Lattice Tower Node Shells for Wind Turbine Assembly
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Solution Overview
Problem
The assembly and production of lattice towers for wind turbines are time-consuming and labor-intensive due to numerous complex welds, limiting automation and modular production, which increases costs and hinders efficient distribution to different production sites.
Innovation Solution
The use of node shells at the ends of struts that complement corner posts over a partial circumference, allowing for direct attachment without welding, and the use of auxiliary shells to form a ring or partial ring around the corner post, reducing the need for extensive welding and simplifying assembly by using prefabricated modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used to join corner posts and struts, then structural strength is achieved, but assembly time and labor costs increase significantly
Solution Approach 1:
The lattice tower is divided into modular segments with standardized nodes. Each node is pre-assembled with struts and corner post sections, allowing factory pre-production of modules that can be quickly erected on-site without extensive welding during assembly.
Solution Approach 2:
Node shells and corner post sections are prepared in advance with pre-drilled holes and pre-positioned connection elements. The modules are manufactured separately in factories with preliminary assembly work completed before transportation to the erection site.
2Reliability
If complex three-dimensional welds are performed to ensure stability, then structural reliability improves, but automation becomes difficult and labor intensity increases
Solution Approach 1:
The complex three-dimensional welded joints are segmented into standardized node shells with standardized connection interfaces. This segmentation allows for automated drilling and bolting operations rather than complex automated welding, significantly improving automation capability while maintaining reliability.
Solution Approach 2:
The node shells are designed as standardized, relatively simple components that can be manufactured cheaply and replaced if necessary. The connection details use standardized bolts and plates rather than complex welded assemblies, facilitating automation and simplifying manufacturing.
3Stability of the object's composition
If lattice towers are produced as complete structures, then structural integrity is maintained, but transportation and handling become more difficult
Solution Approach 1:
The lattice tower is segmented into multiple modular sections (corner posts, struts, node shells) that can be transported separately and assembled on-site. This segmentation maintains structural integrity through standardized connection details while dramatically improving transportation efficiency and handling ease.
Solution Approach 2:
The standardized node shells and connection details serve multiple functions: they provide structural connection, enable modular assembly, facilitate transportation, and allow for on-site assembly without specialized equipment. This universality resolves the contradiction between integrity and ease of operation.
4Productivity
If prefabricated modules are used to simplify assembly, then productivity increases, but the number of joining surfaces and connection points increases
Solution Approach 1:
The node shell is designed as a universal connection component that standardizes multiple joining surfaces into a single standardized interface. This universal node design allows the same connection detail to be used throughout the entire lattice tower structure, reducing the variety of joining surfaces while increasing the number of modular connections, thereby improving productivity without proportionally increasing complexity.
Data Source
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AI summary
The invention relates to a lattice tower (1) for a wind turbine, wherein the lattice tower (1) comprises at least three tubular corner legs (2a, 2b, 2c, 2d) extending in a longitudinal direction (X) and tubular struts (3) running between said corner legs (2a, 2b, 2c, 2d), wherein when the lattice tower (1) is erected the struts (3) are connected to the corner legs (2a, 2b, 2c, 2d). Each corner leg (2a, 2b, 2c, 2d) comprises a plurality of regions referred to as nodes (5) spaced apart in the longitudinal direction of the corner leg, in which regions the struts (3) are connected to the corner legs (2a, 2b, 2c, 2d), wherein the nodes (5) of adjacent corner legs (2a, 2b, 2c, 2d) lie in a common horizontal node plane (6) in the erected lattice tower (1), so that the erected lattice tower (1) comprises a plurality of node planes (6) spaced apart from each other in the vertical direction. At their corner leg-side ends the struts (3) have node shells (8, 14) abutting the corner legs (2a, 2b, 2c, 2d). The lattice tower is characterised in that the node shells (8, 14) are dimensioned and designed in such a manner that in each case they lie against the corner legs (2a, 2b, 2c, 2d) in a partial circumferential region of up to 180°, and in that the node shells (8, 14) lying in a node (5) against the corner leg (2a, 2b, 2c, 2d) and the partial circumferential regions covered by the node shells (8, 14) directly adjoin each other, and wherein the node shells (8, 14) of said node (5) are connected to the corner leg (2a, 2b, 2c, 2d) and/or to one another, so that the node shells (8, 14) form a ring or partial ring around the corner leg (2a, 2b, 2c, 2d). The invention further relates to a method for erecting the lattice tower.