Wind Turbine Support Structure With Partial Longitudinal Welding
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Solution Overview
Problem
The existing methods for constructing support structures for wind power plants, such as foundation piles, require numerous complex and cost-intensive weld seams, especially when joining steel plate sub-segments, which increases manufacturing time and complexity.
Innovation Solution
The approach involves joining support structure segments with longitudinal weld seams, using a combination of full and partial seams along the longitudinal edges, and employing retaining clips to reduce the need for continuous welds while maintaining structural integrity, allowing for reduced heat input and processing time during submerged arc welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support structure segments are joined by continuous longitudinal weld seams along the entire length, then the structural strength and integrity are ensured, but the manufacturing time and cost increase significantly
Solution Approach 1:
The patent applies partial welding by providing weld seams only at specific locations (end edges and longitudinal edges) rather than continuous welding along the entire length of the support structure segments. This partial action approach ensures structural integrity at critical joints while significantly reducing the total welding time and cost.
2Strength
If support structure segments are joined by continuous longitudinal weld seams along the entire length, then the structural strength and integrity are ensured, but the manufacturing cost increases significantly
Solution Approach 1:
The patent applies partial welding by providing weld seams only at specific locations (end edges and longitudinal edges) rather than continuous welding along the entire length of the support structure segments. This partial action approach ensures structural integrity at critical joints while significantly reducing the total welding time and cost.
3Shape
If steel plates are bent along their length extension to form sub-segments, then the sub-segments have height corresponding to plate width, but the number of weld seams increases
Solution Approach 1:
The patent merges multiple steel plates laterally to form a single support structure segment with a common longitudinal axis. By combining several plates into one integrated segment, the number of separate components and their corresponding weld seams are reduced, simplifying the overall structure while maintaining the required geometry.
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 the number and length of weld seams required, lowering production costs and time, while ensuring the mechanical properties and stability of the support structure, even with varying wall thicknesses and diameters, thereby enhancing the efficiency of the manufacturing process.
Implementation Method 1
Welding of the longitudinal edges of sub-segments opposing each other is usually carried out by means of a longitudinal weld, which can, for example, be designed as a butt weld on both sides in accordance with EN ISO 2553, Table 2, by means of submerged arc welding.
Data Source
AI summary
Supporting structure, in particular for a wind power plant, having at least two sub-segments which are at least partially connected to one another and are respectively formed from a metal plate having a longitudinal extent and a width extent. The longitudinal extent being greater than the width extent, and the sub-segments each having longitudinal edges extending in longitudinal extent and being connected to one another at mutually abutting joint surfaces along the longitudinal edges by a welded joint respectively. The sub-segments respectively have end edges extending in width, the sub-segments being bent along their end edges respectively. The respective welded joint has in sections a thickness which is smaller than a wall thickness of the metal plate and in sections a thickness which corresponds at least to the wall thickness of the metal plate.