Precast Concrete Wind Turbine Tower Segmentation
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Solution Overview
Problem
Existing wind turbine tower construction methods, particularly for high systems, face challenges with large pipe diameters required for conical tubular steel towers, which are difficult to transport and costly due to the need for multiple molds for tapered concrete elements, leading to unsustainable production costs and complex on-site assembly.
Innovation Solution
The use of flat, isosceles trapezoidal precast concrete wall elements with adjustable formwork allows for easy transportation and quick assembly, eliminating the need for expensive scaffolding and complex molds, enabling a climbing construction method where elements of varying heights are used to form a polygonal tower structure, with prestressing for enhanced load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conical tubular steel towers with large pipe diameters are used for high systems, then structural stability is improved, but transportation difficulty increases and route accessibility worsens
Solution Approach 1:
The tower is divided into multiple precast concrete wall elements that can be manufactured separately and transported individually, then assembled on-site. This segmentation allows each element to have manageable dimensions for transportation while the final assembled structure achieves the required structural stability for high wind turbine systems
Solution Approach 2:
The patent uses composite construction by combining precast concrete wall elements with steel reinforcement and connection components. This composite approach maintains structural stability comparable to solid steel towers while enabling modular fabrication and easier transportation of individual elements
2Shape
If curved or angled prefabricated concrete components with different bending radii are used for tapered towers, then tower tapering capability is improved, but manufacturing cost increases due to many expensive molds
Solution Approach 1:
The formwork system is designed to be adjustable and dynamic, allowing the same mold to produce wall elements with different bending radii by modifying the formwork configuration. This eliminates the need for multiple expensive fixed-radius molds while maintaining the ability to create tapered tower shapes
Solution Approach 2:
A single universal formwork system is designed to perform multiple functions by producing wall elements with various bending radii and angles through adjustment mechanisms. This multi-functional formwork reduces manufacturing costs by eliminating the need for separate dedicated molds for each radius requirement
3Shape
If rectangular and trapezoidal elements are alternately placed to form a tower, then tower structure is improved, but manufacturing cost increases due to high costs for many forms
Solution Approach 1:
The formwork system is designed as a universal multi-functional tool that can produce both rectangular and trapezoidal wall elements, as well as elements with different bending radii, using the same basic mold structure with adjustable components. This eliminates the need for maintaining multiple separate form sets
4Reliability
If expensive scaffolding is used for tower erection, then construction safety is improved, but construction cost increases
Solution Approach 1:
The precast concrete wall elements are manufactured in advance with integrated connection features, reinforcement, and positioning elements already in place. This preliminary preparation allows for rapid on-site assembly without requiring expensive scaffolding, while maintaining construction safety through pre-engineered connection details
Solution Approach 2:
The tower structure is designed to be self-supporting during construction through the sequential assembly of precast elements that can be connected and stabilized as they are installed. The structure serves its own support function during erection, eliminating the need for external scaffolding systems
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 enables rapid, safe, and cost-effective construction of wind turbine towers, allowing for smaller pipe diameters in upper sections and improved load absorption, facilitating transportation and assembly on difficult terrain.
Implementation Method 1
the precast concrete wall elements are prestressed against one another and, if necessary, against the foundation
Implementation Method 2
the level precast concrete wall elements are provided with sloping cheeks. As a result, the individual precast concrete wall elements can be better adapted to one another. Less concrete has to be poured into the connecting joints between the precast concrete wall elements.
Data Source
Figure 1
Figure 2~3
AI summary
The tower (1) has partial ready-mix concrete wall elements (3,4) which are fitted on a base plate (2) in upright and stacked manner. The ready-mix concrete wall elements have a structure with polygon horizontal projection. The ready-mix concrete wall elements have a form of an equal-sided trapezium. An independent claim is also included for method for installing the tower.