Windmill Tower Door Frame Welding Automation

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Solution Overview

Problem

The existing methods for manufacturing door frames in windmill towers face challenges such as inaccurate shapes, deformation, and large air gaps due to the difficulty in precise manufacturing of thick materials, leading to inefficient welding processes and safety concerns, particularly with the single V groove method which results in excessive weld volume and potential errors.

Innovation Solution

A method using a measuring sensor to control cutting and welding devices for creating a double bevel or square butt weld on both sides of the tubular shell, allowing for accurate fitting and reduced weld volume, with a computer system determining cutting and welding paths to ensure a constant filler metal amount and improved joint quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual torch-cutting and single V groove welding are used, then the door frame can be installed in the tubular shell, but the weld volume becomes excessive and welding errors increase

Engineering Contradiction:

Improvedoor frame installationVSAvoidweld metal consumption

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent changes the geometric parameters of the groove configuration from single V groove to double bevel or square butt weld, optimizing the weld joint design to reduce filler metal consumption while maintaining joint strength

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent performs preliminary measurement of the actual shapes of both the door frame and tubular shell surface before cutting, allowing the opening shape to be pre-adjusted to match the door frame, thereby minimizing air gaps and reducing the volume of weld metal required

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If openings are formed in the thick shell, then the door frame can be installed, but the shell deforms and the opening shape becomes inaccurate

Engineering Contradiction:

Improvedoor frame installationVSAvoidopening shape accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent performs measurement and shape adjustment of the opening before door frame installation, compensating for shell deformation effects in advance to achieve accurate fitting

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses measurement data from the actual shapes of the door frame and tubular shell surface to control the cutting device, creating a feedback loop that adjusts the opening shape based on actual conditions to achieve precise alignment

Inventive Principle:

Principle #23Feedback

3Reliability

If back gouging is performed to repair welding errors, then joint quality can be improved, but the manufacturing time and complexity increase

Engineering Contradiction:

Improvejoint qualityVSAvoidmanufacturing cycle time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent performs preliminary measurement and shape adjustment of the opening before welding, preventing welding errors caused by large air gaps and eliminating the need for time-consuming back gouging repairs

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces manual torch-cutting and manual welding with automated cutting and welding devices controlled by computer systems, improving precision and reducing the need for manual repair operations

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach results in a more accurate, faster, and automated door frame manufacturing process with reduced weld volume and improved joint quality, minimizing the need for back gouging and enhancing work safety by reducing exposure to welding fumes and deformations.

Implementation Method 1

both the shape of the door frame (21) and the shape of the surface of the tubular shell (11) are measured with a measuring sensor (40)

Methodology Applied

Scientific EffectMeasurement:

Implementation Method 2

a cutting device (41) is controlled, based on the measurements, so that an opening corresponding to the shape of the door frame (21) is cut in the shell (11) with the cutting device (41), such as a cutting torch

Methodology Applied

Scientific EffectCutting:

Implementation Method 3

The purpose of the invention is also to provide a new door frame welding arrangement and door frame structure which is attached to the windmill tower shell in a more advantageous and reliable way

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP2427299B9Method for manufacturing a door frame, welding arrangement and structure of a door frame

Publication Date: 2020.08.12 PEMAMEK

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Figure 4a~6
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AI summary

Manufacturing method, welding arrangement and door frame structure for a door frame (21) of a windmill tower (10), wherein a hole (15) is made in the tower shell (10) for the door and a door frame is placed in the hole and welded on the shell. In the method, the shape of the door frame for the shell and the shape of the surface of the shell at the opening (15) to be made are measured with a measuring sensor (40). Based on the measurements, a cutting torch (41 ) is controlled so that an opening corresponding to the shape of the door frame is cut in the shell and bevels (16, 17) are cut in the edge of the opening on both sides. The door frame is welded on the shell with a weld (24), such as a double bevel, double J or square butt weld, from the inside and the outside of the shell.