A pre-fabricated component for an additively manufactured wind turbine tower structure

Abstract

A method of manufacturing a tower structure includes providing an additive printing device having at least one printer head atop a support surface. The method also includes positioning a preform member proximate the support surface. The preform member is comprised of a composite material reinforced with a plurality of reinforcing members. Further, portions of the plurality of reinforcing members protrude from the composite material. Moreover, the method includes printing and depositing a binding material onto the support surface via the at least one printer head to construct the tower structure layer-by-layer around the preform member. As such, the portions of the plurality of reinforcing members protruding from the composite material reinforce the binding material around the preform member.

Description

Technical Field

[0001] This disclosure generally relates to wind turbine tower structures, and more particularly to a prefabricated component, such as a prefabricated door assembly or a prefabricated base assembly, that can be readily incorporated into an additively manufactured wind turbine tower structure. Background Technology

[0002] Wind power is considered one of the cleanest and most environmentally friendly energy sources available today, and wind turbines are receiving increasing attention in this area. 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, in the form of rotational energy, to rotate a shaft that connects the rotor blades to the gearbox (or, if no gearbox is used, directly to the generator). The generator then converts the mechanical energy into electrical energy, which can be deployed to the public grid.

[0003] Wind turbine towers are generally constructed from steel tubing, precast concrete sections, or a combination thereof. Furthermore, the tubing and / or concrete sections are typically not formed on-site, but transported to the site and then arranged together to erect the tower. For example, one manufacturing method involves forming precast concrete rings, transporting the rings to the site, arranging the rings on top of each other, and then securing the rings together. However, as wind turbines continue to increase in size, conventional manufacturing methods are limited by shipping regulations that prohibit the transport of tower sections with diameters greater than approximately 4 to 5 meters. Therefore, some tower manufacturing methods involve forming multiple arc segments and securing the segments together on-site to form the tower's diameter, for example, via bolting and / or welding. However, such methods are labor-intensive and can be time-consuming.

[0004] In light of the foregoing, the art is constantly seeking improved methods for manufacturing wind turbine towers. More recently, for example, progress has been made in using additive printing technology to at least partially construct wind turbine towers. This method allows for the on-site erection of tower structures and also allows for the construction of structures to greater heights. During the construction of existing towers, it is generally desirable to include prefabricated components in the structure, such as prefabricated doors or base sections. However, when constructing the tower, additional reinforcements must also be included around such components. Furthermore, reinforcement replacement can be difficult to automate because reinforcements (e.g., steel bars) must be placed around the prefabricated components in various orientations.

[0005] Accordingly, this disclosure relates to prefabricated components used in additive manufacturing wind turbine tower structures to address the aforementioned problems. 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 practicing the invention.

[0007] In one aspect, this disclosure relates to a method of manufacturing a tower structure. The method includes providing an additive printing apparatus having at least one printhead on top of a support surface. The method also includes positioning a prefabricated member near the support surface (e.g., such as within or on top of the support surface). The prefabricated member may be constructed of a composite material reinforced with a plurality of reinforcing members. Furthermore, portions of the plurality of reinforcing members protrude from the composite material. Moreover, the method includes printing and depositing an adhesive material onto the support surface via at least one printhead to construct the tower structure layer by layer around the prefabricated member. Thus, portions of the plurality of reinforcing members protruding from the composite material reinforce the adhesive material around the prefabricated member.

[0008] In an embodiment, an additive printing apparatus having at least one printhead on top of a support surface of a tower structure may include positioning a vertical support structure above the support surface of the tower structure, suspending a support member from the vertical support structure, and movably coupling at least one printhead to the support member.

[0009] In another embodiment, the prefabricated component may be, for example, a prefabricated door assembly or a prefabricated base assembly.

[0010] For example, in a particular embodiment, the prefabricated door assembly includes a door frame defining a passageway opening, and a door for moving between an open position exposing the passageway opening and a closed position covering the passageway opening. In such embodiments, a plurality of reinforcing members are arranged within the composite material around the passageway opening. More particularly, in some embodiments, the plurality of reinforcing members are arranged within the composite material at multiple different angles relative to the passageway opening.

[0011] In another embodiment, the prefabricated base assembly may include multiple base segments. Therefore, in some embodiments, the method may include arranging the multiple base segments together to form the base of a tower structure. In such embodiments, gaps exist between each of the multiple base segments, with portions of multiple reinforcing members protruding from the composite material within the gaps.

[0012] In an additional embodiment, the method may include constructing a precast component by forming it off-site via a precast composite material.

[0013] In another embodiment, the method may include constructing the precast component by casting a composite material to form the precast component in the field before positioning the precast component near the support surface of the tower structure.

[0014] In another embodiment, the method may include constructing a prefabricated component by printing and depositing a composite material via at least one printhead to form the prefabricated component before positioning it near the support surface of the tower structure.

[0015] For example, in one embodiment, the method may include vertically printing and depositing a composite material via a printhead to form a precast component. In such embodiments, vertically printing and depositing a composite material via at least one printhead to form a precast component in the field may include vertically printing and depositing a composite material via at least one printhead to form a precast component having a plurality of holes formed therein, and placing at least one of a plurality of reinforcing members within each of the plurality of holes to reinforce the precast component.

[0016] In another embodiment, the method may include vertically printing and depositing composite material via a printhead to form a prefabricated component off-site, and placing at least one of a plurality of reinforcing members within each of a plurality of holes to reinforce the prefabricated component on-site.

[0017] In a particular embodiment, the method may further include placing a grommet in each of the plurality of holes before placing at least one of the plurality of reinforcing members in each of the plurality of holes.

[0018] In another embodiment, the method may include horizontally printing and depositing a composite material via a printhead to form a preform. In such embodiments, the method may include placing at least one of a plurality of reinforcing members between layers of the preform while horizontally printing and depositing the preform.

[0019] In another embodiment, the composite material and the bonding material may be the same or different. In one embodiment, the composite material may be a polymer, concrete, asphalt resin, asphalt, clay, adhesive, mortar, bonding composition, etc. Furthermore, the bonding material may include concrete, asphalt resin, asphalt, clay, adhesive, mortar, bonding composition, etc.

[0020] In several embodiments, the tower structure described herein is part of a wind turbine.

[0021] In another aspect, this disclosure relates to a method for manufacturing a tower structure. The method includes printing and depositing a composite material via at least one printhead to construct a prefabricated member layer by layer. The method also includes reinforcing a bonding material with a plurality of reinforcing members, such that portions of the multiple reinforcing members protrude from the composite material. Furthermore, the method includes bonding the prefabricated member to the bonding material to form the tower structure, wherein portions of the multiple reinforcing members protruding from the composite material reinforce the bonding material surrounding the prefabricated member.

[0022] For example, in one embodiment, incorporating a prefabricated component into an adhesive material to form a tower structure may include positioning the prefabricated component on top of a support surface and printing and depositing the adhesive material onto the support surface via at least one printer head to build the tower structure layer by layer around the prefabricated component.

[0023] Technical Solution 1. A method for manufacturing a tower structure, the method comprising: An additive printing apparatus having at least one print head on top of a support surface is provided; Positioning a precast component near the support surface, the precast component being constructed of a composite material reinforced with multiple reinforcing members, portions of which protrude from the composite material; and Adhesive material is printed and deposited onto the support surface via the at least one print head to build the tower structure layer by layer around the precast member, wherein portions of the plurality of reinforcing members protruding from the composite material reinforce the adhesive material around the precast member.

[0024] Technical Solution 2. The method according to Technical Solution 1, wherein the additive printing apparatus having at least one printhead on top of the support surface of the tower structure further includes: Position the vertical support structure above the support surface of the tower structure; The support component is suspended from the vertical support structure; and The at least one printer head is movably connected to the support member.

[0025] Technical Solution 3. The method according to Technical Solution 1, wherein the prefabricated component includes at least one of a prefabricated door assembly or a prefabricated base assembly.

[0026] Technical Solution 4. The method according to Technical Solution 3, wherein the prefabricated door assembly includes a door frame defining a passage opening, and a door for moving between an open position exposing the passage opening and a closed position covering the passage opening.

[0027] Technical Solution 5. The method according to Technical Solution 4, wherein the plurality of reinforcing components are arranged within the composite material around the passage opening.

[0028] Technical Solution 6. The method according to Technical Solution 5, wherein the plurality of reinforcing members are arranged within the composite material at a plurality of different angles relative to the passage opening.

[0029] Technical Solution 7. The method according to Technical Solution 3, wherein the prefabricated base assembly further includes multiple base segments, and the method further includes: The plurality of base segments are arranged together to form the base of the tower structure, wherein there is a gap between each of the plurality of base segments, and portions of the plurality of reinforcing members protrude from the composite material within the gaps.

[0030] Technical Solution 8. The method according to Technical Solution 1 further includes constructing the precast component by precasting the composite material to form the precast component off-site.

[0031] Technical Solution 9. The method according to Technical Solution 1 further includes constructing the precast component by casting the composite material to form the precast component in the field before positioning the precast component near the support surface of the tower structure.

[0032] Technical Solution 10. The method according to Technical Solution 1 further includes constructing the prefabricated component by printing and depositing the composite material via the at least one print head to form the prefabricated component before positioning the prefabricated component near the support surface of the tower structure.

[0033] Technical Solution 11. The method according to Technical Solution 10 further includes vertically printing and depositing the composite material via the at least one print head to form the preform.

[0034] Technical Solution 12. The method according to Technical Solution 11, wherein vertical printing and deposition of the composite material via the at least one print head to form the prefabricated component in the field further comprises: The composite material is vertically printed and deposited via the at least one print head to form the prefabricated component having a plurality of holes formed therein; and At least one of the plurality of reinforcing components is placed inside each of the plurality of holes to reinforce the prefabricated component.

[0035] Technical Solution 13. The method according to Technical Solution 12 further includes vertically printing and depositing the composite material via the at least one print head to form the prefabricated component off-site, and placing at least one of the plurality of reinforcing members in each of the plurality of holes to reinforce the prefabricated component in-situ.

[0036] Technical Solution 14. The method according to Technical Solution 12 further includes placing a grommets in each of the plurality of holes before placing at least one of the plurality of reinforcing members in each of the plurality of holes.

[0037] Technical Solution 15. The method according to Technical Solution 10 further includes horizontally printing and depositing the composite material via the at least one print head to form the preform.

[0038] Technical Solution 16. The method according to Technical Solution 15 further includes placing at least one of the plurality of reinforcing members between layers of the preform during horizontal printing and deposition of the preform.

[0039] Technical Solution 17. The method according to Technical Solution 1, wherein the composite material comprises at least one of a polymer, concrete, asphalt resin, asphalt, clay, adhesive, mortar, or adhesive composition, and wherein the adhesive material comprises at least one of concrete, asphalt resin, asphalt, clay, adhesive, mortar, or adhesive composition.

[0040] Technical Solution 18. The method according to Technical Solution 1, wherein the tower structure is part of a wind turbine.

[0041] Technical Solution 19. A method for manufacturing a tower structure, the method comprising: Prefabricated components are constructed by printing and depositing composite materials via at least one print head, layer by layer. The bonding material is reinforced using multiple reinforcing members, such that portions of the multiple reinforcing members protrude from the composite material; and The prefabricated component is bonded to an adhesive material to form the tower structure, wherein portions of the plurality of reinforcing members protruding from the composite material reinforce the adhesive material surrounding the prefabricated component.

[0042] Technical Solution 20. The method according to Technical Solution 19, wherein incorporating the prefabricated component into the bonding material to form the tower structure further includes: Positioning the prefabricated component on top of the support surface; and The adhesive material is printed and deposited onto the support surface via the at least one printer head to build the tower structure layer by layer around the prefabricated component.

[0043] 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. Embodiments of the invention are illustrated in the accompanying drawings, which are incorporated in and form part of this specification, and together with the description serve to explain the principles of the invention. Attached Figure Description

[0044] The complete and enabling disclosure of the invention (including its best mode) to those skilled in the art is set forth in the description with reference to the accompanying drawings, in which: Figure 1 A perspective view showing one embodiment of a wind turbine according to the present disclosure; Figure 2A cross-sectional view showing one embodiment of a wind turbine tower structure according to the present disclosure; Figure 3 This disclosure shows printable content. Figure 2 A schematic diagram of an additive printing apparatus for an exemplary tower structure; Figure 4 Showing the contents of this disclosure Figure 3 A partial enlarged view of certain components of an exemplary additive printing apparatus; Figure 5 Another partial enlarged view of certain components of an exemplary additive printing apparatus according to this disclosure is shown; Figure 6 A block diagram illustrating one embodiment of a controller for an additive printing apparatus according to the present disclosure; Figure 7 A flowchart illustrating one embodiment of a method for manufacturing a tower structure (e.g., a wind turbine) according to this disclosure; Figure 8 A perspective view of one embodiment of a tower structure is shown, the tower structure having a prefabricated door assembly integrated therewith and formed using a method according to the present disclosure; Figure 9 A perspective view showing one embodiment of a prefabricated base assembly according to the present disclosure; Figure 10 A front view of an embodiment of a prefabricated door assembly according to this disclosure, formed by vertical printing; Figure 11 Show Figure 10 A partial side view of the prefabricated door assembly; Figure 12 Showing information about the formation Figure 10 A partial front view of an embodiment of the flow path of the bonding material in a prefabricated door assembly; Figure 13 A front view showing an embodiment of a prefabricated door assembly according to this disclosure, formed via horizontal printing; and Figure 14 Showing the result formed by horizontal printing Figure 13 Side view of the prefabricated door assembly.

[0045] The repeated use of reference numerals in this specification and figures is intended to indicate the same or similar features or elements of the invention. Detailed Implementation

[0046] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the figures. Each example is provided as an explanation of the invention and is not intended to limit it. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the invention without departing from the scope or spirit thereof. For example, features shown or described as part of one embodiment may be used with another embodiment to produce even further embodiments. Therefore, it is intended that the invention cover such modifications and variations as fall within the scope of the appended claims and their equivalents.

[0047] Generally, this disclosure relates to additive printing apparatuses and methods for manufacturing wind turbine towers using automated deposition of binder materials via techniques such as additive manufacturing, 3D printing, jet 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 method of this disclosure includes using an automated additive printing apparatus to print a tower structure while also incorporating prefabricated components therein. For example, in embodiments, the prefabricated components may include prefabricated door assemblies or prefabricated base assemblies. Furthermore, the prefabricated components are constructed of a composite material reinforced with multiple reinforcing members, portions of which protrude from the composite material. In particular, it is intentional that the reinforcing members around the prefabricated component extend beyond the component and into the surrounding printed or printed casting sections of the entire tower structure. Accordingly, the additive printing apparatus prints additional binder materials to build the tower structure layer by layer around the prefabricated component, such that the portions of the reinforcing members protruding from the composite material reinforce the binder material around the prefabricated component.

[0048] Therefore, the method described herein offers many advantages not found in the prior art. For example, the prefabricated component includes necessary reinforcements to strengthen the overall tower structure in the component area, thereby simplifying the reinforcement placement process (which is relatively complex around the prefabricated component compared to typical tower structures). Furthermore, this disclosure allows for the on-site printing of tower structures with any desired size (e.g., greater than four meters in diameter), enabling the construction of larger tower structures and wind turbines. These tall structures can be formed without the need for large cranes or otherwise freed from the manufacturing or logistical constraints common to existing manufacturing methods. The method also increases design flexibility, eliminates overall size limitations, and allows for the formation of tower structures with any desired profile and cross-sectional shape. The additive printing apparatus can also utilize any suitable number of printheads to reduce manufacturing time. Other features and advantages will be apparent to those skilled in the art.

[0049] Now refer to the diagram. Figure 1A perspective view of one embodiment of a wind turbine 10 according to this disclosure is shown. As shown, the wind turbine 10 includes a tower 12 extending from a base 15 or a support surface, with a nacelle 14 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 a main rotor shaft. Wind turbine power generation and control components (not shown) are typically housed within the nacelle 14. Furthermore, as shown, the tower 12 may also include a door 17.

[0050] Figure 1 The views provided are for illustrative purposes only, to place the invention within an exemplary field 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 on wind turbine towers, but can be used in any application (including, for example, housing, bridges, high towers, and other aspects of the concrete industry) that has a concrete construction and / or a tall tower structure, in addition to wind turbine towers. Moreover, the methods described herein can also be applied to the manufacture of any similar structures that benefit from the advantages described herein.

[0051] Now refer to Figure 2 The exemplary embodiments according to this disclosure will be described in more detail. Figure 1 The tower structure 12 of the wind turbine 10. Specifically, Figure 2 A partial cross-sectional view of one embodiment of the tower structure 12 of a wind turbine 10 according to the present disclosure is shown. As shown, the tower structure 12 defines a generally circumferential tower wall 20 having an outer surface 22 and an inner surface 24. Furthermore, as shown, the circumferential tower wall 20 generally defines a hollow interior 26, which is typically used to house various turbine components (e.g., power converters, transformers, etc.). Additionally, as will be described in more detail below, the tower structure 12 is formed using additive manufacturing.

[0052] Furthermore, as shown, the tower structure 12 is formed of one or more bonding materials 28, which utilize one or more reinforcing members 30 ( Figure 2 Reinforcement, such as elongated cables or wires, helical cables or wires, reinforcing ribs (also known as steel bars), mesh reinforcing fibers (metal or polymer), reinforcing metal rings (circular, elliptical, helical, and other potentially related shapes), and / or couplings. According to an exemplary embodiment, the adhesive material 28 can be supplied via any suitable supply system 32 (see, for example...). Figure 4Provided. Furthermore, as described in more detail below, as shown, the reinforcing component 30 may be embedded in the adhesive material 28 during the printing process. As used herein, the adhesive material 28 may include any suitable usable paste configured to bond together after curing to form a structure. Suitable adhesive materials include, for example, concrete, bitumen resin, bitumen, clay, adhesives, mortar, adhesive compositions, or similar materials or compositions.

[0053] According to exemplary embodiments of this disclosure, an adhesive material (not shown) may also be disposed between one or more of the following: adhesive material 28 and base 15, adhesive material 28 and reinforcing member 30, or multilayer adhesive material 28 and reinforcing member 30. Therefore, the adhesive material can further supplement the interlayer bonding between materials.

[0054] The adhesive materials described herein may include, for example, bonding materials such as mortar, polymeric materials, and / or mixtures of bonding materials and polymeric materials. Adhesive formulations comprising bonding materials are referred to herein as “bonding mortars.” Bonding mortars may include any bonding material that can be combined with fine aggregates. Bonding mortars made using Portland adhesives and fine aggregates are sometimes referred to as “Portland adhesive mortars” or “OPC.” Adhesive formulations comprising mixtures of bonding materials and polymeric materials are referred to herein as “polymeric mortars.” Any bonding material may be included in mixtures with polymeric materials and optionally fine aggregates. Adhesive formulations comprising polymeric materials are referred to herein as “polymer adhesives.”

[0055] Exemplary polymeric materials that can be used in adhesive formulations may include any thermoplastic or thermosetting polymeric material, such as acrylic resins, polyepoxides, vinyl polymers (e.g., polyvinyl acetate (PVA), ethylene-vinyl acetate (EVA)), styrene (e.g., butadine), and copolymers or terpolymers thereof. The properties of exemplary polymeric materials are described in ASTM C1059 / C1059M-13, Standard Specification for Latex Agents for Bonding Fresh To Hardened Concrete.

[0056] Now, in general, refer to Figures 3 to 5This disclosure describes an additive printing apparatus 40 according to exemplary embodiments of the present disclosure. It is noteworthy that all or part of the tower structure 12 can be printed layer-by-layer using the additive printing apparatus 40, which can use any suitable mechanism to deposit layers of additive material (such as concrete) to form the tower structure 12. Therefore, aspects of this disclosure relate to methods for manufacturing wind turbine towers via additive manufacturing. As used herein, additive manufacturing is generally understood to involve a process for synthesizing three-dimensional objects, wherein continuous layers of material are formed under computer control to create the object. Thus, objects of virtually any size and / or shape can be generated from digital model data. It should also be understood that the additive manufacturing methods of this disclosure may include three or more degrees of freedom, such that the printing technology is not limited to printing stacked two-dimensional layers, but is also capable of printing curved and / or irregular shapes.

[0057] It should also be understood that the additive printing apparatus 40 described herein generally refers to any suitable additive printing apparatus having one or more nozzles for depositing material (such as binder material 28) onto a surface, which is automatically controlled by a controller to form a computer-programmed object (such as a CAD file). More specifically, such as Figure 3 As shown in the diagram and described below, the additive printing apparatus 40 includes one or more print heads 42 having any suitable number of nozzles 44, and is independently movable to simultaneously print layers of the tower structure 12.

[0058] Still refer to Figures 3 to 5 The additive printing apparatus 40 according to exemplary embodiments of the present disclosure is described in more detail below. As shown, the additive printing apparatus 40 may include a vertical support structure 50 generally configured to suspend one or more of the printheads 42 above the tower structure 12 during the printing process. In this respect, the vertical support structure 50 may extend substantially upward in the vertical direction V from the ground or from the base 15 to a position at least partially above the top 52 of the tower structure 12 (e.g., and also above the base 15 before printing the first layer).

[0059] As shown, the vertical support structure 50 may include a plurality of support towers 54 and one or more gantry beams 56 extending between at least two support towers 54. Although in Figures 3 to 5 Two support towers 54 and a single gantry beam 56 are shown. It should be understood that any suitable number and location of support towers 54 can be used according to alternative embodiments. Furthermore, the support towers 54 and gantry beam 56 are shown as truss-like structures (e.g., similar to a tower crane), but can be formed in any other suitable manner or have any other construction according to alternative embodiments.

[0060] Additionally, although the vertical support structure 50 is shown positioned on the outside of the tower structure 12, it should be understood that, according to an alternative embodiment, the vertical support structure 50 may be located on the inside of the tower structure 12. According to other embodiments, the vertical support structure 50 may include support towers 54 located on both the inside and outside of the tower structure 12. Furthermore, any other suitable system or mechanism may be used to suspend the additive printing device 40 from the vertical support structure 50.

[0061] It is worth noting that during the additive printing process, the top 52 of the tower structure 12 is constructed layer by layer along the vertical direction V. Therefore, the vertical support structure 50 can be an expandable support structure that can be raised along with the height of the tower 12. In this respect, the vertical support structure 50 can be formed by a plurality of stacked segments 60 positioned near each other and connected along the vertical direction V to form a rigid vertical support structure 50. Therefore, when the tower structure 12 approaches the top 58 of the vertical support structure 50, other segments 62 can be added to the stacked segments 60 to increase the overall height of the vertical support structure 50.

[0062] Special reference Figure 3 The additional segment 62 can be combined with the stacked segment 60 using the jacking system 64 to raise the vertical support structure 50. Generally, as shown, the jacking system 64 can be positioned close to the base 15 and configured to raise the vertical support structure 50 (e.g., including the stacked segment 60 and gantry beam 56) and insert the additional segment 62. In particular, a separate jacking system 64 can be positioned at the bottom of each support tower 54.

[0063] According to an exemplary embodiment, the lifting system 64 may include a lifting frame 66 and a lifting mechanism 68 positioned at the bottom of the stacked segments 60. The lifting mechanism 68 described herein may generally be any suitable hydraulic, pneumatic, or mechanically actuated system for raising the vertical support structure 50. Accordingly, when additional segments 62 need to be added, the dedicated lifting mechanism 68 simultaneously raises each support tower 54 to allow the insertion of the additional segment 62. Specifically, the lifting frame 66 supports the weight of the vertical support structure 50 when the additional segment 62 is positioned below the lowermost stacked segment 60. The additional segment 62 is attached to the stacked segment 60 using any suitable mechanical fasteners, welding, etc. This process may be repeated as needed to raise the overall height of the vertical support structure 50.

[0064] In some cases, it may be desirable to protect the components of the tower structure 12 and the additive printing apparatus 40 from their external operating environment. In such embodiments, the tower cover 70 may generally be any suitable material positioned around the vertical support structure 70. For example, the tower cover 70 may be a fabric-like material draped over or attached to the vertical support structure 50 (e.g., above the support tower 54 and / or gantry beam 56).

[0065] As briefly mentioned above, the vertical support structure 50 is generally configured to support one or more and / or other modules in the print head 42, facilitating the formation of the tower structure 12. See in particular... Figures 3 to 5 The additive printing apparatus 40 may also include one or more support components, such as a support ring 80, which is suspended from the vertical support structure 50, or more particularly from the gantry beam 56 above the tower structure 12. For example, as shown, the support ring 80 is mounted to the gantry beam 56 using a vertical positioning mechanism 82. Generally, the vertical positioning mechanism 82 is configured to adjust the height or vertical distance 84 measured between the top of the gantry beam 56 and the support ring 80 in the vertical direction V. For example, the vertical positioning mechanism 82 may include one or more hydraulic actuators 86 extending between the gantry beam 56 and the support ring 80, which move in the vertical direction V using the support ring 80 and the print head 42 as the tower structure 12 is built layer by layer.

[0066] As shown, the hydraulic actuator 86 is configured to adjust the vertical distance 84 to precisely position the nozzle 44 of the print head 42 directly above the top 52 of the tower structure 12. This allows for precise control of the additive printing process. However, it should be understood that, according to alternative embodiments, the vertical movement of the print head 42 can be adjusted in any other suitable manner. For example, according to an exemplary embodiment, the support ring 80 may be rigidly fixed to the gantry beam 56, and the support ring 80 and / or the print head 42 may be used to facilitate vertical movement to precisely position the nozzle 44. For example, the print head 42 may be slidably mounted to the support ring 80 using vertical guides and positioning mechanisms to adjust its vertical position relative to the support ring 80 and the tower structure 12.

[0067] According to the illustrated embodiment, the print head 42 is movably coupled to the support ring 80 such that the nozzle 44 can deposit adhesive material 28 around the periphery of the tower structure 12, while the support ring 80 remains rotatably fixed relative to the gantry beam 56. In this respect, for example, a drive mechanism 100 can operatively couple the print head 42 to the support ring 80 such that the print head 42 can be configured to move about the periphery 102 of the support ring 80 (e.g., in the circumferential direction C) while selectively depositing adhesive material 28. An exemplary drive mechanism 100 is described below and shown in the figures, but it should be understood that other drive mechanisms are also contemplated and are within the scope of this disclosure.

[0068] For example, such as Figure 4 As best shown, the drive mechanism 100 may include a ring gear 104 positioned on the support ring 80 and a drive gear 106 rotatably mounted to the print head 42. Specifically, as shown, the ring gear 104 is defined on the bottom 108 of the support ring 80. Therefore, when the print head 42 is mounted on the bottom 108 of the support ring 80, the drive gear 106 meshes with the ring gear 104. The drive mechanism 100 may also include a drive motor 110 mechanically coupled to the drive gear 106 to selectively rotate the drive gear 106, thereby moving the print head 42 about the periphery 102 of the support ring 80. In this way, the support ring 80 can remain stationary while the print head 42 moves about the support ring 80 during the deposition of the adhesive material 28 to form the cross-sectional layers of the tower structure 12.

[0069] Although the drive mechanism 100 is shown herein as using a rack and pinion arrangement of drive gear 106 and ring gear 104, it should be understood that any other suitable drive mechanism 100 may be used according to alternative embodiments. For example, the drive mechanism 100 may include a magnetic drive system, a belt drive system, a friction roller drive system, or any other mechanical connection between the print head 42 and the support ring 80 that allows and facilitates selective movement between the two.

[0070] Additionally, in one embodiment, the support ring 80 may have a diameter substantially equal to the diameter of the tower structure 12. However, it is desirable to print the tower structure 12 with a non-fixed diameter or a tapered profile. Furthermore, as in, for example... Figure 5 As shown, the tower structure 12 may include an outer tower wall 120 spaced radially R from the inner tower wall 122. For example, the outer tower wall 120 may be printed to define a mold for receiving poured concrete, for example, to reduce printing time and overall construction time.

[0071] Therefore, as shown, the additive printing apparatus 40 may include a plurality of concentric support rings 80 and a print head 42 for simultaneously printing each of the outer tower wall 120 and the inner tower wall 122. Specifically, as shown, the outer support ring 124 may be positioned above the outer tower wall 120 and has a diameter substantially equal to that of the outer tower wall 120. Similarly, the inner support ring 126 may be located above the inner tower wall 122 and has a diameter substantially equal to that of the inner tower wall 122. It should be understood that, as used herein, approximate terms such as “approximate,” “substantially,” or “about” refer to a margin of error of ten percent. According to this exemplary embodiment, each of the outer support ring 124 and the inner support ring 126 may respectively include a dedicated print head 42 and / or other modules facilitating the printing process of the outer tower wall 120 and the inner tower wall 122.

[0072] Refer again Figure 4 The printhead 42 may include mechanisms for adjusting the position of the nozzle 44 on the printhead 42. For example, the printhead 42 may include a radial adjustment mechanism 130 configured to move the print nozzle 44 in a radial direction R. In particular, according to the illustrated embodiment, the radial adjustment mechanism 130 includes a slide rail 132 mounted on the bottom 134 of the printhead 42. The slide rail 132 extends substantially in a radial direction and is configured to slidably receive the nozzle 44.

[0073] The radial adjustment mechanism 130 may also include an actuation mechanism 136 that moves the print nozzle 44 radially within the slide rail 132. For example, the actuation mechanism 136 may include any suitable actuator or positioning mechanism for moving the nozzle 44 within the slide rail 132. In this respect, for example, the actuation mechanism 136 may include one or more of a plurality of linear actuators, servo motors, track conveyor systems, rack and pinion mechanisms, ball screw linear sliders, etc.

[0074] Still refer to Figure 3 and Figure 4 The additive printing apparatus 40 may include any other suitable number of subsystems or modules to facilitate and improve the printing process or to improve the finishing of the tower structure 12. For example, such as Figure 4 As best shown, the additive printing apparatus 40 may include a reinforcement module 140 movably coupled to a support ring 80 and configured to at least partially embed one or more support members 142 within the tower structure 12. In this respect, for example, the reinforcement module 140 may resemble a print head 42, engaging the support ring 80 and being movable about the periphery 102 of the support ring 80 while depositing the support members 142.

[0075] For example, as briefly explained below, according to an exemplary embodiment, the support member 142 may be a reinforcing rib (i.e., a steel bar), a tension cable, or any other suitable structural support member. For example, as Figure 2 As shown, the reinforcement module 140 can at least partially embed one or more reinforcement members 30 within one or more portions of the tower structure 12. In this respect, the reinforcement module 140 positions the reinforcement members 30 at least partially within the tower structure 12. It should be understood that such reinforcement members 30 can be positioned along the entire height of the tower structure 12 (e.g., as shown in the diagram). Figure 2 (as shown in the diagram) or extends only along a portion of the tower height.

[0076] According to an exemplary embodiment, as the tower structure 12 is configured, the additive printing apparatus 40 can alternate between depositing the reinforcing component 30 using the reinforcing module 140 and printing the adhesive material 28 using the print head 42 and nozzle 44. Alternatively, as Figure 3 and Figure 4 As shown, the reinforcement module 140 may be positioned near the print head 42 and configured to unfold or unwind the reinforcement member 30 or reinforcing bar into the printing area prior to the deposition of the adhesive material 28, such that the reinforcement member 30 becomes embedded within or printed above the adhesive material 28. Alternatively, the additive printing apparatus 40 may include any other suitable features for compressing or embedding the tension cable 30 into the adhesive material 28 prior to solidification or curing of the adhesive material. In an alternative embodiment, the additive printing apparatus 40 is configured to jet the adhesive material 28 having short polymer and / or metal fibers or rings as reinforcements to improve the structural strength of the tower structure 12.

[0077] Furthermore, the reinforcing member 30 can generally be configured to ensure that the stress in the bonding material 28 (e.g., concrete) remains highly compressible. Therefore, the reinforcing member 30 can be pre-tensioned in the bonding material 28 and can be printed around the reinforcing member 30, or the printing process can define holes throughout the tower structure 12 through which the reinforcing member 30 can be placed after curing and then post-tensioned. Additionally, the reinforcing member 30 can be used to place cables, reinforcing bars, and / or subsequently grouting. In an alternative embodiment, the additive printing apparatus 40 can be configured to provide tension to the reinforcing member 30 during the printing of the tower structure 12. In such embodiments, the additive printing apparatus 40 can vary the tension of the reinforcing member 30 according to the cross-section of the tower structure 12 during the printing process. Therefore, this reinforcing member 30 is configured to manipulate the tensile stress of the tower structure 12.

[0078] In another embodiment, the tower structure 12 may include, for example, a plurality of reinforcing ribs formed in a cylindrical configuration arranged to correspond to the shape of a metal mesh (not shown). Furthermore, the cylindrical metal mesh may be periodically embedded into the adhesive material 28 of the tower structure 12 along its height before the material 28 cures. Additionally, the additive printing apparatus 40 is configured to print the adhesive material 28 in a manner that takes into account its curing rate, such that the tower wall 20 (as it is formed) can be bonded to itself. Furthermore, the additive printing apparatus 40 is configured to print the tower structure 12 in a manner that allows it to withstand the weight of the wall 20, because the adhesive material 28 formed additively during printing may be relatively weak.

[0079] Furthermore, while the description herein relates to printing the tower structure 12 from a single material (e.g., concrete), it should be understood that any suitable material (even if different from other sections) can be used to print the tower structure 12. Additionally, the tower structure 12 can have any suitable cross-sectional profile. In this respect, as shown, the tower structure 12 can be substantially cylindrical or have a circular cross-section. However, according to other embodiments, the tower structure 12 can be polygonal, elliptical, egg-shaped, square, teardrop-shaped, airfoil-shaped, or any other suitable shape. Furthermore, according to yet another embodiment, depending on its vertical position along the tower structure 12, the tower structure 12 can be conical or vary in cross-sectional area.

[0080] Now refer to Figure 6 This diagram illustrates a block diagram of one embodiment of a controller 190 for an additive printing apparatus 40. As shown, the controller 190 may include one or more processors 192 and associated memory devices 194, configured to perform various computer-implemented functions (e.g., performing methods, steps, calculations, etc., as disclosed herein, and storing related data). Additionally, the controller 190 may include a communication module 196 to facilitate communication between the controller 190 and various components of the additive printing apparatus 40. Furthermore, the communication module 196 may include a sensor interface 198 (e.g., one or more analog-to-digital converters) to allow signals transmitted from one or more sensors or feedback devices to be converted into signals that can be understood and processed by the processors 192. It should be understood that these sensors and feedback devices can be communicatively coupled to the communication module 196 using any suitable means, for example, via a wired or wireless connection using any suitable wireless communication protocol known in the art.

[0081] As used herein, the term "processor" refers not only to integrated circuits considered to be included in a computer in the art, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits (ASICs), and other programmable circuits. Processor 192 is also configured to compute advanced control algorithms and communicate via various Ethernet or serial-based protocols (Modbus, OPC, CAN, etc.). Additionally, memory device 194 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, high-density optical disc-read-only memory (CD-ROM), magneto-optical disc (MOD), digital versatile disc (DVD), and / or other suitable memory elements). Such memory device 194 may generally be configured to store suitable computer-readable instructions that, when executed by processor 192, configure controller 190 to perform the various functions described herein.

[0082] Now refer to Figure 7 This document provides a flowchart of one embodiment of a method 200 for manufacturing a tower structure for a wind turbine using an additive printing apparatus. Specifically, method 200 can be used to form a tower structure 12 of a wind turbine 10 using additive printing apparatus 40, or to form any other suitable tower or tall concrete structure using any other suitable additive printing apparatus. In this respect, for example, controller 190 may be configured to implement method 200. However, it should be understood that only exemplary method 200 is discussed herein to describe exemplary aspects of this disclosure and is not intended to be limiting.

[0083] In addition, although Figure 7 The control method described herein has steps performed in a specific order for illustrative and explanatory purposes. Those skilled in the art will understand using the disclosure provided herein that any method steps described herein can be adjusted, rearranged, extended, omitted, or modified in various ways without departing from the scope of this disclosure. Furthermore, while aspects of the method explained relating to, for example, tower structure 12 and additive printing apparatus 40, should be understood that these methods can be applied to the operation of the additive printing apparatus to form any suitable tower structure.

[0084] Furthermore, as described herein, it may be advantageous to incorporate one or more prefabricated components into the tower structure 12. Accordingly, method 200 described herein provides a method for manufacturing a tower structure incorporating such prefabricated components using an additive printing apparatus. In particular, as shown at (202), method 200 includes providing an additive printing apparatus 40 having at least one printhead 42 disposed on top of a support surface. For example, Figure 3-5The additive printing apparatus 40 can be used to perform the method 200 described herein. Thus, as previously explained, method 200 may include positioning a vertical support structure 50 above a support surface 15 of the tower structure 12, suspending a support member from the vertical support structure 50 (such as a support ring 80), and movably coupling a print head 42 to the support member.

[0085] Backward reference Figure 7 As shown at (204), method 200 also includes positioning the prefabricated member 90 near the support surface 15 (see example). Figure 8 In particular, such as Figure 8 and Figure 9 As shown, the prefabricated component 90 can be, for example, a prefabricated door assembly 92 of the tower structure 12. Figure 8 ) or prefabricated base components 94 of tower structure 12 Figure 9 Furthermore, as shown, the precast member 90 is constructed of a composite material 34 (which may be the same as or different from the previously described bonding material 28) and is reinforced using a plurality of reinforcing members 30. Thus, as shown, portions 38 of the reinforcing members 30 protrude from the composite material 34.

[0086] Accordingly, such as Figure 7 As shown at (206), method 200 includes printing and depositing an adhesive material 36 (which may be the same as or different from the previously described adhesive material 28) onto a support surface 15 via the print head 42 of an additive printing apparatus 40 to build a tower structure 12 layer by layer around the prefabricated member 90. Thus, once the tower structure 12 is completed and cured, the portion 38 of the reinforcing member 30 protruding from the composite material 34 reinforces the adhesive material 36 around the prefabricated member 90.

[0087] Now refer to Figure 8 and 9 The prefabricated component 90 described herein may include any suitable prefabricated component formed in a variety of ways. For example, in a particular embodiment, such as Figure 8 As shown and mentioned, the prefabricated component 90 may be a prefabricated door assembly 92 of the tower structure 12. Specifically, as... Figure 8 The illustration shows a prefabricated door assembly 92 having a door frame 93 defining a passageway opening 95, and a door 97 for moving between an open position exposing the passageway opening 95 and a closed position covering the passageway opening 95. In such embodiments, as Figure 8 As shown in the illustration, the reinforcing member 30 is arranged within the composite material 34 surrounding the passage opening 95. More specifically, in some embodiments, as shown, the reinforcing member 30 may be arranged within the composite material 34 at multiple different angles relative to the passage opening 95.

[0088] Now refer to Figure 9As mentioned, the prefabricated component 90 may be a prefabricated base assembly 94. Furthermore, as shown, the prefabricated base assembly 94 may include a plurality of base segments 97. Therefore, in some embodiments, method 200 may include arranging the plurality of base segments 97 together to form the base of the tower structure 12. In such embodiments, as shown, a gap 98 exists between each of the plurality of base segments 97, wherein a portion 38 of the reinforcing member 30 protrudes from the composite material 34 within the gap 98.

[0089] Furthermore, as mentioned, this prefabricated component 90 can be constructed prior to printing the tower structure 12, allowing the component 90 to be easily assembled therein. For example, in one embodiment, the prefabricated component 90 can be formed via on-site or off-site casting. In an alternative embodiment, the prefabricated component 90 can be formed via additive printing apparatus 40 before positioning the component 90 near the support surface 15 of the tower structure 12 to print the remainder of the structure 12, i.e., by printing and depositing composite material 34 via printhead 42 to form the prefabricated component 90.

[0090] In one embodiment, such as Figure 10-12 As shown, method 200 may include vertically printing and depositing composite material 34 via print head 42 to form prefabricated component 90. In such embodiments, such as in... Figure 12 As shown, the print head 42 can vertically print and deposit composite material 34 through a path having inlet 101, such that the composite material 34 flows vertically downwards through a path defined by one or more baffles 103. Additionally, as... Figure 12 As shown, the path may also include an exhaust section 105 to help the composite material 34 flow through it.

[0091] In addition, such as Figure 11 As shown, one or more layers 107 of the prefabricated component 90 may be formed to include one or more holes 99. Therefore, in such embodiments, as Figure 10 As shown, method 200 may further include placing at least one of a plurality of reinforcing members 30 within each of a plurality of holes to reinforce the prefabricated member 90. In some embodiments, the print head 42 may vertically print and deposit composite material 34 off-site to form the prefabricated member 90, in which case the reinforcing member 30 may be placed on-site within the holes 99 to reinforce the prefabricated member 90. Accordingly, the prefabricated member 90 without the reinforcing member 30 may be more easily transported to the site (e.g., because it is lighter and does not have the protruding reinforcing member 30), in which case the reinforcing member 30 may be incorporated.

[0092] Still refer to Figure 11In a particular embodiment, method 200 may further include placing a loop 109 in each of the plurality of holes 99 before placing the reinforcing member 30 in the holes 99. In such embodiments, the loop 109 (e.g., which may be formed of a flexible material such as rubber or a metallic material such as steel) at least partially fills the holes 99 and surrounds the reinforcing member 30 to prevent leakage.

[0093] Now refer to Figure 13 and 14 Method 200 may include horizontally printing and depositing composite material 34 via print head 42 to form a preform 90. As used herein, horizontal printing generally refers to the print head 42 printing layer 107 along the thickness direction. In such embodiments, particularly as Figure 14 As shown, method 200 may include placing at least one of the reinforcing members 30 between layers 107 of the prefabricated member 90 while horizontally printing and depositing the prefabricated member 90. Moreover, in such embodiments, as... Figure 13 As shown, the printer head 42 can print composite material 34 to form dovetail features 111 (e.g., around the periphery of the door frame 93).

[0094] Other aspects of the invention are provided by the subject matter of the following provisions: Clause 1. A method for manufacturing a tower structure, the method comprising: An additive printing apparatus having at least one print head on top of a support surface is provided; Positioning the precast component near a support surface, the precast component being constructed of a composite material reinforced with multiple reinforcing members, portions of which protrude from the composite material; and Adhesive material is printed and deposited onto a support surface via at least one print head to build a tower structure layer by layer around a precast component, wherein multiple reinforcing members protruding from the composite material partially reinforce the adhesive material around the precast component.

[0095] Clause 2. The method of Clause 1, wherein the additive printing apparatus having at least one printhead on top of the support surface of the tower structure further comprises: Position the vertical support structure above the support surface of the tower structure; The supporting components are suspended from the vertical support structure; and At least one printhead is movably connected to the support component.

[0096] Clause 3. Any method described in the foregoing clauses, wherein the prefabricated component includes at least one of a prefabricated door assembly or a prefabricated base assembly.

[0097] Clause 4. The method of Clause 3, wherein the prefabricated door assembly includes a door frame defining a passageway opening, and a door for moving between an open position exposing the passageway opening and a closed position covering the passageway opening.

[0098] Clause 5. The method of Clause 4, wherein multiple reinforcing components are arranged within the composite material around the passage opening.

[0099] Clause 6. The method of Clause 5, wherein multiple reinforcing members are arranged within the composite material at multiple different angles relative to the passage opening.

[0100] Clause 7. The method of Clause 3, wherein the prefabricated base assembly further includes multiple base segments, the method further includes: Multiple base segments are arranged together to form the base of the tower structure, wherein there is a gap between each of the multiple base segments, and portions of multiple reinforcing members protrude from the composite material within the gap.

[0101] Clause 8. Any method described in the foregoing clauses also includes constructing precast components by means of precast composite materials to form precast components off-site.

[0102] Clause 9. Any method described in the foregoing clauses also includes constructing precast components by casting composite materials to form precast components on-site before positioning them near the support surface of the tower structure.

[0103] Clause 10. Any method described in the preceding clauses also includes constructing a precast component by printing and depositing composite material via at least one print head to form the precast component before positioning it near the support surface of the tower structure.

[0104] Clause 11. The method of Clause 10 also includes vertically printing and depositing composite materials via at least one print head to form a prefabricated component.

[0105] Clause 12. The method of Clause 11, wherein vertical printing and deposition of composite material via at least one print head to form prefabricated components in the field further includes: Vertical printing and deposition of composite material via at least one print head to form a prefabricated component having a plurality of holes formed therein; and At least one of a plurality of reinforcing components is placed inside each of a plurality of holes to reinforce the precast component.

[0106] Clause 13. The method of Clause 12 further includes vertically printing and depositing composite material via at least one print head to form a precast component off-site, and placing at least one of a plurality of reinforcing members within each of a plurality of holes to reinforce the precast component on-site.

[0107] Clause 14. The method of Clause 12 further includes placing a grommets in each of the plurality of holes before placing at least one of the plurality of reinforcing members in each of the plurality of holes.

[0108] Clause 15. The method of Clause 10 further includes horizontally printing and depositing composite material via at least one print head to form a prefabricated component.

[0109] Clause 16. The method of Clause 15 further includes placing at least one of a plurality of reinforcing members between layers of the precast member when horizontally printing and depositing the precast member.

[0110] Clause 17. Any method in the preceding clauses, wherein the composite material comprises at least one of a polymer, concrete, asphalt resin, asphalt, clay, adhesive, mortar, or bonding composition, and wherein the bonding material comprises at least one of concrete, asphalt resin, asphalt, clay, adhesive, mortar, or bonding composition.

[0111] Clause 18. Any method described in the foregoing clauses, wherein the tower structure is part of a wind turbine.

[0112] Clause 19. A method of manufacturing a tower structure, the method comprising: Prefabricated components are constructed by printing and depositing composite materials via at least one print head, layer by layer. The bonding material is reinforced using multiple reinforcing components, with portions of the reinforcing components protruding from the composite material; and Precast components are bonded to an adhesive material to form a tower structure, wherein multiple reinforcing members protruding from the composite material partially reinforce the adhesive material surrounding the precast components.

[0113] Clause 20. The method of Clause 19, wherein in which prefabricated components are bonded to an adhesive material to form a tower structure, further includes: Positioning the precast components on top of the supporting surface; and Adhesive material is printed and deposited onto the support surface via at least one printer head to build the tower structure layer by layer around the precast components.

[0114] 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 device or system and performing any combined methods. The patentable scope of the invention is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they comprise structural elements that are not different from the literal language of the claims, or if they comprise equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A method for manufacturing a tower structure, the method comprising: An additive printing apparatus having at least one print head on top of a support surface is provided; The prefabricated component is positioned near the support surface. The prefabricated component is made of a composite material reinforced with a plurality of reinforcing members, wherein portions of the plurality of reinforcing members protrude from the composite material. The prefabricated component includes at least one of a prefabricated door assembly or a prefabricated base assembly. as well as Adhesive material is printed and deposited onto the support surface via the at least one print head to build the tower structure layer by layer around the precast member, wherein portions of the plurality of reinforcing members protruding from the composite material reinforce the adhesive material around the precast member.

2. The method according to claim 1, wherein, The additive printing apparatus, which provides at least one printhead on top of the support surface of the tower structure, further includes: Position the vertical support structure above the support surface of the tower structure; The support component is suspended from the vertical support structure; and The at least one printer head is movably connected to the support member.

3. The method according to claim 1, wherein, The prefabricated door assembly includes a door frame defining a passage opening, and a door for moving between an open position exposing the passage opening and a closed position covering the passage opening.

4. The method according to claim 3, wherein, The plurality of reinforcing components are arranged within the composite material around the passage opening.

5. The method according to claim 4, wherein, The plurality of reinforcing components are arranged within the composite material at multiple different angles relative to the passage opening.

6. The method according to claim 1, wherein, The prefabricated base assembly further includes multiple base segments, and the method further includes: The plurality of base segments are arranged together to form the base of the tower structure, wherein there is a gap between each of the plurality of base segments, and portions of the plurality of reinforcing members protrude from the composite material within the gaps.

7. The method of claim 1, further comprising constructing the prefabricated component by precasting the composite material to form the prefabricated component off-site.

8. The method of claim 1, further comprising constructing the prefabricated component in the field by casting the composite material before positioning the prefabricated component near the support surface of the tower structure.

9. The method of claim 1, further comprising constructing the prefabricated member by printing and depositing the composite material via the at least one print head to form the prefabricated member before positioning the prefabricated member near the support surface of the tower structure.

10. The method of claim 9, further comprising vertically printing and depositing the composite material via the at least one print head to form the preform.

11. The method according to claim 10, wherein, Vertically printing and depositing the composite material via the at least one print head to form the prefabricated component in the field also includes: The composite material is vertically printed and deposited via the at least one print head to form the prefabricated component having a plurality of holes formed therein; and At least one of the plurality of reinforcing components is placed inside each of the plurality of holes to reinforce the prefabricated component.

12. The method of claim 11, further comprising vertically printing and depositing the composite material via the at least one print head to form the preform off-site, and placing at least one of the plurality of reinforcing members within each of the plurality of holes to reinforce the preform in-situ.

13. The method of claim 11, further comprising placing a grommets in each of the plurality of holes before placing at least one of the plurality of reinforcing members in each of the plurality of holes.

14. The method of claim 9, further comprising horizontally printing and depositing the composite material via the at least one print head to form the preform.

15. The method of claim 14, further comprising placing at least one of the plurality of reinforcing members between layers of the preform while horizontally printing and depositing the preform.

16. The method according to claim 1, wherein, The composite material includes at least one of a polymer, concrete, asphalt resin, asphalt, clay, adhesive, mortar, or adhesive composition, and wherein the adhesive material includes at least one of concrete, asphalt resin, asphalt, clay, adhesive, mortar, or adhesive composition.

17. The method according to claim 1, wherein, The tower structure is part of the wind turbine.

18. A method for manufacturing a tower structure, the method comprising: A prefabricated component is constructed layer by layer by printing and depositing composite material via at least one printhead, the prefabricated component comprising at least one of a prefabricated door assembly or a prefabricated base assembly; The bonding material is reinforced by multiple reinforcing members, such that portions of the multiple reinforcing members protrude from the composite material; as well as The prefabricated component is bonded to an adhesive material to form the tower structure, wherein portions of the plurality of reinforcing members protruding from the composite material reinforce the adhesive material surrounding the prefabricated component.

19. The method according to claim 18, wherein, Integrating the prefabricated components into the bonding material to form the tower structure further includes: Positioning the prefabricated component on top of the support surface; and The adhesive material is printed and deposited onto the support surface via the at least one printer head to build the tower structure layer by layer around the prefabricated component.

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