New cementitious composite floating platform and manufacturing method.

Abstract

A semi-submersible wind turbine platform capable of supporting a wind turbine while floating on a body of water and a method of manufacturing the semi-submersible wind turbine platform from an advanced cementitious composite material are provided, the method including determining a topology output of a wind turbine platform including a plurality of modular sections made of an advanced cementitious composite (ACC) material in a first iteration, obtaining a second iteration from the topology output, and obtaining additional iterations by simulation to arrive at a final model platform and a final model tower, the final model platform and the final model tower including a layout of the plurality of modular sections and platform-to-tower connections of the wind turbine platform.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE Embodiments of the present disclosure relate generally to wind turbine platforms. In particular, embodiments described herein relate to a semi-submersible wind turbine platform capable of floating on a body of water (or ocean) and supporting a wind turbine, and a method of manufacturing the semi-submersible wind turbine platform from a new cementitious composite material. [Background technology]

[0002] It is desirable for clusters of wind turbines to be located offshore, where the water is greater than 60m deep and therefore there is no possibility of impeding the air flow to the wind turbines due to various obstructions (i.e. hills, forests, buildings), resulting in high average wind speeds and therefore significant power. Currently, the fixed foundations required to mount wind turbines to the ocean floor at such depths are hardly economically feasible. This constraint has led to the development of floating platforms for wind turbines. Thus, what is needed in the art is a semi-submersible wind turbine platform that can support a wind turbine while floating on a body of water (or sea), and a method of manufacturing the semi-submersible wind turbine platform from a new cementitious composite material. Summary of the Invention

[0003] In one embodiment, a method of manufacturing a wind turbine platform is provided, the method including determining, in a first iteration, a topology output for a wind turbine platform including a plurality of modular sections of an advanced cementitious composite (ACC) material, the topology output including one or more of a maximum weight, a wind load case, a minimum global stress, a base diameter, a center of gravity, or a mass. The method includes obtaining a second iteration from the topology output, the second iteration further including a second model platform and a second model tower of the wind turbine platform, the method further includes simulating the second iteration to obtain a third iteration, the third iteration including a third model platform and a third model tower of the wind turbine platform, the third model platform and the third model tower including different components or component dimensions than the second model platform and the second model tower, the method further includes simulating additional iterations to arrive at a final model platform and a final model tower, the final model platform and the final model tower including a layout of the multiple module sections and a platform and tower connection of the wind turbine platform.

[0004] In another embodiment, a method of manufacturing a wind turbine platform is provided, the method including: determining a topology output of a wind turbine platform including a plurality of modular sections of an advanced cementitious composite (ACC) material in a first iteration; obtaining a second iteration from the topology output, the second iteration including a second model platform and a second model tower of the wind turbine platform; the method further includes simulating the second iteration to obtain a third iteration, the third iteration including a third model platform and a third model tower of the wind turbine platform, the third model platform and the third model tower including different components or component dimensions than the second model platform and the second model tower; The method includes obtaining additional iterations through simulation to arrive at a final model platform and a final model tower, the final model platform and the final model tower including a layout of a plurality of modular sections and platform-to-tower connections of the wind turbine platform, the method further including fabricating the modular sections of ACC material and coupling the modular sections together with the connections according to the layout of the final model platform and the final model tower.

[0005] In yet another embodiment, a method of manufacturing a wind turbine platform is provided, the method including determining, in a first iteration, a topology output for a wind turbine platform including a plurality of modular sections of an advanced cementitious composite (ACC) material, the topology output including one or more of a maximum weight, a wind load case, a minimum global stress, a base diameter, a center of gravity, or a mass. The method further includes obtaining a second iteration from the topology output, the second iteration including a second model platform and a second model tower of the wind turbine platform, the method further includes simulating the second iteration to obtain a third iteration, the third iteration including a third model platform and a third model tower of the wind turbine platform, the third model platform and the third model tower including different components or component dimensions than the second model platform and the second model tower, the method further includes obtaining additional iterations by simulation to arrive at a final model platform and a final model tower, the final model platform and the final model tower including a layout of a plurality of modular sections and platform and tower connections of the wind turbine platform, the method further includes fabricating the modular sections of ACC material and coupling the modular sections together with the connections according to the layout of the final model platform and the final model tower.

[0006] Thus, in order that the above-mentioned features of the invention may be understood in detail, a detailed description of the invention as outlined above will now be rendered with reference to embodiments, some of which are illustrated in the drawings. It should be noted, however, that the appended drawings depict only exemplary embodiments and therefore should not be considered as limiting the scope of the invention, which may lead to other equally effective embodiments. [Brief description of the drawings]

[0007] [Figure 1A]FIG. 1 is a plan view of a semi-submersible wind turbine platform according to embodiments described herein. [Figure 1B] FIG. 1 is an exploded view of a semi-submersible wind turbine platform according to embodiments described herein. [Figure 1C] FIG. 1 is a side view of a semi-submersible wind turbine platform according to embodiments described herein. [Figure 2A] 1 is a schematic diagram of a link according to embodiments described herein. [Figure 2B] FIG. 1 is a schematic cross-sectional view of an embodiment described herein. [Diagram 3] 1 is a flow diagram of a method for manufacturing a semi-submersible wind turbine platform according to embodiments described herein. [Figure 4A] 1 is a schematic diagram illustrating a semi-submersible wind turbine platform design iteration during implementation of methods according to embodiments described herein. FIG. [Figure 4B] 1 is a schematic diagram illustrating a semi-submersible wind turbine platform design iteration during implementation of methods according to embodiments described herein. FIG. [Figure 4C] 1 is a schematic diagram illustrating a semi-submersible wind turbine platform design iteration during implementation of methods according to embodiments described herein. FIG. [Figure 4D] 1 is a schematic diagram illustrating a semi-submersible wind turbine platform design iteration during implementation of methods according to embodiments described herein. FIG. [Figure 4E] 1 is a schematic diagram illustrating a semi-submersible wind turbine platform design iteration during implementation of methods according to embodiments described herein. FIG. [Figure 4F] 1 is a schematic diagram illustrating a semi-submersible wind turbine platform design iteration during implementation of methods according to embodiments described herein. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] To facilitate understanding, the same reference numerals have been used, where possible, to designate identical elements common to the figures, and it is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further description.

[0009] FIELD OF THE DISCLOSURE

[0002] Embodiments of the present invention relate generally to wind turbine platforms. In particular, embodiments described herein relate to a semi-submersible wind turbine platform that floats on a body of water and is capable of supporting a wind turbine, and a method of manufacturing the semi-submersible wind turbine platform from a new cementitious composite material.

[0010] FIG 1A is a plan view of a semi-submersible wind turbine platform 100. FIG 1B is an exploded view of the semi-submersible wind turbine platform 100. FIG 1C is a side view of the semi-submersible wind turbine platform 100. As described herein, the semi-submersible wind turbine platform 100 is an exemplary semi-submersible wind turbine platform 100 resulting from a method 300 for manufacturing a semi-submersible wind turbine platform from an advanced cementitious composite (ACC) material 130.

[0011] New cementitious composite materials include, but are not limited to, fiber reinforced high performance concrete (FRHPC), high performance fiber reinforced cementitious composite (HPFRCC), macro defect free (MDF) concrete, multi-scale fiber reinforced concrete (MSFRC), reactive powder concrete (RPC), steel fiber cementitious composite (SFCBC), ultra high performance concrete (UHPC), ultra high performance fiber reinforced cementitious composite (UHPFRCC), ultra high performance fiber reinforced concrete (UHPFRC), ultra high strength concrete (UHSC), ultra high strength cementitious composite, ultra high strength cementitious material, ultra high strength fiber reinforced cementitious composite, combinations thereof, etc. UHPC material is a mixture of Portland cement, silica fume, quartz powder, fine silica sand, super-plasticiser, water and steel or organic fiber. UHPC is characterized by a compressive strength of over 150 megapascals (MPa) and up to 200 MPa, a high flexural strength up to 45 MPa, and a creep coefficient of 0.2 to 1.0, which is much lower than that of normal strength concrete. Other characteristics of UHPC are a high elastic modulus (over 45 GPa), low capillary porosity resulting in very low permeability and air permeability, and low chloride ion diffusivity, which occurs, for example, in seawater.

[0012] The design of the semi-submersible wind turbine platform 100 is optimized with a method 100 for manufacturing a semi-submersible wind turbine platform from ACC material 130. The semi-submersible wind turbine platform 100 includes a platform 102. In one embodiment, the wind turbine platform 100 includes a platform 102 and a tower 104. The platform 102 and the tower 104 are made of multiple modular sections 124 of ACC material 130 bonded together. The platform 102 corresponds to a final model platform 416 and the tower 104 corresponds to a final model tower 417, which are further described herein. The final model platform 416 and the final model tower 417 include multiple modular sections 124 and a layout 418 of connections 200. The connections 200 may include fasteners 206, or cable structures 132, as shown in FIG. 2B. The cable structural members 132 may be utilized in performing a prestressing or post-tensioning process to fabricate the modular sections 124 or to join the modular sections 124 together.

[0013] The platform 102 includes a base 106 with a plurality of columns connected to each other. The base 106 has a hollow interior space 128 formed by each of the modular sections 124 connected to each other. The plurality of columns 108 are connected to a support 112 by a plurality of top beams 110. In one embodiment, the platform 102 further includes a plurality of bottom beams 114 connected to the support 112. The plurality of columns 108 are connected to the support 112 by a plurality of top beams 110 and a plurality of bottom beams 114. The plurality of bottom beams 114 are connected to a lower portion 116a of the columns 108. The plurality of top beams 110 are connected to an upper portion 116b of the columns 108. In an embodiment including the tower 104, the support 112 is connected to a tower shaft 118. At least one rotor blade 120 is coupled to a hub 122. 1B, the hub 122 is located outwardly from the tower shaft 118. In another embodiment, the hub 122 is coupled to the top of the tower shaft 118.

[0014] Each modular section 124 includes at least one wall that defines a hollow interior space 128. Each wall 126 is made of ACC material 130. The platform 102 and tower 104 include modular sections 124 that are coupled to one another by connections 200. For example, the base 106 and support 112 include a plurality of modular sections 124, each of which is coupled to one another by one or more connections 200. Although one connection between each modular section 124 is shown, multiple connections 200 may be utilized between the modular sections 124 according to the layout 418.

[0015] As shown in FIGS. 1A-1C, the tower 104 includes eleven module sections 124. The column 108 is coupled to the outer module section 124 of the base 106. The top beam 110 and the bottom beam 114 each include a module section 124 that are connected to each other by a connector 200. The base 106 includes a base portion of the plurality of module sections 124. The column 108 is coupled to the outer base section of the base 106. At least one of the top beam 110 and the bottom beam 114 includes a beam section of the plurality of module sections 124. A first outer beam section of the beams is coupled to the column 108, and a second outer beam section of the beams is coupled to the support 112. The tower shaft 118 includes a tower section of the plurality of module sections 124. The outer tower section is coupled to the support 112. The cable structures 132 or fasteners 206 may be used interchangeably depending on the layout 418 for the final model platform 416 and the final model tower 417 comprising a plurality of modular sections 124 and connections 200 .

[0016] The availability of ACC material 130, the modularity of the semi-submersible wind turbine platform 100 provided by the multiple modular sections 124 of the ACC material 130, and the method 300 of manufacturing the semi-submersible wind turbine platform from the ACC material 130 provide a semi-submersible wind turbine platform optimized for longevity, design freedom, house factor freedom, inertia, ductility, high fatigue life, freeze / thaw, reduced maintenance, reduced element size, impermeability, and portable buildability. In some embodiments, the connections 131 between the base 106 and the column 108, between the beams (top beam 110 and bottom beam 114) and the column 108, and between the beams and the supports 112 are debris resistant. The debris resistant connections 131 resulting from the method 300 described herein provide increased stability and heavy load carrying capacity. The semi-submersible wind turbine platform 100 may not require pre-stressing or post-tensioning as a result of the tension and compression control of the ACC material 130. Hydrogen production elements may be directly integrated into the semi-submersible wind turbine platform described herein.

[0017] Semi-submersible wind turbine platform 100 exhibits a waterline that is about 20 meters (m) to about 40 meters from base 106, a center of gravity that is about 15 meters (m) to about 30 meters from base 106, a diameter at base 106 of about 90 meters to about 120 meters, and a height from tower 104 of about 100 meters to about 200 meters. Semi-submersible wind turbine platform 100 has a total mass of about 3,500 tons to about 10,000 tons.

[0018] FIG. 2A is a schematic diagram of the coupling 200. FIG. 2B is a cross-sectional view of the coupling 200. The coupling 200 includes a first recess 202A in the wall 126 of the first end 204A of the first section 124A and a second recess 202B in the wall 126 of the second end 204B of the second section 124B. As shown in FIG. 2B, a fastener 206 is provided through a first flange 208A of the first end 204A and a second flange 208B of the second end 204B. The fastener 206 may include a bolt, a threaded rod, a rivet, a weld, or the like. The first section 124A and the second section 124B may be further sealed by a seal, an O-ring, a gasket, a sealant, or an adhesive between the coupling surfaces 210 of the first end 204A and the second end 204B. Covers 214 may be provided in the first recess 202A and the second recess 202B, with only one cover 214 in the first recess 202A being shown for ease of illustration.

[0019] FIG. 3 is a flow diagram of a method 400 for manufacturing a semi-submersible wind turbine platform from ACC material. FIGS. 4A-4F are schematic illustration iterations of the design of the semi-submersible wind turbine platform 100. In operation 301, a topology output is determined as shown in FIG. 4A for a first iteration 401. Example topology outputs include maximum weight, wind load case, minimum global stress, base diameter, center of gravity, or mass. In operation 302, additional iterations 402, 403, 404, 405 are subjected to simulation, e.g., stress simulation. Operation 302 is repeated until a final iteration 406 is obtained that meets the topology output and meets the simulation specifications. Examples of simulation specifications include offshore wind loads and hydrodynamic wave loads.

[0020] The second iteration 402 includes a second model platform 408 of the platform 102 and a second model tower 409 of the tower 104, as shown in FIG. 4B. The second iteration 303 is subjected to a second simulation to obtain a third iteration 403, as shown in FIG. 4C. The third iteration 403 includes a third model platform 410 of the platform 102 and a third model tower 411 of the tower 104, the third model platform 410 and the third model tower 411 having different components and / or component dimensions than the second model platform 408 and the second model tower 409, respectively, to obtain the final design of the platform 102 and the tower 104 of the semi-submersible wind turbine platform 100. The third iteration 403 is subjected to a third simulation to obtain a fourth iteration 404, as shown in FIG. 4D. The fourth iteration 404 includes a fourth model platform 412 of the platform 102 and a fourth model platform 414 of the fourth model tower 413. The fourth model platform 412 and the fourth model tower 413 have different components and / or component dimensions than the third model platform 410 and the third model tower 411, respectively, to obtain a final design for the platform 102 and tower 104 of the semi-submersible wind turbine platform 100. The fourth iteration 404 is subjected to a fourth simulation to obtain a fifth iteration 405, as shown in FIG. 4E. The fifth iteration 405 includes a fifth model platform 412 of the platform 102 and a fifth model platform 414 of the fifth model tower 104. The fifth model platform 414 and the fifth model tower 415 have different components and / or component dimensions than the fourth model platform 412 and the fourth model tower 413, respectively, to obtain the final design of the platform 102 and tower 104 of the semi-submersible wind turbine platform 100.

[0021] The fifth iteration 405 is subjected to a fifth simulation to obtain a final iteration 406, as shown in FIG. 4F. The final iteration 406 corresponds to the design of the semi-submersible wind turbine platform 100. The final iteration 406 includes a final model platform 416 corresponding to the platform 102 of the semi-submersible wind turbine platform 100 shown in FIGS. 1A-1C and described herein, and a final model tower 417 corresponding to the tower 104 of the semi-submersible wind turbine platform 100. The final iteration 406 further includes a modular section 124 of the platform 102 and the tower 104. The final model platform 416 and the final model tower 417 include a layout 418 of connections for the multiple modular sections 124 and the platform 102 and the tower 104. The modular nature of the semi-submersible wind turbine platform 100 provided by the multiple modular sections 124 allows for iterative production of the wind turbine platform 100 .

[0022] In operation 203, the semi-submersible wind turbine platform 100 is manufactured from the ACC material 130. First, the modular sections 124 of the ACC material 130 are manufactured. The modular sections 124 are manufactured using cable net structures, cosmetic workpieces, free-form members, forms, membranes, or combinations thereof to guide the deposition of the ACC material according to the final model platform 416 and the final model tower 417. The free-form members, forms, or the like may be 3D printed. In another embodiment, which may be combined with another embodiment described herein, the ACC material is 3D printed. When the ACC material is 3D printed, cable net structures, cosmetic workpieces, free-form members, forms, membranes, or combinations thereof may be used. Second, the modular sections 124 are joined together with the connectors 200 according to the layout of the final model platform 416 and the final model tower 417.

[0023] In summary, disclosed herein is a semi-submersible wind turbine platform that can float on a body of water and support a wind turbine, and a method for manufacturing the semi-submersible wind turbine platform from a new cementitious composite material. Utilizing the methods described herein, an iterative design method and the resulting ACC material allows for cost-effective fabrication of a semi-submersible wind turbine platform that can be used in offshore locations at depths of over 60 meters.

[0024] While the foregoing is directed to embodiments of the present invention, other and alternate embodiments of the invention may be devised without departing from the basic scope thereof, the scope of which is defined by the following claims.

Claims

1. 1. A method of manufacturing a wind turbine platform, comprising the steps of: determining a topology output for the wind turbine platform including a plurality of modular sections of an advanced cementitious composite (ACC) material in a first iteration, the topology output including a maximum weight, a wind load case, a minimum global stress, a base diameter, a center of gravity, or a mass; obtaining a second iteration from the topology output, the second iteration including a second model platform and a second model tower of the wind turbine platform; performing a simulation on the second iteration to obtain a third iteration, the third iteration including a third model platform and a third model tower of the wind turbine platform, the third model platform and the third model tower including different components or component dimensions than the second model platform and the second model tower; and performing additional iterations through simulation to arrive at a final model platform and a final model tower, the final model platform and the final model tower including a layout of the plurality of modular sections and platform-to-tower connections of the wind turbine platform.

2. fabricating the modular sections of the ACC material; The method of claim 1 , further comprising the step of: coupling said modular sections together with said connections in accordance with a layout of said final model platform and said final model tower.

3. The wind turbine platform comprises: a base including a base section of the plurality of module sections; a column coupled to an outer base section of the base; 3. The method of claim 2, further comprising: a support connected to said column by a beam, a first outer beam section of said beam being connected to said column and a second outer beam section of said beam being connected to said support.

4. The method of claim 3 , wherein the wind turbine platform further comprises a tower shaft, the tower shaft comprising a tower section of a plurality of modular sections, an outer tower section being coupled to the support.

5. The method of claim 4 , wherein at least one rotor blade is coupled to a hub, the hub being outboard of the tower shaft or coupled on top of the tower shaft.

6. The method of claim 3 , wherein said base has a hollow interior space defined by each of said modular sections interconnected together.

7. The method of claim 3 , wherein the connections between the base and the column, the connections between the beam and the column, and the connections between the beam and the support are spall resistant.

8. The method of claim 2 , wherein the connection comprises a fastener or cable structure.

9. The method of claim 8 , wherein the cable structural member is utilized in performing a prestressing or post-tensioning process for the fabrication of the modular sections or the joining of the modular sections.

10. The method of claim 8 , wherein the fastener comprises a bolt, a threaded rod, a rivet, or a weld.

11. The method of claim 2 , wherein the step of fabricating the modular sections comprises using cable net structures, cosmetic workpieces, freeform members, forms, membranes, or combinations thereof to guide deposition of the ACC material.

12. 2. The method of claim 1, wherein the new cementitious composite material comprises fiber reinforced high performance concrete (FRHPC), high performance fiber reinforced cementitious composite (HPFRCC), macro defect free (MDF) concrete, multi-scale fiber reinforced concrete (MSFRC), reactive powder concrete (RPC), steel fiber cementitious composite (SFCBC), ultra high performance concrete (UHPC), ultra high performance fiber reinforced cementitious composite (UHPFRCC), ultra high performance fiber reinforced concrete (UHPFRC), ultra high strength concrete (UHSC), ultra high strength cementitious composite, ultra high strength cementitious material, ultra high strength fiber reinforced cementitious composite, or combinations thereof.

13. 1. A method of manufacturing a wind turbine platform, comprising the steps of: determining a topology output for the wind turbine platform, the wind turbine platform including a plurality of modular sections made of advanced cementitious composite (ACC) material, in a first iteration; obtaining a second iteration from the topology output, the second iteration including a second model platform and a second model tower of the wind turbine platform; performing a simulation on the second iteration to obtain a third iteration, the third iteration including a third model platform and a third model tower of the wind turbine platform, the third model platform and the third model tower including different components or component dimensions than the second model platform and the second model tower; performing additional iterations through simulation to arrive at a final model platform and a final model tower, the final model platform and the final model tower including a layout of the plurality of modular sections and a layout of platform-to-tower connections of the wind turbine platform; fabricating the modular sections of the ACC material; and coupling said modular sections together with said connections in accordance with a layout of said final model platform and said final model tower.

14. The wind turbine platform comprises: a base including a base section of the plurality of module sections; a column coupled to an outer base section of the base; 14. The method of claim 13, further comprising: a support connected to the column by a beam, a first outer beam section of the beam being connected to the column and a second outer beam section of the beam being connected to the support.

15. The method of claim 14 , wherein the connections between the base and the column, the connections between the beam and the column, and the connections between the beam and the support are spall resistant.

16. The method of claim 13 , wherein the connection comprises a fastener or cable structure.

17. The method of claim 16 , wherein the cable structural member is utilized in performing a prestressing or post-tensioning process for the fabrication of the modular sections or the joining of the modular sections.

18. The method of claim 13 , wherein the step of fabricating the modular sections comprises using a cable net structure, a cosmetic workpiece, a freeform member, a form, a membrane, or a combination thereof to guide deposition of the ACC material.

19. 14. The method of claim 13, wherein the new cementitious composite material comprises fiber reinforced high performance concrete (FRHPC), high performance fiber reinforced cementitious composite (HPFRCC), macro defect free (MDF) concrete, multi-scale fiber reinforced concrete (MSFRC), reactive powder concrete (RPC), steel fiber cementitious composite (SFCBC), ultra high performance concrete (UHPC), ultra high performance fiber reinforced cementitious composite (UHPFRCC), ultra high performance fiber reinforced concrete (UHPFRC), ultra high strength concrete (UHSC), ultra high strength cementitious composite, ultra high strength cementitious material, ultra high strength fiber reinforced cementitious composite, or combinations thereof.

20. 1. A method of manufacturing a wind turbine platform, comprising the steps of: determining a topology output for the wind turbine platform including a plurality of modular sections of an advanced cementitious composite (ACC) material in a first iteration, the topology output including one or more of a maximum weight, a wind load case, a minimum global stress, a base diameter, a center of gravity, or a mass; obtaining a second iteration from the topology output, the second iteration including a second model platform and a second model tower of the wind turbine platform; performing a simulation on the second iteration to obtain a third iteration, the third iteration including a third model platform and a third model tower of the wind turbine platform, the third model platform and the third model tower including different components or component dimensions than the second model platform and the second model tower; performing additional iterations through simulation to arrive at a final model platform and a final model tower, the final model platform and the final model tower including a layout of the plurality of modular sections and a platform-to-tower interface of the wind turbine platform; fabricating the modular sections of the ACC material; and coupling said modular sections together with said connections in accordance with a layout of said final model platform and said final model tower.

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