Concrete Formwork Production Using Master Pattern Replication
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Solution Overview
Problem
The production of large concrete components, such as tower segments for wind turbines, faces challenges including high transportation costs, precision requirements, and long procurement times for specialized formwork, which are often expensive and inflexible, and conventional formwork lacks the necessary dimensional accuracy for large components.
Innovation Solution
A method where a sample of the component is created, and a production formwork is erected around it to form a cavity that is filled with liquid concrete, allowing the hardened concrete to serve as formwork for producing components with high precision, using a pattern with high dimensional accuracy that can be simpler and cheaper to transport, and allowing the use of conventional, inexpensive formwork for the production formwork.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional formwork is used for large concrete components, then transportation costs and procurement time are reduced, but dimensional accuracy and precision are insufficient
Solution Approach 1:
The invention applies preliminary action by first creating a precise sample or master model of the component, then using this sample as a template to produce multiple copies. The sample is prepared in advance with high dimensional accuracy, and subsequent formworks are replicated from this pre-prepared template, ensuring consistent precision across all produced components without requiring complex custom formwork for each production run.
Solution Approach 2:
The core of the invention is the copying principle - a high-precision sample or master model is created once, then used as a template to produce multiple formworks through copying processes. This allows the dimensional accuracy of the original sample to be transferred to multiple copies, which can then be used repeatedly for component production. The copying approach eliminates the need to recreate complex precise formwork for each new component batch.
2Manufacturing precision
If special formwork structures are manufactured for large custom components, then dimensional accuracy is improved, but transportation complexity and cost increase
Solution Approach 1:
The invention segments the formwork system into a reusable sample/template and multiple simpler copy formworks. The high-precision sample remains stationary at the production site, while multiple simplified copy formworks can be transported as needed. This segmentation allows the critical precision function to remain fixed while the transportable elements are simpler and more manageable in size and complexity.
Solution Approach 2:
By creating simplified copy formworks from a master sample, the invention enables transportation of lighter, simpler copy versions rather than transporting the original complex precise formwork. The copies maintain the necessary dimensional accuracy through replication from the master sample, reducing transportation complexity while preserving manufacturing precision.
3Manufacturing precision
If steel formwork structures are used, then precision is improved, but cost and transportation difficulty increase
Solution Approach 1:
The invention creates lightweight copy formworks from a master sample, allowing the use of lighter materials for the actual formwork while maintaining precision through the copying process. The master sample serves as the precision reference, while the copies can be made from lighter, more transportable materials without sacrificing dimensional accuracy.
Solution Approach 2:
The invention changes the material parameters of the formwork from heavy steel to lighter materials such as concrete or composite materials. By using the sample-based copying method, the precision traditionally achieved only with heavy steel formwork can be maintained while using lighter materials that are easier and less costly to transport and handle.
4Adaptability or versatility
If conventional formwork is used, then cost is reduced, but adaptability for different component geometries is limited
Solution Approach 1:
The master sample serves as a universal template that can be used to produce formworks for multiple different component geometries. By creating a library of samples for different component types, the same copying process and production line can be used across various geometries, making the system universally applicable while maintaining production simplicity and efficiency.
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 method enables the production of components with high dimensional accuracy, reduces transportation and procurement costs, and allows for the reuse and flexibility in producing multiple components with the same pattern, addressing the limitations of conventional formwork in achieving precise dimensions and handling large, complex geometries.
Implementation Method 1
The cavity is filled with liquid concrete, which is then hardened. The concrete that has hardened in the cavity forms the concrete formwork
Data Source
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AI summary
The invention relates to a method for producing a concrete formwork (500) for a component (800), in particular a tower segment for a tower, preferably a tower (102) of a wind turbine (100), to a method for producing a component, in particular a tower segment for a tower, preferably a tower of a wind turbine, to a concrete formwork for a component, in particular a tower segment for a tower, preferably a tower of a wind turbine, to a component, in particular a tower segment for a tower, preferably a tower of a wind turbine, and to a pattern (200) of a component, in particular a tower segment for a tower, preferably a tower of a wind turbine. The method for producing a concrete formwork for a component has the steps of providing a pattern of the component; erecting a production formwork (300) around the pattern at a distance from the pattern, wherein a cavity (401, 402) which is produced between the production formwork and the pattern corresponds to the dimensions of the concrete formwork to be produced; filling the cavity with liquid concrete; and hardening the concrete.