Modular Support Structures for Offshore Wind via 3D Construction Printing
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Solution Overview
Problem
Conventional methods for manufacturing support structures for energy-generating devices, such as wind turbines and wave energy converters, are costly and time-consuming due to their large size, which complicates transportation and increases production time and costs.
Innovation Solution
The use of additive manufacturing techniques, specifically 3D Construction Printing (3DCP), to create modular support structures that can be assembled on-site or near-site using low-cost cementitious or ceramic materials, reducing the need for expensive temporary formwork and allowing for faster production and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional manufacturing methods are used for large support structures, then structural strength and stability are achieved, but transportation difficulty and time-to-manufacture increase significantly
Solution Approach 1:
The support structure is divided into multiple modular sections that can be manufactured separately and assembled on-site. Each section maintains the required structural strength while being small enough for efficient manufacturing and transportation, thereby reducing overall time-to-manufacture without compromising the final structure's integrity.
Solution Approach 2:
The support structures are designed to be assembled vertically on-site from smaller modular sections. This dimensional approach allows manufacturing to occur in a compact horizontal footprint while achieving large vertical structures, significantly reducing manufacturing time and enabling easier transportation of individual sections.
2Reliability
If conventional manufacturing methods are used for large support structures, then structural integrity is maintained, but transportation cost and complexity increase
Solution Approach 1:
By segmenting the support structure into modular sections, each section becomes small enough for standard transportation methods while maintaining the overall structural integrity through proper connection designs. This segmentation directly addresses transportation difficulties without compromising the reliability of the final assembled structure.
Solution Approach 2:
The modular sections are pre-manufactured with connection interfaces and structural features already integrated, allowing for quick assembly on-site. This preliminary preparation of connection details ensures structural integrity is built-in during manufacturing, eliminating the need for complex field welding or assembly operations.
3Strength
If conventional manufacturing methods are used for large support structures, then structural strength is achieved, but fabrication cost increases
Solution Approach 1:
Segmenting the structure into modular sections enables standardized manufacturing processes that reduce fabrication costs. Each module can be produced using efficient, repeatable techniques with optimized material usage, while the modular design allows for economies of scale in production without compromising the strength of the final assembled structure.
Solution Approach 2:
The invention replaces expensive field welding operations with mechanical connection systems that can be assembled on-site without specialized equipment. This substitution eliminates the need for costly welding processes, skilled welders, and extensive quality control procedures while maintaining structural strength through engineered connection details.
4Stability of the object's composition
If conventional manufacturing methods are used for large support structures, then structural stability is achieved, but transportation time and distance increase
Solution Approach 1:
By dividing the support structure into compact modular sections, the transportation distance and logistics complexity are dramatically reduced. Each section can be transported independently using standard infrastructure, eliminating the need to transport entire large-scale structures over long distances while maintaining structural stability through proper assembly procedures.
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 significantly reduces capital and transportation costs by up to 80% compared to conventional methods, while also speeding up production and eliminating the need for expensive welding processes, thereby making the construction of large support structures more efficient and cost-effective.
Implementation Method 1
forming a wall or a truss by depositing layers of printable material successively
Implementation Method 2
filling the volume with a castable material and hardening the castable material
Data Source
AI summary
In a general aspect, a method is presented for manufacturing support structures for offshore wind turbines. In some implementations, the method includes constructing a plurality of modular sections that assemble to define the support structure. One or more of the plurality of modular sections are configured to anchor to an underwater floor. At least one of the plurality of modular sections is constructed by operations that include forming a wall along a perimeter to bound a volume, filling the volume with a castable material, and hardening the castable material. In some instances, forming the wall includes depositing layers of printable material successively on top of each other. The method also includes joining the plurality of modular sections to assemble the support structure.