Wind Turbine Refurbishment via Matching Flange Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The refurbishment of wind turbines is complex and costly due to the need for substantial modifications to the top tower section to accommodate new machine heads, which house complex internal components that require replacement or refurbishment.
Innovation Solution
A method involving the removal of existing machine heads and top tower sections, followed by the connection of new components with matching fastener hole patterns, allowing for the integration of new machine heads and top tower sections with different size characteristics, and the connection of internal components between the new and existing tower sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If new machine head and top tower section are installed on existing wind turbine, then power generation efficiency is improved, but device complexity and modification cost increase
Solution Approach 1:
The tower is divided into modular sections (lower tower section with existing hole pattern, top tower section that is replaced). This segmentation allows the new top tower section to be independently installed with matching connection interfaces, enabling technology upgrades without requiring complex modifications to the entire tower structure.
Solution Approach 2:
The flange connection interface is designed with universal compatibility - the bottom flange of the new top tower section has fastener holes arranged in the same pattern as the top flange of the lower tower section. This universal interface design allows the same connection method to accommodate different machine head configurations and tower section combinations, reducing modification complexity.
2Adaptability or versatility
If existing internal components are replaced to accommodate new machine head, then adaptability is improved, but loss of time and increased cost occur
Solution Approach 1:
The bottom flange of the new top tower section is pre-configured with fastener holes in a pattern that matches the existing lower tower section. This preliminary design ensures that when the new machine head and top tower section are installed, the internal components can be directly connected without requiring time-consuming modifications or custom fabrication work.
Solution Approach 2:
The hole pattern parameters of the flange connections are maintained consistent between the lower tower section and the new top tower section. By keeping the geometric parameters (hole positions, spacing, arrangement) the same, the system achieves adaptability to new machine heads while avoiding time-consuming reconfiguration of existing component interfaces.
Data Source
AI summary
Methods for refurbishing a wind turbine are provided. A method includes removing an existing machine head and existing top tower section from the wind turbine. The wind turbine further includes a lower tower section, the lower tower section comprising a top flange, the top flange defining a first plurality of fastener holes disposed in a first hole pattern. The method further includes connecting a new machine head and new top tower section to the wind turbine. The new top tower section comprises a bottom flange, the bottom flange defining a second plurality of fastener holes disposed in a second hole pattern. The second hole pattern matches the first hole pattern.