Tubular Slip Joint Ring Geometry for Tolerance-Friendly Load Transfer
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Solution Overview
Problem
The existing Double Slip Joint technology for connecting tubular sections of wind turbine foundations and towers faces challenges in manufacturing due to strict tolerance requirements for conical contact surfaces, leading to increased fabrication costs and limited material strain, which complicates load sharing and alignment.
Innovation Solution
The introduction of a cylindrical and conical ring contact surface configuration allows for axial movement and load transfer, with cylindrical surfaces ensuring alignment and conical surfaces handling bending loads, using separate plate contact elements and elastic materials to simplify manufacturing and enhance load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If both contact surfaces are made conical to enable load transfer by friction, then bending loads can be transferred, but manufacturing precision requirements increase and fabrication costs increase
Solution Approach 1:
The connection system is divided into two functional segments: the upper contact surface is made cylindrical for alignment and positioning, while the lower contact surface is made conical for load transfer. This segmentation allows each surface to be optimized for its specific function, reducing overall manufacturing complexity and tolerance requirements.
Solution Approach 2:
Different geometric qualities are applied to different locations of the connection system. The upper contact surface has cylindrical geometry providing uniform contact and alignment, while the lower contact surface has conical geometry providing friction-based load transfer. This local differentiation optimizes performance while reducing manufacturing constraints.
2Reliability
If strict tolerance requirements are applied to conical contact surfaces, then load sharing between rings is improved, but fabrication costs increase
Solution Approach 1:
The connection is segmented into two contact surfaces with different geometric requirements. The upper cylindrical surface requires precise positioning for alignment but not for load sharing, while the lower conical surface handles load transfer with more tolerant positioning requirements, reducing overall fabrication costs.
Solution Approach 2:
The geometric parameters of the contact surfaces are changed from both conical to a combination of cylindrical and conical. This parameter change fundamentally alters the load transfer mechanism, allowing the upper surface to provide alignment with relaxed tolerance requirements compared to a fully conical design.
3Manufacturing precision
If elastic material is used for contact plates, then fitting tolerances can be larger and sealing is improved, but material strain capacity is reduced
Solution Approach 1:
The contact plates are segmented by material properties: the upper contact plate is made of elastic material (e.g., rubber) to accommodate tolerance variations and provide sealing, while the lower contact plate is made of steel to handle high loads and provide structural strength.
Solution Approach 2:
Different materials are used for different contact plates based on functional requirements. Elastic material is used where tolerance accommodation and sealing are needed, while metallic material is used where high strength and load-bearing capacity are required, creating a composite material system optimized for multiple functions.
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
This configuration reduces the need for precise ring positioning tolerances, lowers manufacturing costs, and provides a reliable, firm connection that can absorb loads and prevent failure, while maintaining structural integrity and corrosion protection.
Implementation Method 1
The conical contact plate will increase during settling, which enable the transfer of bending loads by friction
Implementation Method 2
The soft material also seals off the contact surface from the environment, protecting it from corrosion
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
Structural assembly, comprising a lower pile having an upper end and a superstructure having a lower end, said upper end and said lower end fit inside each other and are being connected to each other at ring contact surfaces, characterized in that at the top and at the bottom of the connection ring contact surfaces are provided by attachment of plate material at the inside of the outer tube or by attachment of plate material at the outside of the inner tube, or by attachment of plate material at the inside of the outer tube and at the outside of the inner tube.