Recirculating Cylindrical Roller Assembly for Stable Heavy Pile Support

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Solution Overview

Problem

Existing pile holding systems face challenges in supporting large and heavy piles for offshore wind turbines due to increased loads, requiring large diameter wheels that cause instability and unfavorable mechanical loading, and struggle with accurate dynamic positioning as weights increase.

Innovation Solution

A recirculating cylindrical roller assembly with a load-bearing housing and an endless chain of steel rollers, supported by a resilient insert, which reduces the need for large wheels and minimizes friction, allowing for smoother movement and improved stability, while the pile holding system allows for versatile mounting angles and reduced complexity in pile transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If large diameter wheels are used to support heavy piles, then the load bearing capacity is improved, but the stability of the support and vessel is worsened

Engineering Contradiction:

Improveload bearing capacityVSAvoidstability of support and vessel

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The invention divides the single large wheel support into multiple smaller cylindrical rollers arranged in a recirculating chain. This segmentation maintains the total load bearing capacity while distributing the weight across multiple contact points, improving stability and reducing the adverse effects of concentrated loads on the vessel.

Inventive Principle:

Principle #1Segmentation

2Strength

If large diameter wheels are used to support heavy piles, then the load bearing capacity is improved, but the mechanical loading on rails becomes unfavorable

Engineering Contradiction:

Improveload bearing capacityVSAvoidmechanical loading on rails

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The single large wheel is segmented into multiple smaller cylindrical rollers. This distribution of contact points transforms the concentrated mechanical loading into distributed loading on the rails, reducing stress concentrations and unfavorable localized loading patterns while maintaining adequate load bearing capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs a recirculating chain mechanism that allows the roller assembly to dynamically adapt to rail conditions. The resilient insert provides dynamic cushioning, enabling the system to accommodate variations in rail surface and distribute loads more evenly throughout the support structure.

Inventive Principle:

Principle #15Dynamics

3Strength

If large diameter wheels are used to support heavy piles, then the load bearing capacity is improved, but the movement smoothness and positioning accuracy is worsened

Engineering Contradiction:

Improveload bearing capacityVSAvoidmovement smoothness and positioning accuracy

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The recirculating roller chain creates a dynamic support system that reduces friction through continuous roller rotation and replacement. The resilient insert provides dynamic cushioning that smooths out irregularities in movement, enabling more precise dynamic positioning even under heavy loads.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention replaces the traditional wheel-rail contact mechanism with a recirculating roller chain system. This substitution reduces stick-slip effects and friction through the continuous rotation and recirculation of rollers, improving movement smoothness and positioning accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhanced stability and smoother movement, reduces mechanical loading on rails, and facilitates accurate dynamic positioning of piles, enabling efficient installation of larger piles with reduced complexity and improved control.

Implementation Method 1

an elastically compressible resilient insert, which resilient insert is sandwiched between the steel central body and the steel raceway member above the work portion, so that the central body is resiliently supported on the operative set of the cylindrical rollers via the insert and the steel raceway member

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12529198B2Recirculating cylindrical rollers assembly for supporting an object on a rail, e.g. in a pile holding system

Publication Date: 2026.01.20 ITREC BV

AI summary

An assembly for supporting an object on a rail comprises a load bearing housing and an endless chain of steel cylindrical rollers arranged for recirculating along a closed path. The assembly comprises an elastically compressible resilient insert which is sandwiched between a steel central body and a steel raceway member above a work portion of the path, so that the central body is resiliently supported on an operative set of the cylindrical rollers via the insert and the steel raceway member.