Wind Turbine Tower Joints Using Tapered Flared Edges
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Solution Overview
Problem
Conventional wind turbine tower joints with flanges require additional material, labor, and welding, and cause positioning and bending issues during transportation and storage due to protruding flanges that interfere with stacking and other structures.
Innovation Solution
The use of tapered and flared edges on tubular wall sections with optional fasteners and relief cuts, eliminating the need for conventional flanges by allowing friction-fitting and secure assembly without welding, and accommodating different sizes and loads through adjustable taper/flare angles and radial bolting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional flanged joints are used to connect tower wall sections, then structural connection is achieved, but additional material, labor, and welding are required, and positioning and bending problems occur during transportation and storage
Solution Approach 1:
The patent removes the conventional flange structure from the tower wall section joints, extracting only the essential connection function. The tapered and flared edges directly engage with each other to provide structural connection without requiring separate flange components, thereby reducing material usage and structural complexity while maintaining connection strength
Solution Approach 2:
The patent combines the connection function and the structural form into a single integrated design. The tapered and flared edges serve both as the structural boundary of the wall section and as the connection interface, merging what were previously separate elements (wall section and flange) into a unified structure
2Reliability
If flanged connections are used for tower wall sections, then structural integrity is maintained, but welding and inspection resources are required
Solution Approach 1:
The patent replaces the welding-based mechanical connection system with a friction-fit mechanical engagement system. The tapered and flared edges create a friction-based connection that relies on mechanical interlocking and friction forces rather than thermal welding processes, eliminating the need for welding equipment, skilled welders, and post-weld inspection
Solution Approach 2:
The friction-fit connection between tapered and flared edges is self-aligning and self-securing. The geometry of the engaged surfaces automatically guides the components into proper alignment and maintains the connection through friction forces, eliminating the need for external welding operations and inspection procedures
3Strength
If flanges are added to tower wall sections for connection purposes, then joint strength is improved, but weight increases
Solution Approach 1:
The patent extracts and eliminates the redundant flange material from the tower structure. By using the wall section's own tapered and flared edges as the connection interface, no additional material is needed to create flanges, directly reducing the overall weight of the tower while maintaining joint strength through the friction-fit engagement
4Reliability
If conventional flanged joints are used, then connection is achieved, but assembly time and labor costs increase
Solution Approach 1:
The tapered and flared edges are pre-formed as integral parts of the wall sections during manufacturing. This preliminary formation of the connection geometry eliminates the need for on-site flange attachment operations, allowing for rapid assembly by simply engaging the pre-formed surfaces and securing with fasteners, thereby increasing assembly speed while maintaining connection reliability
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 solution reduces material and labor costs, minimizes weight, and improves logistical handling by eliminating flanges, providing a direct load path and enhanced flexibility in assembly, while allowing for varied design parameters and load resistance.
Implementation Method 1
The friction fit between the tapered edge of the first wall section and the flared edge of the second wall section resists axial loads
Data Source
AI summary
A wind turbine tower, includes a first substantially tubular wall section having a tapered edge; a second substantially tubular wall section, arranged substantially coplanar with the first wall section, having a flared edge for seating against the tapered edge of the first wall section; and at least one fastener for securing the tapered edge of the first wall section to the flared edge of the second wall section. The at least one fastener includes a bolt extending through the tapered edge and the flared edge, and the bolt is arranged substantially perpendicular to a longitudinal axis of the first and second wall sections.