Wind Turbine Tower Flange Joint With Staggered Bolt Positions
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Solution Overview
Problem
Larger wind turbines require a corresponding structural solution for their towers to support increased power generation, but existing structures face challenges in efficiently connecting segments while accommodating a larger number of bolt connections without increasing the tower diameter.
Innovation Solution
The use of a tower section with an upper and lower flange connected by multiple bolt connections, where first and second bolt connections are positioned differently along the longitudinal axis, and spacers are arranged on the bolts above and below the flanges, allowing for efficient alignment and tightening of bolts from different sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tower diameter is increased to accommodate more bolt connections for larger wind turbines, then the load capacity increases, but the transportation and installation complexity increases
Solution Approach 1:
The tower is divided into multiple segments that can be manufactured and transported separately, then assembled on-site using the differentiated bolt connection system. This allows the tower to achieve high load capacity through proper connection design rather than simply increasing diameter, reducing transportation complexity while maintaining strength.
Solution Approach 2:
The patent employs asymmetric bolt connection arrangements where first and second bolt connections are positioned at different locations and orientations on the flange interface. This asymmetric configuration optimizes load distribution and connection efficiency without requiring a larger tower diameter, thereby maintaining transportability while achieving the required load capacity.
2Strength
If multiple bolt connections are used to increase load capacity, then the connection strength improves, but the manufacturing and assembly complexity increases
Solution Approach 1:
Different bolt connections are assigned different functions and positions based on local requirements. First bolt connections are positioned for optimal load bearing in one direction, while second bolt connections address stress in another direction. This localized optimization achieves high connection strength without uniformly increasing the number of bolts throughout, simplifying manufacturing and assembly.
Solution Approach 2:
The flange connections are designed with pre-positioned first and second bolt connections that align with corresponding features on adjacent tower segments. This preliminary design of connection geometry and bolt positioning facilitates easier assembly on-site, reducing the complexity that would otherwise result from multiple bolt connections.
3Power
If the tower diameter is increased to support larger wind turbines, then the power generation capability increases, but the transportation efficiency decreases
Solution Approach 1:
By segmenting the tower into transportable sections with optimized connection interfaces, the system enables construction of tall towers for high-power turbines without requiring the entire structure to be transported as a single piece. The differentiated bolt connection system ensures structural integrity at segment interfaces, allowing power generation capability to scale while maintaining transportation efficiency.
Solution Approach 2:
The asymmetric bolt connection arrangement optimizes the structural efficiency of each tower segment, allowing smaller-diameter segments to achieve the required load-bearing capacity through optimized connection geometry rather than increased size. This maintains transportation efficiency while supporting the power generation requirements of larger turbines.
Data Source
AI summary
A tower section 12 of a wind turbine is provided, the tower section 12 including an upper segment 100 that includes a lower flange 110; a lower segment 200 that includes an upper flange 210; a plurality of first bolt connections that include first bolts 310 and first nuts 320; a plurality of second bolt connections that include second bolts 410 and second nuts 420; wherein the first bolt connections and the second bolt connections connect the lower flange 110 to the upper flange 210; and wherein the first bolt 310 and the second bolts 410 have different axial positions with respect to the longitudinal axis of the tower section 12.