Rotating Centering Sleeve for Wind Turbine Flange Alignment
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Solution Overview
Problem
Existing flange connections in wind turbines face challenges in reliable production and maintenance, particularly due to the vulnerability of centering bolts which can break and leave residues in holes, leading to stability issues and contamination risks from lubricants.
Innovation Solution
A centering bolt design with a shaft having sections of varying diameters and a rotatably mounted centering sleeve, which is securely axially locked, allowing for precise centering and easy removal without damage, and can be reused, eliminating the need for lubricants and reducing residue issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional centering bolts are used with lubricants to facilitate assembly, then ease of operation is improved, but contamination risks and reliability deteriorate due to lubricant contamination and potential residue in holes
Solution Approach 1:
A centering sleeve made of PTFE (polytetrafluoroethylene) is introduced as an intermediary component between the centering bolt and the hole. This sleeve provides the necessary lubrication and ease of insertion without requiring external lubricants, preventing contamination while maintaining operational ease. The PTFE material inherently provides low friction properties.
Solution Approach 2:
The centering sleeve is designed as a disposable component that is discarded after use. This eliminates the risk of residue or contamination from reusable centering bolts, ensuring reliability while maintaining ease of operation during the assembly process. The sleeve is replaced with each new assembly operation.
2Productivity
If centering bolts are designed for easy removal and reuse, then productivity is improved, but reliability deteriorates as centering bolts can break and leave residues in holes
Solution Approach 1:
The centering bolt system is segmented into two separate components: a reusable centering bolt and a disposable centering sleeve. The bolt can be removed and reused for subsequent assemblies, while the sleeve is discarded after a single use. This segmentation allows the bolt to be recovered for productivity benefits while the sleeve ensures reliability by preventing residue in the holes.
Solution Approach 2:
The centering sleeve acts as an intermediary between the reusable bolt and the hole, protecting the hole from damage and contamination. The sleeve absorbs the wear and potential breaking risks, allowing the bolt itself to remain intact and reusable without leaving residues in the critical hole areas.
3Strength
If bearing bolts with tapered sections are used to absorb bending and tensile forces, then strength is improved, but centering capability deteriorates making them unsuitable for centering operations
Solution Approach 1:
The fastening system is segmented into two distinct functions: centering (performed by the centering bolt with cylindrical shaft) and load-bearing (performed by the bearing bolts with tapered sections). This segmentation allows each component to be optimized for its specific function without compromise - the bearing bolts provide strength while the centering bolt provides centering capability.
Solution Approach 2:
The centering bolt performs the preliminary action of aligning and centering the flange components before the bearing bolts are installed. This preliminary centering action ensures proper positioning, after which the bearing bolts are tightened to provide the final strong connection. The sequence of operations separates the centering function from the load-bearing function.
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 enables secure, cost-effective, and reliable centering of wind turbine components, preventing damage to the centering bolts during disassembly and avoiding contamination, thus ensuring stable and efficient flange connections.
Implementation Method 1
The centering sleeve (182) is rotatably arranged about the longitudinal axis (160) on the shaft (158)
Data Source
Figure 1
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AI summary
The invention relates to a centering bolt (156) for producing a flange connection (144) between two components (146, 148) of a wind turbine (100), comprising: - a shaft (158) with a longitudinal axis (160) which has along the longitudinal axis (160) a first section (166) with a first outer diameter (168) and a second section (170) following the first section (166), which has a second outer diameter (172) that is smaller than the first outer diameter (168); - a centering sleeve (182) which is pushed onto the second section (170) of the shaft (158), wherein the centering sleeve (182) is rotatably mounted on the shaft (158) about the longitudinal axis (160), is secured axially against displacement with respect to the longitudinal axis (160), and has a sleeve outer diameter (196) that is larger than the first and second The outer diameter is (168, 172).The centering bolt (156) is designed to be mounted in two aligned bores (152, 154) of the flange connections (128, 150) of the two components (146, 148) to create the flange connection (144) such that the centering sleeve (182) is arranged in the two aligned bores (152, 154) for centering the components (146, 148). The invention also relates to a method and a flange connection (144).