Wind Turbine Tower Flange Alignment Device with Lever-Actuated Guide
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Solution Overview
Problem
Existing wind turbine alignment devices are difficult to install and remove, and they do not allow for easy assembly of tower sections without personnel inside the hollow tower, posing safety and economic challenges.
Innovation Solution
An alignment device mountable to the bottom face of a flange using a first connector and a guide portion with an elongated bar that balances forces through leverage, allowing for secure positioning and easy installation and removal, with optional magnetic support for steel flanges and multiple devices spaced along the flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional alignment devices are used for tower section assembly, then alignment function is provided, but installation and removal become difficult and time-consuming
Solution Approach 1:
The alignment device is divided into separate components: a mounting component that attaches to the flange, and an alignment component with the guide surface. This segmentation allows the mounting component to be easily installed and removed while the alignment component remains, simplifying the overall installation/removal process.
Solution Approach 2:
The alignment function is extracted as a separate alignment component with a guide surface, distinct from the mounting component. This extraction allows the alignment component to be permanently retained on the structure while the mounting component can be easily installed and removed as needed.
2Object-affected harmful factors
If alignment devices are installed from the outside of the hollow tower section, then alignment is achieved, but personnel safety is compromised due to required entry inside the tower
Solution Approach 1:
Instead of installing the alignment device from the outside of the tower section, the mounting component is designed to be installed from the inside of the hollow tower section. This inversion of the installation approach eliminates the need for personnel to enter the tower, improving safety while maintaining alignment functionality.
3Manufacturing precision
If alignment devices are made secure and stable, then alignment precision is improved, but installation and removal become more difficult
Solution Approach 1:
The alignment device is segmented into a mounting component and an alignment component. The mounting component is designed for easy installation and removal with simple fastening mechanisms, while the alignment component provides precise alignment through its guide surface geometry, resolving the contradiction between security and ease of operation.
Solution Approach 2:
The mounting component includes pre-configured mounting elements and fastening mechanisms that are prepared in advance, allowing for quick and easy installation and removal without compromising the stability or precision of the alignment function.
4Manufacturing precision
If alignment devices allow flange bearing, then assembly accuracy is improved, but device complexity increases
Solution Approach 1:
The flange bearing function is integrated into the alignment component itself, which is extracted as a separate element from the mounting component. The guide surface of the alignment component provides the bearing function, eliminating the need for additional complex bearing structures and maintaining simplicity.
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 safe and efficient assembly of wind turbine tower sections by balancing forces and maintaining alignment, reducing personnel risk and lowering installation/removal complexity while allowing flat flange contact.
Implementation Method 1
the first connector is a magnet configured to provide a magnetic attractive force sufficient to support the weight of alignment device
Implementation Method 2
a leverage action arising from external loads on the alignment device during the assembly procedure provides temporary forces required to maintain the alignment device in correct position, by using a dedicated second connector
Data Source
Figure 1a
Figure 1b~1c
Figure 2
AI summary
The present invention generally relates to a hollow structural part (2) configured to form part of a wind turbine (1), said structural part (2) having a first end (2') and a second end, with an inwardly directed annular flange (70) at said first end (2'), said flange (70) having a plurality of holes (72), at least one alignment de- vice (10) being mounted to said hollow structural part (2), a first connector (22) being connected with said structural part (2) to connect said alignment device (10) to said structural part (2), said alignment device (10) having a guide portion (35) with a protracted guiding surface part (38) extending in the general direction away from said opposite second end and towards a centre line (CL) of said hollow structural part (2), said guiding surface part (38) being for directional guiding of another structural part (5) of said wind turbine (1) during assembly thereof, an elongated bar (40) connected with said guide portion (35), said bar (40) having a portion extending from said bottom face (71) of said flange and into one of said holes (72) of said flange, with an end of said bar (40) located within said hole (72), wherein forces on said guide portion (35) are at least in part balanced by lateral forces acting on said portion of said bar (40).