Wind Turbine Tower Flange Ovality Correction Tool
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Solution Overview
Problem
Ovalities in wind turbine tower section flanges prevent fasteners from passing through apertures, hindering the mating of tower sections during assembly due to manufacturing variations and transportation-induced deformations.
Innovation Solution
A flange ovality correction tool is used to position a pair of flanges adjacent to each other, with one flange being pulled inward and the other outward to align apertures, allowing fasteners to be installed, and then the tool is removed to secure a fastener in its place, correcting the ovality and enabling section mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fastening methods are used on ovalized flanges, then assembly cannot proceed, but specialized correction tools increase device complexity and cost
Solution Approach 1:
The correction tool utilizes the existing fastener application tool to perform dual functions: first as a correction mechanism that applies radial force to reshape the ovalized flange, and second as the fastener installation tool. This eliminates the need for separate specialized correction equipment, reducing device complexity while maintaining assembly productivity.
Solution Approach 2:
The system uses the fastener tool already present in the assembly process to correct the flange ovality before installing fasteners. The tool serves itself by performing the correction function using its own structural components (extension member and reaction member) without requiring external correction equipment.
2Loss of time
If ovalized flanges are forced together, then assembly time is reduced, but fastener installation fails due to misaligned apertures
Solution Approach 1:
The correction tool is positioned and applied to the ovalized flange before the fastener installation process begins. The extension member applies radial force to reshape the flange aperture alignment, creating the proper geometric conditions necessary for subsequent fastener installation to proceed without failure.
3Manufacturing precision
If specialized correction equipment is brought to the site, then flange ovality can be corrected, but transportation and handling costs increase
Solution Approach 1:
The fastener application tool performs dual functions: it serves as both the standard fastener installation device and the flange correction device. By integrating the correction function into existing equipment, the patent eliminates the need to transport and handle separate specialized correction equipment to the assembly site.
4Manufacturing precision
If multiple separate tools are used for correction and fastening, then correction precision improves, but assembly process complexity increases
Solution Approach 1:
The patent merges the correction function and fastener installation function into a single integrated tool system. The extension member with reaction member combination works together with the fastener tool to both reshape the flange and install fasteners, reducing the number of separate tools needed while maintaining aperture alignment precision.
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 method effectively corrects flange ovalities, allowing for proper alignment and secure fastening of wind turbine tower sections, reducing assembly time and crane usage by utilizing existing fastening tools for correction.
Implementation Method 1
An extension member of the tool is extended toward a second of the pair of flanges to urge the second of the pair of flanges away from the first lateral side of the wind turbine tower sections while urging the first of the pair of flanges toward the first lateral side
Data Source
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AI summary
Tooling (10) and a method of using the tooling (10) to deform a flange (12) of a wind turbine tower section (14) to correct any ovalities that might otherwise prevent fasteners from passing through apertures of adjacent flanges. The methods allow for the correction of ovalities with some of the same tooling that is used to fasten tower sections to one another.