METHOD FOR PRODUCING A TOWER SEGMENT AND TOWER SEGMENT

Abstract

A manufacturing method for producing a tower segment, a tower portion and a tower section for a tower, in particular for a tower of a wind power installation. A tower segment, a tower portion and a tower section for a tower, in particular for a tower of a wind power installation, to a tower, and to a wind power installation. The manufacturing method comprises: providing a plate that extends in the longitudinal direction and, orthogonally thereto, in a circumferential direction, wherein the extent in the longitudinal direction is larger than the extent in the circumferential direction; and rolling the plate for incorporating a thickness profile along a longitudinal direction of the plate, wherein the rolling comprises: incorporating a first constant portion having a substantially constant first thickness which differs from a substantially constant second thickness of a second constant portion that in the longitudinal direction is disposed so as to be substantially parallel to said first constant portion; and bending the plate in the circumferential direction.

Claims

1. A manufacturing method comprising: producing a tower segment of a tower, said producing comprising: rolling a plate along a longitudinal direction of the plate, wherein the plate extends in a longitudinal direction and, orthogonally to the longitudinal direction, in a circumferential direction, wherein an extent in the longitudinal direction is larger than an extent in the circumferential direction, wherein the rolling comprises: incorporating a thickness profile having a variable thickness; and bending the plate.

2. The manufacturing method as claimed in claim 1, wherein the rolling comprises at least one of: heating the plate to a hot-rolling temperature; incorporating at least one transition portion, wherein the at least one transition portion has a variable thickness of the incorporated thickness profile; or incorporating at least one constant portion, wherein the at least one constant portion has a constant thickness of the incorporated thickness profile.

3. The manufacturing method as claimed in claim 1, wherein the bending comprises at least one of: heating the plate to a hot-bending temperature; or incorporating a curvature in the circumferential direction in the plate.

4. The manufacturing method as claimed in claim 1, wherein: the thickness of the at least one transition portion varies in a stepless or stepped manner; and/or wherein the curvature incorporated in the circumferential direction varies along the longitudinal direction of the plate.

5. The manufacturing method as claimed claim 1, comprising: producing at least one abutting face on the plate for connecting to another plate, wherein the producing of the at least one abutting face comprises: producing at least one longitudinal abutting face for connecting to another plate in the circumferential direction; and/or producing Sat least one circumferential abutting face for connecting to another plate in the longitudinal direction; and/or removing a peripheral portion of the plate.

6. A manufacturing method for establishing a tower portion comprising: connecting two plates produced according to the manufacturing method as claimed in claim 1 at corresponding longitudinal abutting faces, wherein the connecting comprises: disposing and fixing adjacent plates on one another along the longitudinal abutting faces so as to form an annular tower portion in the circumferential direction; and establishing a longitudinal welded connection between the adjacent plates along the longitudinal abutting faces.

7. A manufacturing method for establishing a tower section, comprising: connecting a plurality of tower portions produced according to the manufacturing method as claimed in claim 1 at corresponding circumferential abutting faces, wherein the connecting comprises: disposing and fixing adjacent tower portions on one another along the circumferential abutting faces so as to form a tower section in the longitudinal direction; and establishing a circumferential welded connection between the adjacent tower portions along the circumferential abutting faces.

8. The manufacturing method as claimed in claim 6, comprising: grinding at least one of the circumferential welded connection or the longitudinal welded connection.

9. A tower segment of a tower, comprising: a plate, wherein the plate extends in a longitudinal direction and, orthogonally to the longitudinal direction, in a circumferential direction, wherein an extent in the longitudinal direction is greater than an extent in the circumferential direction, and wherein the plate has a thickness profile having a variable thickness along the longitudinal direction of the plate and has at least one of: at least one transition portion; at least one constant portion having a substantially constant thickness; or a curvature in the circumferential direction.

10. A tower portion of a tower, comprising: a plurality of tower segments as claimed in claim 9, wherein the plurality of tower segments in the circumferential direction are disposed in an annular manner or as an annular sub-portion, and adjacent tower segments of plurality of tower segments are fastened to one another at longitudinal abutting faces.

11. The tower portion as claimed in claim 10, wherein a thickness of the tower portion in an installed state differs in the circumferential direction between at least two tower segments of the plurality of tower segments.

12. A tower section of a tower, comprising a plurality of tower portions as claimed in claim 10, wherein the tower portions, in an installed state, in the longitudinal direction are vertically stacked, and adjacent tower portions are fastened to one another at the circumferential abutting faces.

13. The tower section as claimed in claim 12, comprising: an upper end, in the installed state, having an upper annular flange for fastening to an upper tower section or a nacelle; and a lower end, in the installed state, having a lower annular flange for fastening to a lower tower section or a foundation.

14. A tower comprising the tower section as claimed in claim 12.

15. A wind power installation comprising the tower as claimed in claim 14.

16. (canceled)

17. The manufacturing method as claimed in claim 3, wherein the bending comprises incorporating a curvature in the circumferential direction in the plate, wherein the incorporating of the curvature comprises at least one of: incorporating the curvature by plastic hot-forming; incorporating a curvature that is constant in the circumferential direction of the plate; disposing on top of one another at least two plates substantially orthogonal to the longitudinal direction and the circumferential direction of the plate; or disposing the plate on a mold.

18. The manufacturing method as claimed in claim 6, annealing the plates in at least one region of the circumferential welded connection or of the longitudinal welded connection.

19. The manufacturing method as claimed in claim 7, comprising: grinding at least one of the circumferential welded connection or the longitudinal welded connection.

20. The manufacturing method as claimed in claim 7, comprising annealing the plates in at least one region of the circumferential welded connection or of the longitudinal welded connection.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0080] Preferred embodiments of the invention will be described in an exemplary manner by means of the appended figures in which:

[0081] FIG. 1 shows a schematic three-dimensional view of a wind power installation having a tower and a nacelle;

[0082] FIG. 2 shows a schematic block diagram which shows the steps of an exemplary embodiment of a manufacturing method for manufacturing a tower segment;

[0083] FIG. 3 shows a schematic block diagram which shows exemplary steps of the method of rolling;

[0084] FIG. 4 shows a schematic block diagram which shows exemplary steps of the method of bending;

[0085] FIG. 5a shows a schematic two-dimensional view of a tower segment for a tower;

[0086] FIG. 5b shows a sectional view A-A through the tower segment shown in FIG. 2a;

[0087] FIG. 5c shows a plan view of the tower segment shown in FIG. 2a;

[0088] FIG. 6 shows a schematic three-dimensional view of the tower segment shown in FIG. 2a before and after the method step of bending, as well as a schematic three-dimensional view of a mold for bending the tower segment;

[0089] FIG. 6a shows a sectional view A-A of a tower segment of a further embodiment having a thickness profile comprising a constant portion and a transition portion;

[0090] FIG. 7 shows a schematic block diagram which shows the steps of a further embodiment of a manufacturing method for manufacturing a tower segment;

[0091] FIG. 8 shows a schematic block diagram which shows exemplary steps of the method of producing an abutting face;

[0092] FIG. 9a: shows a schematic two-dimensional view of a further tower segment for a tower;

[0093] FIG. 9b shows a schematic illustration of a thickness profile of the tower segment shown in FIG. 9a;

[0094] FIG. 9c shows a schematic illustration of a further thickness profile of the tower segment shown in FIG. 9a;

[0095] FIG. 10 shows a schematic block diagram which shows exemplary steps of the method of connecting two plates;

[0096] FIG. 11 shows a schematic three-dimensional view of a tower portion having a plurality of tower segments disposed in an annular manner in the circumferential direction;

[0097] FIG. 12 shows a schematic block diagram which shows exemplary steps of the method of connecting two or a plurality of tower portions that are disposed so as to be mutually parallel in the longitudinal direction, and the grinding and the annealing of abutting faces; and

[0098] FIG. 13 shows a schematic three-dimensional view of a tower section comprising two tower portions that are disposed so as to be mutually parallel in the longitudinal direction.

DETAILED DESCRIPTION

[0099] FIG. 1 shows a schematic illustration of a wind power installation according to the invention. The wind power installation 100 has a tower 102 and a nacelle 104 on the tower 102. An aerodynamic rotor 106 having three rotor blades 108 and a spinner 110 is provided on the nacelle 104. The aerodynamic rotor 106 in the operation of the wind power installation is set in rotation by the wind and thus also rotates an electrodynamic rotor or armature of a generator which is coupled directly or indirectly to the aerodynamic rotor 106. The electric generator is disposed in the nacelle 104 and generates electric power. The pitch angles of the rotor blades 108 can be varied by pitch motors on the rotor blade roots 108b of the respective rotor blades 108.

[0100] FIG. 2 shows a manufacturing method for producing a tower segment 1 of a tower 102, for example of a tower 102 of a wind power installation 100 shown in FIG. 1. The manufacturing method comprises the steps of providing S1, rolling S2 and bending S3 a plate 1a.

[0101] FIG. 3 shows a schematic block diagram with exemplary method steps of the rolling S2. The rolling S2 can in particular comprise the heating S2.1 of the plate 1a to a hot-rolling temperature, and/or the incorporating S2.2 of at least one transition portion U, and/or the incorporating S2.3 of at least one constant portion K1, K2, K3, K4, K5. The method step of rolling S2 can in particular comprise further forming and/or heat-treating method steps.

[0102] When incorporating S2.2 the at least one transition portion Ü, it is in particular provided that the incorporated thickness profile has a variable thickness dÜ. The thickness profile of a transition portion Ü preferably has at least two different thicknesses dÜ. When incorporating S2.3 the at least one constant portion K1, K2, K3, K4, K5 it is provided in particular that a constant portion K has a substantially constant thickness d1, d2, d3, d4, d5. Mutually dissimilar constant portions K1, K2, K3, K4, K5 can have different constant thicknesses d1, d2, d3, d4, d5. It is conceivable that one or a plurality of constant portions have the same thickness.

[0103] FIG. 4 shows a schematic block diagram with exemplary method steps of the bending S3. The method step of bending S3 comprises the steps of heating S3.1 the plate to a hot-bending temperature, and/or the incorporating S3.2 of a curvature x1, x2 in the circumferential direction U in the plate 1a, and/or the disposing on top of one another S3.3 of at least two plates 1a substantially orthogonal to the longitudinal direction L and the circumferential direction U of the plates 1a, and/or the disposing S3.4 of the plate on a mold 40. The plate 1a is in particular disposed on a mold 40 which is a mesh mold and/or a mold comprising concrete.

[0104] The incorporating S3.2 of a curvature x1, x2 in the circumferential direction U in the plate 1a preferably comprises incorporating the curvature by means of plastic hot-forming. For the hot-forming, the plate 1a is heated to a hot-forming temperature which is above an ambient temperature. It is furthermore particularly preferable for a curvature x1, x2 which is constant in the circumferential direction U to be incorporated in the plate 1a.

[0105] FIGS. 5a-5c show a tower segment 1 produced according to the manufacturing method illustrated in FIG. 2.

[0106] Provided according to the manufacturing method shown in FIG. 2 is to provide a plate 1a which extends in the longitudinal direction L and, orthogonal thereto, in a circumferential direction U. The plate 1a in the longitudinal direction presently extends approximately by a factor of 3 to 4 in comparison to the circumferential direction. The planar extent in the longitudinal direction L and the circumferential direction U of the plate 1a here is multiple times larger than the thickness of the plate 1a extending orthogonally thereto.

[0107] As a result of rolling S2 the provided plate 1a, a thickness profile having a variable thickness dÜ is incorporated in the longitudinal direction of said plate 1a along a longitudinal axis LA. In an exemplary manner it is provided here that a thickness profile which has a first constant portion K1 having a first thickness d1, and a second constant portion K2 having a second thickness d2 is incorporated. The tower segment 1 shown in FIGS. 5a-6 has a variable thickness profile with a discrete profile of thickness; the thickness profile of the first constant portion K1 having the thickness d1 transitions abruptly, or in steps, respectively, to the thickness profile of the second constant portion K2 having the thickness d2. The second constant portion K2 has been rolled to a thickness d2 which corresponds to approximately one third of the first thickness d1 of the first constant portion K1. The different thicknesses d1, d2 of the two constant portions K1, K2 can be derived in particular from FIGS. 5b and 5c.

[0108] The second constant portion K2 here has been incorporated in such a manner that the second constant portion K2 in the longitudinal direction L is disposed above the first constant portion K1. In particular, the two constant portions are disposed so as to be substantially mutually parallel. In the case of constant portions K1, K2 that are disposed so as to be substantially mutually parallel, the transition between the two constant portions K1, K2 extends across the circumferential direction U, so as to be perpendicular thereto. The incorporated constant portions K1, K2 here have an extent in the longitudinal direction L, or a length, respectively, which is larger than the extent of said constant portions K1, K2 in the circumferential direction U.

[0109] In the present example, the rolling S2 of the provided plate 1a comprises initially the heating S2.1 of the plate to a hot-rolling temperature. As a result, the constant portions K1, K2 having the respective substantially constant thicknesses d1, d2 in the longitudinal direction L and in the circumferential direction U per constant portion K1, K2 can subsequently be incorporated S2.2 with a lower input of force.

[0110] The bending S3 of the rolled plate 1a is provided subsequently to the rolling S2. FIG. 6 shows a schematic three-dimensional view of the tower segment 1 shown in FIGS. 5a-5c before and after the method step of bending S3, as well as a schematic three-dimensional view of a mold 40 for bending S3 the tower segment 1. A corresponding bending tool as the counterpart of the mold 40 is not shown.

[0111] FIG. 5b here shows a cross section A-A in the longitudinal direction, transversely to the circumferential direction of the tower segment 1 shown in FIG. 5a. Proceeding from a lower end of the tower segment 1, the first constant portion K1 having a thickness d1 extends to approximately the center of said tower segment 1 and, proceeding from approximately the center of the tower segment 1, the second constant portion K2 having a thickness d2 extends to an upper end. This view and the plan view of the tower segment 1 in FIG. 5c show the curvature x1, x2 in the circumferential direction of the two constant portions K1, K2 of the tower segment 1. It becomes evident from the sectional view A-A and the plan view of FIGS. 5b and 5c that the respective constant portions K1, K2 of the present tower segment 1 have been bent to a cylindrical shape. In the installed state or operating state, respectively, of the tower segment 1, the plate 1a in terms of a longitudinal axis LA has a curvature which is constant in the circumferential direction, this being a function of the respective constant portion. In that the constant portions are bent so as to be substantially cylindrical, the constant portions K1, K2, in the installed state or operating state, respectively, do not have any curvature in the longitudinal direction.

[0112] In the present example, the bending S3 comprises initially the heating S3.1 of the plate 1a to the hot-bending temperature. As a result, the plate 1a can consequently be bent S3.2 in the circumferential direction U with a lower input of force. As a result of this hot-forming, the plate is imparted a radius, or a curvature x1, x2 which is constant in the circumferential direction U, respectively, as is shown in FIGS. 5b, 5c and 6 (lower third) S3.3.

[0113] For a further embodiment of a tower segment 1, shown in FIG. 6a, in the method step of rolling S2 in the longitudinal direction L of the tower segment, a transition portion Ü is incorporated in the plate 1a, and in the installed state in the longitudinal direction a constant portion K2 is incorporated thereabove in the plate 1a. In this preferred embodiment of the manufacturing method and of the established tower segment 1, the thickness profile of the transition portion U transitions continuously to the thickness profile of the constant portion K2. The thickness profile of the transition portion Ü has a variable thickness dÜ. The thickness profile of the tower segment 1 in the transition portion Ü follows a concave profile. The thickness of the transition portion increases continuously up to an upper end of the transition portion Ü, or approximately up to the center of the tower segment 1 decreases to a thickness d2, respectively, and continuously transitions to the constant portion K2 having the constant thickness d2. The continuous transition between the transition portion Ü and the constant portion K2 is indicated by the horizontal dashed line in FIG. 6a. The transition portion has a curvature which is constant in the circumferential direction and varies in the longitudinal direction of the tower segment 1. The preferred embodiment of a tower segment 1 shown in FIG. 6a is established in a manner substantially analogous to that of the preferred embodiment of the tower segment having the two constant portions shown in FIGS. 5a-6. To this extent, the embodiments pertaining to the manufacturing method of the tower segments shown in FIGS. 5a-6 apply in a substantially analogous manner to the preferred embodiment of a tower segment illustrated in FIG. 6a.

[0114] Based on the manufacturing method for producing a tower segment 1 of a tower 102 illustrated in FIG. 2, the manufacturing method illustrated in FIG. 7 additionally comprises the step of producing S4 at least one abutting face on the plate 1a.

[0115] FIG. 8 shows a schematic block diagram having exemplary method steps of producing S4 at least one abutting face, for example the producing S4.1, S4.2 of at least one longitudinal abutting face 3a, 3b and/or at least one circumferential abutting face 2a, 2b for connecting at least one further plate, and/or the producing of an abutting face the removal of a peripheral portion S4.3. According to the manufacturing method shown in FIG. 7, it is furthermore provided that the rolling S2 additionally comprises incorporating S2.3 a transition portion U between two constant portions.

[0116] FIGS. 9a, 9b and 9c show a tower segment 1 produced by such a manufacturing method. A tower segment 1 produced by such a method in the longitudinal direction has five mutually parallel constant portions K1, K2, K3, K4, K5 having respective constant thicknesses d1, d2, d3, d4, d5 that in the installed state are disposed on top of one another in the longitudinal direction, for example. Parallel thereto, transition portions U have been incorporated between these constant portions K1 to K5 with a view to a lower notching effect. It may be preferable for a tower segment 1 at an end which in the installed state is a lower and/or an upper end to terminate by way of a transition portion Ü. In the preferred embodiments of a tower segment 1 illustrated in FIGS. 9a, 9b and 9c, the respective constant portions K1, K2, K3, K4, K5 that are disposed so as to be mutually parallel in the longitudinal direction L have an extent which is larger than the extent of the transition portions Ü in the longitudinal direction L. In further preferred embodiments it may be preferable for one or a plurality of transition portions Ü in the longitudinal direction L to have a larger extent than one or a plurality of constant portions of a tower segment 1.

[0117] The tower segment 1 illustrated in FIG. 9b shows a thickness profile in which the thickness dÜ of the respective transition portion Ü between the adjacent constant portions K1, K2, K3, K4, K5 varies in a trapezoidal manner. In particular, the thickness profile varies continuously within the individual transition portions. The thickness profile of the tower segment illustrated in FIG. 9b at the transitions between the individual portions has a discrete profile. FIG. 9c shows a thickness profile of a tower segment 1, for example according to FIG. 9a, in which the thickness dÜ of the respective transition portions U between the adjacent constant portions K1, K2, K3, K4, K5 have a concave and convex profile. In particular, the thickness profile varies continuously within the individual transition portions Ü. The thickness profile of the tower segment 1 illustrated in FIG. 9b at the transitions between the individual portions has a continuous profile. The thickness profiles shown in FIGS. 9b and 9c, in the longitudinal direction L, in terms of the installed state or operating state of the tower segment 1, respectively, proceeding from a lower end of the tower segment 1 via the constant portion K2 up to the center of the tower segment 1, thus the constant portion K3, have an increasing thickness. The thickness of the thickness profile, proceeding from the constant portion K3 via the constant portion K4 then decreases to the constant portion K5, the upper end of the tower segment 1.

[0118] In the present example, the producing S4 of at least one abutting face comprises the producing S4.1, S4.2 of an upper and a lower circumferential abutting face 2a, 2b and two longitudinal abutting faces 3a, 3b. The circumferential abutting faces 2a, 2b in the circumferential direction U extend substantially on the lower side and the upper side of the tower segment 1. The longitudinal abutting faces 3a, 3b extend substantially in the longitudinal direction L so as to be lateral on the tower segment 1. Furthermore, the producing of an abutting face comprises the removing of a peripheral portion S4.3. As a result of removing the peripheral portion S4.3, the tower segment 1 shown in FIG. 9a tapers conically in the longitudinal direction L. In particular, the tower segment 1 produced as a result, in the longitudinal direction, proceeding from a lower end of the circumferential abutting face 2a, has a taper toward an upper end of the circumferential abutting face 2b. The tower segment 1 has in particular inclined longitudinal abutting faces 3a, 3b. Such a tower segment 1 in the installed state or operating state, respectively, is disposed so as to be inclined in relation to a longitudinal axis LA that is aligned so as to be substantially vertical.

[0119] FIG. 10 shows a manufacturing method for establishing a tower portion 10. To this end, it is provided that the established plates 1a previously described are connected to one another S5 at the longitudinal abutting faces 3a, 3b, for example. A tower portion 10 established by this method is shown in FIG. 11. A tower 102 of a wind power installation 100 according to FIG. 1 can comprise, for example, a tower portion 10 established in such a manner. To this end, tower segments were produced according to the manufacturing method described as per FIG. 2, and peripheral portions of the plates 1a additionally removed and circumferential abutting faces 2a, 2b on the upper side and the lower side of the plate 1a as well as longitudinal abutting faces 3a, 3b in the longitudinal direction of the plate 1a produced S4. Eight tower segments 1 were provided and mutually disposed in an annular manner and fixed S5.1 for establishing the tower portion 10. Subsequently, a longitudinal welded connection between adjacent plates 1a was established along the longitudinal abutting faces 3a, 3b so as to be substantially parallel to the longitudinal axis LA in order for the plates 1a to be connected to one another.

[0120] In the presently illustrated exemplary embodiment, a tower portion 10 in which the constant portions K1 of adjacent tower segments 1 and the constant portions K2 of adjacent tower segments 1 have substantially identical constant thicknesses d1, d2 was established. However, it is conceivable for the constant portions K1, K2 of such tower segments that in the installed state or operating state, respectively, are disposed so as to be substantially parallel to a prevailing load direction to be produced with a comparatively smaller thickness d1, d2 than the constant portions K1, K2 of such tower segments that in the installed state or operating state, respectively, are disposed so as to be substantially transverse to the prevailing load direction.

[0121] FIG. 12 shows a manufacturing method for establishing a tower section 20. To this end it is provided that two or a plurality of tower portions are connected S7, welded connections are ground S8 and/or plates in the region of the welded connections are annealed S9. The connecting S6 of two or a plurality of tower portions 10 comprises the disposing and fixing S7.1 of adjacent tower portions 10 on one another along a circumferential abutting face, and the establishing S7.2 of a circumferential welded connection. The grinding S8 comprises the grinding of the circumferential welded connection S8.1 and/or the grinding of the longitudinal welded connection S8.2. The annealing S9 comprises the annealing of the plates in the region of the circumferential welded connection S9.1 and/or the annealing of the longitudinal welded connection S9.2.

[0122] FIG. 13 shows a tower section 20 established so as to be based on the manufacturing method illustrated in FIG. 12. A tower 102 of a wind power installation 100 according to FIG. 1 can comprise a tower section 20 established in such a manner, for example. It may be preferable for a previously described tower portion and/or tower section and/or tower to comprise tower segments that are different from the manufacturing method according to the invention.

[0123] The establishing of such a tower section 20 in the present example comprises the providing of two tower portions 10 established as described above. For connecting S6 these two tower portions 10 it is provided that the two tower portions 10 are disposed and fixed S6.1 along the circumferential abutting faces 2a, 2b so as to form a tower section 20 in the longitudinal direction, and that a circumferential welded connection is subsequently established S6.2 between the adjacent tower portions 10 along the circumferential abutting faces 2a, 2b. With a view to a longer service life, the circumferential welded connections are ground S7.1 and annealed S8.1. It is furthermore provided that the tower section 20 at the lower end thereof and the upper end thereof has a lower and an upper annular flange 21, 22. The upper annular flange is provided for fastening a further tower section 20 or a nacelle 104, and the lower annular flange is provided for fastening a further tower section 20 or a foundation. The upper and the lower annular flange 21, 22 are preferably configured as a screw connection.

LIST OF REFERENCE SIGNS

[0124] 1 Tower segment [0125] 1a Plate [0126] 2a, 2b Circumferential abutting face [0127] 3a, 3b Longitudinal abutting face [0128] 10 Tower portion [0129] 20 Tower section [0130] 40 Mold, mesh mold [0131] 100 Wind power installation [0132] 102 Tower [0133] 104 Nacelle [0134] 106 Rotor [0135] 108 Rotor blade [0136] 110 Spinner [0137] d1 . . . d5 Constant thickness of a constant portion [0138] dÜ Variable thickness of a transition portion [0139] K1 . . . K5 Constant portion [0140] x1, x2 Curvature of a constant and/or transition portion portions [0141] L Longitudinal direction [0142] LA Longitudinal axis [0143] U Circumferential direction [0144] Ü Transition portion