Wind Turbine Foundation Stabilization via Epoxy Injection
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Solution Overview
Problem
Wind turbines experience stability issues due to dynamic loads, leading to movement play and cracking in the foundation, which increases maintenance costs and downtime, as existing stabilization methods are often recognized too late and require costly lifting processes.
Innovation Solution
Early detection of tower movement using length change sensors allows for timely stabilization without lifting, involving drilling of specific bores and injection of low-viscosity epoxy resin to restore the frictional connection between the foundation and tower, reducing maintenance time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stabilization is performed using known methods (lifting the wind turbine), then the foundation stability is improved, but the maintenance time and costs increase significantly
Solution Approach 1:
The patent applies preliminary action by implementing early detection of tower movement through length change sensors before the foundation deterioration becomes critical. This allows stabilization to be performed at an early stage when less invasive and less time-consuming methods are sufficient, avoiding the need for complete dismantling and lifting operations that would be required if stabilization were delayed until severe damage occurred.
Solution Approach 2:
The patent replaces the complex mechanical lifting system with a more straightforward injection-based stabilization method. Instead of lifting the entire wind turbine using hydraulic presses and complex rigging, the invention uses injection of binding material through drilled holes to stabilize the foundation in place, significantly simplifying the maintenance process and reducing downtime.
2Reliability
If stabilization is performed using known methods (lifting the wind turbine), then the foundation stability is improved, but the maintenance costs increase significantly
Solution Approach 1:
By detecting tower movement early through length change sensors, the patent enables intervention before severe foundation deterioration occurs. This preliminary action prevents the need for expensive complete dismantling and lifting operations, reducing maintenance costs while still achieving effective stabilization through simpler injection-based methods.
Solution Approach 2:
The patent uses relatively simple, inexpensive injection materials (binding agents, grout, or concrete) compared to the expensive lifting equipment and complex procedures required by traditional methods. The drilled holes are filled with affordable stabilization materials that provide sufficient strength restoration without requiring costly specialized equipment or extensive labor.
3Loss of time
If early detection of tower movement is implemented, then maintenance time is reduced, but measurement precision requirements increase
Solution Approach 1:
The patent replaces complex mechanical measurement systems with simple length change sensors that can be easily attached to the tower and foundation. These sensors provide sufficient precision for detecting the specific movement criteria that trigger stabilization, without requiring expensive or overly complex measurement equipment. The sensor system is designed to be easily installable and removable, further simplifying the overall maintenance 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 method enables early detection of stabilization needs, reducing downtime and costs by avoiding complex lifting procedures, ensuring continued operation with improved stability and reduced maintenance expenses.
Implementation Method 1
measuring the vertical tower movement by means of one or more length change sensors
Implementation Method 2
introduction of a low-viscosity epoxy resin as the curable mass into the plurality of bores
Implementation Method 3
curing the introduced, hardenable compound in the bores
Implementation Method 4
drilling a large number of holes using the drilling means in the prepared surface
Data Source
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AI summary
The invention relates to a method for stabilizing a wind turbine, in particular for connecting a base section of the wind turbine to the base of the wind turbine, comprising the following steps: carrying out a stabilization measure, comprising preparing at least one section of the surface of a base of the wind turbine for the attachment of drilling means; introducing a multiplicity of holes by means of the drilling means into the prepared surface down to a predetermined depth, preferably as far as to an anchor segment of the base section; introducing a curable compound into the multiplicity of holes; curing the introduced, curable compound in the holes; and consolidating the at least one section of the surface of the plant base. The invention relates in particular to a method for stabilizing a wind turbine, comprising early detection of the need to stabilize the wind turbine by means of measuring the tower movement during the operation of the wind turbine.