Modular Hexagonal Jacket for Offshore Wind Stability
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Solution Overview
Problem
Existing offshore wind turbine foundations face challenges in being efficiently produced, transported, assembled, and repaired due to high mechanical and chemical loads, as well as ocean currents, requiring a structure that balances stability, rigidity, and cost-effectiveness.
Innovation Solution
A jacket construction using prefabricated hexagonal truss segments made of HFI steel tubes with double tube nodes and orbital welding, allowing for easy assembly and reduced material consumption, with a framework that can be anchored securely in the seabed and supports wind turbines effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional offshore foundation structures are used, then stability and rigidity are achieved, but production complexity, transportation difficulty, and assembly effort increase significantly
Solution Approach 1:
The jacket structure is divided into multiple modular segments that can be manufactured separately and assembled on-site. Each segment contains standardized nodes and tubular elements that can be independently produced, transported, and then connected through simple node assemblies, reducing overall production complexity while maintaining structural stability
Solution Approach 2:
The tubular elements and node connections are pre-assembled into complete jacket segments in controlled manufacturing environments before transportation. This preliminary assembly ensures quality control and reduces on-site assembly complexity, as the segments arrive ready-for-installation with pre-attached bracing and connections
2Strength
If traditional offshore foundation structures are used, then structural strength is achieved, but material consumption and production costs increase
Solution Approach 1:
The jacket structure employs varying wall thicknesses and member dimensions at different locations based on local stress requirements. Critical areas near the seabed and tower connection have thicker walls and stronger members, while upper sections use optimized thinner sections, reducing overall material consumption while maintaining required structural strength throughout
Solution Approach 2:
The structure combines different steel grades and material properties in specific regions to optimize strength-to-weight ratios. High-strength steel is used only where absolutely necessary for structural integrity, while lower-cost materials are used in less critical areas, reducing total material consumption without compromising overall structural strength
3Reliability
If complex node connections are used to ensure structural integrity, then reliability is improved, but assembly time and operational complexity increase
Solution Approach 1:
The jacket is segmented into modular units with standardized node designs. Each segment contains pre-assembled node connections that are simplified for rapid assembly using standardized procedures and equipment. This segmentation allows parallel assembly of multiple segments before final on-site connection, significantly reducing total assembly time while maintaining structural integrity through standardized reliable node designs
Solution Approach 2:
The node connections are designed with optimized geometric parameters and connection mechanisms that enable rapid assembly. Standardized node dimensions, pre-drilled connection holes, and simplified fastening procedures reduce assembly time while maintaining the reliability required for offshore structural integrity
4Reliability
If heavy and complex foundation structures are used, then stability in harsh marine environments is achieved, but transportation and assembly effort increase
Solution Approach 1:
The heavy jacket structure is divided into lighter modular segments that can be transported using available offshore equipment. Each segment maintains the structural characteristics needed for marine environment stability but is sized and weighted for practical transportation and handling. On-site assembly connects these segments through standardized nodes, reducing overall assembly effort compared to installing a single heavy structure
Solution Approach 2:
Transportation-ready configurations are prepared in advance during manufacturing, with segments packaged and prepared for optimal transport conditions. This preliminary preparation ensures that when segments arrive on-site, they require minimal additional preparation before assembly, reducing on-site effort while maintaining the structural integrity needed for harsh marine environments
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 solution provides a stable, cost-effective, and efficient offshore foundation that reduces material usage and assembly complexity, enhancing the durability and maintainability of wind turbine installations in harsh marine environments.
Implementation Method 1
HFI (High Frequency Induction Welding) tubes are easily manufactured by rolling sheet metal, bending it into tubes and then sealing it with a longitudinal HFI weld
Implementation Method 2
Such a double tube structure is preferably formed by first heating a length of tube or tube stub. A second piece of pipe, the outer diameter of which essentially corresponds to the inner diameter of the heated pipe stub, is then pushed into the heated pipe stub. Rapid cooling of the stub tube causes it to shrink, forming a bond between the stub tube and the smaller diameter piece of tubing
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The offshore support structure (1) has six tubular poles (2) anchored in the sea-bottom, where one of the poles is connected with a bar, particularly steel pipe (14). A timber-framed structure (4) is assembled from multiple prefabricated timbered segments (6,8,10,12). The timbered segments have six corners (3a,3b,3c,3d).