Floating platform made of new cement-based composite material and manufacturing method

Abstract

The present invention provides a semi-submersible wind turbine platform that can support a wind turbine while floating on water, and a method for manufacturing the semi-submersible wind turbine platform from a new cement-based composite material. [Solution] This method includes the steps of: determining the topology output of a wind turbine platform including multiple module sections made of a new cement-based composite (ACC) material in a first iteration; obtaining a second iteration from the topology output; and obtaining additional iterations by simulation to achieve a final model platform and a final model tower, the final model platform and final model tower including the layout of the multiple module sections and the connection between the platform and tower of the wind turbine platform.

Description

Technical Field

[0001] Embodiments of the present disclosure generally relate to a wind turbine platform. In particular, the embodiments described herein relate to a semi-submersible wind turbine platform that can support a wind turbine while floating on water (or offshore), and a method of manufacturing a semi-submersible wind turbine platform from a new cement-based composite material.

Background Art

[0002] It is desirable to deploy a group of wind turbines offshore, where the water (sea water) is deeper than 60 m, so there is no possibility of interference due to various obstacles (i.e., hills, forests, and buildings) for the air flow to the wind turbines. As a result, a high average wind speed and a large amount of electric power can be obtained. At present, the fixed foundation required to attach a wind turbine to the seabed in such deep waters has little economic feasibility. Due to this constraint, floating platforms for wind turbines have been developed. Therefore, the technology desired in the art is a semi-submersible wind turbine platform that can support a wind turbine while floating on water (or offshore), and a method of manufacturing a semi-submersible wind turbine platform from a new cement-based composite material.

Summary of the Invention

[0003] In one embodiment, a method for manufacturing a wind turbine platform is provided. The method includes, in a first iteration, determining the topology output of a wind turbine platform comprising a plurality of modular sections made of a novel cement-based composite (ACC) material. The topology output includes one or more of the following: maximum weight, wind load case, minimum global stress, base diameter, center of gravity, or mass. The method includes the step of obtaining a second iteration from a topology output, the second iteration further including a second model platform and a second model tower of a wind turbine platform, the method further includes the step of obtaining a third iteration by simulating the second iteration, the third iteration including a third model platform and a third model tower of a wind turbine platform, the third model platform and third model tower including different components or component dimensions from the second model platform and second model tower, the method further includes the step of obtaining additional iterations by simulation to achieve a final model platform and final model tower, the final model platform and final model tower including a layout of multiple module divisions and a connection between the platform and tower of the wind turbine platform.

[0004] In another embodiment, a method for manufacturing a wind turbine platform is provided. The method includes the steps of: determining the topology output of a wind turbine platform comprising a plurality of modular sections made of a new cement-based composite (ACC) material in a first iteration; and obtaining a second iteration from the topology output, the second iteration comprising a second model platform and a second model tower of the wind turbine platform; the method further includes the step of obtaining a third iteration by simulating the second iteration, the third iteration comprising a third model platform and a third model tower of the wind turbine platform, the third model platform and the third model tower comprising different components or component dimensions from those of the second model platform and the second model tower; The method includes the step of obtaining additional iterations through simulation to achieve a final model platform and a final model tower, the final model platform and final model tower including a layout of multiple module sections and a connection between the platform and tower of the wind turbine platform, and the method further includes the step of fabricating module sections of ACC material and the step of joining the module sections together with the connection sections according to the layout of the final model platform and final model tower.

[0005] In yet another embodiment, a method for manufacturing a wind turbine platform is provided. This method includes, in a first iteration, determining the topology output of a wind turbine platform comprising a plurality of modular sections made of a novel cement-based composite (ACC) material. The topology output includes one or more of the following: maximum weight, wind load case, minimum global stress, base diameter, center of gravity, or mass. The method further includes the step of obtaining a second iteration from a topology output, the second iteration including a second model platform and a second model tower of a wind turbine platform; the method further includes the step of obtaining a third iteration by simulating the second iteration, the third iteration including a third model platform and a third model tower of a wind turbine platform, the third model platform and the third model tower including different components or component dimensions from the second model platform and the second model tower; the method further includes the step of obtaining additional iterations by simulation to achieve a final model platform and a final model tower, the final model platform and final model tower including a layout of multiple module divisions and a connection between the platform and tower of the wind turbine platform; the method further includes the step of fabricating module divisions of ACC material and the step of joining the module divisions together with the connection according to the layout of the final model platform and final model tower.

[0006] Thus, in order to understand the above-mentioned features of the present invention in detail, a detailed description of the present invention outlined above will be given with reference to some embodiments shown in the drawings. However, the accompanying drawings show only illustrative embodiments and should not be considered to limit the scope of the present invention, as other equally effective embodiments may be shown. [Brief explanation of the drawing]

[0007] [Figure 1A]This is a plan view of a semi-submersible wind turbine platform according to an embodiment described herein. [Figure 1B] This is an exploded assembly diagram of a semi-submersible wind turbine platform according to the embodiment described herein. [Figure 1C] This is a side view of a semi-submersible wind turbine platform according to an embodiment described herein. [Figure 2A] This is a schematic diagram of a connecting portion according to the embodiment described herein. [Figure 2B] This is a schematic cross-sectional view of an embodiment described herein. [Figure 3] This is a flowchart illustrating a method for manufacturing a semi-submersible wind turbine platform according to the embodiment described herein. [Figure 4A] This is a schematic diagram illustrating the iterations of the design of a semi-submersible wind turbine platform when implementing the method according to the embodiment described herein. [Figure 4B] This is a schematic diagram illustrating the iterations of the design of a semi-submersible wind turbine platform when implementing the method according to the embodiment described herein. [Figure 4C] This is a schematic diagram illustrating the iterations of the design of a semi-submersible wind turbine platform when implementing the method according to the embodiment described herein. [Figure 4D] This is a schematic diagram illustrating the iterations of the design of a semi-submersible wind turbine platform when implementing the method according to the embodiment described herein. [Figure 4E] This is a schematic diagram illustrating the iterations of the design of a semi-submersible wind turbine platform when implementing the method according to the embodiment described herein. [Figure 4F] This is a schematic diagram illustrating the iterations of the design of a semi-submersible wind turbine platform when implementing the method according to the embodiment described herein. [Modes for carrying out the invention]

[0008] For ease of understanding, where possible, identical reference numerals are used to indicate identical elements common to both the figure and the other. It is assumed that elements and features of one embodiment can be usefully incorporated into other embodiments without further description.

[0009] Embodiments of the present invention generally relate to wind turbine platforms. In particular, embodiments described herein relate to semi-submersible wind turbine platforms that float on water and can support wind turbines, and to methods for manufacturing semi-submersible wind turbine platforms from novel cement-based composite materials.

[0010] Figure 1A is a plan view of the semi-submersible wind turbine platform 100. Figure 1B is an exploded view of the semi-submersible wind turbine platform 100. Figure 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 obtained from a manufacturing method 300 for a semi-submersible wind turbine platform from an advanced cementitious composite (ACC) material 130.

[0011] Examples of new cement-based composite materials include, but are not limited to, fiber-reinforced high-performance concrete (FRHPC), high-performance fiber-reinforced cement composites (HPFRCC), macro defect-free (MDF) concrete, multiscale fiber-reinforced concrete (MSFRC), reactive powder concrete (RPC), steel fiber cement composites (SFCBC), ultra-high-performance concrete (UHPC), ultra-high-performance fiber-reinforced cement composites (UHPFRCC), ultra-high-performance fiber-reinforced concrete (UHPFRC), ultra-high-strength concrete (UHSC), ultra-high-strength cement composites, ultra-high-strength cement materials, ultra-high-strength fiber-reinforced cement composites, and combinations thereof. UHPC materials are mixtures of Portland cement, silica fume, quartz powder, fine silica sand, super-plasticizer, water, and steel or organic fibers. UHPC is characterized by a compressive strength exceeding 150 megapascals (MPa) up to 200 MPa, a high flexural strength up to 45 MPa, and a creep coefficient of 0.2 to 1.0, which is significantly lower than that of conventional strength concrete. Other features of UHPC include a high elastic modulus (over 45 GPa), low capillary porosity resulting in extremely low water permeability and air permeability, and low chloride ion diffusivity, such as in seawater.

[0012] The design of the semi-submersible wind turbine platform 100 is optimized by a manufacturing method 100 for the 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 tower 104 are made of multiple modular sections 124 of ACC material 130 joined together. The platform 102 corresponds to the final model platform 416, and the tower 104 corresponds to the final model tower 417, which are described further herein. The final model platform 416 and final model tower 417 include a layout 418 of multiple modular sections 124 and connecting sections 200. The connecting sections 200 may include fasteners 206 or cable structural members 132 as shown in Figure 2B. The cable structural member 132 can be used when manufacturing the module section 124 or when performing a prestressing process or post-tensioning process to connect the module sections 124 to each other.

[0013] The platform 102 includes a base 106 on which a plurality of columns (columnar bodies) are connected to each other. The base 106 has a hollow internal space 128 formed by each of the interconnected module sections 124. 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 the lower portion 116a of the column 108. The plurality of top beams 110 are connected to the upper portion 116b of the column 108. In embodiments including a tower 104, the support 112 is connected to a tower shaft 118. At least one rotor blade 120 is coupled to a hub 122. In one embodiment, as shown in Figure 1B, the hub 122 is located outward from the tower shaft 118. In another embodiment, the hub 122 is coupled to the top of the tower shaft 118.

[0014] Each module section 124 includes at least one wall defining a hollow internal space 128. Each wall 126 is made of ACC material 130. The platform 102 and tower 104 include module sections 124 connected to each other by connecting sections 200. For example, the base 106 and support 112 include multiple module sections 124, each module section 124 being connected to each other by one or more connecting sections 200. Although one connecting section between each module section 124 is shown, multiple connecting sections 200 are utilized between module sections 124 according to layout 418.

[0015] As shown in Figures 1A to 1C, the tower 104 includes 11 module sections 124. The column 108 is connected to the outer module section 124 of the base 106. Each of the top beam 110 and the bottom beam 114 includes a module section 124 connected to each other by a connecting section 200. The base 106 includes the base portion of the plurality of module sections 124. The column 108 is connected 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. The first outer beam section of the beam is connected to the column 108, and the second outer beam section of the beam is connected to the support 112. The tower shaft 118 has tower sections of the plurality of module sections 124. The outer tower sections are connected to the support 112. The cable structural member 132 or fastener 206 consists of multiple module sections 124 and connecting sections 200 and can be used interchangeably according to the layout 418 for the final model platform 416 and the final model tower 417.

[0016] The availability of ACC material 130, the modularity of the semi-submersible wind turbine platform 100 provided by multiple modular sections 124 of ACC material 130, and the manufacturing method 300 for the semi-submersible wind turbine platform from ACC material 130 provide a semi-submersible wind turbine platform optimized for life, design freedom, home factor freedom, inertia, ductility, high fatigue life, freeze / thaw resistance, reduced maintenance, reduced element size, impermeability, and portable constructability. In some embodiments, the connection points 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 support 112 are scrap-resistant. The scrap-resistant connection points 131 resulting from the method 300 described herein result in improved stability and heavy load support capacity. The semi-submersible wind turbine platform 100 does not require prestressing or post-tensioning as a result of tension and compression control of the ACC material 130. Hydrogen production elements can be directly incorporated into the semi-submersible wind turbine platform described herein.

[0017] The semi-submersible wind turbine platform 100 has a water level approximately 20 to 40 meters above the base 106, a center of gravity approximately 15 to 30 meters above the base 106, a diameter of the base 106 of approximately 90 to 120 meters, and a height from the tower 104 of approximately 100 to 200 meters. The semi-submersible wind turbine platform 100 has a total mass of approximately 3,500 tons to 10,000 tons.

[0018] Figure 2A is a schematic view of the connecting part 200. Figure 2B is a cross-sectional view of the connecting part 200. The connecting part 200 includes a first recess 202A provided in the wall 126 of the first end 204A of the first section 124A, and a second recess 202B provided in the wall 126 of the second end 204B of the second section 124B. As shown in Figure 2B, the fastener 206 is provided by inserting through the first flange 208A of the first end 204A and the second flange 208B of the second end 204B. Examples of the fastener 206 include bolts, threaded rods, rivets, welded joints, etc. The first section 124A and the second section 124B may be further sealed by a seal, O-ring, gasket, sealing material, or adhesive between the connecting surfaces 210 of the first end 204A and the second end 204B. A cover 214 may be provided in the first recess 202A and the second recess 202B, and only one cover 214 in the first recess 202A is shown for illustrative purposes.

[0019] Figure 3 is a flowchart of a manufacturing method 400 of a semi-submersible wind turbine platform from ACC materials. Figures 4A - 4F are schematic explanatory diagrams of iterations of the design of the semi-submersible wind turbine platform 100. In operation 301, as shown in Figure 4A for the first iteration 401, a topology output is obtained. Examples of the exemplary topology output include maximum weight, wind load case, minimum global stress, base diameter, center of gravity, or mass. In operation 302, simulations, for example, stress simulations, are performed on additional iterations 402, 403, 404, 405. Operation 302 is repeated until a final iteration 406 that matches the topology output and meets the simulation criteria is obtained. Examples of the simulation criteria include offshore wind loads and hydrodynamic wave loads.

[0020] As shown in FIG. 4B, the second iteration 402 includes a second model platform 408 of the platform 102 and a second model tower 409 of the tower 104. A second simulation is performed on the second iteration 303 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 have different components and / or component dimensions than the second model platform 408 and the second model tower 409, respectively, in order to obtain the final design of the platform 102 and the tower 104 of the semi-submersible wind turbine platform 100. A third simulation is performed on the third iteration 403 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 412 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, in order to obtain the final design of the platform 102 and the tower 104 of the semi-submersible wind turbine platform 100. A fourth simulation is performed on the fourth iteration 404 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, in order to obtain the final design of the platform 102 and the tower 104 of the semi-submersible wind turbine platform 100.

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

[0022] In operation 203, a semi-submersible wind turbine platform 100 is manufactured from ACC material 130. First, a module section 124 of the ACC material 130 is manufactured. In manufacturing the module section 124, cable net structural members, decorative structures, free-form members, formwork, membranes, or a combination thereof are used to guide the deposition of the ACC material according to the final model platform 416 and the final model tower 417. Free-form members, formwork, etc., are preferably 3D printed. In another embodiment that can be combined with another embodiment described herein, the ACC material is 3D printed. When 3D printing the ACC material, cable net structural members, decorative structures, free-form members, formwork, membranes, or a combination thereof are preferably used. Secondly, the module section 124 is joined together with the connecting section 200 according to the layout of the final model platform 416 and the final model tower 417.

[0023] In summary, this specification discloses a semi-submersible wind turbine platform that floats on water and supports a wind turbine, and a method for manufacturing a semi-submersible wind turbine platform from a new cement-based composite material. The method described herein enables the cost-effective fabrication of a semi-submersible wind turbine platform usable in offshore locations at depths exceeding 60 meters, resulting from the iteration design method and ACC material.

[0024] The above describes embodiments of the present invention, but other embodiments and alternative embodiments of the present invention can be devised without departing from the basic scope of the present invention, and the scope of the present invention is defined based on the following claims.

Claims

1. A method for manufacturing a wind turbine platform, The first iteration includes the step of determining the topology output of the wind turbine platform, which includes a plurality of modular sections made of a new cement-based composite (ACC) material, wherein the topology output includes the maximum weight, wind load case, minimum global stress, base diameter, center of gravity, or mass. The process includes the step of obtaining a second iteration from the topology output, wherein the second iteration includes a second model platform and a second model tower of the wind turbine platform. The process includes the step of obtaining a third iteration by performing a simulation on the second iteration, wherein the third iteration includes a third model platform and a third model tower of the wind turbine platform, and the third model platform and the third model tower include components or component dimensions different from those of the second model platform and the second model tower. A method comprising the step of obtaining additional iterations by simulation to achieve a final model platform and a final model tower, wherein the final model platform and the final model tower include the layout of the plurality of module divisions and the connection between the platform and tower of the wind turbine platform.

2. The steps include manufacturing the module section of the ACC material, The method according to claim 1, further comprising the step of joining the module sections together with the connecting sections in accordance with the layout of the final model platform and the final model tower.

3. The aforementioned wind turbine platform is A base including the base section among the aforementioned multiple module sections, A column connected to the outer base section of the aforementioned base, The method according to claim 2, comprising a support connected to the column by a beam, wherein a first outer beam section of the beam is connected to the column and a second outer beam section of the beam is connected to the support.

4. The method according to claim 3, wherein the wind turbine platform further comprises a tower shaft, the tower shaft having a tower section consisting of a plurality of module sections, and the outer tower section is connected to the support.

5. The method according to claim 4, wherein at least one rotor blade is coupled to a hub, the hub is located outward with respect to the tower shaft or is coupled to the top of the tower shaft.

6. The method according to claim 3, wherein the base has a hollow internal space formed by each of the interconnected module sections.

7. The method according to claim 3, wherein the connection between the base and the column, the connection between the beam and the column, and the connection between the beam and the support are resistant to shattering.

8. The method according to claim 2, wherein the connecting portion consists of a fastener or a cable structural member.

9. The method according to claim 8, wherein the cable structural member is used when carrying out a prestressing process or post-tensioning process for the fabrication of the module section or for the joining of the module section.

10. The method according to claim 8, wherein the fastener consists of a bolt, a threaded rod, a rivet, or a welded part.

11. The method according to claim 2, wherein the step of manufacturing the module section comprises a cable net structural member, a decorative workpiece, a free-form member, a formwork, a membrane, or a combination thereof, in order to guide the deposition of the ACC material.

12. The method according to claim 1, wherein the new cement-based composite material includes fiber-reinforced high-performance concrete (FRHPC), high-performance fiber-reinforced cement composite material (HPFRCC), macro defect-free (MDF) concrete, multiscale fiber-reinforced concrete (MSFRRC), reactive powder concrete (RPC), steel fiber cement composite material (SFCBC), ultra-high-performance concrete (UHPC), ultra-high-performance fiber-reinforced cement composite material (UHPFRCC), ultra-high-performance fiber-reinforced concrete (UHPFRRC), ultra-high-strength concrete (UHSC), ultra-high-strength cement composite material, ultra-high-strength cement material, ultra-high-strength fiber-reinforced cement composite material, or a combination thereof.

13. A method for manufacturing a wind turbine platform, The first iteration includes the step of determining the topology output of the wind turbine platform, which includes multiple module sections made of a new cement-based composite (ACC) material. The process includes the step of obtaining a second iteration from the topology output, wherein the second iteration includes a second model platform and a second model tower of the wind turbine platform. The process includes the step of obtaining a third iteration by performing a simulation on the second iteration, wherein the third iteration includes a third model platform and a third model tower of the wind turbine platform, and the third model platform and the third model tower include components or component dimensions different from those of the second model platform and the second model tower. The process includes obtaining additional iterations through simulation to achieve a final model platform and a final model tower, wherein the final model platform and the final model tower include the layout of the plurality of module divisions and the layout of the connection between the platform and the tower of the wind turbine platform. The steps include manufacturing the module section of the ACC material, A method comprising the step of joining the module sections together with the connecting sections in accordance with the layout of the final model platform and the final model tower.

14. The aforementioned wind turbine platform is A base including the base section among the aforementioned multiple module sections, A column connected to the outer base section of the aforementioned base, The method according to claim 13, comprising a support connected to the column by a beam, wherein a first outer beam section of the beam is connected to the column and a second outer beam section of the beam is connected to the support.

15. The method according to claim 14, wherein the connection between the base and the column, the connection between the beam and the column, and the connection between the beam and the support are resistant to shattering.

16. The method according to claim 13, wherein the connecting portion consists of a fastener or a cable structural member.

17. The method according to claim 16, wherein the cable structural member is used when carrying out a prestressing process or post-tensioning process for the fabrication of the module section or for the joining of the module section.

18. The method according to claim 13, wherein the step of manufacturing the module section comprises a cable net structural member, a decorative workpiece, a free-form member, a formwork, a membrane, or a combination thereof, in order to guide the deposition of the ACC material.

19. The method according to claim 13, wherein the new cement-based composite material includes fiber-reinforced high-performance concrete (FRHPC), high-performance fiber-reinforced cement composite material (HPFRCC), macro defect-free (MDF) concrete, multiscale fiber-reinforced concrete (MSFRRC), reactive powder concrete (RPC), steel fiber cement composite material (SFCBC), ultra-high-performance concrete (UHPC), ultra-high-performance fiber-reinforced cement composite material (UHPFRCC), ultra-high-performance fiber-reinforced concrete (UHPFRRC), ultra-high-strength concrete (UHSC), ultra-high-strength cement composite material, ultra-high-strength cement material, ultra-high-strength fiber-reinforced cement composite material, or a combination thereof.

20. A method for manufacturing a wind turbine platform, The first iteration includes the step of determining the topology output of the wind turbine platform, which includes a plurality of module sections made of a new cement-based composite (ACC) material, wherein the topology output includes one or more of the following: maximum weight, wind load case, minimum global stress, base diameter, center of gravity, or mass. The process includes the step of obtaining a second iteration from the topology output, wherein the second iteration includes a second model platform and a second model tower of the wind turbine platform. The process includes the step of obtaining a third iteration by performing a simulation on the second iteration, wherein the third iteration includes a third model platform and a third model tower of the wind turbine platform, and the third model platform and the third model tower include components or component dimensions different from those of the second model platform and the second model tower. The process includes obtaining additional iterations through simulation to achieve a final model platform and a final model tower, wherein the final model platform and the final model tower include the layout of the plurality of module divisions and the connection between the platform and tower of the wind turbine platform. The steps include manufacturing the module section of the ACC material, A method comprising the step of joining the module sections together with the connecting sections in accordance with the layout of the final model platform and the final model tower.

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