Variable-Width Deposition Nozzle for Tower Wall Element Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing wind turbine towers are limited by transportation regulations, requiring extensive labor and being time-consuming, especially as tower heights increase.
Innovation Solution
The method involves using an additive manufacturing process with a printhead assembly and variable-width deposition nozzles to print and deposit layers of wall elements for the tower structure, forming voids, and placing reinforcement members within these voids to position them closer to the neutral axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manufacturing methods (pre-cast concrete rings or steel tubes) are used, then transportation is possible within regulatory limits, but extensive labor and time are required for assembly
Solution Approach 1:
The patent replaces manual labor and mechanical assembly operations with an automated additive manufacturing system. The printhead assembly with variable-width deposition nozzles automatically deposits concrete layers to form tower sections, eliminating the need for manual handling, positioning, and securing of pre-cast rings. This substitution of mechanical assembly with automated deposition directly addresses the labor and time requirements.
Solution Approach 2:
The patent changes the manufacturing process parameters from discrete assembly of pre-fabricated sections to continuous additive deposition. By controlling the deposition rate, layer thickness, and nozzle movement speed, the system achieves rapid tower section formation. The variable-width deposition capability allows dynamic parameter adjustment during printing, optimizing both productivity and structural quality.
2Length of stationary object
If tower diameter is increased to accommodate taller towers, then height capability is improved, but transportation is prohibited by regulations
Solution Approach 1:
The patent divides the tower structure into multiple printable sections that are manufactured separately and then assembled vertically. Each section can be printed with optimized dimensions suitable for on-site construction, avoiding transportation constraints. The segmentation allows the tower to achieve greater overall height while each individual component remains within manageable size limits for local manufacturing.
Solution Approach 2:
The patent transitions from horizontal transportation of large-diameter sections to vertical construction through additive manufacturing. By building towers upward layer-by-layer at the installation site rather than transporting complete or large sections horizontally, the system overcomes transportation diameter limitations while achieving greater heights.
3Strength
If reinforcement members are placed closer to the outer surface for simplicity, then placement is easier, but load distribution is suboptimal
Solution Approach 1:
The patent incorporates reinforcement member placement into the additive manufacturing process itself. The variable-width deposition nozzles can create forms and channels within the concrete layers, and reinforcement members are positioned during the printing process rather than requiring subsequent manual installation. This preliminary action ensures optimal positioning while simplifying the overall manufacturing workflow.
Solution Approach 2:
The patent merges the concrete deposition and reinforcement placement operations into a single integrated process. The additive manufacturing system simultaneously deposits concrete and positions reinforcement members within the wall elements, combining two previously separate operations. This integration optimizes load distribution through precise reinforcement positioning while reducing the overall complexity of the manufacturing process.
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 allows for efficient on-site manufacturing of tower structures with improved load distribution, reducing labor and time requirements while overcoming transportation limitations.
Implementation Method 1
printing and depositing, with at least one variable-width deposition nozzle of a printhead assembly, one or more layers of at least one wall element of the tower structure
Data Source
AI summary
A method for manufacturing a tower structure, the method including printing and depositing, with at least one variable-width deposition nozzle of a printhead assembly, one or more layers of at least one wall element of the tower structure, the at least one wall element having an outer circumferential surface and an inner circumferential surface. The method also including forming, with the at least one variable-width deposition nozzle, at least one void into the at least one wall element. The method also including placing at least one reinforcement member within the at least one void so as to position the at least one reinforcement member closer to a neutral axis of the at least one wall element than at least one of the outer circumferential surface or the inner circumferential surface.