Wind Turbine Tower Flange Alignment Tool
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Solution Overview
Problem
The increasing size of wind turbine towers for larger generators poses challenges in transportation and assembly due to their physical dimensions, leading to difficulties in aligning vertical flanges during reassembly, which can result in misalignment and increased labor costs.
Innovation Solution
An alignment system comprising mounting means and a longitudinal alignment head with a guiding surface to align vertical flanges on wind turbine tower segments, allowing for accurate and efficient connection without damaging the flanges or segments, using tools that can be mounted on existing flanges without modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If tower segments are manufactured separately and assembled at the installation site, then transportation is easier, but alignment precision deteriorates due to manufacturing variations
Solution Approach 1:
The alignment tool acts as an intermediary device between the two flanges, providing a mechanical reference system that mediates the alignment process. The tool includes reference surfaces that engage with corresponding surfaces on both flanges, establishing a precise geometric relationship that compensates for manufacturing variations.
Solution Approach 2:
The alignment tool is mounted on the flanges before the actual connection process begins. This preliminary positioning establishes the correct alignment relationship in advance, allowing the segments to be brought together accurately without requiring high precision in the final positioning operation.
2Ease of manufacture
If traditional alignment methods are used, then assembly process is simpler, but alignment precision and flange protection deteriorate
Solution Approach 1:
The alignment tool serves as a protective intermediary between alignment operations and the flange surfaces. Instead of directly manipulating the flanges, the tool's reference surfaces are used, which prevents damage to the critical flange mating surfaces while maintaining alignment precision.
Solution Approach 2:
The alignment tool is divided into separate mounting components and alignment components. The mounting part attaches to the flange while the alignment part provides the reference surfaces, allowing the tool to be easily assembled and disassembled without complex operations.
3Device complexity
If manual alignment methods are used, then equipment requirements are lower, but assembly time and labor increase
Solution Approach 1:
The alignment tool pre-establishes the correct geometric relationship between flanges through its rigid reference surfaces. This preliminary action eliminates the need for time-consuming manual measurement and adjustment operations, allowing workers to simply bring the segments together along the established alignment.
Solution Approach 2:
The alignment tool's reference surfaces are designed to self-align when the segments are brought together. The geometry of the reference surfaces automatically guides the segments into correct positioning without requiring skilled operators to perform complex alignment maneuvers.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
The application relates to an alignment tool (200) for the alignment of a pair of vertical flanges for the connection of the longitudinal edges of adjacent segments of a cylindrical section of a wind turbine tower, and to a system and method utilising one or more such alignment tools (200). The alignment tool comprises mounting means (202) for connecting the alignment tool to a portion of a vertical flange of a tower segment; and a longitudinal alignment head (204) for aligning the vertical flange with an opposing vertical flange of an adjacent tower segment. The alignment head (204) comprises a front portion (218) extending in a forwards direction from the mounting means (202), the front portion (218) comprising a lower guiding surface (222) adapted to abut with a top guiding edge of the opposing vertical flange or a bracket or tool mounted thereon and to guide the alignment head (204) over the top edge of the opposing flange, bracket or tool as the vertical flanges are brought towards each other during connection of the adjacent tower segments.