Robotic Tower Construction via Layered Extrusion
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Solution Overview
Problem
Current methods for constructing tall towers, such as wind turbine towers, are hazardous, expensive, and challenging due to the need for large steel sections that require specialized transportation and cranes, which are costly and difficult to operate at high elevations.
Innovation Solution
A robotic system that autonomously constructs towers using an extrusion nozzle, positioning system, and climbing apparatus to extrude uncured construction material, allowing for incremental climbing and precise layering, eliminating the need for factory-produced steel segments and reducing transportation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional factory-produced steel segments are used for tower construction, then structural strength and stability are ensured, but transportation cost and device complexity increase significantly
Solution Approach 1:
The patent replaces the mechanical system of transporting pre-fabricated steel segments with a robotic system that extrudes material layer-by-layer to construct the tower in situ. This eliminates the need for specialized transportation equipment and large assembly cranes, directly resolving the contradiction between structural strength and device complexity.
Solution Approach 2:
The invention changes the physical state and form of construction material from pre-fabricated steel segments to extrudable uncured material that is deposited and cured layer-by-layer. This parameter change allows towers to be constructed without traditional transportation and assembly equipment while maintaining structural integrity through controlled material deposition and curing processes.
2Length of moving object
If taller towers are constructed using traditional methods, then wind energy capture is improved, but transportation and assembly difficulty increase
Solution Approach 1:
The robotic extrusion system replaces the mechanical system of transporting and assembling tall steel segments with an automated process that constructs towers vertically layer-by-layer. This eliminates the need for specialized transportation equipment and large assembly cranes that become increasingly difficult to operate at greater heights, enabling construction of taller towers with improved ease of operation.
Solution Approach 2:
The invention transitions from horizontal transportation of long steel segments to vertical construction through layer-by-layer extrusion. This dimensional change allows towers to be built upward from the base without the transportation and assembly challenges associated with moving and positioning long segments at height.
3Adaptability or versatility
If human workers are used for tower assembly at high elevations, then construction flexibility is maintained, but safety risks increase
Solution Approach 1:
The robotic system performs all construction operations autonomously, including material extrusion, positioning, and layer-by-layer tower construction. This self-service capability eliminates human workers from high-elevation environments while maintaining construction flexibility through programmable control, directly resolving the contradiction between adaptability and safety.
Solution Approach 2:
The patent replaces the mechanical system of human-operated assembly with an automated robotic system that extrudes and deposits material layer-by-layer. This substitution eliminates exposure to safety hazards such as falls, heavy object handling, and high-wind conditions while maintaining construction flexibility through programmable control and adaptive positioning.
4Stability of the object's composition
If large base segments are used for taller towers, then structural stability is improved, but transportation difficulty increases
Solution Approach 1:
The invention segments the tower base construction into multiple thin layers that are extruded and deposited sequentially. This segmentation allows the base to be built with the required stability and dimensions without transporting large monolithic segments, as each layer is constructed in place through robotic extrusion and curing.
Solution Approach 2:
The robotic extrusion system replaces the mechanical system of transporting large base segments with in-situ construction through layer-by-layer material deposition. This substitution eliminates transportation difficulties associated with wide and heavy base segments while achieving the required structural stability through controlled extrusion and curing processes.
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
Enables safe, efficient, and cost-effective construction of very tall towers by eliminating human risks at high elevations and reducing material transportation costs, while achieving near-perfect geometry and orientation.
Implementation Method 1
The extrusion nozzle may controllably extrude uncured construction material
Implementation Method 2
uncured construction material
Data Source
AI summary
A robot may extrude a tower or column. The robot may include an extrusion nozzle, a positioning system, a climbing apparatus, and a controller. The extrusion nozzle may controllably extrude uncured construction material. The positioning system may controllably cause the extrusion nozzle to traverse a perimeter layer of the tower or column. A climbing apparatus may controllably cause the robot to climb. A controller may autonomously: direct the positioning system to cause the nozzle to traverse the perimeter layer of the tower or column; direct the nozzle to extrude uncured construction material during the traverse; direct the climbing apparatus to cause the robot to climb an incremental amount; and repeat each of the foregoing positioning, extrusion, and climbing steps until the extruded tower or column attains a desired height.