Multi-Part Tower Section Flange Production via Partial Cutting
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Solution Overview
Problem
The challenge lies in manufacturing multi-part tower sections for wind turbines with large hub heights, where existing methods are inefficient due to limitations in transport clearance heights, requiring innovative approaches to produce sub-sections that are cheaper, simpler, and more dimensionally accurate while accommodating diameters greater than 4.4 meters.
Innovation Solution
A method involving partial cutting of annular flanges at dividing points to maintain web connections, connecting these flanges to a shell, and then separating them, along with creating alignment holes and rotating sections to simplify and improve the production process, allowing for larger diameters without exceeding transport constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If tower sections are split longitudinally to accommodate transport restrictions, then transportability is improved, but manufacturing complexity increases
Solution Approach 1:
The tower section is divided into multiple partial sections by longitudinally splitting the shell and annular flange. The shell is separated into first and second partial sections, and the annular flange is divided into corresponding flange parts. This segmentation allows each partial section to be manufactured and transported separately while maintaining the capability to form a complete tower section with larger base diameters.
Solution Approach 2:
Alignment holes are created through the shell along the desired longitudinal dividing line before separation. These pre-created alignment holes facilitate precise alignment of the partial sections during assembly and guide the separation process, simplifying the overall manufacturing procedure despite the increased segmentation.
2Ease of manufacture
If annular flange is completely cut at parting points, then separation is simplified, but structural stability during manufacturing deteriorates
Solution Approach 1:
The annular flange is partially cut at the parting points rather than being completely severed. The cutting removes material to create separation interfaces while deliberately leaving portions of the web connecting the flange parts intact. This partial cutting approach maintains the structural stability and rigidity of the flange during manufacturing operations, yet still enables subsequent separation when needed.
3Manufacturing precision
If alignment holes are created through the shell, then alignment precision is improved, but manufacturing time increases
Solution Approach 1:
The alignment holes serve multiple functions: they facilitate precise alignment of partial sections during assembly, guide the separation process along the desired longitudinal dividing line, and can be used for fastening longitudinal flanges. This multi-functionality justifies the additional manufacturing step, as the same holes provide alignment, guidance, and assembly functions.
4Stability of the object's composition
If tower sections are manufactured with larger diameters, then hub height capability is improved, but transport restrictions are violated
Solution Approach 1:
The tower section is segmented into multiple partial sections that can be manufactured with larger diameters and then transported in a split configuration. The shell is divided into partial sections and the annular flange into flange parts, allowing the overall structure to exceed 4.4m diameter capability while each component remains within transport restrictions.
Solution Approach 2:
The partial sections and flange parts are designed to nest or fit together during assembly, with alignment holes and connecting structures enabling the components to be precisely positioned relative to each other to form the complete large-diameter tower section.
Data Source
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Figure 2B
AI summary
The invention relates to a method (100) for producing a sub-section of a multi-part tower section of a tower, said method comprising partially cutting (110) a ring flange at separation points between ring flange parts of the ring flange such that, at the separation points, at least parts of a connecting element of the ring flange remain after the partial cutting, connecting the ring flange parts to each other. The method (100) also comprises connecting (120) the ring flange to a shell of the multi-part tower section after the partial cutting (110) of the ring flange, and separating (130) the ring flange parts at the separation points by cutting the remaining parts of the connecting elements after the connection of the ring flange to the shell.