On-Site Additive Printing for Wind Turbine Tower Construction
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Solution Overview
Problem
Conventional manufacturing methods for wind turbine towers are limited by transportation regulations and require extensive labor and time, as they often involve shipping large pre-fabricated sections and on-site assembly, which can be time-consuming and labor-intensive, especially for larger turbines.
Innovation Solution
The use of an automated additive printing device mounted on an expandable vertical support structure that selectively deposits cementitious material to form wind turbine towers on-site, allowing for the construction of larger towers without the need for tall cranes and eliminating size restrictions, enabling the formation of towers with any desirable size and profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-fabricated concrete sections or steel tubes are formed off-site and shipped to the construction site, then the tower structure can be assembled using conventional methods, but transportation regulations limit the diameter to 4-5 meters and require extensive labor and time for on-site assembly
Solution Approach 1:
The patent replaces conventional mechanical assembly methods (shipping, bolting, welding) with an automated additive printing system that deposits cementitious material layer by layer to form the tower structure directly at the construction site, eliminating transportation constraints and reducing manual labor
Solution Approach 2:
The invention changes the manufacturing approach from forming complete sections off-site to additive deposition on-site, enabling towers of any diameter and profile without being constrained by transportation regulations that limit conventional methods to 4-5 meters diameter
2Adaptability or versatility
If arc segments are formed and secured together on site to form the tower diameter, then transportation limitations are overcome, but extensive labor and time are required for assembly via bolting and welding
Solution Approach 1:
The patent replaces manual bolting and welding operations with an automated robotic printing system that deposits and cures cementitious material in place, eliminating the need for extensive on-site assembly labor and significantly reducing construction time
Solution Approach 2:
The additive printing process continuously deposits material layer by layer to build the tower structure without interruption, whereas conventional methods require stopping for bolting and welding operations between segment assemblies
3Volume of moving object
If tower sections are made larger to accommodate bigger wind turbines, then power generation capacity increases, but conventional manufacturing methods are limited by transportation regulations prohibiting shipping of sections greater than 4-5 meters in diameter
Solution Approach 1:
The invention replaces off-site fabrication and shipping with on-site additive manufacturing, allowing towers of any size to be constructed directly at the location without being constrained by transportation regulations that limit conventional methods to 4-5 meters diameter
Solution Approach 2:
The patent transitions from horizontal transportation constraints to vertical construction by building the tower upward layer by layer at the construction site, effectively removing the diameter limitation imposed by road transportation capabilities
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 efficient construction of larger wind turbine towers with increased design flexibility, reducing manufacturing time and eliminating logistical constraints, while allowing for the creation of structures with unique shapes and sizes that were previously unfeasible with traditional methods.
Implementation Method 1
an additive printing device that selectively deposits material in a layer-by-layer manner to form the tower structure
Data Source
AI summary
An additive printing device and a method for using the same to manufacture a tower structure of a wind turbine is provided. The additive printing device includes a vertical support structure, a support ring suspended from the vertical support structure, and a printer head movably coupled to the support ring for selectively depositing cementitious material. A drive mechanism, such as a rack and pinion, moves the printer head around the support ring while selectively depositing cementitious material. The vertical support structure may be raised and/or the relative position between the vertical support structure and the printer head may be adjusted to raise the printer head to print subsequent layers. This process may be repeated to print the tower structure layer-by-layer from the ground up.