Tower Detailing - the tower waist is a crucial area that transfers all of the forces from the upper structure (superstructure) to the lower structure (common body)
Transmission line tower designers have a difficult job designing lightweight yet robust towers that can accommodate varying site conditions. One method they use is including body extensions with multiple leg combinations to suit different tower heights. An important initial task for detailers is determining a common tower stub to allow early foundation work, which involves superimposing leg profiles to find a common bolt pattern. The type of connection joining different tower legs depends on factors like leg type and terrain, with options including multiple plates for each combination, overlapped plates, or single plates with or without small eccentricities between legs.
While reducing steel weight through techniques like removing gusset plates can save thousands in material costs, it's important to also consider manufacturing costs which may exceed savings from lighter designs. Bending angles is becoming more expensive than adding steel with bent plates due to automated manufacturing methods now used. When providing manufacturing data, detailers must include allowances for bends and specify pre- versus post-bend operations to ensure accurate fabrication.
Stan Gad developed tower design software after starting his career detailing radio, TV, and transmission line towers. He shares tips on tower detailing to clarify common myths and challenges. In this document, he explains the correct view of a tower cross-section, how to account for open corners in wide towers, calculating corner openings, and when his software considers applying local corner bends. The goal is to better understand tower detailing challenges and solutions.
The document provides instructions for modeling and 3D printing a wind turbine assembly with 9 main parts. It describes each part in detail and provides diagrams of blade and nacelle cross-sections to model. It outlines a multi-step process for creating the complex nacelle part using lofts and extrusions to add material and cuts to remove it, forming bearing holes and allowing the nacelle to spin on support masts. The overall goal is for students to correctly model each component and assemble a working prototype of the wind turbine.
This document lists specifications for various medical devices including sondes, stylets, and Farrell devices. It provides the length, diameter, and reference number for each item. The sondes are listed as having either a double end or single end and come in lengths from 11.5 to 25 cm with diameters of 1.0 or 2.0 mm. The stylets are listed as either pointed or spatulated and range from 11.5 to 25 cm long with a diameter of 2.0 mm. The Farrell devices are 12 to 18 cm long with diameters between 0.9 and 1.2 mm.
This document provides specifications for various stainless steel float models, including their outer diameter, height, inner diameter, weight, density, and material. The floats are available in different sizes and versions, with outer diameters ranging from 25.0mm to 52.0mm, heights from 24.5mm to 62.5mm, and weights from 6.0g to 49.0g. All floats are made of either SUS304 or SUS316L stainless steel.
This document provides specifications for SL, SS, SN, and SM series precision shafting. It details shaft material options, diameter tolerances, straightness, roundness, hardness depth, chamfer dimensions, and maximum lengths. Diameter options range from 0.25 to 2 inches (SL/SS/SN series) and 8 to 50 mm (SM series). Material options include 1060 steel and 440C stainless steel. Overall length tolerance is +/- 1/32 inches for most, +/- 1/16 inches for 2 inch diameter shafts.
Transmission line tower designers have a difficult job designing lightweight yet robust towers that can accommodate varying site conditions. One method they use is including body extensions with multiple leg combinations to suit different tower heights. An important initial task for detailers is determining a common tower stub to allow early foundation work, which involves superimposing leg profiles to find a common bolt pattern. The type of connection joining different tower legs depends on factors like leg type and terrain, with options including multiple plates for each combination, overlapped plates, or single plates with or without small eccentricities between legs.
While reducing steel weight through techniques like removing gusset plates can save thousands in material costs, it's important to also consider manufacturing costs which may exceed savings from lighter designs. Bending angles is becoming more expensive than adding steel with bent plates due to automated manufacturing methods now used. When providing manufacturing data, detailers must include allowances for bends and specify pre- versus post-bend operations to ensure accurate fabrication.
Stan Gad developed tower design software after starting his career detailing radio, TV, and transmission line towers. He shares tips on tower detailing to clarify common myths and challenges. In this document, he explains the correct view of a tower cross-section, how to account for open corners in wide towers, calculating corner openings, and when his software considers applying local corner bends. The goal is to better understand tower detailing challenges and solutions.
The document provides instructions for modeling and 3D printing a wind turbine assembly with 9 main parts. It describes each part in detail and provides diagrams of blade and nacelle cross-sections to model. It outlines a multi-step process for creating the complex nacelle part using lofts and extrusions to add material and cuts to remove it, forming bearing holes and allowing the nacelle to spin on support masts. The overall goal is for students to correctly model each component and assemble a working prototype of the wind turbine.
This document lists specifications for various medical devices including sondes, stylets, and Farrell devices. It provides the length, diameter, and reference number for each item. The sondes are listed as having either a double end or single end and come in lengths from 11.5 to 25 cm with diameters of 1.0 or 2.0 mm. The stylets are listed as either pointed or spatulated and range from 11.5 to 25 cm long with a diameter of 2.0 mm. The Farrell devices are 12 to 18 cm long with diameters between 0.9 and 1.2 mm.
This document provides specifications for various stainless steel float models, including their outer diameter, height, inner diameter, weight, density, and material. The floats are available in different sizes and versions, with outer diameters ranging from 25.0mm to 52.0mm, heights from 24.5mm to 62.5mm, and weights from 6.0g to 49.0g. All floats are made of either SUS304 or SUS316L stainless steel.
This document provides specifications for SL, SS, SN, and SM series precision shafting. It details shaft material options, diameter tolerances, straightness, roundness, hardness depth, chamfer dimensions, and maximum lengths. Diameter options range from 0.25 to 2 inches (SL/SS/SN series) and 8 to 50 mm (SM series). Material options include 1060 steel and 440C stainless steel. Overall length tolerance is +/- 1/32 inches for most, +/- 1/16 inches for 2 inch diameter shafts.
igs and fixtures are specialised tools used in manufacturing to secure workpi...yhchauhan
igs and fixtures are specialised tools used in manufacturing to secure workpieces and guide cutting or shaping tools, ensuring precision and repeatability in production processes.
This document discusses the design of support structures for additive manufacturing of metal parts. It begins by explaining how designers try to avoid supports, but they are sometimes necessary. The key is to design supports that are easy to remove, strong enough to hold the part, minimize build time, and save on materials. The rest of the document uses a combustion chamber part to illustrate how to optimize the design of supports, such as adding a support block with an internal hexagon to aid removal. Process parameters are also adjusted to improve support performance and part buildability.
The document provides guidance on creating assembly drawings and interpreting machine drawings. It discusses exploring product assemblies by investigating individual parts, functions, materials, and fastening techniques. Key points include representing assembled products through 3D CAD models after understanding individual parts. Assembly drawings should show all components in functional position and how they fit together using views and sections.
Instructions SPUHR Ideal Scope Mounting System | Optics TradeOptics-Trade
This document provides information about an extremely sturdy one-piece scope mount system made in Sweden. It can attach multiple optical accessories directly to the mount, includes a built-in level and 45 degree split rings for better view of scope turrets. Instructions are provided for mounting scopes and accessories, ensuring proper torque, and repeating the mounting configuration. The mount interfaces with various optics and can be configured in straight or tilted orientations.
This document is a comprehensive report for Project 06 in an engineering CAD class. It details the redesign of an adjustable wrench in two phases. Phase 1 involved identifying inaccuracies in the original wrench drawings and proposing design changes. Phase 2 involved 3D modeling the redesigned wrench parts in ProEngineer, creating new 2D drawings, assembling the parts, rendering images, and creating animations of the wrench. The project utilized all the CAD skills learned to that point and took approximately 65 hours to complete.
This document outlines the design of a frame to support a 45kN load 2m above an object. The frame design was developed in Dr Frame 3D software. Calculations were provided to analyze the design for buckling, bending, welding, and fastening. For buckling, the factor of safety was 11.08. For bending, the factor of safety was 1.95. Welding and fastening calculations determined minimum weld and bolt sizes of 10mm would be required. While initial values met requirements, improvements could be made to the design.
design and fabrication ofGear cutting attachment in lathe machineabes ec
In Today’s Fast Life Every One Wants To Save Time And Money, Even Small Scale Industrialist Wants To Earn More Profits With Given Limited Resources .Due To The Globalization The Competition Is Increasing Day By Day, Especially Micro Industries Is Facing Lot Of Trouble To Sustain In Throat Cutting Competition. So We Came Up With An Idea Of Saving Money By Desginning And Fabritacting of Attachment of gear cutting in lathe Which Can Save Money Of Small Industrialist By Avoiding The Subcontarction Of Works Which May Required Specail Machines .
The document discusses turning and drilling operations using a lathe machine. It describes the objective of learning lathe operations and safety procedures. Steps are provided to make a stepper and hinge parts using processes like turning, facing, drilling and boring. Precautions are outlined for boring to obtain a good pattern. Measurement consistency and preventing errors during workshops are also discussed. The document contains diagrams of lathe parts and sample workpieces to explain lathe operations.
IRJET- Design and Fabrication of Drill Bit Grinding Attachment MachineIRJET Journal
This document describes the design and fabrication of a drill bit grinding attachment machine. It aims to develop a fixture to hold drill bits firmly against a grinding wheel during resharpening, making the process less prone to errors and allowing less skilled operators. The fixture design is presented, along with its working principle and advantages such as reducing tool failure, being economical, and ensuring operator safety. Applications are for small manufacturing industries to efficiently resharpen drill bits.
IRJET- Design and Fabrication of Drill Bit Grinding Attachment MachineIRJET Journal
This document describes the design and fabrication of a drill bit grinding attachment machine. It aims to develop a fixture to hold drill bits firmly against a grinding wheel during resharpening, making the process less prone to errors and able to be performed by less skilled operators. The fixture design is intended to eliminate the need for inspection and reduce waste from improperly resharpened bits. It will also help prolong the lifespan of drill bits and reduce costs by enabling repeated resharpening. The document provides details on the working principle, advantages, applications and conclusions of the designed fixture.
1) The document describes a Creo computer aided design project to model an adjustable spanner.
2) The spanner consists of three main parts - the main spanner body, a movable jaw, and an adjustable screw.
3) Views and drawings of the completed CAD model are provided, including an engineering drawing of the movable jaw with dimensions.
This document discusses the design of an angle plate jig by a group of students. The jig is intended to drill 8mm holes on a given workpiece. Key points:
- The group is divided into two sections to collaborate on the design project.
- The design of the jig will consider factors like the material selection for each part and geometric analysis to optimize output and ensure interchangeability.
- The design process will start conceptually and result in a 3D model created in Solidworks.
- The objectives are to produce a jig that increases productivity and reduces costs while maintaining accuracy and consistency.
The document provides details of the design process for a detail sander. It includes research on existing similar products, identifying 3 competitors and comparing their features. Alternative design concepts are proposed and evaluated in a decision matrix. 3D CAD models are created for all individual parts as well as assemblies. The design goals included making the sander ergonomic, portable with battery power, and including dust removal features.
In this guide we review the advantages and disadvantages of the different machine types used for tube forming, define forming requirements, and the questions you need to ask in order to specify the right tooling.
This document describes the design and analysis of an indexing type drill jig. It begins with introducing the purpose and basic elements of jigs and fixtures in manufacturing. It then details the design process which includes modeling the component, base plate, locators, clamps, bushes, and indexing mechanism. An assembly of the drill jig is presented and analyzed using finite element analysis software. The results of the analysis show the clamping force is greater than the drilling force, indicating the design is safe and effective for its intended machining operation. In conclusion, the indexing drill jig design meets the objectives of locating and clamping the component accurately and efficiently for mass production.
The document provides information about an apple peeler including:
1) A breakdown of the apple peeler into five sub-systems and the assembly process for each.
2) Basic facts and specifications for the existing peeler such as its name, function, cost, dimensions, number of parts.
3) An analysis of each sub-system including how the parts are made and assembled.
4) Areas identified as requiring improvement such as parts that are difficult to clean or maintain.
The document describes a student's final project to design and injection mold a golf tee holder hat clip. The student iterated on the design based on prototyping and simulations. A first mold was machined and the design was molded in TPU, identifying areas for improvement. A second, improved mold addressed issues and produced functional clips with minimal defects. The student learned about optimizing the molding process and is pleased with the utility and reception of the final product.
IRJET- Design of Angular Way Drilling MachineIRJET Journal
This document describes the design of an angular way drilling machine. It includes 3 key points:
1) The machine allows for drilling holes at any angle between 0 and 90 degrees, providing more flexibility than traditional vertical drilling machines. It has saddle slide ways that allow the workpiece to be repositioned easily, reducing setting time.
2) The design includes components like lead screws, spur gears, bevel gears, and an angular table that allow the machine head and workpiece to be rotated and positioned in various orientations for angled drilling.
3) Calculations are provided for sizing gears and other components based on design requirements. The overall design is intended to simplify angled drilling and reduce the time required
Design and Analysis of Multi Spindle Drilling Head with Adjustable Centre Dis...IRJET Journal
This document describes the design and analysis of a multi-spindle drilling head attachment. The attachment is designed to increase productivity by allowing multiple holes to be drilled simultaneously in a workpiece. Key aspects of the design include:
1) The attachment can be mounted to an existing drill and powered by its motor. It has two spindles that can drill holes with a center distance ranging from 26mm to 106mm.
2) Components of the attachment like the spindle, gears, shaft and drill holder are designed and their stresses are analyzed using calculations and finite element analysis software.
3) Analysis shows the induced stresses in all components are below the yield stress of the respective materials, indicating the design is safe
igs and fixtures are specialised tools used in manufacturing to secure workpi...yhchauhan
igs and fixtures are specialised tools used in manufacturing to secure workpieces and guide cutting or shaping tools, ensuring precision and repeatability in production processes.
This document discusses the design of support structures for additive manufacturing of metal parts. It begins by explaining how designers try to avoid supports, but they are sometimes necessary. The key is to design supports that are easy to remove, strong enough to hold the part, minimize build time, and save on materials. The rest of the document uses a combustion chamber part to illustrate how to optimize the design of supports, such as adding a support block with an internal hexagon to aid removal. Process parameters are also adjusted to improve support performance and part buildability.
The document provides guidance on creating assembly drawings and interpreting machine drawings. It discusses exploring product assemblies by investigating individual parts, functions, materials, and fastening techniques. Key points include representing assembled products through 3D CAD models after understanding individual parts. Assembly drawings should show all components in functional position and how they fit together using views and sections.
Instructions SPUHR Ideal Scope Mounting System | Optics TradeOptics-Trade
This document provides information about an extremely sturdy one-piece scope mount system made in Sweden. It can attach multiple optical accessories directly to the mount, includes a built-in level and 45 degree split rings for better view of scope turrets. Instructions are provided for mounting scopes and accessories, ensuring proper torque, and repeating the mounting configuration. The mount interfaces with various optics and can be configured in straight or tilted orientations.
This document is a comprehensive report for Project 06 in an engineering CAD class. It details the redesign of an adjustable wrench in two phases. Phase 1 involved identifying inaccuracies in the original wrench drawings and proposing design changes. Phase 2 involved 3D modeling the redesigned wrench parts in ProEngineer, creating new 2D drawings, assembling the parts, rendering images, and creating animations of the wrench. The project utilized all the CAD skills learned to that point and took approximately 65 hours to complete.
This document outlines the design of a frame to support a 45kN load 2m above an object. The frame design was developed in Dr Frame 3D software. Calculations were provided to analyze the design for buckling, bending, welding, and fastening. For buckling, the factor of safety was 11.08. For bending, the factor of safety was 1.95. Welding and fastening calculations determined minimum weld and bolt sizes of 10mm would be required. While initial values met requirements, improvements could be made to the design.
design and fabrication ofGear cutting attachment in lathe machineabes ec
In Today’s Fast Life Every One Wants To Save Time And Money, Even Small Scale Industrialist Wants To Earn More Profits With Given Limited Resources .Due To The Globalization The Competition Is Increasing Day By Day, Especially Micro Industries Is Facing Lot Of Trouble To Sustain In Throat Cutting Competition. So We Came Up With An Idea Of Saving Money By Desginning And Fabritacting of Attachment of gear cutting in lathe Which Can Save Money Of Small Industrialist By Avoiding The Subcontarction Of Works Which May Required Specail Machines .
The document discusses turning and drilling operations using a lathe machine. It describes the objective of learning lathe operations and safety procedures. Steps are provided to make a stepper and hinge parts using processes like turning, facing, drilling and boring. Precautions are outlined for boring to obtain a good pattern. Measurement consistency and preventing errors during workshops are also discussed. The document contains diagrams of lathe parts and sample workpieces to explain lathe operations.
IRJET- Design and Fabrication of Drill Bit Grinding Attachment MachineIRJET Journal
This document describes the design and fabrication of a drill bit grinding attachment machine. It aims to develop a fixture to hold drill bits firmly against a grinding wheel during resharpening, making the process less prone to errors and allowing less skilled operators. The fixture design is presented, along with its working principle and advantages such as reducing tool failure, being economical, and ensuring operator safety. Applications are for small manufacturing industries to efficiently resharpen drill bits.
IRJET- Design and Fabrication of Drill Bit Grinding Attachment MachineIRJET Journal
This document describes the design and fabrication of a drill bit grinding attachment machine. It aims to develop a fixture to hold drill bits firmly against a grinding wheel during resharpening, making the process less prone to errors and able to be performed by less skilled operators. The fixture design is intended to eliminate the need for inspection and reduce waste from improperly resharpened bits. It will also help prolong the lifespan of drill bits and reduce costs by enabling repeated resharpening. The document provides details on the working principle, advantages, applications and conclusions of the designed fixture.
1) The document describes a Creo computer aided design project to model an adjustable spanner.
2) The spanner consists of three main parts - the main spanner body, a movable jaw, and an adjustable screw.
3) Views and drawings of the completed CAD model are provided, including an engineering drawing of the movable jaw with dimensions.
This document discusses the design of an angle plate jig by a group of students. The jig is intended to drill 8mm holes on a given workpiece. Key points:
- The group is divided into two sections to collaborate on the design project.
- The design of the jig will consider factors like the material selection for each part and geometric analysis to optimize output and ensure interchangeability.
- The design process will start conceptually and result in a 3D model created in Solidworks.
- The objectives are to produce a jig that increases productivity and reduces costs while maintaining accuracy and consistency.
The document provides details of the design process for a detail sander. It includes research on existing similar products, identifying 3 competitors and comparing their features. Alternative design concepts are proposed and evaluated in a decision matrix. 3D CAD models are created for all individual parts as well as assemblies. The design goals included making the sander ergonomic, portable with battery power, and including dust removal features.
In this guide we review the advantages and disadvantages of the different machine types used for tube forming, define forming requirements, and the questions you need to ask in order to specify the right tooling.
This document describes the design and analysis of an indexing type drill jig. It begins with introducing the purpose and basic elements of jigs and fixtures in manufacturing. It then details the design process which includes modeling the component, base plate, locators, clamps, bushes, and indexing mechanism. An assembly of the drill jig is presented and analyzed using finite element analysis software. The results of the analysis show the clamping force is greater than the drilling force, indicating the design is safe and effective for its intended machining operation. In conclusion, the indexing drill jig design meets the objectives of locating and clamping the component accurately and efficiently for mass production.
The document provides information about an apple peeler including:
1) A breakdown of the apple peeler into five sub-systems and the assembly process for each.
2) Basic facts and specifications for the existing peeler such as its name, function, cost, dimensions, number of parts.
3) An analysis of each sub-system including how the parts are made and assembled.
4) Areas identified as requiring improvement such as parts that are difficult to clean or maintain.
The document describes a student's final project to design and injection mold a golf tee holder hat clip. The student iterated on the design based on prototyping and simulations. A first mold was machined and the design was molded in TPU, identifying areas for improvement. A second, improved mold addressed issues and produced functional clips with minimal defects. The student learned about optimizing the molding process and is pleased with the utility and reception of the final product.
IRJET- Design of Angular Way Drilling MachineIRJET Journal
This document describes the design of an angular way drilling machine. It includes 3 key points:
1) The machine allows for drilling holes at any angle between 0 and 90 degrees, providing more flexibility than traditional vertical drilling machines. It has saddle slide ways that allow the workpiece to be repositioned easily, reducing setting time.
2) The design includes components like lead screws, spur gears, bevel gears, and an angular table that allow the machine head and workpiece to be rotated and positioned in various orientations for angled drilling.
3) Calculations are provided for sizing gears and other components based on design requirements. The overall design is intended to simplify angled drilling and reduce the time required
Design and Analysis of Multi Spindle Drilling Head with Adjustable Centre Dis...IRJET Journal
This document describes the design and analysis of a multi-spindle drilling head attachment. The attachment is designed to increase productivity by allowing multiple holes to be drilled simultaneously in a workpiece. Key aspects of the design include:
1) The attachment can be mounted to an existing drill and powered by its motor. It has two spindles that can drill holes with a center distance ranging from 26mm to 106mm.
2) Components of the attachment like the spindle, gears, shaft and drill holder are designed and their stresses are analyzed using calculations and finite element analysis software.
3) Analysis shows the induced stresses in all components are below the yield stress of the respective materials, indicating the design is safe
Similar to Tower smart tower_detailing_tips_series_5 (20)
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This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
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2. Tower Detailing TipsTower Detailing TipsTower Detailing TipsTower Detailing Tips
Thick Waist Plate Bent Lower Corner Bent Backing Angle Internal Waist Plates
The tower ‘waist’ is a crucial area that transfers all of the forces from the upper structure
(superstructure) to the lower structure (common body). There are many ways to detail
this connection and the method chosen depends on designers preference and also the
manufacturers capabilities. Below are some of the common options …
3. Tower Detailing TipsTower Detailing TipsTower Detailing TipsTower Detailing Tips
Thick Waist Plate
This solution is probably the simplest to detail and manufacture since it
eliminates the need to bend corners. The engineer needs to determine the
required plate thickness of the waist plate in consideration with bolts being in
single shear.
4. Tower Detailing TipsTower Detailing TipsTower Detailing TipsTower Detailing Tips
Bent Lower Corner
This was the initial solution used when lattice towers were first detailed. It is still fairly
common today but is not manufacturing friendly due to the double bend required on
the lower corner member. Bent hot rolled angles are difficult to control consistency
when mass produced and cumbersome to deliver to site. Refer to our ‘Tower
Detailing Tips – Series 2’ on bends.
5. Tower Detailing TipsTower Detailing TipsTower Detailing TipsTower Detailing Tips
Bent Backing Angle
This solution still requires a bent member but it is on a shorter backing angle instead of
a long corner member. Like the Bent Lower Corner solution, the main issue is fitting
other main members (frame or diagonals) inside the corner due to the extra thickness.
The affect is similar to a ‘Butt’ splice where bolts are in double shear.
6. Tower Detailing TipsTower Detailing TipsTower Detailing TipsTower Detailing Tips
Internal Waist Plates
I have not seen this solution used yet but see no problem why it wont work. Basically
it is similar to the Bent Backing Angle detail but replacing the internal backing angle
with 2 thick bent plates instead. This eliminates the need to bend any hot rolled
angles. The reason I believe this will be as affective as the bent backing angle
method is because the heel of backing angle still has to be ground down to fit inside
the corner, thus creating a similar affect.
7. Tower Detailing TipsTower Detailing TipsTower Detailing TipsTower Detailing Tips
Another issue to consider for waist plates on wide towers
is the ‘gap’ affect. This is caused by utilising a horizontal
bend line at the waist. Refer to our ‘Tower Detailing Tips
– Series 1’ for an explanation on the ‘gap’ affect.
. One solution to eliminate this gap is to rotate the bend
line to where the faces of the upper and lower corners
intersect.
Note that if you are going to use the rotated bend line
then consideration must be given to the incoming lower
main members (KUP or Diagonal) at this point since they
will need small bending (around 1 to 2 degrees)
8. Tower Detailing TipsTower Detailing TipsTower Detailing TipsTower Detailing Tips
For further information on tower detailing,
visit us at …
www.towersmart.com.au
or send us an email …
enquires@towersmart.com.au
I hope you have found these presentations on tower detailing helpful and informative.
This will be the last of my publications for now since I am focusing more on software
development. When I do get some spare time I will endeavour to create more free tips since
I have found that tower detail knowhow is slowly diminishing due to experienced detailers
retiring and not having the benefit to pass on their invaluable knowledge to trainees and
apprentices.