Additive Tower Wall Elements with Reinforced Recesses
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Solution Overview
Problem
Conventional methods for manufacturing wind turbine towers are limited by transportation regulations and require extensive labor and time, as they often involve shipping large pre-fabricated sections that need to be assembled on-site, which can be inefficient and costly.
Innovation Solution
The method involves additively manufacturing tower structures using an automated additive printing device that deposits layers of a wall element with a printhead assembly, incorporating reinforcing elements within recesses defined by the wall element to distribute compressive forces evenly, allowing for on-site construction of taller towers with reduced labor and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional pre-fabricated sections are shipped and assembled on-site, then transportation regulations are satisfied, but manufacturing time and labor requirements increase significantly
Solution Approach 1:
The tower is divided into multiple wall elements that are printed separately and then assembled on-site. Each wall element is a self-contained segment that can be manufactured independently using the additive printing device, allowing for modular construction that reduces overall manufacturing time while maintaining ease of assembly through standardized interfaces
Solution Approach 2:
Wall elements are pre-manufactured off-site using automated additive printing technology before being transported to the installation location. This preliminary manufacturing action allows complex structural components to be produced in a controlled environment with precise reinforcement placement, reducing on-site assembly time and labor requirements
2Length of moving object
If tower height is increased, then wind power generation capacity improves, but transportation regulations prevent shipping of sections with diameter greater than 4-5 meters
Solution Approach 1:
The tower structure is segmented into multiple wall elements with dimensions suitable for transportation. Each wall element can be shipped within regulatory size limits while collectively forming a taller tower structure when assembled on-site, thus achieving greater tower height without violating transportation constraints
Solution Approach 2:
The invention transitions from horizontal/vertical assembly of large-diameter sections to radial assembly of wall elements around a central axis. This dimensional approach allows the tower to achieve greater height by stacking multiple transportable wall elements rather than shipping single large sections
3Adaptability or versatility
If arc segments are formed and secured together on-site, then transportation size limitations are overcome, but extensive labor and time are required for assembly
Solution Approach 1:
Wall elements are pre-manufactured with embedded reinforcement structures and precise geometric features before transportation. This preliminary action ensures that on-site assembly requires minimal additional reinforcement work and can proceed rapidly through simple mechanical connection of pre-prepared components
Solution Approach 2:
The additive manufacturing process automatically integrates reinforcement elements within the wall elements during production. The system self-configures the reinforcement placement and structural integrity features, eliminating the need for extensive manual reinforcement work during on-site assembly and thereby increasing assembly speed
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 the efficient construction of taller wind turbine towers by distributing compressive forces evenly, reducing the need for additional reinforcing elements and minimizing the complexity and cost of the tower structure, while allowing for faster and more precise on-site manufacturing.
Implementation Method 1
depositing one or more layers of a wall element with a printhead assembly
Implementation Method 2
incorporating reinforcing elements within recesses defined by the wall element to distribute compressive forces evenly
Data Source
AI summary
A system and method are provided for manufacturing a tower structure. Accordingly, one or more layers of a wall element are deposited with a printhead assembly. At least one recess is defined in the wall element. The recess(es) has a single, circumferential opening positioned along an inner reference curve or an outer reference curve of the wall element. The recess(es) also has a depth which extends in a radial direction and intersects a midline reference curve. A reinforcing element is placed entirely within the recess(es) at the midline reference curve.