Segmented Wind Turbine Tower Assembly Using Frame Support
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Solution Overview
Problem
The assembly of segmented wind turbine tower sections is labor-intensive, time-consuming, and costly, particularly due to the need for manual fastening at significant heights and the complexity of supporting tower segments during assembly, which is further complicated by adverse conditions such as high winds.
Innovation Solution
A method involving the formation of a tower section frame assembly by connecting at least two tower segments with a support beam, arranging this assembly on a stand, and attaching remaining segments to form the tower section, with options for horizontal and vertical orientation and use of tensioning elements for additional support, as well as pre-installing splice plates for easier alignment and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If segmented tower sections are assembled manually at significant heights, then the tower can be constructed from transportable segments, but the assembly becomes labor-intensive and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-assembling groups of tower segments into frame assemblies on the ground before lifting them to height. Specifically, multiple segments are connected to form a complete tower section frame assembly on the assembly platform, then the entire assembled unit is lifted as one piece to the installation height, eliminating the need to perform fastening operations at height.
Solution Approach 2:
The patent merges multiple tower segments into a single integrated frame assembly that is lifted and installed as one unit. By combining several segments into a pre-assembled frame assembly, the system reduces the number of separate lifting and fastening operations required at height, thereby improving assembly productivity.
2Manufacturing precision
If tower segments are supported in upright position during assembly, then proper alignment is achieved, but the support structure becomes complex and costly
Solution Approach 1:
The patent inverts the traditional assembly approach by assembling tower segments in a horizontal orientation on the ground rather than supporting them upright during assembly. The segments are connected in a horizontal configuration to form frame assemblies, which are then lifted to the vertical installation position as complete units, eliminating the need for complex upright support structures.
Solution Approach 2:
The patent changes the assembly dimension from vertical to horizontal by performing all connection operations while segments are in a horizontal position on the assembly platform. This dimensional change allows workers to access connection points more easily and eliminates the need for complex vertical support and access equipment.
3Ease of operation
If manual fastening is performed at significant heights, then tower segments can be connected, but labor costs and time requirements increase significantly
Solution Approach 1:
The patent applies preliminary action by performing all fastening and connection operations while tower segments are in a horizontal position on the ground assembly platform, before lifting the assembled units to installation height. This allows workers to perform fastening operations under optimal conditions with easy access to all connection points, significantly reducing the time and labor required compared to working at height.
4Adaptability or versatility
If tower segments are assembled in adverse conditions such as high winds, then on-site assembly is possible, but the process becomes more dangerous and inefficient
Solution Approach 1:
The patent applies preliminary action by completing the complex assembly and fastening operations in a controlled ground-based environment before exposure to adverse weather conditions. By pre-assembling frame assemblies on the assembly platform and then lifting them as complete units, the system minimizes the time segments are exposed to high winds and other adverse conditions during the assembly process.
Data Source
AI summary
A method of assembling a wind turbine tower section (12a) from a plurality of tower segments (22) includes providing the plurality of tower segments (22) to a wind turbine installation site (32), forming a tower section frame assembly (96) by connecting at least two tower segments (22a, 22b) with a support beam (72), wherein the tower section frame assembly (96) forms a framework on which to further assemble the tower section (12a), arranging the tower section frame assembly (96) on an assembly stand (42), and attaching the remaining plurality of tower segments (22c-22h) to the tower section frame assembly (96) to form the tower section (12a). A method of preinstalling splice plates (106) on the tower segments (22a-22h) for guiding or assembly simplification purposes is also disclosed. The splice plates (106) may be preinstalled from the factory or at the installation site (32).