Method for manufacturing a wind turbine tower structure based on wind direction

Abstract

A method for manufacturing a tower structure of a wind turbine at a wind turbine site. The method comprises determining an optimized shape of the tower structure based on one or more site parameters. Furthermore, the optimized shape of the tower structure is asymmetric. In a further step, the method comprises printing the optimized shape of the tower structure of the wind turbine at least partially from a cementitious material via an additive printing device at the wind turbine site. In addition, the method comprises allowing the cementitious material to cure so as to form the tower structure of the wind turbine.

Description

Technical Field

[0001] This disclosure generally relates to wind turbines, and more particularly to a method for additive manufacturing a wind turbine tower structure optimized for the prevailing wind direction at the wind turbine. Background Technology

[0002] Wind power is considered one of the cleanest and most environmentally friendly energy sources available today, and wind turbines have received increasing attention in this regard. A modern wind turbine typically consists of a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades use the known airfoil principle to capture the kinetic energy of the wind. The rotor blades transfer this kinetic energy as rotational energy, enabling the shaft that connects the rotor blades to the gearbox or, in the absence of a gearbox, directly to the generator to rotate. The generator then converts this mechanical energy into electrical energy that can be deployed to the public power grid.

[0003] Wind turbine towers are generally constructed from steel pipes, prefabricated concrete sections, or a combination thereof. Furthermore, the pipes and / or concrete sections are typically formed off-site, transported to the site, and then arranged together to erect the tower. For example, one manufacturing method includes: forming precast concrete rings; transporting the rings to the site; arranging the rings one above the other; and then securing the rings together. However, as wind turbines continue to increase in size, conventional manufacturing methods are restricted by regulations prohibiting the transport of tower sections with diameters greater than approximately 4 to 5 meters. Therefore, some tower manufacturing methods involve forming multiple curved segments and securing them together on-site, for example, by bolting, to form the tower's diameter. However, such methods require a large labor force and can be time-consuming.

[0004] Furthermore, typical wind turbine towers are symmetrical to support the various aerodynamic forces acting on the wind turbine (e.g., rotor blades) from all directions. However, individual wind turbines are generally oriented towards the prevailing wind direction. Consequently, the aerodynamic forces acting on a single wind turbine generally load the tower in the direction of the prevailing wind direction. Therefore, symmetrical towers may unnecessarily support the wind turbine relative to loads perpendicular to the prevailing wind direction. Additionally, symmetrical towers may include unnecessary support structures and / or support materials that can increase their weight and cost.

[0005] In view of the foregoing, there has been a search in the art for improved methods for manufacturing wind turbine towers. Therefore, this disclosure relates to a method for manufacturing wind turbine tower structures that addresses the aforementioned problems. In particular, this disclosure relates to a method for manufacturing wind turbine tower structures optimized for prevailing wind directions. Summary of the Invention

[0006] Aspects and advantages of the invention will be set forth in part in the description which follows, or may be apparent from the description, or may be learned by practice of the invention.

[0007] In one aspect, this disclosure relates to a method for manufacturing a tower structure of a wind turbine at a wind turbine site. The method includes determining an optimized shape of the tower structure based on one or more site parameters. Furthermore, the optimized shape of the tower structure is asymmetrical. In a further step, the method includes printing the optimized shape of the wind turbine tower structure at least partially from a cementitious material at the wind turbine site via an additive printing apparatus. Additionally, the method includes allowing the cementitious material to cure in order to form the tower structure of the wind turbine.

[0008] In one embodiment, the field parameters may include the dominant wind direction. In such an embodiment, the method may include determining the dominant wind direction at the wind turbine site. In another embodiment, determining the dominant wind direction may further include monitoring one or more wind parameters at the wind turbine via one or more sensors. In such an embodiment, the dominant wind direction may be determined via a controller communicatively coupled to one or more sensors. Accordingly, the dominant wind direction of the wind turbine may be determined based on the monitored wind parameters.

[0009] In an additional embodiment, the portion of the optimized shape of the tower structure aligned with the prevailing wind direction may be thicker than the portion of the optimized shape offset from the prevailing wind direction. In another embodiment, the optimized shape of the tower structure may define a cross-sectional shape including at least one of an I-beam cross-section, a box girder cross-section, or an elliptical cross-section. In one such embodiment, the elliptical cross-section may define a longitudinal axis aligned with the prevailing wind direction. In yet another embodiment, the method may include printing one or more reinforcing members onto the inner surface of the tower structure via an additive printing apparatus to form the optimized shape.

[0010] In one particular embodiment, the method may include providing one or more molds on the foundation of the wind turbine. In such an embodiment, the method may further include forming an optimized shape of the wind turbine tower structure within one or more molds via an additive printing apparatus. In another such embodiment, the method may further include printing one or more molds via an additive printing apparatus. In yet another embodiment, during printing, the method may further include embedding one or more reinforcing elements at least partially within the cementitious material of the tower structure at one or more locations.

[0011] On the other hand, this disclosure relates to a method for manufacturing a tower structure for a wind turbine at a wind turbine site. The method includes determining the dominant wind direction at the wind turbine site. Additionally, the method includes determining an optimized shape of the tower structure based on the dominant wind direction. Furthermore, the optimized shape of the tower structure is asymmetrical. The method also includes printing one or more molds onto the foundation of the wind turbine via an additive printing apparatus. Furthermore, the one or more molds define the optimized shape of the tower structure. Another step of the method includes filling one or more molds at least partially with a cementitious material. The method further includes curing the cementitious material within the one or more molds to form the tower structure.

[0012] In one embodiment, filling one or more molds with cementitious material may further include printing the cementitious material within the one or more molds via an additive printing apparatus. Printing the cementitious material within the one or more molds may further include stacking the cementitious material of the tower structure in multiple passes via the additive printing apparatus. In another embodiment, filling one or more molds with cementitious material may further include dispensing the cementitious material into the one or more molds via a nozzle of the additive printing apparatus. In yet another embodiment, the optimized shape of the tower structure may define one or more reinforcing members on the inner surface of the tower structure to form the optimized shape. It should be understood that the method may further include any of the additional features described herein.

[0013] In another aspect, this disclosure relates to a method for manufacturing a tower structure for a wind turbine at a wind turbine site. The method includes determining the dominant wind direction at the wind turbine site. Additionally, the method includes determining an optimized shape of the tower structure based on the dominant wind direction. Furthermore, the optimized shape of the tower structure is asymmetrical. In a further step, the method includes optimizing the shape of the tower structure at the wind turbine site, which is at least partially formed of a cementitious material. It should be understood that the method may further include any of the additional features described herein.

[0014] These and other features, aspects, and advantages of the invention will become more readily understood with reference to the following description and the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. Attached Figure Description

[0015] The invention (including its preferred mode) is fully disclosed and can be practiced by one of ordinary skill in the art in the description with reference to the accompanying drawings, in which: Figure 1 The figure is a perspective view of one embodiment of a wind turbine according to the present disclosure; Figure 2The figure shows a partial cross-sectional view of an embodiment of a tower structure for a wind turbine manufactured using an additive printing apparatus according to the present disclosure. Figure 3 The illustration shows an embodiment of a tower structure according to aspects of the present disclosure, particularly illustrating a cross-section of an optimized tower structure including a portion aligned with the main wind direction that is thicker than the portion offset from the main wind direction. Figure 4 The illustration shows another embodiment of the tower structure according to aspects of the present disclosure, particularly illustrating the cross-section of an optimized tower structure including the cross-section of an I-beam within the tower structure; Figure 5 The illustration shows another embodiment of the tower structure according to aspects of the present disclosure, particularly illustrating the cross-section of an optimized tower structure including the cross-section of a box beam within the tower structure; Figure 6 The illustration shows another embodiment of the tower structure according to aspects of the present disclosure, particularly illustrating a cross-section of an optimized tower structure including beams configured in an X-shaped pattern. Figure 7 The illustration shows another embodiment of the tower structure according to aspects of the present disclosure, particularly illustrating a cross-section of an optimized tower structure including one or more reinforcing components; Figure 8 The illustration shows another embodiment of the tower structure according to aspects of the present disclosure, particularly illustrating a cross-section of the tower structure configured with an elliptical cross-section; Figure 9 A flowchart depicting an embodiment of a method for manufacturing a tower structure for a wind turbine at a wind turbine site, according to aspects of this subject matter; Figure 10 The figure is a schematic diagram of an embodiment of an additive printing apparatus according to the present disclosure; Figure 11 A flowchart depicting another embodiment of a method for manufacturing a tower structure for a wind turbine at a wind turbine site, according to aspects of this subject matter; and Figure 12 The figure shows a block diagram of one embodiment of the controller according to the present disclosure. Detailed Implementation

[0016] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The various examples are provided by way of explanation rather than limitation of the invention. Indeed, it will be apparent to those skilled in the art that many modifications and variations can be made to the invention without departing from its scope or spirit. For example, a feature illustrated or described as part of one embodiment may be used with another embodiment to produce yet another embodiment. Therefore, it is intended that the invention cover such modifications and variations as fall within the scope of the appended claims and their equivalents.

[0017] Generally, this disclosure relates to methods for manufacturing wind turbine towers, including tower structures with shapes optimized for prevailing wind directions. Such methods include the automated deposition of cementitious materials via techniques such as additive manufacturing, 3D printing, spray deposition, extrusion additive manufacturing, concrete printing, automated fiber deposition, and other techniques utilizing computer numerical control and multiple degrees of freedom to deposit materials. More specifically, the methods of this disclosure include printing and / or embedding cementitious materials into shapes optimized for prevailing wind directions. Thus, in several embodiments, the shape of the tower structure may include thicker portions oriented along the prevailing wind direction, such as I-beams and / or box beams oriented along the prevailing wind direction, elliptical portions oriented along the prevailing wind direction, optimized cross-sectional shapes oriented along the prevailing wind direction, one or more reinforcing members located on the inner surface of the tower structure along the prevailing wind direction, and / or any other suitable optimized shapes.

[0018] Therefore, the method described herein offers many advantages not found in existing technologies. For example, the optimized shape of the tower structure can be configured to compensate for loads along the prevailing wind direction that are larger compared to other orientations (e.g., perpendicular to the prevailing wind direction). By optimizing the shape of the tower structure, it can be manufactured using less overall material, thus saving costs while still meeting the load requirements on the wind turbine. Furthermore, by determining the prevailing wind direction at the tower site and printing the tower structure there, the tower structure can be optimized for the prevailing wind direction at the tower site. It should be recognized that printing the tower structure at the tower site reduces labor and transportation costs associated with prefabricated tower structure components.

[0019] Now refer to the attached diagram, Figure 1 The figure shows a perspective view of one embodiment of a wind turbine 10 located at a wind turbine site 11 according to this disclosure. As shown, the wind turbine 10 includes a tower 12 (also referred to herein as a tower structure) extending from a foundation 15 or a supporting surface, wherein a nacelle 14 is mounted on top of the tower 12. A plurality of rotor blades 16 are mounted to a rotor hub 18, which is then connected to a main flange that rotates the main rotor shaft. Wind turbine power generation and control components are housed within the nacelle 14. Figure 1 The views provided are for illustrative purposes only to place the invention within exemplary fields of use. It should be understood that the invention is not limited to any particular type of wind turbine construction. Furthermore, the invention is not limited to use with wind turbine towers, but can be utilized in any application other than wind turbine towers that has a concrete construction and / or a tall tower (including, for example, residential buildings, bridges, tall towers, and other aspects of the concrete industry). Moreover, the methods described herein are also applicable to the manufacture of any similar structures that benefit from the advantages described herein.

[0020] As in Figure 1 As further illustrated, the wind turbine 10 may be oriented based on one or more site parameters. For example, the site parameters may include the elevation and / or topography at the wind turbine site 10. The site parameters may also include wind speed, wind direction, and / or wind shear at the wind turbine site 11. Specifically, in several embodiments, the wind turbine 10 may be oriented towards the prevailing wind direction 13 at the wind turbine site 11. For example, the rotor 18 (e.g., rotor blades 16) may be oriented towards the prevailing wind direction 13 to efficiently convert the kinetic energy of the wind into mechanical energy, for example, to drive the main rotor shaft. Furthermore, the wind turbine 10 may be oriented towards the prevailing wind direction 13 based on historical data. More specifically, historical data indicating real-time wind direction may be used to determine the prevailing wind direction 13. For example, a wind direction distribution spectrum may be used to determine the prevailing wind direction 13 before construction of the tower 12 begins.

[0021] In some cases, the prevailing wind direction 13 at the wind turbine site 11 may be unknown. Therefore, it may be necessary to determine the prevailing wind direction 13. Consequently, as shown, the wind turbine 10 may include a controller 44 configured to determine the prevailing wind direction 13. Additionally, as shown, the wind turbine 10 may include one or more sensors 19 communicatively coupled to the controller 44 for monitoring one or more wind parameters at the wind turbine site 11. In some embodiments, the sensors 19 may be positioned on a mast or column to determine the prevailing wind direction 13 along the height of the tower 12.

[0022] Therefore, controller 44 is configured to receive sensor signals from sensor(s) ...

[0023] Now for reference Figure 2 An embodiment of the tower structure 12 is illustrated according to aspects of this disclosure. Specifically, Figure 2 The illustration shows a partial cross-sectional view of one embodiment of the tower structure 12 of a wind turbine 10. As shown, the illustrated tower 12 defines a tower wall 20 having an outer surface 22 and an inner surface 24. Furthermore, as shown, the tower wall 20 generally defines a hollow interior 26 typically used to accommodate various turbine components (e.g., power converters, transformers, etc.). Additionally, as will be described in more detail below, the tower structure 12 can be formed at least partially using additive manufacturing. Furthermore, as shown, the tower structure 12 is at least partially formed of a cementitious material 28. Additionally, the tower structure 12 can define an optimized shape 17, such as, as described below regarding... Figure 3-8 The tower structure 12 can have any shape as described. Furthermore, the tower structure 12 may have a variable, optimized shape along its height. For example, the tower structure may include [various features] at different locations along its height. Figure 3-8 Two or more of the optimized shapes in shape 17.

[0024] Furthermore, in some embodiments, the tower structure 12 may also include one or more reinforcing elements 30. In specific embodiments, the reinforcing elements 30 may include, for example, one or more reinforcing sensors, elongated cables or wires, helical cables or wires, reinforcing ribs (also known as steel bars) (hollow or solid), reinforcing fibers (metal or polymer), reinforcing metal rings (circular, oval, helical, and other shapes as may be associated) or connectors, mesh, and / or any such structures known in the art for reinforcing concrete structures. For example, as Figure 2 As shown, the tower structure 12 includes helical cables 33 embedded in a cementitious material 28 and a plurality of pre-tensioned linear cables 35. Additionally, as used herein, the cementitious material 28 may include any suitable feasible paste configured to bond together after curing to form the structure. Suitable cementitious materials include, for example, concrete, bitumen resin, asphalt, clay, cement, cementitious components, or the like.

[0025] Now for reference Figure 3-8 The tower is illustrated according to aspects of this subject (such as, Figure 1 Several cross-sections of several embodiments of the tower structure 12 (tower 12). As shown, the tower structure 12 defines a tower wall 20, which defines the external shape of the tower 12 (see, for example...). Figure 1More specifically, as illustrated, the tower wall 20 of the illustrated embodiment is defined by an optimized shape 17 based on one or more site parameters such as the prevailing wind direction 13. Furthermore, as illustrated, the optimized shape 17 of the tower structure 12 is asymmetrical. For example, in some embodiments, the optimized shape 17 of the tower structure 12 may define a larger moment of second section along the prevailing wind direction 13 than a moment of second section perpendicular to the prevailing wind direction 13. Generally, the moment of second section provides an indication of the relationship between the structure's resistance to bending of moments, forces, or loads applied perpendicular to the neutral axis and the shape of the structure. In other words, a larger moment of second section along the prevailing wind direction 13 can increase the bending stiffness of the tower structure 12 along the prevailing wind direction 13. Accordingly, various embodiments of the optimized shape 17 described herein are configured to allow the tower structure 12 to withstand greater loads oriented along the prevailing wind direction 13 compared to its ability to withstand loads in other orientations (e.g., perpendicular to the prevailing wind direction 13).

[0026] For specific references Figure 3 An embodiment of the tower structure 12 is illustrated according to aspects of this disclosure. Specifically, Figure 3 The illustration shows an embodiment of an optimized cross-section of the tower structure 12, wherein the upstream portion 21 and downstream portion 23 of the tower structure 12 are thicker than the side portions or offset portions 25 of the tower structure 12. Additionally, as shown, the upstream portion 21 and downstream portion 23 of the tower structure 12 are aligned with the prevailing wind direction 13. Accordingly, it should be appreciated that the thicker upstream portion 21 and / or downstream portion 23 can increase the second moment of the cross-section along the prevailing wind direction 13, and thus improve the bending stiffness along the prevailing wind direction 13.

[0027] Now for reference Figure 4 Another embodiment of the tower structure 12 is illustrated according to aspects of this disclosure. In particular, Figure 4 The illustration shows one embodiment of an optimized cross-section of the tower structure 12, including an I-beam cross-section within the tower structure 12. As illustrated, the cross-sectional shape may be oriented along the prevailing wind direction 13 to improve the bending stiffness of the tower structure 12 against loads along the prevailing wind direction 13. For example, as shown, the I-beam cross-section may include a crossbeam 27 extending between the upstream portion 21 and the downstream portion 23 of the tower wall 20. Additionally, as shown, the crossbeam 27 may extend substantially parallel to the prevailing wind direction 13.

[0028] Now for reference Figure 5 Another embodiment of the tower structure 12 is illustrated according to aspects of this disclosure. In particular, Figure 5The illustration shows an optimized cross-section of the tower structure 12, including a box girder cross-section within the tower structure 12. As illustrated, the cross-sectional shape may be oriented along the prevailing wind direction 13 to improve the bending stiffness of the tower structure 12 against loads along the prevailing wind direction 13. Furthermore, as shown, the box girder cross-section may include a first crossbeam 27 and a second crossbeam 27 extending between the upstream portion 21 and the downstream portion 23 of the tower wall 20 (e.g., generally parallel to the prevailing wind direction 13). It should be further understood that in other embodiments, the tower structure 12 may include more than two crossbeams 27, such as three or more.

[0029] Now for reference Figure 6 Another embodiment of the tower structure 12 is illustrated according to aspects of this disclosure. In particular, Figure 6 The illustration shows a cross-section of an optimized tower structure 12 comprising crossbeams 27 configured in an X-shaped pattern. For example, each of the crossbeams 27 may define an angle 40 relative to the prevailing wind direction 13. In some embodiments, the angle 40 may be at least five degrees but less than forty degrees, such as at least ten degrees but less than thirty-five degrees. Accordingly, the crossbeams 27 may intersect each other as the individual crossbeams 27 extend between the upstream portion 21 and the downstream portion 23 of the tower wall 20.

[0030] For specific references Figure 4 , Figure 5 as well as Figure 6 It should be recognized that the cross-sections of I-beams, box beams, and / or X-shaped patterns can at least partially increase the bending stiffness of the tower structure 12 along the prevailing wind direction 13 due to the increased thickness of the upstream portion 21 and / or downstream portion 23 of the tower wall 20. However, unlike... Figure 3 In the illustrated embodiment, the (multiple) crossbeams 27 can further enhance the bending stiffness along the prevailing wind direction 13. However, in other embodiments, the upstream portion 21 and / or the downstream portion 23 may still define the same thickness as the side portion 25 of the tower wall 20. In such embodiments, the (multiple) crossbeams 27 can be increased in terms of bending stiffness along the prevailing wind direction 13. It should be appreciated that in such embodiments, the cross-sectional shape may include at least one of a hollow cross-section or a solid cross-section.

[0031] Now for reference Figure 7 Another embodiment of the tower structure 12 is illustrated according to aspects of this disclosure. In particular, Figure 7The illustration shows a cross-section of the tower structure 12 including one or more reinforcing members 29 on the inner surface 24 of the tower structure 12 to form an optimized shape 17. As shown, the reinforcing members 29 may be located on the inner surface 24 of the tower wall 20. Furthermore, as shown, the reinforcing members 29 may be oriented generally aligned with the prevailing wind direction 13. For example, the reinforcing members 29 may be positioned on the inner surface 24 of the upstream portion 21 and / or the downstream portion 23 of the tower wall 20. In another embodiment, as shown, the cross-sectional shape of the tower structure 12 may include a plurality of reinforcing members 29 located on the inner surface 24 of at least one of the upstream portion 21 or the downstream portion 23. For example, in the depicted embodiment, the reinforcing members 29 may be constructed in an isogrid 31 comprising a plurality of individual reinforcing members 29 positioned adjacent to each other. Furthermore, one or both of the upstream portion 21 and the downstream portion 23 of the tower wall 20 may include reinforcing members 29 arranged in the isogrid 31. Furthermore, one of the upstream portion 21 or the downstream portion 23 may include a reinforcing member 29 in the grid 31, while the other of the portions 21 and 23 may include one or more individual reinforcing members 29.

[0032] Now for reference Figure 8 Another embodiment of the tower structure 12 is illustrated according to aspects of this disclosure. In particular, Figure 8 The diagram illustrates the cross-section of a tower structure 12 with an elliptical cross-section. Furthermore, as shown, the elliptical cross-section shape can also be oriented along the prevailing wind direction 13. For example, the elliptical cross-section can define a longitudinal axis 39 aligned with the prevailing wind direction 13. Moreover, the elliptical cross-section shape can increase the bending stiffness along the prevailing wind direction 13. More specifically, the elliptical cross-section can position the upstream portion 21 and / or downstream portion 23 of the tower wall 20 further from the center of the tower structure 12 relative to the side portion 25. Accordingly, the second moment of the section of the tower structure 12 can increase along the prevailing wind direction 13, and thus increase the bending stiffness along the prevailing wind direction 13.

[0033] Despite Figure 3-8 The embodiments shown are individual examples, but it should be understood that the optimized shape 17 of the tower structure 12 may include... Figure 3-8 Any combination of features of the embodiments. For example, in one embodiment, the elliptical tower structure 12 may be defined by increased thickness at the upstream portion 21 and the downstream portion 23, one or more crossbeams 27, and one or more reinforcing members 29.

[0034] Now for reference Figure 9-12This disclosure relates to a method for manufacturing wind turbine towers via additive manufacturing. As used herein, additive manufacturing is generally understood to involve a process for synthesizing a three-dimensional object in which, under computer control, continuous layers of material are formed to produce the object. Accordingly, objects of virtually any size and / or shape can be produced based on digital model data. It should be further understood that the additive manufacturing method of this disclosure may include three degrees of freedom or more, such that the printing technology is not limited to printing stacked two-dimensional layers, but can also print curved and / or irregular shapes.

[0035] Special reference Figure 9 This document describes a flowchart of an embodiment of a method 100 for manufacturing a tower structure for a wind turbine at a wind turbine site, based on aspects of this subject matter. Generally, reference will be made herein to... Figure 1-8 Method 100 is described using the wind turbine 10 and tower structure 12 shown. However, it should be recognized that the disclosed method 100 can be implemented using a tower structure with any other suitable construction. Furthermore, although... Figure 9 The steps performed in a particular order are depicted for illustrative and discussion purposes, but the methods discussed herein are not limited to any particular order or arrangement. Those skilled in the art using the disclosures provided herein will recognize that various steps of the methods disclosed herein can be omitted, rearranged, combined, and / or adapted in various ways without departing from the scope of this disclosure.

[0036] As shown at (104), method 100 may include determining an optimized shape 17 of the tower structure 12 based on one or more site parameters. (See also: Regarding...) Figure 1 The explained field parameters may include the elevation, topography, wind speed, and / or prevailing wind direction 13 at the wind turbine site 11. Furthermore, the optimized shape 17 of the tower structure 12 may be asymmetrical. For example, the optimized shape 17 may include... Figure 2-8 The tower structure 12 may be any of its features or any combination thereof; however, it should be recognized that other shapes are conceived for the tower structure 12. For example, the tower structure 12 may include any cross-sectional shape that improves the bending stiffness of the tower structure 12 based on (a plurality of) field parameters. Furthermore, the optimized shape 17 of the tower structure 12 may vary along the height of the tower structure 12.

[0037] In one embodiment, the field parameters may include the dominant wind direction 13. In such an embodiment, as shown at (102), method 100 may include determining the dominant wind direction 13 at the wind turbine site 11. For example, as per [reference to...] Figure 1The dominant wind direction 13 described herein can be determined based on historical real-time wind direction data. In other embodiments, the dominant wind direction 13 may not be known at the wind turbine site 11. Accordingly, the dominant wind direction 13 can be determined by the plurality of sensors 19 and / or controller 44 described herein. Figure 1 )Sure.

[0038] Method 100 may include forming an optimized shape 17 of the tower structure 12 of the wind turbine 10 at the wind turbine site 11, at least partially from cementitious material 28. For example, at least a portion of the wind turbine 10 may be formed from prefabricated concrete sections assembled into the optimized shape 17 of the tower structure 12. However, as shown at (106), method 100 may include via additive printing apparatus 32 ( Figure 10 The optimized shape 17 of the tower structure 12 of the wind turbine 10 is printed at least partially from cementitious material 28 at the wind turbine site 11. For example, as... Figure 10 The diagram shown illustrates one embodiment of the additive printing apparatus 32 according to aspects of this subject matter. It should be understood that the additive printing apparatus 32 described herein generally refers to any suitable additive printing apparatus having one or more nozzles 34 for depositing material (such as cementitious material 28) onto a surface automatically controlled by controllers 44, 45 to form an object (such as a CAD file) programmed in a computer. It should be appreciated that controllers 44, 45 may be the same controller 44 used to determine the primary wind direction 13. Figure 1 However, in other embodiments, the additive printing apparatus 32 may be controlled via its own dedicated controller 45, which may or may not communicate with the controller 44 used to determine the primary wind direction 13. For example, the controller 44 that determines the primary wind direction 13 may transmit the primary wind direction 13 to the controller 45 that controls the additive printing apparatus 32.

[0039] As shown, the additive printing apparatus 32 may include one or more nozzles 34 for depositing various materials. For example, as illustrated in the embodiment shown, the additive printing apparatus 32 includes two nozzles 34. In other embodiments, the additive printing apparatus 32 may include any suitable number of nozzles 34. Additionally, the additive printing apparatus 32 may include an injector 36, which will be discussed in more detail below. Furthermore, it should be appreciated that different sections of the tower structure 12 may be made of different materials. For example, the top section of the tower structure 12 located near the nacelle 14 may be made of metal (e.g., steel). Such metal may be printed by a dedicated nozzle 34, or a pre-fabricated section formed of metal may be assembled at the top of the tower structure 12.

[0040] Still referencing Figure 10Method 100 may include, for example, providing one or more molds 38 on the foundation 15 of the wind turbine 10. It should be understood that the molds 38 described herein may be solid, porous, and / or printed. Additionally, in one embodiment, the molds(s) 38 may be prefabricated and delivered to the wind turbine site 11. In alternative embodiments, such as... Figure 10 As shown, the additive printing apparatus 32 can also be configured to print multiple molds 38. For example, as shown, one of the nozzles 34 can be configured to dispense polymer material for depositing multiple molds 38 on the foundation 15 of the wind turbine 10 (or any other suitable site location). Suitable polymer materials may include, for example, thermosetting materials, thermoplastic materials, biodegradable polymers configured to degrade / dissolve over time (such as corn-based polymer systems, fungal-based additive materials, or algae-based polymer systems), or combinations thereof. Accordingly, in one embodiment, the outer polymer mold may be able to biodegrade over time, while the inner polymer mold remains intact. In an alternative embodiment, the outer and inner molds 38 may be made of the same material.

[0041] One or more molds 38 can define an optimized shape 17 for the tower structure 12. More specifically, the molds(s) 38 can be printed with shapes as described above. Figure 3-8 The described tower structure 12 can have any cross-sectional shape. For example, the additive printing device 32 can be defined. Figure 4 The I-beam profile allows the profile to be filled with cementitious material 28. However, in other embodiments, method 100 may further include forming an optimized shape 17 of the tower structure 12 of the wind turbine 10 within one or more molds 38 via an additive printing apparatus 32. For example, forming the optimized shape 17 of the tower structure 12 via the additive printing apparatus 32 may include printing cementitious material 28 within one or more molds 38. Printing cementitious material 28 within the mold(s) 38 of the tower structure 12 may further include stacking the cementitious material 28 of the tower structure 12 in multiple passes via the additive printing apparatus 32. Furthermore, it should be appreciated that the tower structure 12 may be printed without utilizing molds 38. For example, Figure 3-8 Any of the optimized shape 17 or its features (e.g., reinforcement component 29) can be printed by the additive printing device 32. For example, cementitious material 28 can be printed layer by layer to define the tower structure 12.

[0042] In additional embodiments, an adhesive material may be provided between the cementitious material 28 and the foundation, the cementitious material 28 and (multiple) molds 38, the cementitious material 28 and one or more of the metal or polymer materials, or the multilayer cementitious material 28, polymer materials, and / or metal materials. Thus, the adhesive material can further supplement the interlayer bonding between the materials.

[0043] The binder materials described herein may include, for example, cementitious materials (such as mortar), polymeric materials, and / or admixtures of cementitious and polymeric materials. Binder formulations comprising cementitious materials are referred to herein as “cementous mortar.” Cementous mortar may include any cementitious material that can be combined with fine aggregates. Cementous mortar made using Portland cement and fine aggregates is sometimes referred to as “Portland cement mortar” or “OPC.” Binder formulations comprising admixtures of cementitious and polymeric materials are referred to herein as “polymeric mortar.” Any cementitious material may be included in an admixture with polymeric materials and optional fine aggregates. Binder formulations comprising polymeric materials are referred to herein as “polymer binders.”

[0044] The binder materials described herein may include, for example, cementitious materials (such as mortar), polymeric materials, and / or admixtures of cementitious and polymeric materials. Binder formulations comprising cementitious materials are referred to herein as “cementous mortar.” Cementous mortar may include any cementitious material that can be combined with fine aggregates. Cementous mortar made using Portland cement and fine aggregates is sometimes referred to as “Portland cement mortar” or “OPC.” Binder formulations comprising admixtures of cementitious and polymeric materials are referred to herein as “polymeric mortar.” Any cementitious material may be included in an admixture with polymeric materials and optional fine aggregates. Binder formulations comprising polymeric materials are referred to herein as “polymer binders.”

[0045] Furthermore, the additive printing apparatus 32 is configured to print the cementitious material 28 in a manner that takes into account the curing rate of the cementitious material 28, allowing the tower structure 12 to bond to itself during its formation. Additionally, the additive printing apparatus 32 is configured to print the tower structure 12 in a manner that allows it to withstand the weight of the tower wall 20, since the additively formed cementitious material 28 may be fragile during printing. Furthermore, multiple reinforcing elements 30 may be provided for the tower structure 12 to enable it to withstand wind loads that could make the tower 12 susceptible to cracking.

[0046] Return to reference Figure 9 As shown at (108), method 100 may also include allowing cementitious material 28 to cure in order to form tower structure 12 of wind turbine 10.

[0047] Now for reference Figure 11 A flowchart illustrating another embodiment of a method 200 for manufacturing a tower structure for a wind turbine at a wind turbine site, according to aspects of this disclosure, is provided herein. Generally, reference will be made herein to... Figure 1-8Method 200 is described using the wind turbine 10 and tower structure 12 shown. However, it should be recognized that the disclosed method 200 can be implemented using the tower structure 12 with any other suitable construction. Furthermore, although... Figure 11 The steps performed in a particular order are depicted for illustrative and discussion purposes, but the methods discussed herein are not limited to any particular order or arrangement. Those skilled in the art using the disclosures provided herein will recognize that various steps of the methods disclosed herein can be omitted, rearranged, combined, and / or adapted in various ways without departing from the scope of this disclosure.

[0048] As shown at (202), method 200 may include determining the prevailing wind direction 13 at the wind turbine site 11. As shown at (204), method 200 may include determining an optimized shape 17 of the tower structure 12 based on the prevailing wind direction 13. Furthermore, as mentioned, the optimized shape 17 of the tower structure 12 may be asymmetrical. For example, the optimized shape 17 may include... Figure 2-8 Any of the tower structure 12 or any combination of its features. As shown at (206), method 200 may include printing one or more molds 38 of the tower structure 12 onto the foundation 15 of the wind turbine 10 via an additive printing apparatus 32. As described herein, the molds 38 may define an optimized shape 17 of the tower structure 12. More specifically, the molds 38 may be configured as described regarding Figure 3-8 The cross-sectional shape of the described tower structure 12 is printed in any cross-sectional shape.

[0049] As shown at (208), method 200 may include filling one or more molds 38 with at least a portion of a cementitious material 28. For example, as per [reference to...] Figure 10 As described in method 100, one or more of the nozzles 34 of the additive printing apparatus 32 may be configured to print cementitious material 28 into molds 38. However, in an alternative embodiment, instead of printing cementitious material 28, the injector 36 of the additive printing apparatus 32 may simply utilize cementitious material 28 to inject or fill molds 38, for example, by injecting cementitious material 28 from the top of mold(s) 38 or by injecting cementitious material 28 through an opening in mold(s) 38. In such an embodiment, it should be appreciated that the optimized shape 17 of the tower structure 12 may be entirely determined by mold(s) 38. Alternatively, more specifically, the contour of the optimized shape 17 of the tower structure 12 may be defined in mold(s) 38 during printing and subsequent filling with cementitious material 28. As shown at (210), method 200 may include curing cementitious material 28 within one or more molds 38 to form the tower structure 12.

[0050] Now for reference Figure 12 The block diagram illustrated below illustrates an embodiment of suitable components that may be included in a controller (such as controllers 44, 45 described herein). As shown, controllers 44, 45 may include one or more processors 46 and associated memory devices(s) 48 configured to perform various computer-implemented functions (e.g., performing methods, steps, calculations, etc., as disclosed herein and storing related data). Additionally, controllers 44, 45 may also include a communication module 50 for facilitating communication between controllers 44, 45 and various components of the additive printing apparatus 32. Furthermore, communication module 50 may include a sensor interface 52 (e.g., one or more analog-to-digital converters) for allowing signals transmitted from one or more sensors 19 to be converted into signals that can be understood and processed by processor 46. It should be appreciated that sensors (e.g., sensors(s) 19) may be communicatively coupled to communication module 50 using any suitable means. For example, as shown below... Figure 11 As shown, the (multiple) sensors 19 can be connected to the sensor interface 52 via a wired connection. However, in other embodiments, the (multiple) sensors 19 can be connected to the sensor interface 52 wirelessly, such as by using any suitable wireless communication protocol known in the art. Accordingly, the (multiple) processors 46 can be configured to receive one or more signals from the sensors.

[0051] As used herein, the term "processor" refers not only to integrated circuits known in the art as included in a computer, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits (ASICs), and other programmable circuits. Processor 46 is also configured to compute advanced control algorithms and communicate with various Ethernet-based or serial protocols (Modbus, OPC, CAN, etc.). Additionally, memory device 48 may generally include memory elements, including but not limited to computer-readable media (e.g., random access memory (RAM)), computer-readable non-volatile media (e.g., flash memory), floppy disks, compact disc-read-only memory (CD-ROM), magneto-optical disks (MOD), digital universal discs (DVDs), and / or other suitable memory elements. Such memory device 48 may generally be configured to store suitable computer-readable instructions that, when implemented by processor 46, configure controllers 44, 45 to perform various functions as described herein.

[0052] This written description uses examples to disclose the invention (including the best mode) and also enables any person skilled in the art to practice the invention (including making and using any apparatus or system, and performing any incorporated methods). The patentability of the invention is defined by the claims and may include other examples that would occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A method for manufacturing a tower structure for a wind turbine at a wind turbine site, the method comprising: The optimized shape of the tower structure is determined based on the prevailing wind direction at the wind turbine site; The optimized shape of the tower structure of the wind turbine is printed, at least partially, from cementitious material at the wind turbine site using an additive printing device, wherein the tower defines tower walls; A crossbeam extending between the first and second sections of the tower wall along the prevailing wind direction is formed by printing using cementitious materials; and Allow the cementitious material to cure in order to form the tower structure of the wind turbine; The tower structure includes one or more first sections aligned with the prevailing wind direction and one or more second sections offset from the prevailing wind direction. The one or more first portions and the one or more second portions are printed using a cementitious material to form the integral parts defining the tower structure. Wherein, the one or more first portions are thicker than the one or more second portions, and Wherein, the one or more first parts and the one or more second parts transition smoothly between each other; During printing, one or more reinforcing elements are at least partially embedded in the cementitious material of the tower structure at one or more locations; The tower structure has a variable, optimized shape along its height, and at different heights of the tower structure, beams with different constructions are formed by printing using cementitious material, the beams with different constructions extending between a first and a second portion of the tower wall along the prevailing wind direction.

2. The method according to claim 1, characterized in that, The method further includes: Monitoring at least one wind parameter at the wind turbine site via one or more sensors; and The dominant wind direction of the wind turbine is determined based on the monitored at least one wind parameter by a controller communicatively connected to the one or more sensors.

3. The method according to any one of claims 2, characterized in that, The optimized shape of the tower structure is defined by a cross-sectional shape including an elliptical cross-section.

4. The method according to claim 3, characterized in that, The elliptical cross-section defines a longitudinal axis aligned with the prevailing wind direction.

5. The method according to any one of claims 1-4, characterized in that, Further includes: One or more reinforcing components are printed onto the inner surface of the tower structure via the additive printing apparatus to form the optimized shape.

6. The method according to any one of claims 1-4, characterized in that, Further includes: One or more molds are provided on the foundation of the wind turbine; as well as The optimized shape of the tower structure of the wind turbine is formed within one or more molds via the additive printing apparatus.

7. The method according to claim 6, characterized in that, This further includes printing the one or more molds via the additive printing apparatus.

8. The method according to claim 6, characterized in that, The optimized shape is a first optimized shape located at a first position along the height of the tower structure, and the method further includes: A second optimized shape of the tower structure is printed, at least partially in cementitious material, at a second position along the height of the tower structure via an additive printing device.

9. The method according to claim 8, characterized in that, The one or more molds define the optimized shape of the tower structure.

10. The method according to claim 7, characterized in that, The optimized shape of the tower structure of the wind turbine formed in one or more molds via the additive printing apparatus includes further printing the cementitious material in the one or more molds by depositing the cementitious material of the tower structure in multiple passes via the additive printing apparatus.

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