Steel Tower Ring Segment Separation With Temporary Flange Bridging

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Solution Overview

Problem

Existing methods for manufacturing partial shells of steel tower ring segments for wind turbines are inefficient, costly, and unsafe, particularly for large segments that cannot be transported as a single ring due to transport restrictions.

Innovation Solution

A method involving temporary connecting flanges at planned separation lines, allowing for the separation and transportation of steel tower ring segments into partial shells, using a relative movement between the segment and cutting device, and avoiding connections that could be damaged during cutting, enabling flexible cutting and efficient assembly at the installation site.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the steel tower ring segment is separated into partial shells at multiple separation lines, then the transportability and assembly flexibility are improved, but the structural stability and safety during the separation process deteriorate

Engineering Contradiction:

Improvetransportability and assembly flexibilityVSAvoidstructural stability during separation

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Connecting flanges are provided at the planned separation lines before the actual separation process begins. These flanges are temporarily connected to form a stable structure that maintains structural integrity during the separation operations, allowing subsequent separation at multiple lines without compromising safety

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connecting flanges act as intermediary elements that temporarily bridge the separation lines. During separation at one line, the flanges at other lines provide structural support and stability. After separation is complete, these intermediary flanges are removed, enabling both transportability and structural stability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If connecting flanges are provided at all planned separation lines, then the structural stability during separation is improved, but the device complexity and manufacturing costs increase

Engineering Contradiction:

Improvestructural stability during separationVSAvoidnumber of connecting flanges and temporary connections

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Connecting flanges are installed at all planned separation lines before separation begins, but they are designed to be temporarily connected only where needed during the separation process. This preliminary placement allows flexibility in the separation sequence while avoiding unnecessary permanent connections

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connection state of the flanges is dynamic rather than static. Flanges are temporarily connected during separation operations and then removed afterward. This dynamic approach allows the same flange structure to serve multiple separation lines sequentially, reducing overall complexity compared to having all flanges permanently connected

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If the separation process is performed without temporary connections, then the manufacturing simplicity is improved, but the safety and risk of damage to connecting flanges deteriorate

Engineering Contradiction:

Improvesimplicity of separation processVSAvoidrisk of damage to connecting flanges

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The connecting flanges are installed and temporarily connected before the separation process begins. This preliminary action creates a protected structural framework that prevents damage to the flanges during separation operations, while the temporary nature of the connection maintains manufacturing simplicity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The temporary connections of connecting flanges act as a cushioning or protective measure beforehand. They provide structural support and protection during the separation process, preventing harmful forces from damaging the flanges, while being easily removable afterward to maintain process simplicity

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentEP4191056B1Method for producing partial shells of a steel tower ring segment of a tower of a wind turbine

Publication Date: 2026.01.21 WOBBEN PROPERTIES GMBH

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AI summary

The invention relates to a method (1000) for manufacturing partial shells (310, 320) of a steel tower ring segment (200), in particular for erecting a tower (102) of a wind turbine (100). The method (1000) comprises providing a steel tower ring segment (200), providing first connecting flanges (411a, b) at a first planned dividing line (410) and second connecting flanges (421a, b) at a second planned dividing line (420), separating at the first planned dividing line (410), separating at the second planned dividing line (420), wherein during the separation at the second planned dividing line (420) the first connecting flanges (411a, b) are temporarily connected to each other.