Segmented Flange for Wind Turbine Tower Welding Deformation
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Solution Overview
Problem
Current wind turbine steel tower assembly methods are inefficient due to heavy sections requiring costly and inflexible transportation, challenging on-site handling, and high manufacturing and assembly costs, with existing flange connections leading to dimensional inaccuracies and deformation during welding.
Innovation Solution
A flange segment with a part-ring-shaped base body and a flange projection that extends from one end to the other, allowing for precise connection and reduced deformation during welding, enabling a stronger and more cost-effective assembly of wind turbine steel tower ring segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy sections are used for tower construction, then structural strength is improved, but transportation cost and flexibility deteriorate
Solution Approach 1:
The tower is divided into multiple segments that can be manufactured separately and transported individually. Each segment contains integrated flange connections, allowing the tower to be assembled on-site from smaller, more manageable pieces that are easier and less costly to transport while maintaining overall structural strength.
2Adaptability or versatility
If flanges are attached as additional components, then connection flexibility is improved, but manufacturing precision deteriorates
Solution Approach 1:
The flange connections are merged into the segment components themselves during manufacturing, rather than being attached as separate additional components. This integration ensures that the flanges and segment bodies are produced as unified structures with consistent dimensional accuracy, while still providing the flexibility of flanged connections for assembly.
3Strength
If flanges are welded together, then connection strength is improved, but manufacturing complexity deteriorates
Solution Approach 1:
The flange connections are prepared and positioned in advance during segment manufacturing, with pre-drilled holes and pre-aligned connection surfaces. This preliminary preparation simplifies the on-site welding process by eliminating complex alignment procedures, reducing assembly complexity while maintaining strong welded connections.
4Weight of moving object
If segmented components are used, then transportation ease is improved, but assembly effort deteriorates
Solution Approach 1:
The tower is segmented into smaller components that are easier to transport, with each segment designed to include integrated flange connections. This segmentation reduces transportation effort while the standardized connection design minimizes assembly complexity.
Solution Approach 2:
All segment components use standardized flange connection designs with consistent dimensions, hole patterns, and tolerances. This homogeneity allows for repeatable assembly procedures and reduces the skill level and effort required for on-site assembly, counteracting the increased assembly steps from segmentation.
Data Source
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AI summary
The invention relates to a flange segment (1, 214, 224, 235, 244) for a wind turbine steel tower ring segment, a wind turbine tower section, a wind turbine tower, a wind turbine, and a method for producing a wind turbine steel tower ring segment. The invention relates particularly to a flange segment (1, 214, 224, 235, 244) for a wind turbine steel tower ring segment, comprising a partially annular base body (2, 216, 226) that extends from a first end (3) to a second end (4) in the annular direction, with an upper side (10) and a lower side opposite the upper side, an inner peripheral side (11) and an outer peripheral side, and a first abutment side on the first end and a second abutment side on the second end, and a flange projection (20, 218, 228) arranged on the upper side (10) of the base body and extending substantially from the first end to the second end in the annular direction.