Tubular Segment Assembly Frame for Offshore Wind Jacket Precision
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Solution Overview
Problem
The production of offshore wind turbine foundation structures, particularly jacket constructions, is inefficient due to high costs, complex processes, and dimensional inaccuracies resulting from manual alignment and welding of heavy, large steel tubular segments.
Innovation Solution
A method utilizing an assembly frame to align and weld tubular segments, which includes arranging segments on a leadframe, fixing them with clamps, heating for uniform expansion, and using hydraulic elements and automated measuring devices for precise alignment, followed by orbital welding or robotic welding for improved accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment and welding methods are used for tubular segments, then flexibility and adaptability are maintained, but production time increases and dimensional accuracy deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-assembling tubular segments into complete nodes on the ground before lifting them into position. This ground-based assembly allows for precise alignment and welding without the time-consuming manual operations required at height, thereby improving dimensional accuracy while reducing overall production time.
Solution Approach 2:
The patent replaces manual mechanical alignment methods with automated positioning systems and robotic welding equipment. This substitution eliminates the time-consuming nature of hand operations while maintaining or improving dimensional accuracy through more precise control systems.
2Productivity
If manual welding operations are used, then adaptability to complex geometries is maintained, but productivity decreases and manufacturing precision deteriorates
Solution Approach 1:
The patent replaces manual welding operations with automated welding systems, including robotic welders and orbital welding equipment. This substitution dramatically increases productivity by performing multiple welds simultaneously and improves manufacturing precision through consistent, programmable welding parameters that eliminate human error and variability.
Solution Approach 2:
The patent changes the operational parameters from manual control to automated control with precise programmable settings. This allows for optimized welding parameters to be consistently applied, improving both productivity through faster welding speeds and manufacturing precision through controlled heat input and consistent bead placement.
3Manufacturing precision
If simple scaffolding and supports are used for assembly, then device complexity is reduced, but manufacturing precision and worker safety deteriorate
Solution Approach 1:
The patent applies preliminary action by assembling segments on the ground using simple supports before lifting the complete node into position. This eliminates the need for complex scaffolding systems during welding operations, as the precision alignment is achieved during ground-based assembly when simple jigs and fixtures suffice.
Solution Approach 2:
The patent segments the assembly process into ground-based preparation and elevated installation phases. By completing alignment and welding on the ground where simple supports are adequate, the complex lifting and positioning equipment is only used for transportation, not for precision work, thereby reducing overall device complexity while maintaining manufacturing precision.
4Measurement precision
If hand-operated alignment tools are used, then equipment cost is reduced, but productivity decreases and measurement precision deteriorates
Solution Approach 1:
The patent replaces hand-operated alignment tools with electronic measurement systems, including laser trackers, total stations, and digital level systems. These electronic systems provide superior measurement precision through automated data collection and processing, while also increasing productivity by eliminating manual measurement and calculation steps.
Solution Approach 2:
The patent implements feedback systems where electronic measurement devices continuously monitor alignment parameters and provide real-time data to the positioning system. This closed-loop feedback enables rapid correction of alignment deviations, improving both measurement precision and the speed at which accurate alignment can be achieved compared to manual methods.
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
This method significantly reduces production time, lowers costs, and enhances dimensional accuracy, enabling the industrial manufacture of offshore foundation structures with improved efficiency and reduced manpower.
Implementation Method 1
heating the segments to a common, uniform temperature... heating is advantageous in order to reduce excessive stresses which are caused by the welding or the local heating of the material during the welding
Data Source
Figure 1
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AI summary
The method involves arranging several tubular segments (14) on mounting frame. The individual segments are aligned and welded to each other. The individual segments are heated at common unitary temperature before aligning the segments. Ends of individual segments are chamfered before placing the tubular segments on assembly frame. An independent claim is included for an assembly frame.