Flange Hole Alignment Mechanism for Wind Turbine Tower Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The deformation of tubular wind turbine tower sections due to weight-induced forces leads to misalignment of flange holes, increasing stress on fasteners and complicating the assembly process, which is time-consuming and costly, especially when using heavy cranes and requiring on-site personnel.
Innovation Solution
A device with a shaft and pushers that extends into the holes and radially exerts pressure against the inner walls to align flanges, allowing for precise alignment without pre-alignment of the device and enabling remote and efficient coupling of wind turbine tower sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
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 including the flange, leading to misalignment of holes
Solution Approach 1:
The alignment device is attached to the flange in advance before assembly, and the shaft is extended to push against the inner wall of the hole to pre-align it with the corresponding hole on the mating flange. This preliminary alignment action compensates for the ovalization that occurred during storage, ensuring proper hole alignment when the tower sections are assembled.
2Productivity
If heavy mobile cranes are used for erecting wind turbines, then the assembly can be performed, but the cranes are expensive and reducing their usage time is desirable
Solution Approach 1:
The alignment device enables the tower sections to self-align during the assembly process. The shaft automatically pushes the misaligned hole into alignment with the mating hole when the sections are brought together by the crane, eliminating the need for complex pre-alignment procedures and reducing crane operation time.
3Reliability
If personnel are required inside the tower for assembly operations, then safety protocols can be followed, but remote operation capability is also desired
Solution Approach 1:
The alignment device acts as an intermediary mechanism that performs the alignment function automatically during assembly. By attaching the device to the flange before assembly and allowing it to self-align during crane operation, the system enables remote operation without requiring personnel to be inside the tower, while maintaining safety through automated alignment.
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 solution simplifies the alignment process, reduces installation time, and minimizes the use of cranes, making the assembly faster and cheaper while ensuring secure connections between tower sections.
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
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.