Precast Concrete Mould With Adjustable Side Walls
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Solution Overview
Problem
The assembly process of wind turbine towers using precast concrete sections is lengthy and costly due to the need for precise alignment and joining of sections with rigid moulds, which are expensive and prone to deformation, and existing solutions either require extensive curing times or precise manufacturing tolerances.
Innovation Solution
A mould for precast concrete element production where the side walls defining the upper and lower flanks are independent of the base and countermould, allowing for parallel and perpendicular positioning through adjustable means, such as beams and rods, to maintain flank orientation despite mould deformation, thus simplifying and expediting the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid moulds are used to ensure precise flank orientation, then manufacturing precision is improved, but mould cost and complexity increase
Solution Approach 1:
The mould is divided into independent components: base, countermould, and side walls. The side walls can be positioned and adjusted independently using positioning means (beams and rods), allowing each component to be optimized separately rather than requiring the entire mould to be rigidly constructed from high-strength materials.
Solution Approach 2:
The side walls are made adjustable through positioning means that allow modification of their relative positions. This dynamic capability enables precise flank orientation to be achieved and maintained, while the mould components themselves can be made from less expensive, more flexible materials since they don't need to maintain rigid precision under all conditions.
2Manufacturing precision
If wet joint assembly method is used to absorb section deviations, then assembly tolerance is improved, but assembly time and cost increase
Solution Approach 1:
The precise flank orientation is established during the concrete element manufacturing process itself, through the independent positioning of side walls in the mould. This preliminary precision work eliminates the need for corrective actions during assembly, such as using wet joints with formwork and curing time, thereby significantly reducing assembly time and cost.
3Productivity
If dry joint assembly method is used to reduce assembly time, then productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The required flank precision (flatness, parallelism, and perpendicularity) is built into the concrete elements during manufacturing by using the mould with independently positionable side walls. This preliminary precision ensures that when dry joint assembly is used, the sections fit together correctly without requiring extensive precision work during assembly, thus maintaining high productivity.
4Manufacturing precision
If expensive rigid moulds are used to maintain flank orientation, then manufacturing precision is improved, but mould cost increases
Solution Approach 1:
The mould is segmented into independent components (base, countermould, side walls) that can be manufactured from less expensive materials. The side walls are positioned using adjustable positioning means rather than being rigidly fixed, allowing the use of lower-cost materials while maintaining precision through adjustability rather than material rigidity.
Solution Approach 2:
The positioning means (beams and rods) allow the side walls to be adjusted to precise positions and then fixed. This dynamic positioning capability replaces the need for expensive rigid mould construction, as precision is achieved through adjustment and fixation rather than through the inherent rigidity and cost of the mould materials themselves.
Data Source
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AI summary
The present invention can be included in the technical field of moulds for precast concrete element production and relates to a mould for precast concrete element production wherein the relative position of the side walls that define the upper and lower flanks of the precast concrete element is defined by elements that are independent from the rest of the mould, as well as to the manufacturing process that uses the aforementioned mould for precast concrete element production, the precast concrete element thus obtained and a wind turbine comprising, in turn, at least one precast concrete element produced using said mould.