Welded Dome Assembly Using Cooling-Induced Angle Reduction
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Solution Overview
Problem
The existing methods for manufacturing domed containment vessels for power stations are time-consuming, expensive, and require significant space and favorable weather conditions due to the traditional forging and assembly processes of petal-like components.
Innovation Solution
A method involving a plurality of component pairs, where each pair consists of a first and second component with angled surfaces, joined by melting a volume of material that increases in thickness and solidifies to reduce the angle, allowing the components to form part of a dome, potentially using a filler material and involving advanced welding techniques like multi-pass welding and rotary taper friction welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional forging and assembly processes are used for petal components, then the dome structure is achieved, but the manufacturing process is time-consuming and expensive
Solution Approach 1:
The dome is divided into multiple pairs of components that can be manufactured separately and then assembled. Each component pair is designed to be joined through welding, allowing parallel manufacturing and reducing overall assembly time while maintaining structural integrity
Solution Approach 2:
The traditional mechanical assembly process is replaced with a welding-based joining system. The welding apparatus uses thermal energy to melt and fuse components together, eliminating the need for complex mechanical fastening systems and reducing assembly time
2Ease of manufacture
If traditional assembly processes are used, then the dome is constructed, but significant space on site is required
Solution Approach 1:
The dome structure is segmented into multiple smaller component pairs that can be manufactured off-site and transported to the installation location in compact forms. This reduces the on-site assembly space required while still achieving the final dome structure
Solution Approach 2:
Components are designed to nest together during assembly, with each component pair fitting into a compact configuration during transport and storage. The nested arrangement minimizes the space footprint on-site while maintaining the ability to assemble the complete dome structure
3Ease of manufacture
If traditional assembly methods are used, then the dome is assembled, but good weather conditions are required
Solution Approach 1:
The assembly process replaces weather-sensitive mechanical operations with welding, which can be performed in controlled environments or with protective shielding. The welding process is less affected by weather conditions such as wind, rain, or humidity, allowing assembly to proceed in a wider range of environmental conditions
4Shape
If components are joined with angled surfaces, then the dome geometry is achieved, but the angle must be precisely controlled during cooling
Solution Approach 1:
The joining process utilizes the phase transition of material during welding and cooling. By controlling the thermal cycle and the angle of the angled surfaces, the phase transition during cooling causes the material to contract and self-align, achieving the precise dome geometry without requiring extremely tight initial angular tolerances
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 method enables the rapid, cost-effective, and space-efficient construction of domes with minimal on-site requirements, allowing for the assembly of domed structures like containment vessels for power stations, reducing the need for scaffolding and crane payload, and enabling automation in the assembly process.
Implementation Method 1
melting a volume of material extending between the first body portion and the second body portion
Implementation Method 2
the volume of material cooling and solidifying so as to join the first component and the second component together
Implementation Method 3
the cooling of the volume of material reducing the angle between the first surface of the first body portion and the first surface of the second body portion to a second angle less than the first angle
Data Source
AI summary
Method of manufacturing a dome comprising: providing a plurality of components; joining a first and a second component together, joining the first and second components together comprising: positioning the first component and the second component in an initial position in which the first surfaces of components are angled from each other by a first angle; melting a volume of material extending between the first and the second component, the volume of material increasing in thickness from the second surfaces to the first surfaces; and the volume of material cooling and solidifying so as to join the first component and the second component together, the cooling of the volume of material reducing the angle between the first surfaces to a second angle less than the first angle such that the first surfaces face towards a centre of the dome and the first and second components form part of the dome.