload checks and adjustments, reducing maintenance frequency while ensuring connection reliability.
4Stability of the object's composition
If bolts are arranged all around the circumference of flanges, then the connection distributes loads evenly, but the gap between adjacent bolts becomes very limited
Solution Approach 1:
The connector is segmented into multiple parts that can be assembled in sequence rather than requiring simultaneous installation of multiple bolts around the circumference. This segmentation allows for easier alignment and assembly while maintaining even load distribution through the distributed contact surfaces of the connector parts.
5Stability of the object's composition
If conventional flange connections are used, then the assembly is structurally stable, but it is insufficiently scalable for larger wind turbines and greater depths
Solution Approach 1:
The connector design is universal and can be applied to various sizes and types of members, from small wind turbine components to large monopiles and transition pieces. The radial expansion mechanism and segmented structure allow the same basic connector design to be scaled up or down for different applications, providing adaptability and versatility while maintaining structural stability.
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 solution provides a reliable, low-fatigue connection with reduced load fluctuations, less material usage, and easier assembly, eliminating the need for heavy tools and frequent maintenance, while being applicable in underwater conditions and suitable for larger wind turbines.
Implementation Method 1
a connector (24) that is axially insertable in said channel (23) to an end position and consecutively expandable radially relative to said channel (23), to connect the first (18) and second member (19) relative to each other
Implementation Method 2
the connector (24), in an expanded state thereof, pushes the first member (18) against the main body (35) of the second member (19) to define a pre-tensioned connection between the first member (18) and the second member (19)
Data Source
AI summary
An assembly includes a first and a second member, where the second member has a fork-shaped cross section with a main body and two substantially parallel walls that each comprise at least one through hole and the first member is arranged between the two walls of the second member, having a through hole. The through hole of the first member and the through holes of the second member define a channel. A connector is axially insertable in the channel to an end position and consecutively expandable radially relative to said channel, to connect the first and second member relative to each other. The connector, in an expanded state thereof, pushes the first member against the main body of the second member to define a pre-tensioned connection between the first member and the second member. A method of assembling a first and a second member.