Slotted Beam Lattice Dome Assembly for Faster On-Site Construction
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Solution Overview
Problem
The existing methods for manufacturing domes, such as those used in power station reactors, are time-consuming, expensive, and require significant space and good weather conditions for assembly, as they involve forging or fabricating petals off-site and craning them into position.
Innovation Solution
A method involving beams with angled slots and curved flanges, where curvature is induced by weld build-up or rolling, allowing for on-site assembly of a dome using a lattice structure with hexagonal, triangular, or rectangular arrangements, and incorporating exterior and interior skins with voids filled with solid mass or insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If domes are forged or fabricated from forged petals off-site and craned into position, then structural integrity is ensured, but the manufacturing process becomes time-consuming and expensive
Solution Approach 1:
The dome is divided into multiple beam segments with slots that can be assembled on-site. Each beam can be manufactured separately and then connected through slot engagement, allowing parallel manufacturing and faster assembly while maintaining structural integrity through the lattice configuration
Solution Approach 2:
Slots are pre-formed in the beams during manufacturing, and curvature is induced in flanges through weld build-up or rolling before assembly. This preliminary preparation enables rapid on-site connection without requiring complex field operations, speeding up the overall manufacturing process
2Strength
If domes are assembled using traditional forging methods, then structural strength is achieved, but significant space on site is required
Solution Approach 1:
The dome structure is segmented into multiple beams that can be manufactured off-site and transported in compact form. The lattice configuration allows these segments to be assembled in a relatively small on-site area compared to traditional methods requiring large forging spaces
Solution Approach 2:
The slot connections allow beams to interlock and nest together, with the lattice structure enabling compact arrangement during assembly. The curved flanges engage with slots to create a space-efficient configuration that minimizes on-site space requirements
3Reliability
If traditional dome assembly methods are used, then proper assembly is achieved, but good weather conditions are required
Solution Approach 1:
Critical assembly features such as slots and curved flanges are prepared during off-site manufacturing. This preliminary action allows on-site assembly to proceed with simple connection operations that are less sensitive to weather conditions, enabling work to continue in conditions that would prevent traditional assembly methods
Solution Approach 2:
The segmented beam structure with standardized slot connections creates a modular assembly process that can be performed in smaller, more manageable steps. This segmentation allows assembly operations to be completed more quickly and with less exposure to adverse weather conditions
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
Facilitates faster, cost-effective, and space-efficient on-site assembly of domes with enhanced structural integrity and functionality for power stations, enabling efficient use of space and improved assembly conditions.
Implementation Method 1
Cooling of the weld may induce the curvature in the web and/or the flange
Data Source
Figure 1
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AI summary
There is described a method of manufacturing a dome (2), the method comprising: providing a plurality of beams (6, 106, 206, 306), each of the plurality of beams (6, 106, 206, 306) comprising one or more slots (16, 22); and engaging at least one of the slots (16, 22) of each of the plurality of beams (6, 106, 206, 306) with a slot (16, 22) of the one or more slots (16, 22) of another of the plurality of beams (6, 106, 206, 306) so as to form at least part of the dome (2). There is also described a dome (2) manufactured in accordance with the method.