Telescopic Tower Assembly with Jacking Tendons
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Solution Overview
Problem
Current construction methods for tall tower structures, such as wind turbine towers, require large and expensive cranes for assembly and maintenance, limiting tower height and being labor-intensive and unsuitable for non-parallel sections.
Innovation Solution
A method using coaxial telescopic sections with jacking tendons and tendon jacks to lift and assemble sections without a large crane, allowing for faster and more efficient assembly of sections in any order, including those with non-parallel walls, by distributing the weight across multiple tendons and using tensionable connecting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If large cranes are used to lift tower sections and generator units to great heights, then the tower can be constructed to greater heights, but the equipment size, cost and complexity increase dramatically
Solution Approach 1:
The tower is divided into multiple pre-fabricated sections that can be assembled in a nested configuration at ground level. Each section is a complete, self-contained unit that can be handled by small cranes. The segmentation allows the tower to be constructed in sections rather than requiring one massive lifting operation for the entire structure.
Solution Approach 2:
The patent employs a nested arrangement where inner tower sections are placed inside outer sections at ground level before erection. The innermost section is erected first, followed by successive outer sections that are lifted and nested around the previous section. This nesting principle allows multiple heavy sections to be positioned using small cranes at ground level rather than requiring one enormous crane to lift all sections to great heights.
2Productivity
If traditional crane-based assembly methods are used, then tower sections can be erected, but the process is labor-intensive and requires specialist staff and heavy machinery
Solution Approach 1:
Tower sections are pre-assembled at ground level in a nested configuration before erection. The innermost section is prepared first with its flanges and connecting elements in place. Subsequent outer sections are pre-positioned around it, with all connecting flanges and alignment features prepared in advance. This preliminary ground-level assembly eliminates the need for complex high-altitude assembly operations and reduces labor intensity during the actual erection process.
3Device complexity
If the jacking method with inner wall construction is used to raise sections, then sections can be lifted without large cranes, but the method is exceedingly labor-intensive involving construction and dismantling of inner wall structures
Solution Approach 1:
Instead of constructing inner wall structures to support and jack up sections from the inside out, the patent inverts the approach by using the outer sections themselves as the supporting structure. The outer sections are erected first and serve as the permanent support framework. Inner sections are then lifted and nested within the already-erected outer sections, using the outer sections' flanges and connecting elements for support rather than requiring temporary inner wall constructions.
4Ease of operation
If sections are raised in a specific order with each inner section resting on its outer neighbour, then lifting can be achieved, but the sections must be raised in a particular order limiting flexibility
Solution Approach 1:
The patent employs dynamic, adjustable lifting mechanisms at each section interface rather than fixed mechanical supports. Hydraulic jacks or adjustable shims are used at multiple points around each section flange, allowing sections to be lifted and positioned in various sequences. The supporting elements can be dynamically adjusted to accommodate different assembly orders and section weights, providing flexibility in the erection process rather than requiring a rigid predetermined sequence.
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
Enables the construction of towers of unlimited height using small-scale lifting equipment, reducing labor and costs, and allowing for efficient assembly and disassembly of sections with improved structural quality and reduced need for extensive formwork.
Implementation Method 1
a fourth step of attaching a tendon jack to one or more of said plurality of jacking tendons, a fifth step of operating the tendon jacks to apply tension to the jacking tendons (5) such that the weight of the first section is supported by the upper jacking points of the second section, and a sixth step of operating said tendon jacks to lift the first section with respect to the second section
Data Source
AI summary
A method of constructing a tower structure by assembling a set of coaxial telescopic sections (2, 3a, 3b) in position on site and then raising the assembled sections using hydraulic crawler jacks (8) and tendons (5). The telescopic sections are assembled or constructed in situ, starting with the inner section and then each subsequent section around the outside of the previously constructed sections. Each individual tower section may be cast in situ or assembled from multiple pre-fabricated segments. This method permits the construction of very tall structures while obviating the need for very large cranes. It also removes the design constraints on the height of the individual telescopic sections.