Multi-Part Wind Turbine Tower Erection via Segmented Flange Assembly
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Solution Overview
Problem
The challenge lies in efficiently and cost-effectively erecting large wind turbine towers with multi-part tower sections, as existing methods face difficulties in production, verification, assembly, and transportation due to the need for large base diameters and limited transport clearance heights.
Innovation Solution
A method involving a multi-part tower section with at least two sub-sections, where each sub-section is positioned and connected using transverse and longitudinal flanges, allowing for sequential assembly and reducing the weight lifted, enabling the use of cheaper cranes and parallel work on multiple sections, thus facilitating quicker and more cost-effective construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If tower sections are longitudinally segmented to achieve large base diameters, then the tower can meet economical operation requirements with hub heights >130m, but new challenges arise during assembly and erection
Solution Approach 1:
The tower section is divided into multiple sub-sections (first sub-section, second sub-section, etc.) that can be manufactured separately and assembled on-site. Each sub-section has a manageable diameter (≤4.4m) but together they form the required large base diameter tower section, resolving the contradiction between large diameter requirement and transport/assembly constraints
Solution Approach 2:
Sub-sections are pre-positioned at designated locations before final connection. The first sub-section is positioned and connected to foundation or lower tower section, then the second sub-section is positioned adjacent to it, allowing for preparatory work to be done before final assembly, reducing on-site erection complexity
2Length of stationary object
If multi-part tower sections are used to overcome transport restrictions, then tower base diameters greater than 4.4m are achievable, but manufacturing and verification challenges increase
Solution Approach 1:
The tower section is segmented into multiple sub-sections that can be manufactured separately using standard manufacturing processes and transport infrastructure. Each sub-section meets the transport diameter constraint (≤4.4m) while collectively achieving the required large base diameter, making manufacturing and verification more manageable
Solution Approach 2:
Instead of manufacturing one large-diameter tower section that cannot be transported, the solution transitions to manufacturing multiple smaller-diameter sub-sections that can be transported and then assembled vertically to achieve the required large base diameter, solving the problem by changing from a single-dimension approach to a multi-dimensional assembly approach
3Length of moving object
If traditional tower erection methods are used with large base diameters, then transport restrictions are exceeded, but if segmented sections are used, then assembly complexity increases
Solution Approach 1:
The tower is divided into longitudinally segmented sub-sections with diameters suitable for transport within clearance height restrictions. These sub-sections are then assembled on-site through controlled positioning and connection processes, managing assembly complexity through systematic procedures
Solution Approach 2:
Sub-sections are pre-positioned at their designated locations before final connection to minimize on-site assembly complexity. The first sub-section is positioned and connected to the foundation or lower tower section, then subsequent sub-sections are positioned adjacent to them, allowing for organized sequential assembly
4Productivity
If heavier tower sections are erected as single units, then fewer assembly steps are required, but larger and more expensive cranes are needed
Solution Approach 1:
The tower section is segmented into multiple lighter sub-sections that can be handled by smaller, more economical cranes. While this increases the number of assembly steps, it reduces crane size requirements and associated costs, balancing productivity with device complexity
Solution Approach 2:
Sub-sections are pre-positioned at designated locations before final connection, allowing lighter cranes to be used. The sequential positioning and connection process (first sub-section to foundation, then second sub-section adjacent to first) enables the use of smaller cranes while maintaining reasonable erection efficiency
Data Source
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AI summary
The invention relates to a method (100) for erecting a tower comprising a multi-part tower section, the multi-part tower section comprising at least two sub-sections, the sub-sections being in the form of a truncated cone shell segment or a cylinder shell segment. Said method comprises: positioning (110) a first sub-section of the multi-part tower section in a position provided for the first sub-section; connecting (120) a transverse flange of the first sub-section to a foundation of the tower or a lower-lying tower section; positioning (130) a second sub-section of the multi-part tower section adjacently to the first sub-section following the connection (120) of the transverse flange; and connecting (140) a longitudinal flange of the first sub-section to a longitudinal flange of the second sub-section following the positioning (130) of the second sub-section.