Flange Hole Alignment Device for Wind Turbine Towers
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Solution Overview
Problem
The alignment of flanges in wind turbine towers is challenging due to deformation caused by the weight of the tower sections, leading to misalignment and increased stress on fasteners, which prolongs the assembly process and requires expensive mobile cranes and on-site personnel.
Innovation Solution
A device with a shaft and pushers that can extend into and align holes of flanges, allowing for precise alignment without pre-alignment, facilitated by pushers exerting pressure against the inner walls to overcome misalignment and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If tower sections are stored for long periods, then the sections can be prepared in advance for assembly, but the weight force causes ovalization of the circular section and misalignment of holes
Solution Approach 1:
The alignment device is attached to the tower section in advance during storage, before assembly takes place. This preliminary attachment allows the device to maintain alignment of the holes throughout the storage period, preventing misalignment caused by ovalization from prolonged storage.
2Force
If heavy mobile cranes are used for erecting wind turbines, then tower sections can be lifted and positioned, but the assembly process becomes expensive and time-consuming
Solution Approach 1:
The alignment device enables the tower sections to self-align during the assembly process. By maintaining hole alignment through the storage period and enabling simple attachment/detachment operations, the device allows workers to quickly connect sections without requiring heavy cranes for precise positioning, thereby speeding up assembly.
3Strength
If tower sections are made with thicker walls and larger diameters to withstand increased loads, then the tower can support higher loads, but the sections become heavier and more difficult to handle
Solution Approach 1:
The alignment device is pre-attached to the heavy tower sections during storage, creating a ready-to-assemble configuration. This preliminary action reduces the complexity of handling heavy sections during assembly, as the alignment function is already in place and does not require additional manual adjustment operations.
4Ease of operation
If multiple personnel are required inside the tower for assembly operations, then alignment and fastening can be performed manually, but safety risks increase and operational complexity increases
Solution Approach 1:
The alignment device performs the alignment function automatically through its mechanical design, reducing the need for multiple personnel to manually adjust and align holes inside the tower. This self-aligning capability minimizes human presence in confined spaces, thereby reducing safety risks while maintaining operational simplicity.
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
This device simplifies the coupling of flanges, reduces installation time, and allows for a more efficient and cost-effective assembly process by minimizing the need for cranes and on-site personnel.
Implementation Method 1
The first and second pushers are also configured to be moved radially outwardly from the shaft to exert pressure against an inner wall of the first and second holes, respectively
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present disclosure is related to a device 100 configured for aligning a first hole 131 of a first flange 130 with a second hole 141 of a second flange 140. The device 100 comprises a base 101, a shaft 110 extending from the base 101 and a first and a second pusher 115, 116. The shaft 110 is configured to move between a retracted position and an extended position. The shaft 110 in the extended position extends from the first hole 131 into the second hole 141. The first and second pushers 115, 116 are also configured to be moved radially outwardly from the shaft 110 to exert pressure against an inner wall of the first and second holes 131, 141. Methods for aligning a first and a second hole 130, 140 are also provided.