Coiled Polymer Reinforcement Rings for 3D-Printed Tower Walls
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Solution Overview
Problem
Conventional methods for manufacturing wind turbine towers face challenges due to the large size of steel reinforcement rings, which are limited by transportation regulations and require labor-intensive on-site assembly, and existing reinforcement methods are not compatible with additive manufacturing.
Innovation Solution
The method involves using coiled polymer reinforcement materials, such as pultruded fiberglass or carbon fiber, unwound and formed into continuous reinforcement ring members, which are then integrated with additively manufactured concrete structures, allowing for on-site assembly and reducing logistical challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional steel rings are shipped in complete ring format for reinforcing concrete tower structures, then the reinforcement strength is improved, but transportation is limited by regulations prohibiting shipping of objects greater than about 4.5 meters in diameter
Solution Approach 1:
The patent divides the complete reinforcement ring into multiple segments that can be shipped separately in compact forms (coiled or bent into smaller radii) and then assembled on-site to form the complete reinforcement ring, resolving the contradiction between maintaining reinforcement strength and reducing transportation dimensions
Solution Approach 2:
The patent coils the reinforcement ring into a compact nested form that fits within transportation size limits, allowing the full-length reinforcement material to be shipped in a space-efficient configuration and then uncoiled/assembled on-site to achieve the required structural dimensions
2Length of moving object
If steel rings are shipped in segments and assembled on-site, then transportation limitations are avoided, but labor intensity and assembly time increase significantly
Solution Approach 1:
The patent performs preliminary actions by pre-coiling the reinforcement material in standardized compact forms and preparing connection elements in advance, so that on-site assembly involves primarily uncoiling and connecting pre-prepared segments rather than assembling raw materials from scratch, significantly reducing labor intensity
3Adaptability or versatility
If additive manufacturing is used to print tower structures on-site, then transportation limitations are avoided and design flexibility is improved, but existing reinforcement methods are not compatible with the additive manufacturing process
Solution Approach 1:
The patent merges the additive manufacturing process with reinforcement integration by incorporating reinforcement material delivery systems and placement mechanisms directly into the printing system, allowing reinforcement to be deposited simultaneously with or between concrete layers, achieving full compatibility between the two processes
Solution Approach 2:
The patent creates a universal system where the additive manufacturing apparatus can handle both concrete deposition and reinforcement material delivery through integrated feed mechanisms and printheads, enabling a single machine to perform multiple functions and ensuring compatibility across different tower designs
Data Source
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AI summary
A method of manufacturing a tower structure includes printing and depositing, via a printhead assembly of an additive printing system, one or more printed layers of a wall of the tower structure. The method also includes unwinding at least one continuous roll of a reinforcement material to form at least one continuous reinforcement ring member layer, the reinforcement material comprising a pultruded polymer material. Further, the method includes placing the at least one continuous reinforcement ring member layer atop the one or more printed layers of the wall of the tower structure. Moreover, the method includes printing and depositing, via the printhead assembly of the additive printing system, one or more additional printed layers of the wall of the tower structure atop the at least one continuous reinforcement ring member layer.