Non-symmetrical Wind Turbine Tower via Additive Manufacturing
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Solution Overview
Problem
Conventional wind turbine tower manufacturing methods are limited by transportation regulations and result in symmetrical towers that unnecessarily support loads perpendicular to the predominant wind direction, leading to increased material usage, weight, and cost.
Innovation Solution
The method involves determining the predominant wind direction at a wind turbine site and using additive manufacturing to create a non-symmetrical tower structure optimized for that direction, with thicker sections aligned with the wind direction and incorporating stiffening members, such as I-beam or elliptical cross-sections, to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If symmetrical tower structures are used to support aerodynamic forces from all directions, then structural stability is improved, but material usage and weight increase unnecessarily
Solution Approach 1:
The patent applies asymmetry by designing the tower structure with non-uniform thickness distribution, where the tower wall thickness varies around the circumference to match the directional wind load pattern. The upstream portion (facing predominant wind) has greater thickness while downstream and lateral portions have reduced thickness, eliminating unnecessary material while maintaining structural stability against the predominant wind direction.
Solution Approach 2:
The patent implements local quality by providing different structural properties at different locations of the tower. Specifically, the tower wall thickness is locally increased in the upstream portion to withstand higher wind pressures, while lateral and downstream portions have thinner walls since they experience lower loads. This localized differentiation optimizes material usage by concentrating structural strength only where needed.
2Ease of manufacture
If conventional manufacturing methods are used, then transportation and assembly are simplified, but transportation regulations limit tower diameter to 4-5 meters
Solution Approach 1:
The patent applies segmentation by dividing the tower structure into multiple arc segments that can be manufactured separately and then assembled on-site to form the complete circular tower. Each arc segment can be produced within transportation size limits and then joined together using bolting or welding, enabling the construction of larger diameter towers that would otherwise be impossible to transport as complete structures.
3Length of stationary object
If arc segments are assembled on-site to form the tower diameter, then transportation limitations are overcome, but extensive labor and time are required
Solution Approach 1:
The patent applies preliminary action by pre-manufacturing the arc segments with all necessary connection interfaces, reinforcement elements, and structural features already integrated during the molding process. This preliminary preparation of segments with built-in connection points and structural details reduces on-site assembly complexity and labor requirements, as the segments arrive ready-to-assemble rather than requiring extensive field fabrication or modification.
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 reduces material usage, labor, and transportation costs while ensuring the tower can withstand greater loads along the predominant wind direction, optimizing structural efficiency and cost-effectiveness.
Implementation Method 1
printing, via an additive printing device, the optimized shape of the tower structure of the wind turbine at the wind turbine site, at least in part, of a cementitious material
Implementation Method 2
allowing the cementitious material to cure so as to form the tower structure of the wind turbine
Data Source
AI summary
A method for manufacturing a tower structure of a wind turbine at a wind turbine site. The method includes determining an optimized shape of the tower structure based on one or more site parameters. Further, the optimized shape of the tower structure is non-symmetrical. In a further step, the method include printing, via an additive printing device, the optimized shape of the tower structure of the wind turbine at the wind turbine site, at least in part, of a cementitious material. In addition, the method includes allowing the cementitious material to cure so as to form the tower structure of the wind turbine.