Wind Turbine Tower Segment Thickness Profiling for Fewer Joints
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Solution Overview
Problem
Existing wind turbine tower manufacturing processes are inefficient and costly, particularly due to the need for extensive resource use and increased complexity with larger rotor diameters and higher loads, which compromise the lifespan and cost-effectiveness of the towers.
Innovation Solution
A manufacturing process that involves creating tower segments with a varying thickness profile along the longitudinal direction, using a combination of rolling and bending techniques to reduce the number of circumferential joints and optimize material usage, thereby enhancing the fatigue strength and lifespan of the tower.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional tower manufacturing processes are used with larger rotor diameters and higher power ratings, then the tower can support greater loads, but the manufacturing costs and resource consumption increase significantly
Solution Approach 1:
The patent applies local quality by varying the plate thickness along the longitudinal direction of the tower segment. The thickness profile is optimized such that thicker sections are located where higher structural strength is needed (e.g., at the ends for connection joints), while thinner sections are used where lower loads are applied. This allows the tower to support greater loads while reducing overall material consumption and manufacturing complexity.
2Ease of manufacture
If more circumferential joints are used in tower construction, then the tower can be assembled from standard segments, but the fatigue strength and lifespan are reduced
Solution Approach 1:
The patent applies segmentation by dividing the tower into multiple tower segments that can be assembled together. Each segment is formed from a plate with an optimized thickness profile. While segmentation enables easier assembly and transport, the patent mitigates the fatigue strength reduction by carefully designing the thickness profile to strengthen the connection regions, thus maintaining reliability while improving ease of manufacture.
3Ease of manufacture
If uniform thickness plates are used for tower segments, then the manufacturing process is simpler, but material usage is not optimized leading to higher costs
Solution Approach 1:
The patent directly applies local quality by implementing a variable thickness profile in the tower segment plates. The thickness varies along the longitudinal direction, with thicker sections at the ends (0.5-2 meters from each end) to strengthen connection joints, and thinner sections in the middle where loads are lower. This optimizes material usage by placing material only where structurally necessary, reducing overall material consumption while maintaining manufacturing feasibility through rolling and bending processes.
4Duration of action of stationary object
If additional resources such as time, materials, and personnel are allocated to build larger towers, then the required lifespan can be achieved despite increased strain, but the manufacturing costs increase
Solution Approach 1:
The patent applies parameter changes by modifying the thickness parameter of the tower segment plates along their longitudinal direction. This creates an optimized thickness profile that provides enhanced strength at critical connection regions while reducing material consumption overall. The parameter change enables the tower to achieve the required lifespan under increased strain from larger rotor diameters without proportionally increasing resource consumption, thus resolving the contradiction between lifespan and resource usage.
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
The proposed manufacturing process reduces material usage and costs while increasing the lifespan of wind turbine towers by minimizing the number of circumferential joints and optimizing the thickness profile of tower segments, thus improving the structural integrity and durability of the towers.
Implementation Method 1
rolling (S2) of the provided plate (1a), wherein a thickness profile with varying thickness (dÜ) is introduced in a longitudinal direction (L) of the tower segment (1)
Implementation Method 2
bending (S3) of the rolled plate (1a), wherein a curvature (x1, x2) in the circumferential direction (U) is introduced into the rolled plate (1a)
Data Source
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AI summary
The invention relates to a production method for producing a tower segment, a tower portion and a tower section for a tower, in particular for a tower of a wind power plant. The invention furthermore relates to a tower segment, a tower portion and a tower section for a tower, in particular for a tower of a wind power plant, a tower and a wind power plant. The production method comprises: providing (S1) a plate (1a), which extends in a longitudinal direction (L) and in a circumferential direction (U) orthogonally thereto, wherein the extension in the longitudinal direction (L) is greater than the extension in the circumferential direction (U); and rolling (S2) of the plate (1a) for introducing a thickness profile in a longitudinal direction (L) of the plate (1a), wherein the rolling comprises: introducing a first constant portion (K1) having a substantially constant first thickness (d1), which is different from a substantially constant second thickness (d2) of a second constant portion (K2) arranged substantially parallel thereto in the longitudinal direction (L); and bending (S3) of the plate (1a) in the circumferential direction (U).