Tower section production process
AssigneeVestas Wind Systems A/S
InventorBo Michel
Life of this patent
Estimating the term…
Abstract
The application relates to wind turbine tower section production methods and in particular to methods of manufacturing a plurality of elongate tower segments for forming a wind turbine tower section, the tower section constructed from a plurality of elongate tower segments connected along their respective longitudinal edges. The tower section is formed from a plurality of cans connected end to end and is divided into elongate segments by cutting along two or more cut lines extending along the length of the tower. A method of providing a horizontal flange at the end of a wind turbine tower is also discussed, as is a vertical flange preassembly including a pair of vertical flanges for connecting the longitudinal edges of adjacent first and second tower segments.
Claims61
A method of manufacturing a plurality of elongate tower segments for forming a wind turbine tower section, the tower section constructed by connecting the plurality of tower segments along their respective longitudinal edges, the method comprising the steps of:
- forming each of a plurality of cans by rolling a metal sheet into a tube having a longitudinal seam formed by welding first and second opposed edges of the rolled sheet, wherein at least some of the welded seams comprise tack welds;
- forming the tower section by connecting the plurality of cans end to end;
- and
- cutting along two or more cut lines extending along the length of the tower section to divide the tower section into a plurality of elongate tower segments, wherein the step of cutting along two or more cut lines comprises cutting along the longitudinal seams through the tack welds.
A wind turbine tower section comprising a plurality of cans connected end to end, wherein each of the plurality of cans comprises:
- a tubular rolled metal sheet, wherein first and second opposed edges of the rolled sheet are welded together along a longitudinal seam;
- wherein the longitudinal seam of at least one of the plurality of cans comprises a welded seam including at least some tack welds.
A method of manufacturing a plurality of elongate tower segments for forming a wind turbine tower section, the tower section constructed by connecting the plurality of tower segments along their respective longitudinal edges, the method comprising the steps of:
- forming a plurality of tubular cans;
- forming the tower section by connecting the plurality of cans end to end;
- supporting the tower section on a plurality of supports such that its longitudinal axis is substantially horizontal;
- and
- cutting along two or more cut lines extending along the length of the tower section to divide the tower section into a plurality of elongate tower segments, wherein at least one of the cut lines is curved with a curvature that corresponds to the deflection of the tower section as it deflects under its own weight between adjacent supports.
A method of providing an annular or penannular horizontal flange at the end of a wind turbine tower section, the horizontal flange being arranged to couple the tower section end to end with an adjacent wind turbine tower section or to a foundation, the method comprising the steps of:
- providing two or more planar flange segments, each having a part-annular shape, the two or more planar flange segments combining to form the horizontal flange;
- arranging the two or more planar flange segments to form the horizontal flange;
- and
- welding the two or more planar flange segments to an open end of the tower section.
A set of horizontal flange segments for forming an annular or penannular horizontal flange for the end of a wind turbine tower section, the horizontal flange being arranged to couple the tower section end to end with an adjacent wind turbine tower section, the set of horizontal flange segments comprising two or more planar flange segments, each having a part-annular shape, the two or more planar flange segments together forming the horizontal flange.
A method of manufacturing first and second elongate tower segments for forming a wind turbine tower section, the tower section constructed by connecting a plurality of tower segments along their respective longitudinal edges, the first tower segment having a first vertical flange and the second tower segment having a second vertical flange, the first and second vertical flanges being elongate and arranged to connect the first and second tower segments, the method comprising the steps of:
- connecting the first and second vertical flanges together in a coupled configuration;
- welding the coupled configuration of the first and second vertical flanges to a wind turbine tower section, after connecting the first and second vertical flanges together in the coupled configuration such that the vertical flanges extend longitudinally along the tower section;
- and
- dividing the tower section into first and second tower segments by cutting along two or more longitudinal cut lines, wherein one of the longitudinal cut lines is between the first and second vertical flanges, such that the first vertical flange is attached to the first tower segment and the second vertical flange is attached to the second tower segment.
A vertical flange preassembly comprising a pair of vertical flanges for connecting the longitudinal edges of adjacent first and second tower segments of a wind turbine tower section when the vertical flanges are attached to the first and second tower segments, the pair of vertical flanges comprising an elongate first vertical flange for attachment to the first tower segment and an elongate second vertical flange for attachment to the second tower segment, wherein the first and second vertical flanges of the vertical flange preassembly are connected together in a coupled configuration.
A method of manufacturing a plurality of elongate tower segments for forming a wind turbine tower section, the tower section constructed by connecting the plurality of tower segments along their respective longitudinal edges, the method comprising the steps of:
- providing a portable cutting unit, comprising:
- at least one elongate support rail;
- a carrier mounted on the at least one support rail such that it is moveable along the at least one support rail;
- a cutting head mounted on the carrier;
- and
- attachment means for removably attaching the at least one support rail to a tower section;
- removably attaching the portable cutting unit to the tower section with the attachment means so that the at least one support rail extends along at least part of the length of the tower section;
- cutting along a first longitudinal cut line by engaging the cutting head of the portable cutting unit with the tower section and moving the carrier along the at least one support rail;
- and
- dividing the tower section into a plurality of elongate tower segments by cutting along the first longitudinal cut line along the length of the tower section and along one or more additional longitudinal cut lines at different positions around the tower section circumference.
A method of manufacturing a plurality of elongate tower segments for forming a wind turbine tower section, the tower section constructed by connecting the plurality of tower segments along their respective longitudinal edges, the method comprising the steps of:
- providing a fixed cutting unit, comprising:
- at least one elongate support rail fixed directly or indirectly to a ground surface;
- a carrier mounted on the at least one support rail such that it is moveable along the at least one support rail;
- and
- a cutting head mounted on the carrier;
- rotatably supporting the tower section on a support unit along side the at least one elongate support rail such that the tower section is rotatable about its longitudinal axis and such that the longitudinal axis of the tower section is substantially parallel to the at least one elongate support rail;
- rotating the tower section about its longitudinal axis on the support unit to align the cutting head of the fixed cutting unit with a first desired cut position around the tower section circumference;
- cutting along a first longitudinal cut line extending along the length of the tower section by engaging the cutting head with the tower section in the first desired cut position and moving the carrier along the at least one support rail;
- rotating the tower section about its longitudinal axis on the support unit to align the cutting head of the fixed cutting unit with a second desired cut position around the tower section circumference, the second desired cut position differing from the first;
- and
- cutting along a second longitudinal cut line extending along the length of the tower section by engaging the cutting head with the tower section in the second desired cut position and moving the carrier along the at least one support rail, such that the tower section is divided into tower segments along the first and second longitudinal cut lines.
Dependencies are inferred from the claim text.