Stacked 3D-Printed Wind Turbine Tower Sections for Taller Builds
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Solution Overview
Problem
Conventional methods for constructing wind turbine towers are limited by transportation regulations and require extensive labor, making it difficult to build taller towers efficiently.
Innovation Solution
A tower structure composed of additively manufactured, stacked sections with printed layers and lift connection elements, allowing for on-site construction using additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional methods form pre-cast concrete rings and ship them to site, then transportation is feasible within regulations, but tower height is limited to 4-5 meters diameter
Solution Approach 1:
The tower is divided into multiple stackable sections that are manufactured separately and assembled on-site. Each section can be produced in smaller, transportation-friendly dimensions while the final assembled tower achieves greater height. The segmentation allows compliance with transportation regulations (4-5 meter diameter limit) while enabling taller overall tower structures through vertical stacking.
2Length of stationary object
If arc segments are formed and secured together on site, then tower diameter requirements are met, but extensive labor and time are required
Solution Approach 1:
Tower sections are pre-manufactured with integrated connection elements (bolts, welds, or interlocking features) already in place during fabrication. This preliminary preparation of connection mechanisms eliminates the need for extensive on-site assembly work, reducing both labor requirements and construction time while maintaining the required tower diameter specifications.
3Length of stationary object
If additive manufacturing is used to erect towers on site, then transportation limitations are overcome, but manufacturing time and complexity increase
Solution Approach 1:
The additive manufacturing process is applied to create modular tower sections rather than attempting to print the entire tower in one continuous operation. This segmentation reduces the complexity of each individual printing operation, allows for easier quality control, and enables parallel manufacturing of multiple sections that are subsequently assembled on-site.
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 the construction of taller wind turbine towers with reduced labor and time, overcoming transportation limitations and improving manufacturing efficiency.
Implementation Method 1
at least one tower section of the plurality of stacked tower sections includes a wall element having one or more printed layers
Data Source
AI summary
The present disclosure is directed to embodiments of a tower structure with at least partially additively manufactured, stacked tower sections. Embodiments of the tower structure have a plurality of stacked tower sections, wherein at least one tower section of the plurality of stacked tower sections includes a wall element having one or more printed layers, and a base holding thereon the one or more printed layers. The present disclosure also is directed to a method of manufacturing a tower structure using a stacked tower sections and additive manufacturing. Embodiments of the method include forming a base of poured concrete or cast material, printing and depositing one or more printed layers to form a wall element, and stacking the plurality of tower sections to form the tower structure.