Method for manufacturing a wind turbine tower structure with embedded reinforcing elements

Abstract

A system for fabricating a structure includes a support frame assembly (104) movable in a vertical direction of the structure. Further, the system includes an additive printing assembly (118) secured to the support frame assembly. The additive printing assembly includes at least one printer head (120, 122, 130) configured to dispense a first cementitious material. The system also includes a reinforcement dispensing assembly (136) supported by the support frame assembly. Accordingly, the reinforcement dispensing assembly is configured to automatically and continuously dispense a plurality of reinforcement components as the structure is printed and built via the at least one printer head and as the support frame assembly is moved in the vertical direction.

Description

Technical Field

[0001] This disclosure generally relates to wind turbine towers, and more specifically, to a method of manufacturing a wind turbine tower structure with embedded reinforcement elements. 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 as rotational energy to rotate a shaft that connects the rotor blades to the gearbox, or, if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy into electrical energy, which can be deployed to the public power grid.

[0003] Wind turbine towers are generally constructed from steel pipes, precast 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 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 restricted by transportation 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 curved segments and securing the segments together on-site to form the tower's diameter, for example, via bolted connections. However, such methods require significant labor and can be time-consuming.

[0004] In view of the foregoing, there is a continuous 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. Specifically, this disclosure relates to a method for manufacturing wind turbine tower structures with embedded reinforcing elements. Summary of the Invention

[0005] 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.

[0006] In one aspect, this disclosure relates to a system for manufacturing structures, such as tower structures for wind turbines. The system includes a support frame assembly movable in the vertical direction of the structure. Furthermore, the system includes an additive printing assembly secured to the support frame assembly. The additive printing assembly includes at least one printer head configured to dispense a first cementitious material. The system also includes a reinforcement dispensing assembly supported by the support frame assembly. Thus, the reinforcement dispensing assembly is configured to automatically and continuously dispense a plurality of reinforcement components as the structure is printed and built via the at least one printer head, and as the support frame assembly moves in the vertical direction.

[0007] In one embodiment, the additive printing assembly may include at least an outer printer head for printing the outer wall of the structure and an inner printer head for printing the inner wall of the structure. Furthermore, in another embodiment, the additive printing assembly may include an intermediate printer head fixed between the outer and inner printer heads for filling the area between the outer and inner tower walls using a second cementitious material.

[0008] In some embodiments, the second cementitious material may be different from the first cementitious material. Specifically, in one embodiment, the second cementitious material may be a self-compacting cementitious material.

[0009] In another embodiment, the support frame assembly may include at least one annular platform assembly supported by a plurality of rod members. More specifically, in an embodiment, the annular platform assembly may include a platform supporting an outer annular support member and an inner annular support member arranged concentrically with each other, wherein a plurality of rod members extend between the outer annular support member and the inner annular support member. In a particular embodiment, both the outer annular support member and the inner annular support member may have an adjustable diameter.

[0010] In additional embodiments, the system may include lifting jacks capable of moving along each of a plurality of bar components to vertically move the support frame assembly by raising the outer and inner annular support components. In some embodiments, the lifting jacks may be hydraulically driven, pneumatically driven, or mechanically driven (such as via screws), and / or combinations thereof.

[0011] In another embodiment, the reinforcement distribution assembly may further include multiple roller devices, and the multiple reinforcement components may be reinforcement cables. In such embodiments, the reinforcement cables can be distributed from the multiple roller devices by automatically and continuously rolling the reinforcement cables under tension. Furthermore, in embodiments, the roller devices may be arranged on top of an outer annular support member or an inner annular support member.

[0012] Alternatively, the enhanced distribution assembly may include a plurality of pulley sets, wherein one of the plurality of pulley sets is arranged together with each of a plurality of roller assemblies, the plurality of pulley sets are arranged on top of at least one annular platform assembly, and the plurality of roller assemblies are arranged below the plurality of pulley sets.

[0013] In another embodiment, the enhanced dispensing assembly may include a plurality of feeder devices arranged on top of at least one of an outer annular support member or an inner annular support member. In such embodiments, the reinforcing member may be a reinforcing rod. Thus, the reinforcing rod can be dispensed from the plurality of feeder devices by automatically and continuously pushing the reinforcing rod from the plurality of feeder devices.

[0014] In another aspect, this disclosure relates to a method for manufacturing a structure. The method includes (a) providing a support frame assembly having at least one annular platform assembly supported by a plurality of rod members. Furthermore, the method includes (b) arranging an additive printing assembly and a reinforcement dispensing assembly together with the at least one annular platform assembly. Furthermore, the method includes (c) raising the at least one annular platform assembly a vertical distance by moving it along the plurality of rod members. Additionally, the method includes (d) dispensing a plurality of reinforcement members from the reinforcement dispensing assembly under tension. The method further includes (e) printing at least a portion of a structure made of at least one cementitious material via at least one printer head of the additive printing assembly to embed the dispensed plurality of reinforcement members therein.

[0015] In an embodiment, the method may include repeating steps (c) through (d) to complete the structure.

[0016] In another embodiment, moving at least one annular platform assembly vertically along a plurality of bar components may include hydraulically driving at least one annular platform assembly along the plurality of bar components via a plurality of lifting jacks.

[0017] In another embodiment, printing at least a portion of a structure made of at least one cementitious material via at least one printer head of the additive printing assembly may include: printing the outer and inner walls of the structure of a first cementitious material via an outer printer head and an inner printer head of the additive printing assembly; and filling the area between the outer and inner walls of the structure with a second cementitious material via an intermediate printer head fixed between the outer and inner printer heads. It should be understood that the method may also include any of the additional features and / or steps described herein.

[0018] These and other features, aspects, and advantages of the present 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, explain the principles of the invention. Attached Figure Description

[0019] The complete and practicable disclosure of the invention, including its best mode for those skilled in the art, is set forth in the description with reference to the accompanying drawings, in which:

[0020] Figure 1 A perspective view showing one embodiment of a wind turbine according to the present disclosure;

[0021] Figure 2 A cross-sectional view is shown of one embodiment of a wind turbine tower structure according to the present disclosure;

[0022] Figure 3 A partial perspective view is shown of one embodiment of a system for manufacturing tower structures according to the present disclosure;

[0023] Figure 4 A cross-sectional view is shown of one embodiment of a system for manufacturing tower structures according to the present disclosure;

[0024] Figure 5 A schematic diagram illustrating one embodiment of an enhanced distribution assembly for a system for manufacturing tower structures according to the present disclosure;

[0025] Figure 6 A schematic diagram illustrating another embodiment of an enhanced distribution assembly for a system for manufacturing tower structures according to the present disclosure;

[0026] Figure 7 A schematic diagram of yet another embodiment of an enhanced distribution assembly for a system for manufacturing tower structures according to the present disclosure is shown;

[0027] Figure 8 A top view is shown of one of the outer annular support component and the inner annular support component of a system for manufacturing a tower structure according to the present disclosure;

[0028] Figure 9 A flowchart illustrating one embodiment of a method for manufacturing a tower structure according to the present disclosure; and

[0029] Figure 10 A block diagram illustrating one embodiment of a controller for an additive printing apparatus according to the present disclosure is shown. Detailed Implementation

[0030] Reference will now be made in detail to embodiments of the invention, one or more of which are illustrated in the accompanying drawings. Each example is provided by way of illustration and not by way of limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the invention without departing from the scope or spirit of the invention. For example, a feature shown 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 that fall within the scope of the appended claims and their equivalents.

[0031] Generally, this disclosure relates to systems and methods for manufacturing structures (such as tower structures) via automated deposition of cementitious materials using 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 systems and methods of this disclosure include automated reinforcement integration modules to progressively supply reinforcement components into the tower structure during the construction process, allowing for the incorporation of continuous vertical reinforcement components into the finished concrete structure.

[0032] Therefore, the methods described herein offer many advantages not found in the prior art. For example, the systems and methods of this disclosure allow for the automation of integrating both vertical and horizontal reinforcement components into the tower structure during construction, enabling full automation of concrete structure construction, simplifying the construction process at a faster pace, providing both steel cables and conventional reinforcing bars as reinforcements, and directly forming the conduits necessary for post-tensioning or cable laying in the concrete tower.

[0033] Now refer to the attached diagram, Figure 1 An 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 support surface, with a nacelle 14 mounted on top of the tower 12. A plurality of rotor blades 16 are mounted on 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. Provided for illustrative purposes only. Figure 1 The views provided are intended to place the invention within an exemplary field of application. 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 having concrete structures and / or tall towers other than wind turbine towers, including, for example, residential buildings, bridges, tall towers, and other aspects of the concrete industry. Moreover, the methods described herein can also be applied to the manufacture of any similar structures that benefit from the advantages described herein.

[0034] Now refer to Figure 2This illustration shows a cross-sectional view of the tower structure 12 of a wind turbine 10 manufactured according to the present disclosure. As shown in the illustrated embodiment, the tower structure 12 defines a 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. Furthermore, as shown, the tower structure 12 is formed of a cementitious material 28, which is reinforced using one or more reinforcing elements 30. In certain embodiments, the reinforcing elements 30 may include, for example, elongated reinforcing cables or wires, reinforcing rods (also referred to as reinforcing bars) (hollow or solid), fibers (such as metal, glass, or carbon fiber), and / or any such structure or material known in the art for reinforcing concrete structures. For example, as shown... Figure 2 As shown, the tower structure 12 may include a plurality of pre-tensioned linear cables 32 embedded in cementitious material 28.

[0035] Additionally, the cementitious material 28 described herein may include any suitable processable paste configured to bond together after curing to form a structure. As examples, the cementitious material may include lime or calcium silicate-based hydraulic binders such as Portland cement, fly ash, blast furnace slag, volcanic ash, limestone powder, gypsum, or silica fume, and combinations thereof. In some embodiments, the cementitious material 28 may additionally or alternatively include non-hydraulic binders such as slaked lime and / or other materials hardened by carbonation. The cementitious material may be combined with fine aggregates (e.g., sand) to form mortar, or with coarse aggregates (sand and gravel) to form concrete, including both cement-based and non-cement-based concrete. For example, in some embodiments, the cementitious material may include geopolymer concrete, biopolymer concrete, or any other suitable concrete. Cementitious materials can be provided in the form of slurry, which can be formed by combining any one or more cementitious materials with water and other known additives, including accelerators, retarders, expanders, weight-increasing agents, dispersants, filtration control agents, loss-of-cycle agents, strength retreat inhibitors, free water / free fluid control agents, expansive agents, plasticizers (e.g., superplasticizers, such as polycarboxylate superplasticizers or polynaphthalene sulfonate superplasticizers), etc. The relative amounts of the respective materials to be provided in the cementitious material can be varied in any way to achieve the desired effect.

[0036] Now refer to Figure 3-9This disclosure relates to systems and methods for manufacturing tower structures (such as wind turbine towers) via additive manufacturing. As used herein, additive manufacturing is generally understood to encompass a process for synthesizing three-dimensional objects, wherein continuous layers of material are formed under computer control to create the object. In this regard, 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 can encompass three degrees of freedom, as well as more than three 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.

[0037] Special reference Figure 3 This figure shows a perspective view of one embodiment of a system 100 for manufacturing a tower structure 102 according to the present disclosure. As shown, the system 100 includes a support frame assembly 104, which is movable in the vertical direction of the tower structure 102. More specifically, as Figure 3 and Figure 4 As shown, the support frame assembly 104 may include an annular platform assembly 106 supported by a plurality of rod members 108. For example, as shown in the illustrated embodiment, the annular platform assembly 106 may include a platform 110 supporting an outer annular support member 112 and an inner annular support member 114, which are arranged concentrically with each other, wherein a plurality of rod members 108 extend between the outer annular support member 112 and the inner annular support member 114.

[0038] In certain embodiments, both the outer annular support member 112 and the inner annular support member 114 can have adjustable diameters. For example, as Figure 8 As shown, the outer annular support member 112 and the inner annular support member 114 may be segmented, with segments 115 connected together via a slidable hollow sleeve 117. Thus, as shown, the slidable hollow sleeve 117 is configured to receive segments 115 of different lengths to adjust the diameters of the outer annular support member 112 and the inner annular support member 114. In some embodiments, the hollow sleeve 117 and / or the segments 115 may be sufficiently flexible to allow the radius of curvature to vary within the range of the tower diameter. Therefore, the outer annular support member 112 and the inner annular support member 114 can be adjusted to accommodate tower structures of different sizes.

[0039] Now, specifically refer to Figure 3 and Figure 4System 100 may include a lifting jack 116 movable along each of a plurality of bar members 108 to move the support frame assembly 104 in the vertical direction V (i.e., by continuously or incrementally raising the outer annular support member 112 and the inner annular support member 114). In some embodiments, the lifting jack 116 may be a hydraulically driven screw jack. In other embodiments, the lifting jack 116 may be driven by any suitable means (such as pneumatic means, mechanical means, etc.). Thus, by raising the lifting jack(s) 116, the support frame assembly 104 can be raised to any desired height.

[0040] Special reference Figure 3 The system 100 also includes an additive printing assembly 118 mounted on a support frame assembly 104. It should be understood that the additive printing assembly 118 described herein generally refers to any suitable additive printing device having one or more nozzles or printer heads for depositing material (such as the cementitious material described herein) onto a surface automatically controlled by a controller to form an object programmed within a computer (such as a CAD file). More specifically, as shown, the additive printing assembly 118 may include at least one printer head 120, 122 configured to dispense a first cementitious material 124. For example, in... Figure 3 In the embodiment shown, the additive printing assembly 118 may include at least an outer printer head 120 for printing the outer wall 126 of the tower structure 102 and an inner printer head 122 for printing the inner wall 128 of the tower structure 102.

[0041] Furthermore, as shown, the additive printing assembly 118 may also include an intermediate printer head 130 fixed between the outer printer head 120 and the inner printer head 122. In this regard, in some embodiments, the intermediate printer head 130 may be a pump for filling the region 132 between the outer tower wall 126 and the inner tower wall 128 with a second cementitious material 134, which may be different from the first cementitious material 124. Specifically, in one embodiment, the first cementitious material 124 may be quick-setting concrete. Therefore, the printed outer and inner walls can harden very rapidly, and the hydrostatic pressure of the poured concrete can thus be maintained. Therefore, the second cementitious material 134 may be a self-compacting cementitious material. In other embodiments, the additive printing assembly 118 may include any suitable number of printer heads, comprising more than three printer heads or fewer than three printer heads.

[0042] Now refer to Figure 3-7The system 100 also includes a reinforcement distribution assembly 136 supported by a support frame assembly 104. Therefore, the reinforcement distribution assembly 136 is configured to automatically and continuously distribute a plurality of reinforcement members 138 as the tower structure 102 is printed and built via the printer heads(multiple) 120, 122, 130, and as the support frame assembly 104 moves in the vertical direction V. For example, as Figure 3-5 and Figure 7 As shown, the reinforcement distribution assembly 136 may include a plurality of roller devices 140. In such embodiments, the reinforcement member 138 may be a reinforcement cable 142 or wire. In such embodiments, for example, the reinforcement cable 40 may be distributed from the roller device 140 by automatically and continuously rolling the reinforcement cable 142 under tension from the roller device 140. Furthermore, in... Figure 3-5 In the embodiment shown, the roller assembly 140 may be arranged on top of the outer annular support member 112 or the inner annular support member 114.

[0043] Alternative locations, such as Figure 7 As shown, the enhanced distribution assembly 136 may include a plurality of pulley sets 144, wherein one of the plurality of pulley sets 144 is arranged together with each of the plurality of roller assemblies 140. Thus, as shown, the pulley sets 144 may be arranged on top of the outer annular support member 112 or the inner annular support member 114, and the roller assemblies 140 may be arranged below the pulley sets 144, such as on the ground.

[0044] Reference Figure 6 In an alternative embodiment, the enhanced dispensing assembly 136 may include a plurality of feeder devices 146 arranged on top of the outer annular support member 112 or the inner annular support member 114. In such embodiments, the reinforcing member 138 may be a reinforcing rod. Thus, as shown, the reinforcing rod 148 can be dispensed from the feeder device 146 by automatically and continuously pushing it from the feeder device 146.

[0045] Special reference Figure 9 The diagram illustrates a flowchart of one embodiment of a method 200 for manufacturing a tower structure 102 according to the present disclosure. Generally, method 200 will be described herein with reference to tower structure 102 (such as a wind turbine tower), which uses... Figure 3-8 The system 100 shown is formed. However, it should be recognized that the disclosed method 200 can be implemented to form other similar tower structures with any other suitable construction. Furthermore, although for illustrative and explanatory purposes, Figure 9The steps described herein are performed in a specific order, 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 the individual 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.

[0046] As shown at (202), method 200 may include providing the support frame assembly 104 described herein. As shown at (204), method 200 may include arranging the additive printing assembly 118 and the reinforcement dispensing assembly 136 together with the annular platform assembly 106 of the support frame assembly 104. As shown at (206), method 200 may include raising the annular platform assembly 106 in the vertical direction V a certain distance by moving the annular platform assembly 106 along a plurality of bar members 108, for example, via a plurality of lifting jacks 116.

[0047] When or after the annular platform assembly 106 is raised, as shown at (208), method 200 may include distributing a plurality of reinforcement members 138 from reinforcement distribution assembly 136. For example, as mentioned, in an embodiment, the reinforcement members 138 may be reinforcement cables 142 that unfold from rolling device 140 under tension. Alternatively, as mentioned, the reinforcement members 138 may be reinforcement rods 148 that are pushed downward and into spaces that will eventually be filled or printed with cementitious material.

[0048] It should be understood that the reinforcement members 138 may extend along the entire height of the tower structure 102 or only along a portion of the tower height. Additionally, in such embodiments, the additive printing assembly 118 is configured to print a cementitious material around the reinforcement members 138. In alternative embodiments, the reinforcement distribution assembly 136 may be configured to provide tension to the reinforcement members 138, such as when the members are cables, during printing of the tower structure 102 and / or during the raising of the support frame assembly 104. In such embodiments, method 200 may also include varying the tension of one or more reinforcement members 138 as the cross-section of the tower structure 102 changes during the printing process. Therefore, such reinforcement members 138 are configured to manage tensile stresses in the tower structure 102.

[0049] Still refer to Figure 9 As shown at (210), method 200 may include printing at least a portion of a tower structure 102 made of at least one cementitious material via at least one printer head of additive printing assembly 118 to embed distributed plurality of reinforcing members 138 therein. For example, in... Figure 4In the embodiments shown, method 200 may include printing the outer walls 126 and inner walls 128 of the tower structure 102 of a first cementitious material 124 via the outer printer head 120 and inner printer head 122 of the additive printing assembly 118. These walls 126, 128 may be printed simultaneously to save time, or printed individually as needed. Next, method 200 may include filling the area 132 between the outer walls 126 and inner walls 128 with a second cementitious material 134 via an intermediate printer head 130 fixed between the outer printer head 120 and the inner printer head 122 to completely cast the tower structure 102. This process (i.e., steps 206, 208, and 210) may be repeated to complete the tower structure 102 up to any suitable height. Furthermore, in some embodiments, the rod members 108 of the support frame assembly 104 may be removed after the construction of the tower structure 102, thereby creating holes or channels that can be used as conduits for post-tensioning rods or cables.

[0050] Additionally, in some embodiments, the additive printing assembly 118 is configured to print the cementitious material in a manner that takes into account the curing rate of the cementitious material, such that the tower structure 102 can be bonded to itself during its formation. Furthermore, the additive printing assembly 118 is configured to print the tower structure 102 in such a way that the tower structure 102 can withstand the weight of the walls 126, 128 even when the additively formed cementitious material may be fragile during printing. Therefore, the tower structure 12 is provided with (a plurality of) reinforcing elements 138 to enable the tower to withstand wind loads that could make the tower 12 susceptible to breakage.

[0051] Now refer to Figure 10 This diagram illustrates a block diagram of one embodiment of a controller 300 configured to control the additive printing assembly 118 described herein. As shown, the controller 300 may include one or more processors 302 and associated storage devices 304 configured to perform various computer-implemented functions (e.g., performing methods, steps, calculations, etc., and storing related data, as disclosed herein). Additionally, the controller 300 may include a communication module 306 to facilitate communication between the controller 300 and various components of the additive printing assembly 118. Furthermore, the communication module 306 may include a sensor interface 308 (e.g., one or more analog-to-digital converters) to allow signals transmitted from one or more sensors 310, 312 to be converted into signals that can be understood and processed by the processors 302. It should be appreciated that the sensors may be communicatively coupled to the communication module 306 using any suitable means. For example, as... Figure 10As shown, sensors 310, 312 may be coupled to sensor interface 308 via a wired connection. However, in other embodiments, sensors 310, 312 may be coupled to sensor interface 308 via a wireless connection (such as by using any suitable wireless communication protocol known in the art). In this regard, processor(s) 302 may be configured to receive one or more signals from the sensors.

[0052] 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. The processor(s) 302 are also configured to compute advanced control algorithms and communicate with various Ethernet or serial-based protocols (Modbus, OPC, CAN, etc.). Additionally, the storage device(s) 304 may generally include storage 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, optical disc read-only memory (CD-ROM), magneto-optical disc (MOD), digital versatile optical disc (DVD), and / or other suitable storage elements. Such storage device(s) 304 may generally be configured to store suitable computer-readable instructions that, when implemented by the processor(s) 302, configure the controller 300 to perform various functions as described herein.

[0053] This written description uses examples to disclose the invention (including the best mode) and also enables those skilled in the art to practice the invention (including making and using any device or system and performing any incorporated methods). The patentable scope of the invention is defined by the claims and may include other examples that may 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 significantly different from the literal language of the claims.

Claims

1. A system for manufacturing a structure, the system comprising: A support frame assembly that is movable in the vertical direction of the structure; An additive printing assembly, which is fixed to the support frame assembly, the additive printing assembly including at least one printer head configured to dispense a first cementitious material; as well as, A reinforcement distribution assembly, supported by the support frame assembly, is configured to automatically and continuously distribute a plurality of reinforcement components as the structure is printed and built via the at least one printer head, and as the support frame assembly moves in the vertical direction. The support frame assembly includes at least one annular platform assembly supported by a plurality of rod components. The at least one annular platform assembly includes a platform supporting an outer annular support member and an inner annular support member, the outer annular support member and the inner annular support member being arranged concentrically with each other, wherein the plurality of rod members extend between the outer annular support member and the inner annular support member, and The system further includes a lifting jack arranged together with each of the plurality of rod components and movable along each of the plurality of rod components to move the support frame assembly in the vertical direction by raising the outer annular support component and the inner annular support component.

2. The system according to claim 1, wherein, The at least one printer head of the additive printing assembly further includes at least an outer printer head for printing the outer wall of the structure and an inner printer head for printing the inner wall of the structure.

3. The system according to claim 2, wherein, The additive printing assembly also includes an intermediate printer head, which is mounted between the outer printer head and the inner printer head, for filling the area between the outer tower wall and the inner tower wall with a second cementitious material.

4. The system according to claim 3, wherein, The second cementitious material is different from the first cementitious material.

5. The system according to claim 4, wherein, The second cementitious material is a self-compacting cementitious material.

6. The system according to claim 1, wherein, Both the outer annular support component and the inner annular support component include an adjustable diameter.

7. The system according to claim 1, wherein, The lifting jack is driven by at least one of hydraulic, pneumatic or mechanical means.

8. The system according to claim 1, wherein, The reinforcement distribution assembly also includes a plurality of roller devices, the plurality of reinforcement components including reinforcement cables, which are distributed from the plurality of roller devices by automatically and continuously rolling the reinforcement cables under tension.

9. The system according to claim 8, wherein, The plurality of roller devices are arranged on top of at least one of the outer annular support member or the inner annular support member.

10. The system according to claim 1, wherein, The enhanced distribution assembly also includes a plurality of pulley groups, wherein one of the pulley groups is arranged together with each of the plurality of roller devices, the plurality of pulley groups being arranged on top of the at least one annular platform assembly, and the plurality of roller devices being arranged below the plurality of pulley groups.

11. The system according to any one of claims 1 to 10, wherein, The enhanced dispensing assembly further includes a plurality of feeder devices disposed on top of at least one of the outer annular support member or the inner annular support member, the plurality of reinforcing members including a reinforcing rod, wherein the reinforcing rod is dispensed from the plurality of feeder devices by automatically and continuously pushing the reinforcing rod from the plurality of feeder devices.

12. A method for manufacturing a structure, the method comprising: (a) Provide a support frame assembly having at least one annular platform assembly supported by a plurality of rod components; (b) Arrange the additive printing assembly and the reinforcement dispensing assembly together with the at least one annular platform assembly; (c) The at least one annular platform assembly is raised a certain distance in the vertical direction by moving the at least one annular platform assembly along the plurality of bar components; (d) Distribute multiple enhancement components from the enhancement allocation component; (e) At least a portion of the structure is printed via at least one printer head of the additive printing assembly using at least one cementitious material to embed the distributed plurality of reinforcing members within in, The at least one annular platform assembly includes a platform supporting an outer annular support member and an inner annular support member, the outer annular support member and the inner annular support member being arranged concentrically with each other, wherein the plurality of rod members extend between the outer annular support member and the inner annular support member, and The movement of the at least one annular platform assembly along the plurality of bar components in the vertical direction further includes hydraulically driving the at least one annular platform assembly along the plurality of bar components via a plurality of lifting jacks.

13. The method of claim 12, further comprising repeating steps (c) through (d) to complete the structure.

14. The method according to any one of claims 12-13, wherein, Printing at least a portion of the structure via the at least one printer head of the additive printing assembly via the at least one cementitious material further includes: The outer and inner walls of the structure, made of a first cementitious material, are printed via the outer and inner printer heads of the additive printing assembly; and... The area between the outer and inner walls of the structure is filled with a second cementitious material via an intermediate printer head fixed between the outer and inner printer heads.

15. The method according to any one of claims 12-13, wherein, The reinforcement distribution assembly further includes a plurality of roller devices, the plurality of reinforcement components including reinforcement cables, wherein distributing the plurality of reinforcement components from the reinforcement distribution assembly under tension further includes distributing the reinforcement cables from the plurality of roller devices by automatically and continuously rolling the reinforcement cables from the plurality of roller devices under tension.

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