Wind Turbine Tension Connection Using Removable Lifters and Spacers

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Solution Overview

Problem

Existing mechanical fasteners in wind turbines are prone to installation failures due to human error and require regular maintenance to withstand external loads and weather conditions.

Innovation Solution

An apparatus comprising a fastener with a flange, lifting elements, and spacers that provides a secure tension connection by forming a gap between the support member and the flange, which is then maintained by the spacers after the lifting elements are removed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If mechanical tensioners are arranged in an outer circumference of a fastener to maximize preload, then the preload on the fastener is improved, but the installation is prone to failures due to technician boredom or mistake and requires regular maintenance

Engineering Contradiction:

Improvepreload on fastenerVSAvoidinstallation reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention divides the preload application function into two separate components: lifting elements that apply the preload force, and spacers that maintain the preload after installation. This segmentation allows the lifting elements to be removed after use, eliminating the need for ongoing maintenance while preserving the preload benefit.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spacers are pre-positioned in the gap between the support member and flange during the installation process. This preliminary action ensures that once the lifting elements are removed, the preload is already maintained without requiring any subsequent adjustment or maintenance interventions.

Inventive Principle:

Principle #10Preliminary action

2Strength

If mechanical tensioners are used to provide preload on fasteners, then the tension connection is improved, but the tensioners are prone to external influences such as weather and require regular maintenance and inspection

Engineering Contradiction:

Improvetension connectionVSAvoidweather influence

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The lifting elements, which are susceptible to weather and maintenance requirements, are extracted from the final connection structure. They are used only temporarily during installation to apply preload, then removed. The spacers remain as permanent maintenance-free components that maintain the preload without being exposed to the same environmental degradation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The lifting elements function as temporary, disposable components that perform their preload application function during installation and are then removed. This eliminates the need for long-term durability against weather conditions, as these elements are not part of the permanent connection structure.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If spacers are inserted in the gap between the fastener and support member to maintain tension forces, then the maintenance requirement is reduced, but the device complexity increases due to additional components

Engineering Contradiction:

Improvemaintenance-free operationVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The spacers are self-installing components that maintain the preload force passively through their physical presence in the gap. They require no active control, adjustment, or monitoring systems, providing maintenance-free operation through simple geometric constraint rather than complex active mechanisms.

Inventive Principle:

Principle #25Self-service

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

The apparatus ensures a stable and reliable tension connection that is maintenance-free, resistant to external influences, and reduces the risk of self-loosening dynamics, allowing for a larger flange-to-shank ratio and potentially smaller fastener sizes.

Implementation Method 1

Each lifting element of the plurality of lifting elements is configured to engage in a hole of the plurality of holes, to extend from the holes and to abut against the support member under an applied torque in order to tension the fastener

Methodology Applied

Scientific EffectTorque: Torque

Implementation Method 2

Each spacer of the plurality of spacers is configured to engage into the gap between the support member and the flange, such that tension forces applied on the fastener are maintained after the plurality of lifting elements are removed from the fastener

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS12331773B2Apparatus and method for providing a secure tension connection

Publication Date: 2025.06.17 GAMESA INNOVATION & TECH SL

AI summary

Provided is an apparatus for providing a secure tension connection, the apparatus including a fastener) with a flange for interaction with a shank, a plurality of lifting elements, and a plurality of spacers. Also provide is a wind turbine with such an apparatus, a tool for securing an apparatus and a method for providing a secure tension connection.