Method of constructing a tower

Patent metadata

Field	Value
Publication number	US-11021887-B2
Application number	US-201615182656-A
Country	US
Kind code	B2
Filing date	Jun 15, 2016
Priority date	Jul 13, 2015
Publication date	Jun 1, 2021
Grant date	Jun 1, 2021

Abstract

A method of constructing a tower is provided, the method including the steps of providing an elevation mechanism including a dynamic engaging mechanism realized to engage with a tower surface, arranging a 3D printing device on the elevation means, actuating the dynamic engaging mechanism to effect a vertical elevation of the elevation mechanism, actuating the 3D printing device to deposit an essentially horizontal material layer including at least a tower body region, and repeating the steps to obtain a tower structure. A tower constructed using such a method, and a 3D tower printing apparatus, is also provided.

First claim

The invention claimed is:

1. A method of constructing a concrete tower, the method comprising:
A: providing an elevation means comprising a dynamic engaging mechanism configured to engage with a tower surface;
B: arranging a 3D printing device on the elevation means, the 3D printing device including a robot configured to dispense a fluid concrete from a feed head, the fluid concrete being pumped to the 3D printing device, the robot being an industrial concrete printing robot having a swivel base mounted on a platform of the elevation means and an articulated robot arm that moves radially with respect to the swivel base of the robot to reach a circumference of the concrete tower;
C: actuating the dynamic engaging mechanism to effect a vertical elevation of the elevation means upwardly through a central opening within the concrete tower such that the dynamic engaging mechanism is surrounded by the tower surface that faces towards a central axis of the concrete tower;
D: actuating the 3D printing device to deposit an essentially horizontal material layer of the fluid concrete along the circumference of the concrete tower to form at least a tower body region without using a slipform;
E: adjusting the dynamic engaging mechanism in a radial direction to accommodate for changes in a diameter of the central opening of the concrete tower; and
F: repeating steps C-E to obtain a tower structure.

2. The method according to claim 1 , comprising the step of actuating the 3D printing device to deposit a number of climbing structure regions, wherein a climbing structure region of the number of climbing structure regions is shaped to complement the dynamic engaging mechanism of the elevation means, to obtain a tower structure incorporating a climbing structure that engages with the dynamic engaging mechanism of the elevation means.

3. The method according to claim 1 , wherein a climbing structure is formed to extend at least partially into a body of the tower structure and/or to extend at least partially beyond the body of the tower structure and/or to extend into a tower interior.

4. The method according to claim 1 , wherein the dynamic engaging mechanism of the elevation means comprises a number of toothed wheels, and wherein a climbing structure is formed to comprise at least one toothed rack to engage with a toothed wheel of the number of toothed wheels.

5. The method according to claim 1 , wherein the elevation means comprises a plurality of vertically arranged toothed wheels, and a climbing structure comprises a corresponding number of vertical toothed racks.

6. The method according to claim 1 , wherein a climbing structure comprises a plurality of helical screw threads to accommodate a corresponding number of climbing wheels of the elevation means.

7. The method according to claim 1 , comprising the step of actuating the elevation means to raise the platform at a rate corresponding to a hardening time of a previously applied material layer.

8. The method according to claim 1 , wherein adjusting the dynamic engaging mechanism in the radial direction includes hydraulically extending a portion of the dynamic engaging mechanism towards the tower surface as the diameter of the central opening increases.

9. The method according to claim 1 , wherein adjusting the dynamic engaging mechanism in the radial direction includes hydraulically retracting a portion of the dynamic engaging mechanism as the diameter of the central opening decreases.

10. A 3D tower printing apparatus comprising:
an elevation means comprising a dynamic engaging mechanism configured to engage with a tower surface;
an elevation controller for actuating the dynamic engaging mechanism to effect a vertical elevation of the elevation means upwardly through a central opening within the concrete tower such that the dynamic engaging mechanism is surrounded by the tower surface that faces towards a central axis of the concrete tower;
a 3D printing device arranged on the elevation means, the 3D printing device including a robot configured to dispense a fluid concrete from a feed head, the fluid concrete being pumped to the 3D printing device, the robot being an industrial concrete printing robot having a swivel base mounted on a platform of the elevation means and an articulated robot arm that moves radially with respect to the swivel base of the robot to reach a circumference of the concrete tower;
a print controller for actuating the 3D printing device to deposit material in a series of essentially horizontal layers without using a slipform, each layer comprising at least a tower body region to obtain a tower structure; and
an adjustment arrangement for adjusting the dynamic engaging mechanism in a radial direction to accommodate for changes in a diameter of the central opening of the concrete tower.

11. The apparatus according to claim 10 , wherein the dynamic engaging mechanism of the elevation means comprises a plurality of wheels, and wherein the print controller is configured to control the 3D printing device to print a plurality of climbing structure regions, wherein the plurality of climbing structure regions are shaped to complement a wheel.

12. The apparatus according to claim 10 , wherein the dynamic engaging mechanism of the elevation means comprises a stemming arrangement configured to apply opposing pressure on an interior tower surface.

13. The apparatus according to claim 12 , wherein the stemming arrangement comprises at least one star configuration of stemming arms.

14. The apparatus according to claim 10 , wherein the elevation means comprises a hydraulic drive system.

15. The apparatus according to claim 10 , wherein the feed head is configured to dispense the fluid concrete in response to a print instruction from the print controller.

16. The apparatus according to claim 10 , comprising a mixing and pumping apparatus to mix the fluid concrete and to pump the fluid concrete to the 3D printing device, and a controller configured to adjust a fluid concrete composition and a pumping pressure according to a height above ground of the 3D printing device.

Assignees

• Siemens Gamesa Renewable Energy As
• Kuka Roboter Gmbh

Inventors

• Keller Henrik
• Kuth Rainer
• Mewes Philip

Classifications

• E04H12/341 Primary

  Arrangements for casting in situ concrete towers or the like · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• E04G21/0427

  on a static support, e.g. crane · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• E04G21/0436

  on a mobile support, e.g. truck · CPC title