Adjustable Formwork for Wind Tower Segments
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Solution Overview
Problem
The manufacturing and transportation of concrete tower segments for wind turbines face challenges due to deviations in shape and size, leading to increased costs, time delays, and logistical complexities, particularly with the need for multiple formworks and precise fitting to ensure stability under wind loads.
Innovation Solution
A method involving the use of formworks that allow for precise measurement and adjustment of tower segments using three-dimensional modeling and laser measuring devices to create accurate virtual models, enabling the detection and correction of deviations, and a system for efficiently handling and moving the formworks during production and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional concrete tower segments are manufactured using fixed formworks, then production follows standard procedures, but deviations in shape and size occur leading to segments being sorted out as scrap
Solution Approach 1:
The formwork is designed with adjustable elements that allow dynamic adaptation to compensate for deviations in the tower segment dimensions. The formwork can be adjusted in real-time during the pouring process to ensure precise final dimensions, preventing segments from being rejected due to manufacturing variations.
Solution Approach 2:
The invention changes the parameters of the formwork system by introducing adjustable components that can modify the formwork's geometry. This allows the formwork to adapt to slight variations in the reinforcement cage dimensions and ensure the concrete segment achieves the required precision, thereby reducing waste.
2Adaptability or versatility
If multiple different tower segments are manufactured for tapering towers, then the tower can be constructed, but a correspondingly large number of different formworks are required increasing logistics and organization effort
Solution Approach 1:
The formwork is designed as a universal system that can produce multiple different tower segment types. By incorporating adjustable elements, the same formwork can be configured to manufacture segments of various sizes and shapes, eliminating the need for separate dedicated formworks for each segment type and significantly reducing logistical complexity.
Solution Approach 2:
The formwork is divided into modular, adjustable components that can be reconfigured for different segment productions. This segmentation allows the formwork system to be adapted to various tower segment requirements without requiring entirely different formworks, thereby reducing the total number of formworks needed.
3Strength
If heavy outer formwork weighing 5t to 10t is used for production, then the formwork provides structural stability, but lifting and moving requires heavy machines increasing manufacturing effort and cost
Solution Approach 1:
The invention replaces the traditional heavy mechanical formwork system with a lighter alternative that uses mechanical advantage principles. By incorporating lever systems and pulley mechanisms, the formwork achieves the necessary structural stability without requiring heavy materials, thereby reducing the need for heavy lifting equipment and associated manufacturing costs.
4Productivity
If tower segments are transported standing up to minimize space, then transport efficiency is improved, but the segments are vulnerable to tipping over in curves or slipping when braking
Solution Approach 1:
The invention implements preliminary action by pre-attaching restraining elements to the tower segments before transport. These elements are positioned in advance to prevent tipping and slipping, ensuring safety while maintaining the vertical transport orientation that maximizes space efficiency.
Solution Approach 2:
The invention introduces intermediary restraining elements as mediators between the tower segment and the transport platform. These elements provide the necessary mechanical connection to prevent unwanted movements during transport, allowing the segments to be transported vertically without compromising safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves high accuracy in the millimeter range for tower segments, reduces waste, simplifies logistics, and enhances the reproducibility and interchangeability of segments, thereby improving manufacturing efficiency and reducing costs.
Implementation Method 1
a laser measuring device for measuring the geometric dimensions of the tower segment
Data Source
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AI summary
The present invention relates to a method for producing a tower segment of a concrete tower of an wind energy installation, comprising the steps: providing a segment mold having at least an isolation for defining a mold of the tower segment that is to be produced and for filling with concrete; filling the segment mold with concrete in order to form the tower segment by the subsequent hardening of the concrete; measuring the tower segment thus hardened for creating a three-dimensional, virtual actual model of said tower segment; producing said three-dimensional actual model; comparing the three-dimensional actual model with a predefined mold, in particular a stored three-dimensional, virtual target model; and determining a deviation between both virtual models and changing the segment mold, in particular changing the at least one isolation when the deviation exceeds a first predefined threshold value.