Segmented Bearing Plate for Wind Turbine Tower Construction
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Solution Overview
Problem
The construction of concrete wind turbine towers faces challenges such as reduced construction speed, sensitivity to weather, and high costs due to the need for grouting and specialized equipment, especially when transporting and machining large diameter steel rings for connections between tower segments.
Innovation Solution
A segmented bearing plate is formed using multiple smaller plates, which are mounted to a template during the concrete casting process to achieve a tight tolerance surface, allowing for cost-effective machining and transportation, and the template can be reused multiple times to reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single large diameter steel ring is used for connections between tower segments, then the connection strength is improved, but the cost of machining and transporting the ring increases significantly
Solution Approach 1:
The patent divides a single large diameter steel ring into multiple smaller steel plates or segments. These segments are positioned around the concrete tower segment and connected together to form a complete circular connection structure. This segmentation reduces the cost of machining and transporting each individual component while maintaining the overall connection strength through the collective arrangement of segments.
2Ease of manufacture
If multiple smaller plates are used instead of a single large ring, then the cost of machining and transporting is reduced, but the connection stability may be compromised
Solution Approach 1:
The patent combines multiple smaller steel plates or segments into a unified circular connection structure. The segments are positioned adjacent to each other around the concrete tower segment and connected through overlapping edges or joining elements, creating a stable integrated structure that functions as a complete bearing surface for the upper tower segment.
Solution Approach 2:
The segmented plate structure serves multiple functions: it provides a bearing surface for load transfer, maintains circular geometry for structural integrity, and allows for modular assembly. The design enables the same configuration to be used across different tower segment sizes by adjusting the number and dimensions of individual segments while maintaining the overall functional performance.
3Ease of manufacture
If cast-in-place construction methods are used, then the tower can be fabricated at or near the tower location using local materials, but the construction speed is reduced and the process is sensitive to inclement weather
Solution Approach 1:
The patent incorporates the steel plate connection structure into the precast concrete tower segment during the concrete pouring process. The steel plates are positioned within the concrete formwork before the concrete is poured and cured, creating an integrated connection system that is built-in during manufacturing rather than added later during assembly.
4Strength
If grout is pumped to tower heights of up to 300 feet or more to ensure strong connections, then the connection strength is improved, but the time consumption and equipment requirements increase
Solution Approach 1:
The patent extracts the grouting process from the connection system by providing a built-in bearing surface through the steel plate segments that are integrated into the precast concrete segment. This eliminates or reduces the need for subsequent grouting operations to achieve strong connections, as the steel plates provide immediate load-bearing capability upon assembly.
Data Source
AI summary
A concrete wind turbine tower segment is provided with a bearing plate formed by a plurality of individual smaller plates secured within the concrete body of the tower segment. The tower segment may include an anchor bar cage assembly made of an embedded plate with a plurality of anchor bars extending there through and through the plates. A protective sleeve may be positioned over the anchor bars. A method of forming the tower segment includes attaching the plate segments to a precision formed template ring as part of the cage assembly, pouring concrete/grout around the cage assembly against the plates, and removing the template ring to reveal a precision mate face of the bearing plate. The single large, expensive ring may be reused to form multiple tower segments.