Modular Composite Spreader Structures for Offshore Lifting
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Solution Overview
Problem
Conventional spreader structures used for offshore lifting of bulky loads are heavy, wasteful, and prone to corrosion and fatigue, requiring bespoke designs that are not suitable for repeated use due to limited crane capacity and harsh marine environments.
Innovation Solution
A modular spreader structure composed of elongate primary tubular elements made of composite material with axial couplers and node connectors, allowing for lightweight, adjustable, and reusable configurations that reduce weight and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spreader structures are fabricated from steel to provide strength and durability, then the structural strength and reliability are improved, but the weight of the spreader structure increases significantly, reducing the effective lifting capacity of the crane
Solution Approach 1:
The patent applies composite materials (specifically fibre-reinforced polymers) to fabricate spreader structures, combining the high strength-to-weight ratio benefits of composites with the structural requirements of lifting equipment. This resolves the contradiction by providing sufficient structural strength while significantly reducing weight compared to traditional steel construction.
Solution Approach 2:
The spreader structure is divided into multiple modular tubular elements that can be assembled together. Each element is made from composite material, and the modular design allows for optimized weight distribution while maintaining overall structural strength through proper joint design and material selection.
2Adaptability or versatility
If bespoke spreader structures are designed and fabricated for each specialised lift to match the specific load requirements, then the adaptability to different load shapes and sizes is improved, but the manufacturing complexity and resource waste increase due to single-use disposal
Solution Approach 1:
The spreader structure is designed as a modular assembly of standardized tubular elements with various connectors. This segmentation allows flexible configuration to match different load shapes and sizes while using a limited set of standardized components, reducing design complexity and enabling reuse across multiple applications.
Solution Approach 2:
The modular design allows the spreader structure to be dynamically reconfigured for different lifting scenarios. Standardized elements can be assembled in various configurations to adapt to different load requirements, providing versatility without requiring complete custom design for each application.
3Productivity
If spreader structures are used repeatedly in harsh marine environments subject to corrosion, fatigue, and temperature variations, then the productivity and cost-effectiveness are improved, but the reliability decreases due to degradation from environmental influences
Solution Approach 1:
Fibre-reinforced polymer composite materials are used to construct the spreader structure, providing inherent resistance to corrosion, fatigue, and temperature variations associated with marine environments. These composite materials do not rust like steel and maintain structural integrity under cyclic loading and environmental exposure, enabling repeated use without significant degradation.
4Adaptability or versatility
If an oversized standard spreader frame is used for onshore lifts where large-capacity cranes are available, then the adaptability to large and bulky loads is improved, but the suitability for offshore lifting decreases due to limited crane capacity
Solution Approach 1:
The spreader structure is designed as modular tubular elements that can be assembled in different configurations. For offshore applications, lighter-weight composite elements can be used with appropriate numbering to achieve the required lifting capacity without excessive weight. For onshore applications, additional elements can be combined to handle larger loads, providing adaptability across different operating contexts.
Solution Approach 2:
The design allows changing key parameters such as the number of tubular elements, their arrangement configuration, and material properties to optimize the spreader structure for different lifting scenarios. This enables the same modular system to be adapted for both offshore (weight-critical) and onshore (capacity-critical) applications.
Data Source
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AI summary
A modular spreader structure (10) for use in offshore lifts comprises a plurality of elongate tubular elements (26, 22) made primarily of composite material. Primary tubular elements (26) each comprise an axial coupler formation (28) for end-to-end coupling with a complementary axial coupler formation of another primary tubular element, aligned on a common longitudinal axis. The adjoining primary tubular elements are interengageable by longitudinal overlap between male and female axial coupler formations. Secondary tubular elements (22) each comprise a node connector (30) that is configured for attachment to the structure at an orientation inclined relative to the common longitudinal axis of the primary tubular elements. In particular, the secondary tubular elements can be attached to an outer surface of one of the primary tubular elements.