Modular Guyed Mast for Emergency Power Line Support
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Solution Overview
Problem
Existing temporary support structural systems for power transmission lines are cumbersome, difficult to handle, and costly, with designs prone to local and torsional buckling, requiring complex connections and heavy components that increase weight and inventory costs, limiting their scalability and efficiency in emergency restoration.
Innovation Solution
A lightweight, modular guyed mast system using structural grade aluminum alloy with closed sections and a unique two-pin gimbal joint, along with an easy-to-construct foundation system, designed to be scalable for various voltage classes from 33 to 800 kV, meeting IEEE 1070 standards and simplifying assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If open cross section modules (angles or box sections with slotted holes) are used for guyed mast, then the structure can be fabricated, but it is susceptible to local buckling and torsional buckling modes requiring increased design weight
Solution Approach 1:
The patent employs composite construction by combining closed box section modules with diagonal bracing elements to create a truss-like structure. This composite approach provides torsional stiffness and buckling resistance without requiring increased weight of individual members, resolving the contradiction between structural stability and weight.
Solution Approach 2:
The patent uses closed box section modules rather than open cross sections. The closed circular-like geometry of the box sections provides superior torsional rigidity and resistance to local buckling compared to open sections, achieving structural stability without weight penalty.
2Ease of operation
If separate box sections are used for connections with spherical ball assembly or shafts with special casting, then connections can be made, but precision machining or complicated forged components are required increasing device complexity
Solution Approach 1:
The patent divides the connection system into standardized modular components: pre-fabricated box section modules with integrated connection plates, separate diagonal bracing elements, and simple pin connections. This segmentation allows each component to be manufactured independently using standard fabrication processes, reducing complexity while maintaining ease of assembly.
Solution Approach 2:
The patent introduces simple connection plates and pin joints as intermediary elements between the box section modules and diagonal bracing. These intermediaries provide straightforward connection mechanisms that eliminate the need for complex spherical ball assemblies or specially cast components, reducing manufacturing complexity while maintaining operational ease.
3Ease of operation
If whole assembly of the gimbal joint is handled at site, then the connection can be made, but it is bulky and heavy making handling difficult
Solution Approach 1:
The patent replaces the traditional whole-assembly gimbal joint with segmented, field-assembled connections. The box section modules are designed with integrated connection plates that accept simple pin joints, allowing assembly in the field without handling bulky pre-assembled gimbal units. This segmentation dramatically reduces handling weight and complexity.
4Reliability
If conventional temporary support systems are used, then power lines can be supported during restoration, but the design and construction/fabrication is cumbersome and handling is difficult at site
Solution Approach 1:
The patent employs modular box section modules that can be fabricated separately and assembled in the field. This segmentation makes fabrication easier and more reliable compared to conventional monolithic temporary support structures, while maintaining the required structural reliability for supporting power lines during restoration.
Solution Approach 2:
The patent uses composite construction with box section modules and diagonal bracing to achieve reliable temporary support with simplified fabrication. The modular composite structure can be manufactured using standard fabrication processes and assembled in the field, improving both ease of manufacture and reliability compared to conventional systems.
Data Source
AI summary
Natural disasters, such as cyclones, earthquakes, landslides, etc., or manmade damages, such as structural member's theft, terrorist attacks, etc., can cause collapse of transmission line towers. If these are not restored in time, there will be monetary loss to utilities as well as loss of service to consumers leading to societal impact. Generally, permanent restoration takes several weeks. Hence, a temporary solution for quick retrieval of power transmission is required. This invention provides a temporary support structural system comprising light weight guyed masts (1) made of readymade robust modules (6 and 7), easy to connect connection system, two pin gimbal joint (8) and easy to construct foundation system (9 and 10). The invention is flexible enough to develop various configurations for single or double circuit transmission lines. It is also scalable and can be used for 33 to 800 kV transmission lines.