Leveling Ring for Wind Pylon Segment Alignment
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Solution Overview
Problem
The existing methods for erecting a pylon for wind power installations require a large crane to handle the lower pylon segment after grouting material sets, leading to inefficient use of resources as the crane is idle for 24 hours while waiting for the grouting to set, and the process is costly due to the need for precise alignment and handling of heavy components.
Innovation Solution
A method involving the use of a leveling ring that allows for the alignment and placement of a lower pylon segment on a surface leveled by fluid grouting material, enabling the crane to be used for other tasks during the setting time, and allowing for the efficient and precise alignment of the pylon segments once the grouting has hardened.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large crane is used to handle the lower pylon segment after grouting material sets, then the pylon can be constructed with structural integrity, but the crane remains idle for 24 hours during grouting setting time
Solution Approach 1:
The patent applies preliminary action by performing the grouting operation before the pylon segment is placed. The foundation is grouted in advance, and only after the grouting material has set does the crane need to handle the pylon segment. This separates the grouting process from the crane operation, allowing the crane to be used for other tasks during the setting period while still ensuring structural integrity through proper preliminary grouting.
2Manufacturing precision
If precise alignment of the lower pylon segment is performed manually, then the pylon can be properly leveled, but the process is costly and time-consuming
Solution Approach 1:
The patent applies self-service by using the fluid grouting material to automatically level itself within the formwork, creating a self-leveled surface. This eliminates the need for manual alignment operations on the pylon segment itself. The grouting material's self-leveling property provides precise alignment automatically, while the crane can quickly place the segment without waiting for manual alignment procedures.
3Strength
If a thick layer of grouting material is used to ensure adequate coverage, then the structural connection is stronger, but the setting time increases
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the grouting material. It uses fluid grouting material with specific flow characteristics that allow it to self-level and penetrate effectively at controlled thicknesses. The material's rheological parameters are optimized to achieve adequate coverage and strength without requiring excessive thickness, thereby reducing setting time while maintaining connection strength.
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 approach reduces the time and cost associated with pylon construction by allowing the crane to be used for other tasks during grouting, simplifies alignment, and enables the use of less expensive materials for the leveling ring and pylon flange, while ensuring structural integrity through adequate grouting thickness and material selection.
Implementation Method 1
The fluid grouting material which is introduced into the formwork levels itself so that, after the grouting material has set, an exactly leveled surface is automatically available for receiving the ring
Implementation Method 2
After the grouting material has set and the formwork has been removed
Data Source
AI summary
An annular preform is constructed of predeterminable width and height and filled with a predeterminable quantity of a fluid grouting material. After setting of the grouting material and removal of the formwork a ring is placed on the surface of the set grouting material and a lower pylon segment is placed on the ring and connected thereto.