Wind Turbine Component Connection via Hardened Intermediate Interface
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Solution Overview
Problem
Existing connections in wind turbines, particularly for large-volume components, face challenges in achieving high load-bearing capacity and reliability under unfavorable conditions such as high stress, dirt, oil, and adverse weather, due to limitations in frictional engagement and maintenance.
Innovation Solution
A connection method involving an intermediate component with harder and rougher surfaces than the components being connected, utilizing prestress through screws or bolts to create a non-positive, friction-enhanced coupling, which increases the coefficient of friction and load-bearing capacity, allowing for secure attachment of heavy components even in challenging conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screw connections are used for large-volume wind turbine components, then the connection can be assembled, but the load-bearing capacity and reliability are insufficient under high stress and adverse conditions
Solution Approach 1:
The patent changes the surface properties of the intermediate component by hardening and roughening its contact surfaces. This parameter change increases the coefficient of friction at the contact interfaces, thereby enhancing the load-bearing capacity and reliability of the connection without requiring additional fastening elements.
Solution Approach 2:
The patent introduces an intermediate component with hardened and roughened contact surfaces between the two components to be connected. This intermediary element acts as a friction-enhancing mediator that transfers and distributes loads more effectively, improving the overall connection strength and reliability under adverse operating conditions.
2Strength
If the contact surfaces are made harder to increase friction, then the load-bearing capacity increases, but the manufacturing cost increases due to surface hardening
Solution Approach 1:
The patent applies surface hardening and roughening only to the contact surfaces of the intermediate component that require high frictional engagement, rather than hardening the entire component. This localized treatment reduces manufacturing costs while still achieving the desired increase in load-bearing capacity at the critical contact interfaces.
Solution Approach 2:
The patent uses a separate intermediate component with hardened surfaces rather than hardening the main components. This segmentation allows the expensive hardening process to be applied only where necessary, minimizing overall manufacturing costs while maximizing frictional engagement at the connection interfaces.
3Ease of repair
If a non-positive connection is used to allow disassembly for maintenance, then ease of maintenance improves, but the connection stability deteriorates under high stress
Solution Approach 1:
The patent changes the surface parameters of the intermediate component (hardness and roughness) to create high frictional engagement that provides connection stability comparable to positive connections. This allows the non-positive connection to maintain stability under high stress while retaining the advantage of easy disassembly for maintenance and repair.
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 provides a detachable, high-friction connection with increased load-bearing capacity, enabling reliable assembly and maintenance of wind turbine components under adverse conditions, such as high heights and inclement weather, while minimizing surface hardening costs.
Implementation Method 1
the surfaces of the contact surfaces of the second component each have a higher hardness and roughness than the surfaces of the contact surfaces of the first and third component... a non-positive connection with increased friction values is achieved
Implementation Method 2
a friction value-increased coupling of the components is achieved between the two components by the prestress applied via the connecting elements due to a micro-plastic deformation of the contact surfaces generated during the joining process
Data Source
Figure 1~2
Figure 3a~3b
Figure 4a~4b
AI summary
The connection has a contact junction for opposite contact surfaces of the two components to be interconnected. The components are braced with each other in the connected condition. The face of the contact surfaces of one component of the wind power plant is soft than the face of the contact surface of other component of the wind power plant. The surface of the contact surface of the latter component has a higher roughness than the surface of the contact surface of the former component. An independent claim is also included for a method for manufacturing a connection for components of a wind power plant.