Non-Uniform Connection Elements for Offshore Wind Tower Load Transfer
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Solution Overview
Problem
Existing methods for manufacturing connection apparatuses for tower-like structures, such as those in wind turbines, result in undesirable voltage peaks due to deviations in component dimensions, particularly at the lower end of the upper component and the upper end of the lower component.
Innovation Solution
A method that involves determining the specific shape, position, and nature of plate-like connection elements to optimize load transfer and compensate for component deviations, using data from actual component sizes to produce or assemble connection elements that ensure uniform load distribution across the largest possible surface area, even when components differ from desired dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection elements are produced from metal plates with deviations from desired dimensions, then manufacturing is simplified, but voltage peaks occur at the lower end of the upper component and upper end of the lower component
Solution Approach 1:
The connection elements are designed with non-uniform thickness distribution, where the thickness varies along the longitudinal axis. Specifically, the connection elements have a first thickness at the first end and a second thickness at the second end, with the thickness gradient tailored to compensate for dimensional deviations in the tower components. This local variation in thickness ensures uniform electrical potential distribution and eliminates voltage peaks at the critical interfaces.
Solution Approach 2:
The invention changes the geometric parameter of the connection elements by introducing a specific thickness distribution profile. The thickness is not constant but varies according to a defined pattern that compensates for the dimensional deviations of the tower components. This parameter change transforms the connection elements from standard uniform sections to optimized non-uniform sections that eliminate voltage peaks while maintaining ease of manufacture from metal plates.
2Reliability
If connection elements are designed to compensate for component deviations, then load transfer is optimized, but the complexity of determining and producing customized connection elements increases
Solution Approach 1:
The connection elements are segmented into distinct functional zones with different thickness characteristics. The first end portion has a first thickness optimized for connection to the lower component, while the second end portion has a second thickness optimized for connection to the upper component. This segmentation allows each portion to be independently optimized for its specific function while maintaining a manageable overall structure that can be produced from standard metal plates.
Solution Approach 2:
The thickness distribution of the connection elements is predetermined and designed in advance based on the expected dimensional deviations of the tower components. The connection elements are produced with the optimized thickness profile before installation, so that when installed, they automatically compensate for the deviations without requiring complex adjustments or custom determinations during the assembly process.
Data Source
AI summary
The invention relates to a method for manufacturing a connecting device for a tower-like structure, in particular an offshore wind turbine, wherein the connecting device comprises a plurality of connecting elements, in particular planar connecting elements, which are to be arranged between an upper component of the structure and a lower component of the structure when a slip joint is produced and, for the purpose of load transfer between the upper component and the lower component, are to be positioned next to one another in the peripheral direction about the longitudinal axis and/or in the longitudinal direction thereof with respect to a central longitudinal axis of the structure, wherein data relating to an actual size of the lower component and of the upper component is provided, whereupon the shape, the position and/or the condition of individual or several as well as in particular all connecting elements of the connecting device are least in part determined in a manner specific to the connecting element in order to optimise the load transfer and/or in order to compensate for any deviations of the lower component and/or of the upper component from their desired size, and the connecting elements, that have been manufactured in advance and/or subsequently, are provided for assembly on at least one of the components. The invention also relates to: a tower-like structure, in particular part of an offshore wind turbine; and a wind turbine, in particular an offshore wind turbine.