Wind Turbine Flange Bolt Tensioning With Automated Rotation Control
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Solution Overview
Problem
Manual bolt tensioning in wind turbine flange joints is labor-intensive, prone to errors, and difficult in harsh conditions, making it challenging to ensure consistent stiffness and strength, and complicates post-incident analysis.
Innovation Solution
An automated method and system for controlled bolt tensioning, using a fixture and bolt tensioning tool mounted to a nacelle, with a control unit that rotates the flange joint to position bolts within the tool's working area, allowing for precise and automated tensioning of bolts, reducing manual labor and improving safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual bolt tensioning is used, then flexibility and adaptability in working conditions are maintained, but labor intensity increases and consistency of tensioning quality deteriorates
Solution Approach 1:
The automated tensioning system performs operations autonomously without continuous manual intervention. The control unit automatically sequences the tensioning of multiple bolts, moves the tensioning tool between bolts, and maintains consistent tensioning parameters, enabling the system to serve itself and eliminate manual labor while ensuring uniform quality across all bolts.
2Reliability
If automated tensioning system is implemented, then tensioning consistency and safety are improved, but device complexity increases
Solution Approach 1:
The automated tensioning system integrates multiple functions into a single unified platform. The control unit coordinates flange rotation, positions the tensioning tool, sequences bolt tensioning operations, and logs tensioning data. This multi-functional integration improves reliability through consistent automated execution while managing complexity by consolidating control functions rather than requiring separate systems for each operation.
3Ease of operation
If manual bolt tensioning is performed in harsh conditions, then adaptability to difficult positions is maintained, but health and safety risks increase
Solution Approach 1:
The automated tensioning system acts as an intermediary between the operator and the hazardous environment. The control unit and automated tensioning tool perform all operations in difficult-to-reach positions around the flange, eliminating the need for personnel to manually access hazardous areas. The system logs and transmits data remotely, allowing operators to monitor and control the process from a safe location while maintaining full operational capability in harsh conditions.
4Productivity
If automated flange rotation and tensioning is used, then productivity and precision are improved, but device complexity and initial setup requirements increase
Solution Approach 1:
The system merges flange rotation, tool positioning, and tensioning operations into a single coordinated automated process. The control unit synchronizes the rotation of the flange with the movement and operation of the tensioning tool, combining multiple sequential manual operations into one integrated automated sequence. This merging dramatically increases productivity by eliminating manual repositioning and setup time while managing complexity through unified control of all motion and tensioning functions.
Data Source
AI summary
The invention relates to a method for the controlled and automatic tensioning of bolts pre-installed in a flange joint between a hub and a main shaft in a nacelle of a wind turbine as well as to a bolt tensioning system for such method. The method comprises arranging a fixture inside the nacelle and mounting a bolt tensioning tool to the fixture which is mounted movable in an axial direction and in a working area perpendicularly hereto. First the flange joint is rotated to position a first set of bolts within the working area of the bolt tensioning tool, and then the bolt tensioning tool is controlled alternately to move the tensioning tool into a position for tensioning a bolt and to tension the bolt, until all bolts of the first set of bolts have been tensioned. The rotation of the flange joint may be controlled by operating a rotation tool operably connected to the main shaft, gearbox, and/or generator.