Precast Concrete Wind Tower Segment Formwork with Removable Anchors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of precast concrete segments for wind turbine towers is inefficient due to the need for complex and costly methods to securely fasten built-in parts like ladders and cable holders without compromising the structural integrity of the tower.
Innovation Solution
A method involving an inner formwork with pre-drilled holes and integrated holding units that allow for the secure placement and removal of concrete anchors, enabling efficient assembly and disassembly, with removable elements that can be screwed into the anchors for attaching additional parts, ensuring stability and ease of production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to fasten built-in parts to concrete segments, then the structural integrity is maintained, but the production process becomes complex and costly
Solution Approach 1:
The holding units are pre-installed on the inner formwork before concrete pouring, and concrete anchors are pre-positioned in these holding units. This preliminary arrangement eliminates the need for complex post-pouring fastening operations, reducing both production cost and method complexity while maintaining structural integrity.
Solution Approach 2:
The holding units serve as intermediary components between the inner formwork and the concrete anchors. These intermediaries simplify the fastening process by providing a standardized interface that automatically positions and secures the anchors, eliminating the need for complex drilling and fastening operations after concrete hardening.
2Productivity
If multiple people are required for assembly operations, then structural integrity is ensured, but productivity decreases
Solution Approach 1:
The holding units are designed to automatically guide and secure the concrete anchors through their inherent structure (e.g., resilient elements that deflect and lock). The system serves itself by automatically positioning and fixing the anchors without requiring manual alignment or multiple operators, thereby increasing productivity while maintaining reliability through the self-locking mechanism.
3Ease of operation
If the inner formwork is permanently fixed, then structural integrity is maintained, but ease of operation decreases
Solution Approach 1:
The connection between the inner formwork and the concrete structure is segmented into removable components (holding units with concrete anchors) rather than being permanent. This segmentation allows the formwork to be easily removed after concrete hardening while maintaining stability during the pouring and curing process, as the anchors provide temporary but secure fixation.
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 reduces production costs and simplifies the assembly process by allowing one-person operation, maintaining structural integrity while enabling easy removal of the inner formwork and facilitating the attachment of built-in parts, thus enhancing the efficiency and cost-effectiveness of producing precast concrete segments.
Implementation Method 1
The holding unit has a resilience when inserting the removable element and a locking in the opposite direction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for producing a precast concrete tower segment of a wind turbine tower is provided. An inner formwork (220) with at least one bore (240) and at least one holding unit (400) on an inner side of the inner formwork (220) in the region of the bore (240) is placed. A first end (310) of a concrete anchor (300) or a first end (310) of a removable element (410) at the first end (310) of the concrete anchor (300) is introduced from the outer side of the inner formwork (220) through the bore (240) into the holding unit (400) to hold the concrete anchor (300). An outer formwork (210) is placed. Concrete is introduced between the inner and outer formwork (220, 210). The removable element (410) in the first end (310) or the first end (310) of the concrete anchor (300) is removed and the precast concrete segment is removed.