STRUCTURAL FLANGE CONNECTION SYSTEM AND METHOD

• US 20100307097A1
• Filed: 05/20/2010
• Published: 12/09/2010
• Est. Priority Date: 06/09/2009
• Status: Active Grant

• Current Assignee: Cecil Leon Jr. Hartman, Thomas Nott Iii Word
• Original Assignee: Cecil Leon Jr. Hartman, Thomas Nott Iii Word
• Inventors: Word, Thomas Nott III, Hartman, Cecil Leon JR.
• Granted Patent: US 8,490,337 B2
• Time in Patent Office: Days
• US Class Current: 52/651.07
• CPC Class Codes: E04H 12/085 Details of flanges for tubular masts
• CPC Class Codes: F05B 2230/604 using positioning or alignment devices for aligning or centering, e.g. pins
• CPC Class Codes: F05B 2240/912 on a tower
• CPC Class Codes: F05B 2260/301 Retaining bolts or nuts

Abstract

A structural flange connection system and method that utilizes structural flanges having a standard bolted connection and a mechanical bond to effectively manage and assist the retention of bolt preloads and substantially eliminate movement between the flange faces due to a reduction in the need for friction load being generated by the bolt clamping force in the flange connection. The structural flanges of the structural flange connection system and method each include an outer rim and a flange lip having a face and a shoulder. The structural flange connection system and method may be utilized in the manufacture and installation of a wind turbine tower, which may be made up of one or more tower sections, and each tower section may terminate in structural flanges of the structural flange connection system and method. When properly aligned, the structural flanges may be bolted together. When each tower section is properly aligned and bolted, the mechanical bond of the structural flanges is also joined together. Such manufacture of the wind turbine tower may occur in the field during installation of the wind turbine tower.

Claims

1. A method of manufacturing a wind turbine tower with a structural flange connection, comprising the steps of:

aligning a first tower section and a second tower section to form at least part of the wind turbine tower, where the first tower section has at least one end terminating in a first structural flange, the second tower section has at least one end terminating in a second structural flange, and the first structural flange is proximate to and aligns with the second structural flange when the first tower section is aligned with the second tower section;

forming a mechanical bond between the first structural flange and the structural second flange; and

bolting the first structural flange and the second structural flange together.

2. The method of claim 1 where the first structural flange and the second structural flange each have a face, where the first tower section abuts the second tower section along the face of the first structural flange and the face of the second structural flange when the first tower section and the second tower section are aligned.

3. The method of claim 2 where:

the first structural flange has a series of bolt apertures upon the face of the first structural flange;

the second structural flange has a series of bolt apertures upon the face of the first structural flange;

the series of bolt apertures of the first structural flange and of the second structural flange are located on the face of the first structural flange and the face of the second structural flange, respectively, such that the series of bolt apertures of the first structural flange aligns with the series of bolt apertures of the second structural flange when the first tower section is aligned with the second tower section; and

wherein the step of bolting the first structural flange and the second structural flange together comprises the step of bolting the first structural flange and the second structural flange together such that the mechanical bond is retained intermediate of the first structural flange and the second structural flange.

4. The method of claim 3 where:

the first structural flange has a first ring groove located upon the face of the first structural flange;

the second structural flange has a second ring groove located upon the face of the second structural flange;

the first ring groove and the second ring groove are located on the face of the first structural flange and the face of the second structural flange, respectively, such that the first ring groove aligns with the second ring groove when the first tower section is aligned with the second tower section; and

wherein the step of forming the mechanical bond between the first structural flange and the second structural flange comprises the step of placing a ring gasket between the first structural flange and the second structural flange such that the ring gasket is retained within the first ring groove and the second ring groove.

5. The method of claim 4 where the first ring groove extends around the face of the first structural flange in an annular pattern and the second ring groove extends around the face of the second structural flange in an annular pattern.

6. The method of claim 3 where:

the first structural flange has a groove located upon the face of the first structural flange;

the second structural flange has a mating protrusion located upon the face of the second structural flange;

the groove and the mating protrusion are located on the face of the first structural flange and the face of the second structural flange, respectively, such that the groove aligns with the mating protrusion when the first tower section is aligned with the second tower section; and

wherein the step of forming the mechanical bond between the first structural flange and the second structural flange further comprises the step of nesting the mating protrusion within the groove.

7. The method of claim 6 where the groove is substantially V- or U-shaped and extends around the face of the first structural flange in an annular pattern and the mating protrusion is substantially an inverted V- or U-shape and extends around the face of the second structural flange in an annular pattern.

8. The method of claim 3 where:

the first structural flange has a series of apertures located upon the face of the first structural flange;

the second structural flange has a series of apertures located upon the face of the second structural flange;

the series of apertures located upon the face of the first structural flange and the series of apertures located upon the face of the second structural flange are located on the face of the first structural flange and the face of the second structural flange, respectively, such that the series of apertures located upon the face of the first structural flange aligns with the series of apertures located upon the face of the second structural flange when the first tower section is aligned with the second tower section; and

wherein the step of forming the mechanical bond between the first structural flange and the second structural flange further comprises the step of placing a series of pins in the series of apertures located upon the face of the first structural flange and the series of apertures located upon the face of the second structural flange, such that each pin has a first end and a second end, the first end of each pin is located in one of the apertures in the series of apertures located upon the face of the first structural flange, and the second end of each pin is located in one of the apertures in the series of apertures located upon the face of the second structural flange.

9. The method of claim 8 where each of the pins is tapered on both the first end and on the second end, and where the series of pins alternate around the face of the first structural flange with a series of bolt apertures in the face of the first structural flange and around the face of the second structural flange with a series of bolt apertures in the face of the second structural flange.

10. The method of claim 9 where the arctangent of the angle of the taper of each of the pins and the series of apertures in the first structural flange and the second structural flange is less than the coefficient of friction between each of the pins and the series of apertures in the first structural flange and the second structural flange.

11. The method of claim 3 where:

the face of the first structural flange has an inner span and an outer span, the outer span has a series of protruding frusta located on the face of the first structural flange, and the inner span has a series of mating detents located upon the face of the first structural flange;

the face of the second structural flange has an inner span and an outer span, the outer span has a series of mating detents located upon the face of the second structural flange, and the inner span has a series of protruding frusta located upon the face of the second structural flange;

the series of protruding frusta located upon the outer span of the face of the first structural flange and the series of mating detents located upon the outer span of the face of the second structural flange are located on the outer span of the face of the first structural flange and the outer span of the face of the second structural flange, respectively, such that the series of protruding frusta located upon the outer span of the face of the first structural flange aligns with the series of mating detents located upon the outer span of the face of the second structural flange when the first tower section is aligned with the second tower section;

the series of protruding frusta located upon the inner span of the face of the second structural flange and the series of mating detents located upon the inner span of the face of the first structural flange are located on the inner span of the face of the first structural flange and the inner span of the face of the second structural flange, respectively, such that the series of protruding frusta located upon the inner span of the face of the second structural flange aligns with the series of mating detents located upon the inner span of the face of the first structural flange when the first tower section is aligned with the second tower section; and

wherein the step of forming the mechanical bond between the first structural flange and the second structural flange further comprises the step of fitting the series of protruding frusta located on the outer span of the face of the first structural flange in the series of mating detents located on the outer span of the face of the second structural flange and the series of protruding frusta located on the inner span of the face of the second structural flange in the series of mating detents located on the inner span of the face of the first structural flange, such that each of the protruding frustum located on the outer span of the face of the first structural flange is fit into one of the mating detents located on the outer span of the face of the second structural flange and each of the protruding frustum on the inner span of the face of the second structural flange is fit into one of the mating detents located on the inner span of the face of the first structural flange.

12. The method of claim 11 where:

the inner span of the face of the first structural flange has the series of bolt apertures located upon the face of the first structural flange;

the inner span of the face of the second structural flange has the series of bolt apertures located upon the face of the second structural flange; and

the series of bolt apertures located upon the inner span of the face of the first structural flange and of the second structural flange are located on the inner span of the face of the first structural flange and the inner span of the face of the second structural flange, respectively, such that the series of bolt apertures located upon the inner span of the face of the first structural flange aligns with the series of bolt apertures located upon the inner span of the face of the second structural flange when the first tower section is aligned with the second tower section.

13. The method of claim 12 where the arctangent of the angle of the taper of each of the pins and the series of apertures in the first structural flange and the second structural flange is less than the coefficient of friction between each of the pins and the series of apertures in the first structural flange and the second structural flange.

14. A tower section of a wind turbine tower, comprising:

a tower section comprising a tubular wall with opposing terminal ends;

a first structural flange comprising an outer rim and a flange lip having a face and a shoulder, the shoulder and the face of the flange lip are substantially perpendicular to the outer rim of the first structural flange, the first structural flange has a series of bolt apertures through the face and the shoulder of the flange lip of the first structural flange, the first structural flange has at least one structural element on the face of the first structural element, the outer rim of the first structural flange is attached to a first terminal end of the tower section;

a second structural flange comprising an outer rim and a flange lip having a face and a shoulder, the shoulder and the face of the flange lip are substantially perpendicular to the outer rim of the second structural flange, the second structural flange has a series of bolt apertures through the face and the shoulder of the flange lip of the second structural flange, the second structural flange has at least one structural element on the face of the second structural element, the outer rim of the second structural flange is attached to a second terminal end of the tower section; and

wherein the face of the first structural flange opposes and is aligned along a parallel plane to the face of the second structural flange, and wherein the first structural flange is axially spaced from and coaxially aligned with the second structural flange.

15. The tower section of claim 14 further comprising:

the first structural flange having a first ring groove located upon the face of the first structural flange;

the second structural flange having a second ring groove located upon the face of the second structural flange; and

wherein the first ring groove and the second ring groove are located on the face of the first structural flange and the face of the second structural flange, respectively, such that the first ring groove aligns with the second ring groove when a first tower section is aligned with a second tower section.

16. The tower section of claim 15 further comprising a ring gasket between the first structural flange and the second structural flange such that the ring gasket is retained within the first ring groove and the second ring groove when the first tower section is aligned with the second tower section.

17. The tower section of claim 15 where the first ring groove extends around the face of the first structural flange in an annular pattern and the second ring groove extends around the face of the second structural flange in an annular pattern.

18. The tower section of claim 14 further comprising:

the first structural flange having a groove located upon the face of the first structural flange;

the second structural flange having a mating protrusion located upon the face of the second structural flange; and

wherein the groove and the mating protrusion are located on the face of the first structural flange and the face of the second structural flange, respectively, such that the groove aligns with the mating protrusion when a first tower section is aligned with a second tower section.

19. The tower section of claim 18 where the groove is substantially V- or U-shaped and extends around the face of the first structural flange in an annular pattern and the mating protrusion is substantially an inverted V- or U-shape and extends around the face of the second structural flange in an annular pattern.

20. The tower section of claim 14 further comprising:

the first structural flange having a series of apertures located upon the face of the first structural flange;

the second structural flange having a series of apertures located upon the face of the second structural flange; and

wherein the series of apertures located upon the face of the first structural flange and the series of apertures located upon the face of the second structural flange are located on the face of the first structural flange and the face of the second structural flange, respectively, such that the series of apertures located upon the face of the first structural flange aligns with the series of apertures located upon the face of the second structural flange when a first tower section is aligned with a second tower section.

21. The tower section of claim 20 further comprising a series of pins in the series of apertures located upon the face of the first structural flange and the series of apertures located upon the face of the second structural flange, such that each pin has a first end and a second end, the first end of each pin is located in one of the apertures in the series of apertures located upon the face of the first structural flange, and the second end of each pin is located in one of the apertures in the series of apertures located upon the face of the second structural flange when the first tower section is aligned with the second tower section.

22. The tower section of claim 21 where each of the pins is tapered on both the first end and on the second end, and where the series of pins alternate around the face of the first structural

23. The method of claim 22 where the arctangent of the angle of the taper of each of the pins and the series of apertures in the first structural flange and the second structural flange is less than the coefficient of friction between each of the pins and the series of apertures in the first structural flange and the second structural flange.

24. The tower section of claim 14 further comprising:

the face of the first structural flange having an inner span and an outer span, the outer span having a series of protruding frusta located on the face of the first structural flange, and the inner span having a series of mating detents located upon the face of the first structural flange;

the face of the second structural flange having an inner span and an outer span, the outer span having a series of mating detents located upon the face of the second structural flange, and the inner span having a series of protruding frusta located upon the face of the second structural flange; and

wherein the series of protruding frusta located upon the outer span of the face of the first structural flange and the series of mating detents located upon the outer span of the face of the second structural flange are located on the outer span of the face of the first structural flange and the outer span of the face of the second structural flange, respectively, such that the series of protruding frusta located upon the outer span of the face of the first structural flange aligns with the series of mating detents located upon the outer span of the face of the second structural flange when a first tower section is aligned with a second tower section; and

wherein the series of protruding frusta located upon the inner span of the face of the second structural flange and the series of mating detents located upon the inner span of the face of the first structural flange are located on the inner span of the face of the first structural flange and the inner span of the face of the second structural flange, respectively, such that the series of protruding frusta located upon the inner span of the face of the second structural flange aligns with the series of mating detents located upon the inner span of the face of the first structural flange when the first tower section is aligned with the second tower section.

25. The tower section of claim 24 wherein:

the inner span of the face of the first structural flange has the series of bolt apertures located upon the face of the first structural flange;

the inner span of the face of the second structural flange has the series of bolt apertures located upon the face of the second structural flange; and

the series of bolt apertures located upon the inner span of the face of the first structural flange and of the second structural flange are located on the inner span of the face of the first structural flange and the inner span of the face of the second structural flange, respectively, such that the series of bolt apertures located upon the inner span of the face of the first structural flange aligns with the series of bolt apertures located upon the inner span of the face of the second structural flange when the first tower section is aligned with the second tower section.

26. The tower section of claim 24 where the arctangent of the angle of each of the protruding frusta and the series of mating detents in the first structural flange and the second structural flange is less than the coefficient of friction between each of the protruding frusta and the series of mating detents in the first structural flange and the second structural flange.

27. A structural flange connection for joining adjacent elements, comprising:

a first structural flange comprising an outer rim and a flange lip having a face and a shoulder, the shoulder and the face of the flange lip are substantially perpendicular to the outer rim of the first structural flange, the first structural flange has a series of bolt apertures through the face and the shoulder of the flange lip of the first structural flange, and the first structural flange having a series of apertures located upon the face of the first structural flange;

a second structural flange comprising an outer rim and a flange lip having a face and a shoulder, the shoulder and the face of the flange lip are substantially perpendicular to the outer rim of the second structural flange, the second structural flange has a series of bolt apertures through the face and the shoulder of the flange lip of the second structural flange, and the second structural flange having a series of apertures located upon the face of the second structural flange; and

wherein the series of apertures located upon the face of the first structural flange and the series of apertures located upon the face of the second structural flange are located on the face of the first structural flange and the face of the second structural flange, respectively, such that the series of apertures located upon the face of the first structural flange aligns with the series of apertures located upon the face of the second structural flange when a first element is aligned with a second element.

28. The structural flange connection of claim 27 further comprising a series of pins in the series of apertures located upon the face of the first structural flange and the series of apertures located upon the face of the second structural flange, such that each pin has a first end and a second end, the first end of each pin is located in one of the apertures in the series of apertures located upon the face of the first structural flange, and the second end of each pin is located in one of the apertures in the series of apertures located upon the face of the second structural flange when the first element is aligned with the second element.

29. The structural flange connection of claim 28 where each of the pins is tapered on both the first end and on the second end, and where the series of pins alternate around the face of the first structural flange with a series of bolt apertures in the face of the first structural flange and around the face of the second structural flange with a series of bolt apertures in the face of the second structural flange.

30. The structural flange connection claim 29 where the arctangent of the angle of the taper of each of the pins and the series of apertures in the first structural flange and the second structural flange is less than the coefficient of friction between each of the pins and the series of apertures in the first structural flange and the second structural flange.

31. The structural flange connection of claim 27 further comprising:

the face of the first structural flange having an inner span and an outer span, the outer span having a series of protruding frusta located on the face of the first structural flange, and the inner span having the series of apertures located upon the face of the first structural flange;

the face of the second structural flange having an inner span and an outer span, the outer span having a series of apertures located upon the face of the second structural flange, and the inner span having a series of protruding frusta located upon the face of the second structural flange;

wherein the series of protruding frusta located upon the outer span of the face of the first structural flange and the series of apertures located upon the outer span of the face of the second structural flange are located on the outer span of the face of the first structural flange and the outer span of the face of the second structural flange, respectively, such that the series of protruding frusta located upon the outer span of the face of the first structural flange aligns with the series of apertures located upon the outer span of the face of the second structural flange when the first element is aligned with the second element; and

wherein the series of protruding frusta located upon the inner span of the face of the second structural flange and the series of apertures located upon the inner span of the face of the first structural flange are located on the inner span of the face of the first structural flange and the inner span of the face of the second structural flange, respectively, such that the series of protruding frusta located upon the inner span of the face of the second structural flange aligns with the series of apertures located upon the inner span of the face of the first structural flange when the first element is aligned with the second element.

32. The structural flange connection of claim 31 wherein:

the inner span of the face of the first structural flange has the series of bolt apertures located upon the face of the first structural flange;

the inner span of the face of the second structural flange has the series of bolt apertures located upon the face of the second structural flange; and

the series of bolt apertures located upon the inner span of the face of the first structural flange and of the second structural flange are located on the inner span of the face of the first structural flange and the inner span of the face of the second structural flange, respectively, such that the series of bolt apertures located upon the inner span of the face of the first structural flange aligns with the series of bolt apertures located upon the inner span of the face of the second structural flange when the first element is aligned with the second element.

33. The structural flange connection of claim 29 where the arctangent of the angle of each of the protruding frusta and the series of mating detents in the first structural flange and the second structural flange is 1 than the coefficient of friction between each of the protruding frusta and the series of mating detents in the first structural flange and the second structural flange.