Tubular Tower Segmentation for Wind Turbine Assembly
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Solution Overview
Problem
Existing methods for constructing tubular tower structures, such as wind turbine towers, face challenges in achieving precision, speed, and cost-effectiveness, particularly when dealing with large diameters and complex assembly processes involving concrete or reinforced concrete components.
Innovation Solution
The method involves manufacturing tubular tower structures in partial lengths at a manufacturing facility using sheet steel, rolling it into ring segments, welding them, and then separating them into partial shells with axially welded flanges for precise alignment and assembly at the site, allowing for efficient transportation and quick reassembly with improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tubular tower structures are assembled from individual segments with circumferential welds or overlapping flanges, then the tower can be constructed with standard materials and processes, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The tower structure is divided into modular segments with standardized connection elements. Each segment can be manufactured independently and then assembled through simplified connection processes, reducing overall assembly complexity while maintaining manufacturability
Solution Approach 2:
Multiple connection functions are integrated into unified connection elements that combine flanges, welds, and alignment features into a single component, simplifying the assembly process while maintaining structural integrity
2Length of stationary object
If concrete substructures are used for tall wind turbine towers, then large diameters and greater heights can be achieved, but the assembly effort and delivery complexity increase significantly
Solution Approach 1:
The concrete substructure is divided into manageable segments that can be delivered and assembled in sections. Connection elements are designed to simplify the assembly of these segments, reducing the overall assembly effort while enabling greater tower heights
Solution Approach 2:
Specialized connection elements act as intermediaries between concrete segments, facilitating precise alignment and secure attachment. These intermediaries reduce the complexity of direct concrete-to-concrete connections and enable easier assembly
3Stability of the object's composition
If reinforced concrete towers are constructed with embedded connecting elements, then structural stability is improved, but the casting process becomes complex and dimensional precision is difficult to achieve
Solution Approach 1:
Connection elements are pre-fabricated with precise dimensions and tolerances before being embedded in the concrete. This preliminary preparation ensures dimensional precision is achieved during casting without requiring complex real-time adjustments, while maintaining structural stability
Solution Approach 2:
Connection elements are strategically positioned at specific locations where structural stability is most needed. These localized reinforcement points provide enhanced stability without requiring complex casting processes throughout the entire structure, maintaining dimensional precision
4Adaptability or versatility
If tower segments are connected with flanges and bolts, then disassembly and reassembly become possible, but the connection process becomes more complex compared to welding
Solution Approach 1:
The tower is designed as a modular segmented structure where standardized flange connections enable easy disassembly and reassembly. Each segment maintains its structural integrity while allowing flexible configuration through standardized connection interfaces
Solution Approach 2:
Universal flange connection elements are designed to work across all tower segments and applications. These multi-functional connectors provide both structural connection and alignment functions, reducing overall connection complexity while enabling versatile disassembly and reassembly capabilities
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 approach enables the rapid and precise assembly of tubular tower structures with large diameters, reducing assembly time and costs while ensuring stability and accuracy, facilitating the construction of taller wind turbine towers with better wind accessibility.
Implementation Method 1
rolling it into ring segments
Implementation Method 2
welding them
Data Source
Figure 1a~1c
Figure 2~3
Figure 4~5
AI summary
Method for erecting a tubular tower structure, wherein sheet steel is bent into a substantially annular-shaped tube section (1a, b) and welded along a longitudinal edge (2) to form a closed tube (1a, b), a pair of axial flanges (7, 8) is welded to the inside or outside of the tube wall along planned axial separation lines, wherein each pair of flanges (7, 8) is arranged axially adjacent to each other in the circumferential direction, wherein the tube body (6) is separated along planned separation lines (20) which run between two flanges (7, 8) of a flange pair, so that at least two partial shells (6a) of the tube body are formed, each of which has a flange (7, 8) along axial edges (11), and for the erection of the tower structure the partial shells (6a) are arranged one another by means of the flanges of a flange pair and are connected by the flanges (7,8) a pair of flanges are joined to form a pipe body and a pipe tower structure is produced using this method.