Flange Bolting Sequence Based on Measured Gap Dimensions
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Solution Overview
Problem
Large flange connections, such as those in wind turbines, face issues with non-planar contact surfaces leading to gaps and potential premature failure due to uneven tightening, which existing methods fail to address effectively in terms of cost, efficiency, and security.
Innovation Solution
A method involving a measuring carriage with a gap measuring device and a movement device to assess and store gap dimensions between flanges, followed by a sequence-based tightening process using a robot and hydraulic bolt tensioning device to ensure optimal and secure screwing, closing gaps and achieving flange compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flanges are bolted without measuring gap dimensions, then the bolting process is faster and simpler, but the flange connection reliability deteriorates due to cupping and uneven contact
Solution Approach 1:
The gap dimensions are measured before the bolting process begins, allowing the tightening sequence to be predetermined based on actual gap measurements. This preliminary measurement action enables the subsequent bolting to proceed efficiently while ensuring reliability, as the sequence is optimized in advance rather than requiring complex real-time adjustments during tightening.
Solution Approach 2:
The flange connection itself provides the measurement information through its gap dimensions. By measuring the actual gaps between flange surfaces, the system uses the flange's own geometric characteristics to determine the optimal tightening sequence, eliminating the need for external complex control systems while ensuring reliable connection.
2Reliability
If gap dimensions are measured and stored for each bolt system, then the tightening sequence can be optimized, but the measurement and data processing time increases
Solution Approach 1:
All gap dimension measurements are performed before the bolting process begins, and the data is stored for subsequent reference. This preliminary measurement and data storage allows the optimized tightening sequence to be executed without time-consuming measurements during the actual bolting operation, thus maintaining reliability while minimizing time loss.
Solution Approach 2:
The patent replaces complex real-time control systems with a simpler data storage and retrieval approach. By storing the measured gap dimensions and using this stored data to determine the tightening sequence, the system avoids the need for complex real-time processing and control mechanisms, reducing time loss while maintaining optimization benefits.
3Productivity
If bolts are tightened without considering gap dimensions, then the bolting process is simpler and faster, but cupping occurs leading to premature failure
Solution Approach 1:
The gap dimensions are measured and the tightening sequence is determined before the bolting process begins. This preliminary action allows the bolting to proceed at high speed following a pre-optimized sequence, eliminating the need for slow, iterative adjustments during tightening while preventing cupping and ensuring connection durability.
Solution Approach 2:
The gap dimension measurements provide feedback information that determines the optimal tightening sequence. This feedback is captured in advance and used to guide the bolting process, ensuring that bolts are tightened in the correct sequence to prevent cupping while maintaining high productivity throughout the operation.
Data Source
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AI summary
A method for bolting a flange connection is proposed, comprising at least a first flange, a second flange, and a plurality of bolt systems. The first flange and the second flange each have a plurality of flange recesses, each of which can be aligned relative to the other and in which the plurality of bolt systems can be arranged. In particular, at least a plurality of gap dimensions between the first flange and the second flange, attributable to the bolt systems, are measured by means of a gap measuring device. The individual measured gap dimensions are stored in a way that allows for evaluation and assignment to the individual bolt systems. The bolt systems are then tightened in a sequence depending on the gap dimensions assigned to them, using a tightening device.