Wind Turbine Tower Segment Reinforcement
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Solution Overview
Problem
The existing methods for creating door openings in wind turbine towers, such as welding door frames or reinforced panels, lead to mechanical weakening and are time-consuming and costly.
Innovation Solution
A wind turbine tower design featuring a steel wall with a door opening reinforced by a hardened casting compound and toothed elements attached to the inside of the wall, which improves the structural integrity by providing a reinforcing element around the opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If door frames or reinforced panels are welded onto or into the tower segment, then the mechanical strength of the tower segment is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies composite materials by combining steel wall segments with concrete reinforcing elements. The concrete is cast around steel reinforcement bars that are embedded in the steel wall, creating a composite structure that leverages the high strength of steel and the mass/stability of concrete. This composite approach provides superior mechanical strength compared to simple welding, while the reinforcement bars serve as pre-prepared elements that simplify the overall manufacturing process.
Solution Approach 2:
The patent employs preliminary action by pre-attaching interlocking elements and reinforcement bars to the steel wall segments before the concrete casting process. The steel reinforcement bars are positioned and secured in advance, and the interlocking elements are attached to facilitate later assembly of tower segments. This preliminary preparation reduces on-site manufacturing complexity and enables more efficient construction.
2Stability of the object's composition
If door frames or reinforced panels are welded onto or into the tower segment, then the structural stability is improved, but the production time and cost increase
Solution Approach 1:
The patent employs preliminary action by pre-attaching interlocking elements and reinforcement bars to the steel wall segments before the concrete casting process. The steel reinforcement bars are positioned and secured in advance, and the interlocking elements are attached to facilitate later assembly of tower segments. This preliminary preparation reduces on-site manufacturing complexity and enables more efficient construction.
Solution Approach 2:
The patent merges multiple functions into a single integrated structure. The concrete casting process simultaneously creates the reinforcing element around the door opening and forms part of the tower segment structure. The steel reinforcement bars and concrete work together as a unified reinforcing system, eliminating the need for separate welding operations and reducing production time while maintaining structural stability.
3Ease of operation
If openings are provided in the tower wall, then the ease of operation is improved, but the mechanical strength of the tower segment deteriorates
Solution Approach 1:
The patent applies local quality by providing localized reinforcement around the door opening rather than reinforcing the entire tower segment uniformly. The concrete reinforcing element is concentrated in the specific region where the opening is located, particularly around the door frame area. This localized approach maintains the mechanical strength of the tower segment in the critical opening region while leaving other areas with their original steel structure intact.
Solution Approach 2:
The patent applies composite materials by combining steel wall segments with concrete reinforcing elements. The concrete is cast around steel reinforcement bars that are embedded in the steel wall, creating a composite structure that leverages the high strength of steel and the mass/stability of concrete. This composite approach provides superior mechanical strength compared to simple welding, while the reinforcement bars serve as pre-prepared elements that simplify the overall manufacturing process.
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 reduces the mechanical weakening of the tower segment while being cost-effective by enhancing the attachment of door frames or panels, thereby improving the structural stability and efficiency of the tower production process.
Implementation Method 1
Casting compound is poured into the formwork and cured
Data Source
Figure 1
Figure 2~3
AI summary
A wind turbine (100) with a tower (200) is provided, which has at least one first and one second tower segment (210, 220). The first tower segment (210) has a steel wall (212) and at least one first opening (211) in the steel wall (212). Furthermore, at least one reinforcing element (300) with a hardened grout (330) is provided around a region of the first opening (211).