Pylon Section Assembly at Ground Level
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Solution Overview
Problem
The existing manufacturing methods for pylons, particularly those intended for offshore wind turbine masts, require access at height, leading to safety concerns, increased costs, and longer completion times due to the need for welding and assembly of sub-assemblies in elevated positions.
Innovation Solution
A method involving the assembly of pylon sections in a horizontal plane, using inclined tubes connected by crosses, where each section is formed and assembled at ground level, then positioned vertically and interconnected to form a right truncated pyramid structure, utilizing gantries or cranes for safe and efficient manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pylon sections are assembled at height using traditional methods, then the pylon can be constructed vertically, but safety risks increase and manufacturing time extends
Solution Approach 1:
The patent applies preliminary action by pre-assembling complete pylon sections horizontally on the ground before final installation. Faces are constructed, positioned vertically, and interconnected on the ground level, allowing all welding and assembly operations to be completed before the section is lifted into its final vertical position, thereby eliminating the need for work at height and reducing manufacturing time
Solution Approach 2:
The patent transitions from vertical assembly (traditional method requiring work at height) to horizontal assembly (ground-level operation). By changing the assembly dimension from vertical to horizontal, the process enables safe ground-level construction while maintaining the ability to achieve the required vertical configuration through subsequent positioning and lifting operations
2Shape
If pylon sections are assembled at height, then vertical configuration is achieved, but assembly complexity and costs increase
Solution Approach 1:
The patent pre-configures complete faces and sub-assemblies in horizontal position on the ground, including all welding and connection operations, before final vertical positioning. This preliminary ground-level preparation simplifies the assembly process by eliminating complex overhead operations while achieving the required vertical configuration through controlled positioning and lifting
Solution Approach 2:
The patent divides the pylon into modular sections that can be independently assembled, positioned, and interconnected. Each section is constructed as a complete unit with all necessary faces and connections, allowing simplified ground-level assembly followed by systematic vertical integration, thereby reducing overall assembly complexity
Data Source
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AI summary
The present invention relates in particular to a method for manufacturing a pylon, which is formed of a single section or of several sections, each section being formed of tubes (1) materializing the edges of a truncated pyramid, these tubes (1) being connected in pairs by a cross (2), characterized in that it comprises the implementation of the following steps: a) assembling two tubes (1) and a cross (2), to form a "first face" (F1); b) repeating step a) to form a "second face" (F2); c) positioning vertically, according to the angle of inclination of said truncated pyramid with respect to the vertical, and exactly opposite each other, the first and second faces (F1, F2) obtained in steps a) and b); d) positioning and assembling a cross (2) with the lower tubes (1) of the two faces (F1, F2) erected vertically, so as to obtain a sub-assembly consisting of three faces;e) proceeded to lift and turn over on itself said sub-assembly obtained in step d); f) proceed to place and assemble a cross (2) on said tubes (1) so as to constitute the fourth face of the section.;