3D-Printed Tower Walls With Coiled Polymer Ring Reinforcement
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Solution Overview
Problem
Existing methods for manufacturing wind turbine towers face challenges due to the large size of conventional steel rings, which require shipment in segments and subsequent on-site assembly, leading to labor-intensive and time-consuming processes.
Innovation Solution
The method involves additively manufacturing tower structures using a pultruded polymer material for reinforcement, where a continuous roll of reinforcement material is unwound and formed into a continuous reinforcement ring member, which is then placed atop printed layers of the tower structure and further reinforced with additional printed layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional steel rings are used for reinforcing tower structures, then structural strength is provided, but the large size requires shipment in segments and on-site assembly, increasing labor and time
Solution Approach 1:
The patent segments the reinforcement structure into discrete rings that can be manufactured separately and assembled efficiently. Each ring is formed from continuous pultruded polymer material but is produced as an independent component, allowing for streamlined manufacturing and reduced on-site assembly complexity
Solution Approach 2:
The patent changes the material parameter from conventional steel to pultruded polymer material, which maintains structural strength while enabling different manufacturing approaches. This material parameter change allows for continuous production methods and reduces the need for complex segmented assembly
2Length of moving object
If conventional steel rings are shipped in segments, then transportation regulations are satisfied, but extensive on-site assembly labor is required
Solution Approach 1:
The reinforcement structure is divided into manageable ring segments that can be transported efficiently while minimizing on-site assembly requirements. Each ring is a discrete unit that can be handled and installed with reduced labor complexity
Solution Approach 2:
The rings are pre-manufactured with precise dimensions and structural properties before shipment. The pultrusion process creates consistently formed rings that require minimal on-site adjustment or assembly work, transferring the manufacturing precision to the factory setting
3Adaptability or versatility
If tower structures are additively manufactured with large diameter sections, then design flexibility is improved, but transportation regulations limit the maximum diameter to 4-5 meters
Solution Approach 1:
The tower structure is divided into multiple sections that can be additively manufactured separately within transportation size limits. Each section can be produced with optimized dimensions for manufacturing and transport, then assembled to create the complete tower structure
Solution Approach 2:
The patent transitions from horizontal/vertical assembly to radial assembly by forming complete circular rings. This dimensional approach allows the tower to achieve large overall diameters through the assembly of circular cross-sections rather than through linear section joining
4Strength
If steel reinforcement material is used, then structural strength is achieved, but corrosion resistance is reduced
Solution Approach 1:
The patent changes the material composition parameter from steel to pultruded polymer material. This material substitution maintains the required structural strength while providing inherent corrosion resistance, improving the reliability of the reinforcement system in harsh environments
Solution Approach 2:
The use of pultruded polymer material represents a composite material approach that combines reinforcement fibers with polymer matrix to achieve both strength and corrosion resistance. This composite material properties the reinforcement to resist environmental degradation while maintaining structural integrity
Data Source
AI summary
A method of manufacturing a tower structure includes printing and depositing, via a printhead assembly of an additive printing system, one or more printed layers of a wall of the tower structure. The method also includes unwinding at least one continuous roll of a reinforcement material to form at least one continuous reinforcement ring member layer, the reinforcement material comprising a pultruded polymer material. Further, the method includes placing the at least one continuous reinforcement ring member layer atop the one or more printed layers of the wall of the tower structure. Moreover, the method includes printing and depositing, via the printhead assembly of the additive printing system, one or more additional printed layers of the wall of the tower structure atop the at least one continuous reinforcement ring member layer.