Segmented Wind Tower Flange for Higher Load Transfer
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Solution Overview
Problem
The existing L-flange connections in wind turbine towers are limited by their load-bearing capacity, leading to constraints on tower structure design, especially for turbines with long rotor blades, and the XL-flange solution results in larger, more costly forgings due to increased material waste and complex manufacturing processes.
Innovation Solution
A flange connection system comprising two separate flange segments, with a primary bolt circle for inclined openings and a secondary bolt circle for vertical openings, allowing for reduced material usage and efficient load transfer without sacrificing structural integrity, enabling the use of thinner forgings and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If XL-flange is used to increase load-bearing capacity, then the load transfer capability is improved, but the forging size and material cost increase
Solution Approach 1:
The flange is divided into two separate segments: a first flange segment that is integral with the tower section, and a second flange segment that is separate and attached to the first segment. This segmentation allows the load-bearing functions to be distributed across two smaller components rather than requiring one large monolithic forging, thereby maintaining strength while reducing individual component size and material waste.
2Strength
If XL-flange is used to increase load-bearing capacity, then the load transfer capability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
By segmenting the flange into two parts, each segment can be manufactured using simpler, more standard processes. The first segment integrates with the tower section using conventional methods, while the second segment can be manufactured separately and attached, avoiding the need for extremely large, complex forgings and reducing overall manufacturing difficulty.
Solution Approach 2:
The first flange segment acts as an intermediary component between the tower section and the second flange segment. This intermediate structure allows for modular assembly, where each component can be optimized and manufactured independently, then combined to achieve the required load-bearing capacity without requiring a single complex large-scale manufacturing process.
3Ease of manufacture
If L-flange is used for tower connection, then the manufacturing is simpler, but the load-bearing capacity is insufficient
Solution Approach 1:
The flange connection is segmented into two functional parts: the first flange segment maintains the simple L-shape configuration that is easy to manufacture and integrate with the tower section, while the addition of the second flange segment provides the enhanced load-bearing capacity through the X-shaped aperture pattern, combining manufacturing simplicity with structural strength.
Data Source
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Figure 3
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AI summary
The invention describes a flange for connecting to a complementary flange (1), and wherein the flange (1) comprises first flange-segment (1A) and a second flange-segment (1B), wherein a) the first flange-segment (1A) comprises - a primary bolt circle (1P) comprising an annular arrangement of inclined openings (10_thru, 10_part); and - a first annular connection face (1C) adapted to lie against a complementary second annular connection face (1D) of the second flange-segment (1B); and b) the second flange-segment (1B) comprises - on two opposite sides annular connection faces (1D, 1F) adapted to lie against complementary annular connection faces (1C, 1F); - a primary aperture circle (1Q) comprising an annular arrangement of openings (10_thru); and - a second body section with a secondary bolt circle (IS) comprising an annular arrangement of openings (1B_thru).