Tower Sector Mounting Structure for Wind Turbine Assembly
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Solution Overview
Problem
The existing methods for assembling wind turbine towers from tower sections are labor-intensive and time-consuming, requiring precise alignment and connection of edge flanges, which complicates the process and increases labor requirements.
Innovation Solution
A mounting structure and system that uses trunnions to support tower sectors, allowing for easier alignment and connection of edge flanges by adjusting the distance between mounting structures, enabling parallel positioning and secure assembly of tower sectors into a cylindrical form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If tower sectors are assembled by connecting edge flanges with screws, bolts or rivets in a lying position, then the tower can be constructed from transportable sections, but the assembly process becomes extensive and labor-intensive requiring precise alignment of flange surfaces
Solution Approach 1:
The patent introduces a mounting structure with bearing elements as an intermediary between the tower sectors during assembly. These bearing elements receive the trunnions and automatically guide the sectors into correct alignment, mediating the connection process and eliminating the need for manual precision alignment of flange surfaces
Solution Approach 2:
The mounting structure performs preliminary alignment actions before the actual connection of edge flanges. By providing predetermined bearing elements that receive trunnions at specific positions, the system pre-aligns the tower sectors in the correct spatial relationship, so that when the sectors are brought together, their edge flanges are already in the correct position for connection
2Ease of manufacture
If tower sectors are arranged to form a complete cylinder in lying position and then turned upright, then the tower can be assembled from sections, but the process requires serious amount of labor time for proper arrangement and connection
Solution Approach 1:
The patent replaces the manual mechanical process of arranging and aligning tower sectors with a mechanical system of mounting structures and bearing elements. The bearing elements automatically guide the trunnions into correct positions, substituting manual alignment operations with a mechanical guiding system that reduces labor time
Solution Approach 2:
The mounting structure changes the spatial parameters of the assembly process by providing fixed bearing elements at predetermined positions. This constrains the degrees of freedom of the tower sectors during assembly, fixing their orientation and position parameters to reduce the time required for proper arrangement
Data Source
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AI summary
The invention describes a mounting structure (3) for supporting a tower sector (2a) with face flanges (2b) covering the curved faces of the surface shell of the tower sector (2a) with a predefined radius R, and two trunnions (7) releasable fastened at a face flange (2b) so that the center of mass of the tower sector (2a) is between the trunnions (7), the mounting structure (3) comprising a support frame (3c) designed to be mounted on a surface with a base area (3f) on its bottom side, the support frame (3c) comprising a first bearing (3a) and a second bearing (3b), each bearing (3a, 3b) adapted for supporting a trunnion (7), wherein the relative arrangement of the bearings (3a, 3b) on the support frame (3c) is such that the first bearing (3a) is positioned higher than the second bearing (3b), and that the bearings (3a, 3b) lie on the arc of a circular sector with the radius R, a central angle <100°, a vertically oriented edge-radius outside the second bearing (3b) and a center of mass between the bearings (3a, 3b). The invention further describes a respective mounting system, a special tower sector, a construction system and a method of connecting tower sectors.