Modular Tower Sections With Flexible Connectors
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Solution Overview
Problem
The height of modular towers, such as wind turbine towers, is limited by transportation logistics, which restricts the size of unitary components, and existing solutions struggle to enhance structural integrity and reduce on-site assembly time effectively.
Innovation Solution
The use of larger modular tower sections with spacer elements for alignment and flexible connectors to reduce hoop stresses, allowing for the assembly of taller towers with improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If larger tower sections are assembled on-site to increase tower height, then tower height is improved, but transportation logistics become more difficult
Solution Approach 1:
The tower is divided into multiple modular sections that can be transported separately and assembled on-site. Each section is designed as a discrete unit with standardized connection interfaces, allowing them to be shipped via conventional logistics and then quickly assembled to form the complete tall tower structure.
Solution Approach 2:
The solution transitions from transporting single large tower components to transporting multiple smaller modular sections that assemble in the vertical dimension. By changing the transport approach from moving one large piece to moving multiple smaller pieces that stack vertically, the transportation constraints are overcome while achieving greater tower height.
2Length of stationary object
If more tower sections are assembled to increase height, then tower height is improved, but on-site assembly time increases
Solution Approach 1:
Connection components such as flanges and fasteners are pre-positioned and pre-aligned on the tower sections during manufacturing. The sections are pre-assembled with connection interfaces ready, so that on-site assembly requires only connecting pre-prepared elements rather than assembling from scratch, significantly reducing on-site time.
Solution Approach 2:
Multiple connection functions are merged into integrated connection components. The flanges and fasteners are designed as unified assembly units that combine alignment, connection, and reinforcement functions, allowing multiple sections to be joined efficiently in a single operation rather than requiring multiple separate steps.
3Device complexity
If larger tower sections are used to reduce the number of components, then assembly simplicity is improved, but transportation limitations are exceeded
Solution Approach 1:
The tower structure is segmented into modular sections of optimal size for transportation. Each section is designed as a self-contained unit with standardized dimensions that fit within transportation constraints, while the modular nature allows multiple sections to be easily combined to achieve the desired overall tower size.
Solution Approach 2:
The modular sections are designed with universal connection interfaces that can be used across all sections. The standardized flange and fastener systems provide multi-functional capability, allowing the same connection mechanism to join any two sections together, simplifying both manufacturing and assembly while maintaining transportation efficiency.
4Strength
If rigid connection methods are used to ensure structural integrity, then strength is improved, but hoop stresses increase
Solution Approach 1:
The connection system incorporates flexible elements that change the mechanical parameters of the joint. The flexible flanges and spaced fasteners allow for controlled movement and stress distribution, transforming the connection from a rigid fixed-stress joint to a flexible stress-distributing joint that maintains strength while reducing hoop stresses.
Solution Approach 2:
Flexible flange components are used in the connection system instead of rigid fixed connections. These flexible elements can deform to accommodate stress variations and distribute loads more evenly around the tower circumference, reducing concentrated hoop stresses while maintaining overall structural integrity through the flexible connection mechanism.
Data Source
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AI summary
A tower assembly (200) for use with a modular tower (102) is provided. The tower assembly includes a plurality of assembly panels (202) each including a pair of opposing circumferential edges (206, 208), and, a plurality of connectors (214) for use in coupling adjacent assembly panels of the plurality of assembly panels to one another, each connector of the plurality of connectors including an outer flange (302), an inner flange (304), and a spacer (306) extending therebetween, the outer flange is spaced a distance from the inner flange such that a first slot (308) and a second slot (310) are defined between the outer and inner flanges, each of the first and the second slots is sized to receive one of the assembly panel circumferential edges therein to enable the adjacent assembly panels to be coupled to one another.