Tower structure manufacturing system and manufacturing method

Abstract

A system and method (400) for manufacturing a tower structure (500) is provided. A first printed layer (512) of a wall element is deposited using a print head assembly (302) and an actual midline perimeter of the first printed layer is determined. A horizontal reinforcement assembly (514) is then formed based at least in part on the actual midline perimeter. The formed horizontal reinforcement assembly is positioned on the first printed layer in a horizontal orientation and axially aligned with a vertical axis of the tower structure. With the horizontal reinforcement assembly positioned on the first printed layer, a second printed layer of the wall element is deposited on the horizontal reinforcement layer via the print head assembly.

Description

Technical Field

[0001] The present disclosure generally relates to tower structures, and more particularly, to systems and methods for additive manufacturing of tower structures for supporting wind turbines.

Background Art

[0002] Wind power generation is considered to be one of the cleanest and most environmentally friendly currently available energy sources, and wind turbines have attracted attention in this regard. Modern wind turbines typically include a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The nacelle includes a rotor assembly coupled to the gearbox and the generator. The rotor assembly and the gearbox are attached to a bedplate support frame disposed within the nacelle. One or more rotor blades capture the kinetic energy of the wind using known airfoil principles. The rotor blades transmit the kinetic energy in the form of rotational energy so as to rotate a shaft connecting the rotor blades to the gearbox, or directly to the generator if no gearbox is used. The generator then converts the mechanical energy into electrical energy, which is transmitted to a converter and / or transformer housed within the tower and then deployed to the utility grid. Modern wind power generation systems generally take the form of a wind farm having a plurality of wind turbine generators operable to supply power to a power transmission system that supplies power to the electrical grid.

[0003] Tower structures, particularly wind turbine towers, are often constructed from steel pipes, prefabricated concrete sections, or a combination thereof. Furthermore, the steel pipes and / or concrete sections are typically formed off-site, transported to the site, and then assembled to construct the tower. For example, one manufacturing method involves forming precast concrete rings, shipping the rings to the site, placing them on top of each other, and then fastening them together. However, as tower heights increase, conventional manufacturing methods are limited by transport regulations prohibiting the transport of tower sections exceeding approximately 4-5 meters in diameter. Therefore, some tower manufacturing methods involve forming multiple arc segments and then bolting and / or welding the segments together on-site to form the tower's diameter. However, such methods are labor-intensive and time-consuming.

[0004] Therefore, there is a continuous demand in the art for novel and improved methods for manufacturing towers. Accordingly, this disclosure relates to systems and methods for manufacturing towers that address the aforementioned problems. In particular, this disclosure is directed toward a method for reinforcing tower structures by additively manufacturing them on-site using automated additive printing devices. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] U.S. Patent No. 10066413 [Overview of the project]

[0006] Aspects and advantages of the present invention are partially described in the following description, or are evident from the description, or can be learned through the practice of the present invention.

[0007] In one embodiment, the disclosure is directed to a method for manufacturing a tower structure. The method may include depositing a first printed layer of wall elements using a printhead assembly via an additive printing system. The wall elements may surround the vertical axis of the tower structure. A controller of the additive printing system can determine the actual midline perimeter length of the first printed layer. The method may also include forming a horizontal reinforcement assembly based at least partially on the actual midline perimeter length. The horizontal reinforcement assembly may be positioned horizontally on the first printed layer and aligned vertically and axially. Furthermore, the method may include depositing a second printed layer of wall elements on the horizontal reinforcement assembly using a printhead assembly via an additive printing system.

[0008] In another embodiment, the disclosure is directed to an additive printing system for manufacturing a tower structure. The tower structure may include wall elements surrounding the vertical axis of the tower structure. The additive printing system may include a support structure and an optical scanner. The additive printing system may also include a print head assembly operably coupled to the support structure. Furthermore, the additive printing system may include a controller communicably coupled to the print head assembly and the optical scanner. The controller may include at least one processor configured to perform or direct a plurality of operations. The plurality of operations may include any of the operations and / or features described herein.

[0009] These and other features, aspects and advantages of the present invention will be better understood by referring to the following description and the appended claims. The appended drawings incorporated herein and constituting part thereof illustrate embodiments of the present invention and are useful in illustrating the principles of the present invention together with this specification. [Brief explanation of the drawing]

[0010] A complete and effective disclosure of the present invention, including its best mode, directed to those skilled in the art, is described in the specification with reference to the accompanying drawings. [Figure 1] This is a perspective view showing one embodiment of a tower structure supporting a wind turbine according to the present disclosure. [Figure 2] Figure 1 shows a portion of the additive printing system, a portion of the tower structure, and an overhead view of the horizontal reinforcement assembly according to this disclosure. [Figure 3] This is a perspective view of the tower structure shown in Figure 1 in this disclosure. [Figure 4] This diagram shows an overhead view of one embodiment of the horizontal reinforcement assembly and jig table according to the present disclosure. [Figure 5] Figure 5A is a perspective top view of a portion of the horizontal reinforcement assembly according to the present disclosure. Figure 5B is a perspective bottom view of a portion of the horizontal reinforcement assembly of Figure 5A according to the present disclosure. Figure 5C shows a simplified cross-sectional view of a portion of the horizontal reinforcement assembly of Figure 5A according to the present disclosure. [Figure 6] This is a simplified top view showing a part of the horizontal reinforcement assembly and material processing apparatus according to the present disclosure. [Figure 7] This is a simplified side view of an additive manufacturing system for the tower structure described herein. [Figure 8] This is a simplified profile diagram of one embodiment of a printhead assembly of an additive manufacturing system for additive manufacturing of tower structures according to the present disclosure. [Figure 9] This is a simplified rear view showing a portion of the printhead assembly of an additive printing system for additive manufacturing of a tower structure according to the present disclosure. [Figure 10]This is a schematic diagram of a controller for use with the additive printing system described herein. [Figure 11] This flowchart shows one embodiment of the method for manufacturing a tower structure according to this disclosure.

[0011] The repeated use of reference letters in this specification and drawings is intended to represent identical or similar features or elements of the present invention. [Modes for carrying out the invention]

[0012] Embodiments of the present invention will now be described in detail, with one or more examples shown in the drawings. Each embodiment is provided for illustrative purposes of the invention and does not limit it. Indeed, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment can be used in conjunction with another embodiment to obtain yet another embodiment. Thus, the present invention is intended to cover modifications and variations that fall within the scope of the appended claims and their equivalents.

[0013] In this specification, the terms “First,” “Second,” and “Third” may be used interchangeably to distinguish one component from another, and do not imply the position or importance of any individual component.

[0014] Unless otherwise specified herein, terms such as “coupled,” “fixed,” and “attached to” refer to both direct coupling, fixing, or attachment, as well as indirect coupling, fixing, or attachment via one or more intermediate components or features.

[0015] The approximate expressions used throughout this specification and the claims are applied to modify any quantitative expressions that may vary within an acceptable range without altering the fundamental function to which they relate. Thus, values ​​modified by terms such as “about,” “approximately,” and “substantially” are not limited to specified exact values. In at least some examples, approximate expressions may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture components and / or systems. For example, an approximate expression may refer to being within a 10% margin.

[0016] Throughout this specification and the claims, limitations are combined and interchangeable, and such scopes are identified and include all sub-scopes unless the context or wording indicates otherwise. For example, all scopes disclosed herein include endpoints, and endpoints are independently combinable with respect to one another.

[0017] Generally, the present disclosure is directed to an additive printing system and method for manufacturing tower structures such as wind turbine towers. Additively printed tower structures are typically formed via the deposition of successive layers of a cementitious material such as concrete (e.g., print layers). However, in order to achieve the desired structural strength, additively printed towers generally require reinforcement. Known methods for reinforcing towers often utilize vertical rebar and / or a rebar cage. For example, a common construction method is to manually position a prefabricated rebar cage in the desired location prior to pouring the concrete. While such methods can reinforce the tower structure, they are often labor intensive and costly and may not be compatible with construction by additive manufacturing. Additionally, known methods for reinforcing additively printed tower structures may not be able to accurately position reinforcement elements at optimal locations within the structure. Accordingly, the present application presents a novel method for forming and positioning a horizontal reinforcement assembly for tower structures that is simple, accurate, not labor intensive, and cost-effective.

[0018] To provide simple, accurate, not labor intensive, and cost-effective reinforcement to an additively printed tower structure, the present invention utilizes a ring-shaped horizontal reinforcement assembly that is placed with precise dimensions on the print layer of the tower structure prior to an additional print layer being added thereon. To that end, the length around the actual centerline of the first print layer can be determined. Thereafter, the horizontal reinforcement assembly is formed, at least in part, based on the length around the actual centerline. Put another way, the dimensions of the horizontal reinforcement assembly can be adjusted to match the actual physical dimensions of the first print layer deposited by the additive printing system prior to placement on the first print layer.

[0019] Referring now to the drawings, FIG. 1 shows a perspective view of an embodiment of a tower structure 500 according to the present disclosure. As depicted in FIG. 1, the tower structure can be a component of a wind turbine 100. As shown, the wind turbine 100 generally includes a tower structure 500 extending from a support surface 104, a nacelle 106 attached to the tower structure 500, and a rotor 108 coupled to the nacelle 106. The rotor 108 includes a rotatable hub 110 and at least one rotor blade 112 coupled to the hub 110 and extending outwardly from the hub 110. For example, in the illustrated embodiment, the rotor 108 includes three rotor blades 112. However, in alternative embodiments, the rotor 108 can include more or fewer than three rotor blades 112. Each rotor blade 112 can be spaced relative to the hub 110 to enable the rotation of the rotor 108 to convert kinetic energy from the wind into mechanical energy, and thus electrical energy, that can be utilized. For example, the hub 110 can be rotatably coupled to a generator (not shown) disposed within the nacelle 106 to enable the generation of electrical energy.

[0020] Although the wind turbine tower is described herein, it should be understood that the present disclosure is not limited to wind turbine towers and can be utilized in any application having a concrete structure and / or a tall tower structure. For example, the present disclosure can be utilized in the additive manufacturing of houses, buildings, building parts, bridges, towers, utility poles, and other aspects of the concrete industry. Further, the methods described herein can also be applied to the manufacture of similar structures that benefit from the advantages described herein.

[0021] Referring here to Figures 2 to 9, several embodiments of a tower structure 500 and an additive printing system 300 for forming it are depicted in accordance with this disclosure. As shown, the tower structure 500 can be formed by depositing one or more layers of wall elements 502 using a printhead assembly 302 of the additive printing system 300. In one embodiment, the wall elements 502 can circumscribe the vertical axis (VA) of the tower structure 500. Each wall element 502 may be, for example, one of several printed layers arranged axially to form the tower structure 500. As shown, the wall elements 502 can generally define a hollow interior 504 which can be used in a wind turbine 100 to house various turbine components. Furthermore, as will be described in more detail below, the tower structure 500 can be formed using an additive manufacturing method. The tower structure 500 can be formed from at least one cementitious material 506.

[0022] It should be understood that the tower structure 500 may include structures having a height greater than the maximum horizontal dimension. As a non-limiting example, the tower structure 500 may include a wind turbine support tower, a cooling tower, a communications tower, a bridge pylon, a smokestack, a transmission tower, an observation tower, a dwelling, an office, an ornamental tower, a water tower, and / or other similar structures.

[0023] As used herein, the cementitious material 506 may include any suitable processable paste that can be configured to bond together to form a structure after curing. Suitable cementitious materials may include, for example, concrete, pitch resin, asphalt, clay, cement, mortar, cementitious compositions, or other similar materials or compositions.

[0024] As shown in the overhead view (e.g., layer view) of the tower 500 illustrated in Figure 2, in this embodiment, the wall element 502 may have an outer circumferential face 508 corresponding to each layer of the wall element 502. The outer circumferential face 508 may have a maximum radial distance from the vertical axis (VA). The outer circumferential face 508 may be, for example, a generally circular shape that orbits the vertical axis (VA).

[0025] In one embodiment, the wall element 502 may have an inner circumferential face 510 corresponding to each layer of the wall element 502. The inner circumferential face 510 may have a minimum radial distance from the vertical axis (VA). The inner circumferential face 510 may be, for example, a generally circular shape that encircles the vertical axis (VA).

[0026] As particularly illustrated in Figures 2 and 7, in one embodiment, a midline reference curve (CM) can be defined for each layer of the tower structure 500. The midline reference curve (CM) may be equidistant between the outer surface 508 and the inner surface 510 of that layer. Therefore, the midline reference curve (CM) can be approximately circular, orbiting the vertical axis (VA). It should be understood that the midline reference curve (CM) may represent the radial neutral point corresponding to the width / thickness (W) of the wall element 502.

[0027] According to aspects of this disclosure, the tower structure 500 can be manufactured additively via an additive printing system 300. In particular, all or part of the tower structure 500, especially the wall elements 502, can be printed layer by layer using the additive printing system 300. The additive printing system 300 can use any suitable means for depositing layers of additive material, such as concrete, to form the tower structure 500. Accordingly, aspects of this subject matter are directed toward a method for manufacturing a tower structure 500, such as a wind turbine tower, by additive manufacturing.

[0028] As used herein, “additive manufacturing” may generally be understood to encompass processes used to synthesize three-dimensional objects in which continuous layers of material are formed under computer control to create an object, so that objects of any size and / or shape can be manufactured from digital model data. Furthermore, it should be understood that the additive manufacturing methods of this disclosure may encompass not only three degrees of freedom but more than three degrees of freedom, so that printing techniques are not limited to printing stacked two-dimensional layers, but also enable the printing of curves and / or irregular shapes.

[0029] In one embodiment, as particularly depicted in Figures 3 and 7, the additive printing system 300 may include a support structure 304. The support structure 304 may extend from the ground and / or from the support surface 104, generally along the vertical direction (V). In an embodiment, the support structure 304 may include at least one vertical support component 306. As depicted, in one embodiment, one or more vertical support components 306 may be located radially outward of the tower structure 500. However, in an additional embodiment, the vertical support components 306 may be located radially inward of the wall element 502.

[0030] One or more vertical support components 306 can, in embodiments, support horizontal support components 308. One or more vertical support components 306 and horizontal support components 308 may, in embodiments, form a truss structure (similar to, for example, a tower crane). However, one or more vertical support components 306 and horizontal support components 308 may be formed in other suitable ways or have any other configuration according to alternative embodiments. In one embodiment, the horizontal support component 308 may be rotatable with respect to one or more vertical support components 306. In an additional embodiment, the horizontal support component 308 may be movably coupled to one or more vertical support components 306 so as to allow the horizontal support component 308 to move in the vertical direction (V).

[0031] In at least one embodiment, the vertical support component 306 may be configured to have a height that increases in step with the tower structure 500 during its manufacture. In such an embodiment, additional segments can be combined with the vertical support component 306 to raise the vertical support structure using a jacking system. Generally, the jacking system is positioned close to the support surface 104 and is configured to raise the vertical support component 306 and insert the additional segments.

[0032] The support structure 304 may be configured to support at least one support arm 310 movably coupled thereto. The support arm 310 may be configured to position at least one component of the additive printing system 300 adjacent to the tower structure 500. The support arm 310 may also be configured to supply power, air, cementitious material, form material, or other resources to the supported component. In an additional embodiment, the support arm 310 may also include at least one sensor 311 for detecting the position of the support arm 310 relative to the tower structure 500.

[0033] The additive printing system 300 may include a print head assembly 302 supported by a support structure 304. The print head assembly 302 may be positioned on the support surface 104 or the preceding layer of the wall element 502 by a horizontal support member 308 and / or at least one of one or more support arms 310. The print head assembly 302 may include a print nozzle 312. The print nozzle (print nozzle) 312 may be configured to direct and / or form the flow of cement-based material 506 during additive printing of the tower structure 500.

[0034] Generally referring again to Figures 2 to 9, in one embodiment, an additive printing system 300 may be employed to deposit a first printed layer 512 on a wall element 502. The first printed layer 512 can be deposited using a print head assembly 302. The controller 200 of the additive printing system 300 may then be used to determine the actual midline perimeter length of the first printed layer 512. The actual midline perimeter length may correspond to the circumferential length (CM) of the midline reference curve. A horizontal reinforcement assembly 514 may be formed at least partially based on the actual midline perimeter length of the first printed layer 512. The fully assembled / formed horizontal reinforcement assembly 514 may then be positioned on the first printed layer 512 in the horizontal (H) direction and aligned with the vertical axis (VA) and axial direction. Following the positioning of the fully assembled / formed horizontal reinforcement assembly 514 on the first printed layer 512, the additive printing system 300 can deposit a second printed layer 516 of the wall element 502 on the horizontal reinforcement assembly 514 using the print head assembly 302. It should be understood that forming the horizontal reinforcement assembly 514 may include, for example, establishing the inner circumference (CI) and / or outer circumference (CO) of the horizontal reinforcement assembly 514 that are proportional to the actual midline circumference.

[0035] Figure 2 shows part of Method 400 for manufacturing the tower structure 500 before positioning the horizontal reinforcement assembly 514 on the first printed layer 512. According to Method 400, the horizontal reinforcement assembly 514 can be positioned on the first printed layer 512 as indicated by arrow A1. Thus, Figure 3 shows part of Method 400 following the positioning of the horizontal reinforcement assembly 514 on the first printed layer 512. Figure 3 also shows part of the second printed layer 516 deposited on the horizontal reinforcement assembly 514.

[0036] In one embodiment, the horizontal reinforcement assembly 514 may include an inner rail 518. The inner rail 518 may have a length shorter than the actual length around the midline. In an embodiment, the horizontal reinforcement assembly 514 may include an outer rail 520. The outer rail 520 may have a length longer than the actual length around the midline. Furthermore, in an embodiment, the horizontal reinforcement assembly 514 may include a plurality of lateral members 522. Each of the plurality of lateral members 522 may have a first end 524 connected to the inner rail 518. In one embodiment, each of the plurality of lateral members 522 may have a second end 526 connected to the outer rail 520.

[0037] It should be understood that the inner rail 518 and / or outer rail 520 may have a shape corresponding to the horizontal shape of the first printed layer. For example, in embodiments where the tower structure 500 is generally cylindrical or conical, the horizontal shape may be generally circular. In such embodiments, the inner rail 518 and / or outer rail 520 may have a generally circular shape. As an additional example, in embodiments where the tower structure 500 is generally polygonal, the horizontal shape may include multiple angles / corners joined by multiple straight sections and / or curved sections. In such embodiments, the inner rail 518 and / or outer rail 520 may have a shape that reflects multiple angles / corners joined by multiple straight sections and / or curved sections.

[0038] In particular, as shown in Figure 4, in the embodiment, the horizontal reinforcement assembly 514 may include a plurality of prefabricated reinforcement segments 528. For example, in the embodiment, the horizontal reinforcement assembly 514 may include three prefabricated reinforcement segments 528, each prefabricated reinforcement segment 528 covering a 120-degree arc of the midline reference curve (CM). In a further embodiment, the horizontal reinforcement assembly 514 may include four prefabricated reinforcement segments 528, each prefabricated reinforcement segment 528 covering a 90-degree arc of the midline reference curve (CM). In a further embodiment, the horizontal reinforcement assembly 514 may include six prefabricated reinforcement segments 528, each prefabricated reinforcement segment 528 covering a 60-degree arc of the midline reference curve (CM). Therefore, it should be understood that in the embodiment, forming the horizontal reinforcement assembly 514 may involve receiving a plurality of prefabricated reinforcement segments 528.

[0039] Each of the multiple prefabricated reinforcing segments 528 may, in one embodiment, include an inner rail segment 530 connected to an outer rail segment 532 via a portion of a plurality of transverse members 522. Each of the multiple prefabricated reinforcing segments 528 may have a first segment end 534 and a second segment end 536 on the opposite side. The first segment end 534 and the second segment end 536 may be defined by the inner and outer rail segments 530, 532.

[0040] It should be understood that the midline reference curve (CM) of the printed layer of the wall element 502 may have different actual midline perimeters at various heights of the tower structure 500. For example, the tower structure 500 may taper as its height increases. As a result, the midline reference curve (CM) of the printed layer near the support surface 104 may have a larger actual midline perimeter than the actual midline perimeter of the midline reference curve (CM) adjacent to the ultimate height of the tower structure 500. However, in embodiments, each of the multiple prefabricated reinforcing segments 528 of the tower structure 500 may be pre-formed / manufactured to have a fixed length (e.g., arc length). Thus, the fixed length of the prefabricated reinforcing segment 528 may be accommodated, as further described below, to form a horizontal reinforcing assembly 514 according to the actual midline perimeter of the printed layer to be placed thereon before the deposition of the second printed layer 516.

[0041] To form (e.g., tailor) a horizontal reinforcing assembly 514 to match the actual midline perimeter of the first printed layer 512, at least one overlap 538 can be provided between adjacent prefabricated reinforcing segments 528 of a plurality of prefabricated reinforcing segments 528. The size (M) of the overlap 538 can facilitate the establishment of the inner circumference (CI) and / or outer circumference (CO) at values ​​proportional to the midline reference curve (CM). In other words, the overlap 548 can facilitate the establishment of the reinforcing assembly midline perimeter based on the actual midline perimeter of the first printed layer 512. For example, in one embodiment, the reinforcing assembly midline perimeter may be equal to the actual midline perimeter. It should be understood that the reinforcing assembly midline perimeter may represent the length of the assembly midline reference curve (AM) that is radially equidistant between the inner and outer rail segments 530, 532.

[0042] In one embodiment, each of the multiple prefabricated reinforcing segments 528 may be coupled to an adjacent segment to form a horizontal reinforcing assembly 514. For example, the first segment end 534 of each of the multiple prefabricated reinforcing segments 528 may be coupled to the second segment end 536 of each adjacent segment. The coupling of adjacent segments can establish an overlap 538 based on a determined magnitude (M). In one embodiment, the magnitude (M) of the overlap 538 may correspond to a determined degree of arc where the respective first and second segment ends 534, 536 can directly contact and be fixedly coupled to each other. In an additional embodiment, the magnitude (M) of the overlap 538 may correspond to zero degrees of the arc, and the adjacent segments may be coupled to each other via a coupler unit 540. In further embodiments, the size (M) may correspond to the gap / separation (G) between adjacent segments (e.g., as depicted in Figure 5B), and therefore the use of a coupler unit 540 is required to join adjacent sections together. It should be understood that the coupler unit 540 may be configured to determine the midline perimeter of the reinforcement assembly based on the actual midline perimeter.

[0043] As shown in Figures 5A-5C, in embodiments, the coupler unit 540 may include a first channel 542 configured to receive a portion of the inner rail 518. The coupler unit 540 may also, in embodiments, include a second channel 544 configured to receive a portion of the outer rail 520. The first channel 542 and the second channel 544 may be substantially parallel to each other. In embodiments, the first and second channels 542, 544 can facilitate the connection of the coupler unit 540 to an adjacent prefabricated reinforcing segment 528. In other words, the corresponding portions of the first and second ends 534, 536 of the prefabricated reinforcing segment 528 may be fixed into the first and second channels 542, 544 by crimping (e.g., as shown in Figures 5A and 5B), welding, adhesive, fasteners, and / or other means suitable for establishing a fixed connection between the prefabricated reinforcing segment 528 and the coupler unit 540.

[0044] As further illustrated in Figures 5A-5C, in one embodiment the coupler unit 540 may include a plate structure 546. The plate structure 546 may extend radially to define the radial positions of the first channel 542 and the second channel 544. The plate structure 546 may also define a guide orifice 548. The guide orifice can facilitate the positioning of, for example, cables, conduits, and / or tensioning elements of a tower structure 500.

[0045] Referring further to Figures 5A and 5C, in one embodiment, the coupler unit 540 may include a lifting interface 550. The lifting interface 550 may be configured to couple to at least one lifting element 326 to facilitate the positioning of a fully assembled horizontal reinforcing assembly 514 on the first printed layer 512. The lifting interface 550 may be a flexible element configured to translate from a generally vertical to a generally horizontal orientation when the horizontal reinforcing assembly 514 is positioned on the first printed layer 512 and one or more lifting elements 326 are detached. For example, in one embodiment, the lifting interface 550 may be a cable, a hinged element, and / or a deformable plate element. It should be understood that by moving the lifting interface 550 to a generally horizontal orientation, damage to the second printed layer 516 caused by the lifting interface 550 can be mitigated.

[0046] As shown in Figure 5C, in one embodiment, an operable coupling can be established between one or more lifting elements 326 and a horizontal reinforcement assembly 514 via a lifting interface 550. The one or more lifting elements 326 can be positioned to establish a separation 328 with respect to the first printed layer 512 when the horizontal reinforcement assembly 514 is positioned on it. After the horizontal reinforcement assembly 514 is positioned on the first printed layer 512, the one or more lifting elements 326 can be released. Thus, the one or more lifting elements 326 can be separated from the horizontal reinforcement assembly 514 while the separation 328 is maintained or increased with respect to the first printed layer 512. By maintaining at least the separation 328, contact between the one or more lifting elements 326 and the first printed layer 512 can be prevented. Preventing contact between the lifting element 326 and the cement-based material 506 of the first printed layer 512, which may remain soft / uncured during the positioning of the horizontal reinforcement assembly 514, can mitigate / prevent damage to the first printed layer 512. It should be understood that preventing damage to the first printed layer 512 may improve the structural integrity of the tower structure 500 compared to what would be obtained if a damaged first printed layer 512 were present.

[0047] As shown in Figure 4, in one embodiment, the additive printing system 300 may include a jig table 316. The jig table 316 may be positioned on the ground / support surface 104 at the installation location of the tower structure 500. For example, the jig table 316 may be positioned adjacent to the tower structure 500. The jig table 316 may be configured to receive a plurality of prefabricated reinforcing segments 528 (for example, as indicated by arrow A2). In one embodiment, the jig table 316 may be sized to support a horizontal reinforcing assembly 514 when fully formed (for example, with adjacent segments of the plurality of prefabricated reinforcing segments 528 joined together) and in a horizontal direction.

[0048] In one embodiment, the jig table 316 may include a plurality of movable stops 318. The plurality of movable stops 318 may be configured to orient / position a plurality of prefabricated reinforcing segments 528 to form a horizontal reinforcing assembly 514, for example. Thus, in one embodiment, the plurality of movable stops 318 may be positioned based on the midline perimeter of the reinforcing assembly. At least a portion of the plurality of prefabricated reinforcing segments 528 may be positioned via the plurality of movable stops 318. Such positioning may establish overlaps 538 between each adjacent segment of the plurality of prefabricated reinforcing segments 528.

[0049] In one embodiment, the fixture table 316 may include at least one servo 320. One or more servos 320 may be operably coupled to some of the movable stoppers 318, for example, via a linkage 322. In such an embodiment, one or more servos 320 can be actuated to change the position of at least one of the movable stoppers 318 relative to the support surface 324 of the fixture table 316.

[0050] In one embodiment, the jig table 316 can be communicatively coupled to a controller 200. In such an embodiment, the controller 200 of the additive printing system 300 can determine the required position for each of the plurality of movable stoppers 318. The required position may correspond to the positioning of the plurality of movable stoppers 318 to establish the magnitude (M) of the overlap 538 between adjacent prefabricated reinforcing segments 528 of the plurality of prefabricated reinforcing segments 528. In one embodiment, the controller 200 can then generate setpoints for one or more servos 320 calculated to position each of the movable stoppers 318 at the required position.

[0051] As shown in Figure 6, in one embodiment, forming the horizontal reinforcement assembly 514 may include determining the required reinforcement assembly midline perimeter based on the actual midline perimeter. Then, the required inner rail radius 552 may be determined based on the required reinforcement assembly midline perimeter. In one embodiment, the required outer rail radius 554 may similarly be determined based on the required reinforcement assembly midline perimeter. The required inner and outer rail radii 552, 554 may then be formed via the material working apparatus 330 of the additional printing system 300. For example, the material working apparatus 330 may apply a bend to a first portion of the rail stock 556 corresponding to the required inner rail radius 552. The first portion of the rail stock 556 may have a length corresponding to the inner rail length. Similarly, in an embodiment, the material working apparatus 330 may add a bend to a second portion of the rail stock 556 corresponding to the required outer rail radius 554. The second portion of the rail stock 556 may have a length corresponding to the outer rail length. Furthermore, in one embodiment, the material processing apparatus 330 may be configured to connect (for example, by welding, bonding, or otherwise fixing) a plurality of lateral members 522 between the inner and outer rails 518, 520.

[0052] Referring again to Figures 3 and 7, in order to determine the actual midline perimeter length of the first print layer 512, the controller 200 may, in one embodiment, record the actual print path 332 of the print head assembly 302. The actual print path 332 may be recorded by the controller 200 during the deposition of the first print layer 512. For example, in an embodiment, one or more sensors 311 may be used to continuously monitor the position of one or more support arms 310. The position of the print head assembly 302, and thus the print path 332, may be derived from the monitored positions of the support arms 310. Thus, the actual midline perimeter length of the first print layer 512 may be determined based on the actual print path 332 of the print head assembly 302.

[0053] As specifically depicted in Figure 7, the additive printing system 300 may include at least one optical scanner 334. One or more optical scanners 334 may be 3D scanners. Thus, one or more optical scanners 334 may be non-contact scanners that utilize a camera (e.g., a stereoscopic system) and / or a laser (e.g., a triangulation-based 3D laser scanner) to capture the physical properties of the tower structure 500. In one embodiment, one or more optical scanners 334 may be integrated with the print head assembly 302. However, in additional embodiments, one or more optical scanners 334 may be independent elements supported by the support structure 304.

[0054] Following the deposition of the first printed layer 512, in one embodiment, one or more optical scanners 334 may be employed to optically scan the first printed layer 512.3 The controller 200 can then generate a three-dimensional map 336 of the first printed layer 512 (as depicted by arrow A) based on the optical scan.In an embodiment, the controller 200 can determine the actual midline perimeter length of the first printed layer 512 based on the three-dimensional map 336 of the first printed layer 512.

[0055] Referring further to Figure 7, in one embodiment, the additional printing system 300 may include at least one laser emitter 338. One or more laser emitters 338 may be supported by a support structure 304 and / or one or more support arms 310. In one embodiment, one or more laser emitters 338 may project at least one placement guide onto the first printed layer 512. One or more placement guides may be configured to facilitate the positioning of horizontal reinforcement assemblies 514 on the first printed layer 512. One or more placement guides may be, for example, an illuminated ring, a plurality of alignment marks, an orientation point, and / or other similar features. It should be understood that the precise placement of the horizontal reinforcement assemblies 514, as well as the placement of the second printed layer 516, may facilitate the maximization of the structural integrity of the tower structure 500.

[0056] Referring now to Figure 8, in one embodiment, the print head assembly 302 may include an actuatable roller 340. The actuatable roller 340 may be positioned to precede the print nozzle 312 during the deposition process. In other words, the actuatable roller 340 may advance along the print path 332 ahead of the print nozzle 312.

[0057] Following the positioning of the horizontal reinforcing assembly 514 on the first printed layer 512, in the embodiment, the operable roller 340 may be used to apply a downward force (F) to the horizontal reinforcing assembly 514. In response to the downward force (F), the horizontal reinforcing assembly 514 may be at least partially embedded within the first printed layer 512. It should be understood that by at least partially embedding the horizontal reinforcing assembly 514 within the first printed layer 512 while the cement-based material 506 remains soft / uncured, the impact of the horizontal reinforcing assembly 514 on the second printed layer 516 and subsequent printed layers of the wall element 502 may be mitigated.

[0058] Referring further to Figures 8 and 9, in one embodiment, the print head assembly 302 may include an actuatable groover 342. The actuatable groover 342 may be positioned to trail the print nozzle 312. In an embodiment, the actuatable groover may include at least one grooving element 344. One or more grooving elements 344 may be configured to form at least one depression / recess on the upper surface of the first print layer 512 parallel to the midline reference curve (CM). Thus, in an embodiment, the actuatable groover 342 may be positioned in contact with a portion of the moist cement-based material 506 of the first print layer 512. In an embodiment, the actuatable groover 342 may be used to develop a depression / recess in the portion of the moist cement-based material 506 of the first print layer 512.

[0059] In one embodiment, an operable groover 342 may be used to form a positioning line (L) in a portion of the moist cement-based material 506. The positioning line (L) may be configured to facilitate the precise placement of the horizontal reinforcement assembly 514 onto the first printed layer 512. Thus, the positioning line (L) may have a cross-sectional depth (D1) smaller than the cross-sectional maximal width (W1). The cross-sectional maximal width (W1) may correspond, for example, to the maximum diameter of the inner and / or outer rails 518, 520. It should be understood that if the cross-sectional depth (D1) is smaller than the cross-sectional width (W1), the majority of the horizontal reinforcement assembly 514 is more likely to be positioned above the upper surface of the first printed layer 512.

[0060] As shown in Figure 9, in one embodiment, the operable groover 342 may include at least two grooving elements 344. The grooving elements 344 may be utilized by the additive printing system 300 to form at least two parallel receiving grooves 346 (a single receiving groove 346 is depicted in Figure 9 for illustrative purposes) in the first printed layer 512. The parallel receiving grooves 346 may be configured to receive at least the inner and outer rails 518, 520 of the horizontal reinforcement assembly 514. In one embodiment, each of the receiving grooves 346 may have a cross-sectional width (W2) corresponding to the cross-sectional width of the respective inner and outer rails 518, 520. In an embodiment, each of the receiving grooves 346 may have a cross-sectional depth (D2) configured to at least partially embed the horizontal reinforcement assembly 514 in the first printed layer 512.

[0061] As depicted in Figure 8, in one embodiment, the additive printing system 300 may include both an actuated roller 340 and an actuated groover 342. In such an embodiment, the actuated groover 342 may be positioned to engage with the first printed layer 512 during its deposition (as depicted in Figure 9). Following the deposition of the first printed layer 512, a separation may be established between the grooved element 344 and the wet cement-based material 506 (as depicted in Figure 8). The horizontal reinforcement assembly 514 may then be positioned in contact with the resulting positioning line (L) or parallel receiving groove 346. With the horizontal reinforcement assembly 514 precisely positioned on the first printed layer 512, the actuated roller 340 may be positioned in contact with the horizontal reinforcement assembly 514 to at least partially embed the horizontal reinforcement assembly 514 into the first printed layer 512. In conjunction with the downward force (F) exerted by the operable roller 340, the print head assembly can deposit a portion of the cement-based material 506 to print the second print layer 516.

[0062] Figure 10, in particular, shows a schematic diagram of one embodiment of a preferred configuration of a controller 200 capable of controlling the add-on printing system 300. For example, as shown, the controller 200 may include one or more processors 202 and one or more associated memory devices 204 configured to perform various computer implementation functions (e.g., performing methods, steps, calculations, etc., as disclosed herein and storing associated data). Furthermore, the controller 200 may also include a communication module 206 for facilitating communication between the controller 200 and various components of the add-on printing system 300. Furthermore, the communication module 206 may include a sensor interface 208 (e.g., one or more analog-to-digital converters) for enabling the conversion of signals transmitted from one or more sensors 311 into signals that can be understood and processed by the processor 202. It should be understood that the sensors 311 may be communicatively coupled to the communication module 206 using any suitable means, such as wired or wireless connections. Furthermore, the communication module 206 can also be operably coupled to the components of the add-on printing system 300 to direct the formation of the tower structure 500.

[0063] As used herein, the term “processor” refers not only to integrated circuits as referred to in the art as being included in a computer, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits, and other programmable circuits. Furthermore, one or more memory devices 204 can consist of one or more memory elements, including, but not limited to, computer-readable media (e.g., random access memory (RAM)), computer-readable non-volatile media (e.g., flash memory), floppy disks (trademark), compact disc-read-only memory (CD-ROM), magneto-optical disks (MOD), digital versatile discs (DVDs), and / or other suitable memory elements. Such one or more memory devices 204 can generally be configured to store suitable computer-readable instructions that, when executed by one or more processors 202, configure the controller 200 to perform a variety of functions, including, but not limited to, the manufacture of tower structures as described herein, as well as a variety of other suitable computer implementation functions.

[0064] Referring here to Figure 11, a flowchart of one embodiment of Method 400 for manufacturing a tower structure is shown. Method 400 can be carried out, for example, using the additive manufacturing system 300 of the present disclosure described above with reference to Figures 1 to 10, for manufacturing a tower structure. Figure 11 depicts the steps to be performed in a specific order for illustrative and discussion purposes. Those skilled in the art will understand that, using the disclosures provided herein, various steps of Method 400, or any of the methods disclosed herein, can be adapted, modified, rearranged, performed concurrently, or changed in various ways without departing from the scope of the present disclosure.

[0065] As shown in (402), method 400 may include depositing a first printed layer of wall elements using a printhead assembly via an additive printing system. The wall elements may surround the vertical axis of a tower structure. As shown in (404), method 400 may include determining the actual midline perimeter length of the first printed layer via a controller of the additive printing system. As shown in (406), method 400 may include forming a horizontal reinforcement assembly based at least partially on the actual midline perimeter length. As shown in (408), method 400 may include positioning the horizontal reinforcement assembly horizontally on the first printed layer and aligned with the vertical axis and axially. As shown in (410), method 400 may include depositing a second printed layer of wall elements on the horizontal reinforcement assembly using a printhead assembly via an additive printing system.

[0066] Furthermore, those skilled in the art will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents to each such method and feature, can be mixed and adapted by those skilled in the art to construct additional systems and technologies in accordance with the principles of this disclosure. Of course, it should be understood that not all of the above-mentioned objectives or benefits can necessarily be achieved according to any particular embodiment. Therefore, for example, those skilled in the art will recognize that the systems and technologies described herein can be embodied or implemented in a manner that achieves or optimizes one benefit or group of benefits as taught herein, without necessarily achieving other objectives or benefits that may be taught or suggested herein.

[0067] This specification discloses the present invention, including best embodiments, using examples, and enables anyone skilled in the art to practice the invention, including the manufacture and use of any device or system, and the execution of incorporated methods. The patentable scope of the present invention is defined by the claims and may include other embodiments that a person skilled in the art can conceive. Such other embodiments are intended to be included in the claims if they include structural elements that are not different from the language of the claims, or equivalent structural elements that are substantially different from the language of the claims.

[0068] Further aspects of the present invention are provided by the subject matter of the following clauses. [Embodiment 1] A method for manufacturing a tower structure, comprising the steps of: depositing a first printed layer of wall elements using a print head assembly via an additive printing system, wherein the wall elements surround the vertical axis of the tower structure; determining the actual midline perimeter of the first printed layer via a controller of the additive printing system; forming a horizontal reinforcement assembly based at least partially on the actual midline perimeter; arranging the horizontal reinforcement assembly horizontally on the first printed layer and aligned with the vertical axis and axially; and depositing a second printed layer of the wall elements on the horizontal reinforcement assembly using the print head assembly via the additive printing system. [Embodiment 2] The method according to Embodiment 1, wherein the horizontal reinforcement assembly includes an inner rail having a length less than the actual circumference of the midline, and an outer rail having a length greater than the actual circumference of the midline, wherein the inner rail and the outer rail have a shape corresponding to the horizontal shape of the first printed layer, and a plurality of lateral members, each of which has a first end connected to the inner rail and a second end connected to the outer rail. [Embodiment 3] The method according to any of the preceding embodiments, wherein the step of forming the horizontal reinforcement assembly further includes the step of receiving a plurality of prefabricated reinforcement segments, each of the plurality of prefabricated reinforcement segments comprising an inner rail segment coupled to an outer rail segment via a portion of the plurality of lateral members, and each of the plurality of prefabricated reinforcement segments comprising a first segment end and a second segment end defined by the inner rail segment and the outer rail segment; the step of determining the magnitude of the overlap between adjacent prefabricated reinforcement segments of the plurality of prefabricated reinforcement segments, configured to establish the midline perimeter of the reinforcement assembly based on the actual midline perimeter; and the step of joining the first segment end of each of the plurality of prefabricated reinforcement segments to the second segment end of each adjacent segment of the plurality of prefabricated reinforcement segments to establish the overlap between them, based on the determined magnitude of the overlap. [Embodiment 4] The method according to any of the preceding embodiments, wherein the step of establishing the overlap further includes the steps of positioning a plurality of movable stoppers on a fixture table based on the length around the midline of the reinforcing assembly, and positioning a portion of the plurality of prefabricated reinforcing segments via the plurality of movable stoppers to establish the overlap between each adjacent segment of the plurality of prefabricated reinforcing segments. [Embodiment 5] The method according to any of the prior embodiments, wherein the step of positioning the plurality of movable stoppers of the jig table further includes the steps of acting on at least one servo operably coupled to the plurality of movable stoppers, and changing the position of at least one of the plurality of movable stoppers with respect to the support surface of the jig table. [Embodiment 6] The method of any of the prior embodiments, wherein the step of activating the at least one servo further includes, via the controller, determining a requested position for each of a plurality of movable stoppers to establish the magnitude of the overlap between adjacent prefabricated reinforcing segments of the plurality of prefabricated reinforcing segments; and via the controller, generating a setpoint for the at least one servo calculated to position each of the movable stoppers at the requested position. [Embodiment 7] The method according to any of the preceding embodiments, wherein the step of forming the horizontal reinforcement assembly further comprises the step of receiving the plurality of prefabricated reinforcement segments, each of the plurality of prefabricated reinforcement segments comprising an inner rail segment coupled to an outer rail segment via a portion of the plurality of lateral members; and the step of coupling each pair of adjacent prefabricated reinforcement segments of the plurality of prefabricated reinforcement segments via a coupler unit, the coupler unit being configured to establish the midline perimeter of the reinforcement assembly based on the actual midline perimeter. [Embodiment 8] The method according to any of the prior embodiments, wherein the step of positioning the horizontal reinforcement assembly further includes the step of operably coupling at least one lifting element to the lifting interface of the coupler unit. [Embodiment 9] The method according to any of the preceding embodiments, wherein the step of forming the horizontal reinforcement assembly further includes the steps of determining the length around the midline of the required reinforcement assembly based on the actual length around the midline; determining the required inner rail radius based on the length around the midline of the required reinforcement assembly; and applying a bend corresponding to the required inner rail radius to a first portion of the rail stock via a material processing apparatus, wherein the first portion of the rail stock has a length corresponding to the inner rail length; and determining the required outer rail radius based on the midline perimeter of the required reinforcement assembly; and applying a bend corresponding to the required outer rail radius to a second portion of the rail stock via the material processing apparatus, wherein the second portion of the rail stock has a length corresponding to the outer rail length. [Embodiment 10] The method according to any of the preceding embodiments, comprising the steps of: positioning the horizontal reinforcing assembly horizontally on the first printed layer; further, establishing a movable coupling between at least one lifting element and the horizontal reinforcing assembly, wherein the at least one lifting element is positioned to establish a separation with respect to the first printed layer when the horizontal reinforcing assembly is positioned thereon; and, following the positioning of the horizontal reinforcing assembly on the first printed layer, separating the at least one lifting element from the horizontal reinforcing assembly while maintaining at least the separation with respect to the first printed layer, wherein the step of maintaining at least the separation prevents contact between the at least one lifting element and the first printed layer. [Embodiment 11] A method of any prior embodiment, wherein the step of determining the actual midline perimeter of the first print layer further includes, via the controller of the additive printing system, recording the actual print path of the print head assembly during the deposition of the first print layer, and determining the actual midline perimeter of the first print layer based on the actual print path of the print head assembly. [Embodiment 12] A method of any prior embodiment, wherein the step of determining the length of the actual midline of the first printed layer further includes: optically scanning the first printed layer via an optical scanner of the additive printing system following the deposition of the first printed layer; generating a three-dimensional map of the first printed layer based on the optical scanning via the controller of the additive printing system; and determining the length of the actual midline of the first printed layer based on the three-dimensional map of the first printed layer via the controller of the additive printing system. [Embodiment 13] The method according to Embodiment 1, wherein the additional printing system further comprises at least one laser emitter, and the method includes the step of projecting at least one placement guide onto the first printing layer via the at least one laser emitter, wherein the at least one placement guide is configured to guide the positioning of the horizontal reinforcement assembly on the first printing layer. [Embodiment 14] The method according to any of the preceding embodiments, wherein the print head assembly further comprises an operable roller positioned to precede the print nozzles during the deposition operation, and the method further comprises the steps of: positioning the horizontal reinforcement assembly on the first print layer, followed by applying a downward force to the horizontal reinforcement assembly via the operable roller; and embedding the horizontal reinforcement assembly at least partially within the first print layer in response to the downward force. [Embodiment 15] The method according to any of the prior embodiments, wherein the print head assembly further comprises an operable groover positioned to follow the print nozzle during a deposition operation, and the step of deposition of the first print layer further comprises the steps of positioning the operable groover to contact a portion of the moist cement-based material of the first print layer, and developing a depression in the portion of the moist cement-based material through the operable groover. [Embodiment 16] The method according to any of the preceding embodiments, wherein the print head assembly further comprises an operable roller positioned to precede the print nozzle during the deposition operation, and the method further comprises the steps of: establishing a separation between the operable groover and the first print layer, following the positioning of the horizontal reinforcement assembly onto the first print layer; positioning the operable roller to contact the horizontal reinforcement assembly; applying a downward force to the horizontal reinforcement assembly via the operable roller; and embedding the horizontal reinforcement assembly at least partially within the first print layer in response to the downward force. [Embodiment 17] The method according to any of the preceding embodiments, wherein the step of developing a depression in the portion of the wet cement-based material further includes the step of forming a positioning line in the portion of the wet cement-based material via the operable groover, the positioning line having a cross-sectional depth less than the maximum cross-sectional width. [Embodiment 18] The method according to any of the preceding embodiments, wherein the operable groover comprises at least two grooving elements, and the step of developing a depression in the portion of the moist cement-based material further includes the step of forming at least two parallel receiving grooves in the first printed layer via at least two grooving elements configured to receive at least the inner rail and the outer rail of the horizontal reinforcement assembly, each of the at least two parallel receiving grooves having a cross-sectional width corresponding to the cross-sectional width of the respective inner rail and outer rail, and a cross-sectional depth configured to at least partially embed the horizontal reinforcement assembly in the first printed layer. [Embodiment 19] An additive printing system for manufacturing a tower structure, wherein the tower structure includes wall elements surrounding the vertical axis of the tower structure, the additive printing system includes a support structure, an optical scanner, a print head assembly operably coupled to the support structure, and a controller communicatively coupled to the print head assembly and the optical scanner, the controller including at least one processor configured to perform or instruct a plurality of operations, the plurality of operations being: a step of depositing a first print layer on the wall elements using the print head assembly; a step of optically scanning the first print layer via the optical scanner; a step of generating a three-dimensional map of the first print layer based on the optical scanning; and a step of actually printing the first print layer based on the three-dimensional map of the first print layer The process includes determining the midline perimeter length and forming a horizontal reinforcement assembly based at least partially on the actual midline perimeter, wherein the horizontal reinforcement assembly comprises an inner rail having a length less than the actual midline perimeter length and an outer rail having a length greater than the actual midline perimeter length and a plurality of lateral members, each lateral member having a first end connected to the inner rail and a second end connected to the outer rail, and the inner rail and outer rail having a shape corresponding to the horizontal shape of the first printed layer, wherein the plurality of operations include positioning the horizontal reinforcement assembly horizontally aligned with the vertical axis and axially on the first printed layer and depositing a second printed layer of the wall element on the horizontal reinforcement layer using the print head assembly. [Embodiment 20] The step of forming the horizontal reinforcement assembly further comprises: receiving the plurality of prefabricated reinforcement segments, each of the plurality of prefabricated reinforcement segments comprising an inner rail segment coupled to an outer rail segment via a plurality of lateral members, and each of the plurality of prefabricated reinforcement segments having a first segment end and a second segment end defined by the inner rail segment and the outer rail segment; determining the magnitude of the overlap between adjacent prefabricated reinforcement segments of the plurality of prefabricated reinforcement segments configured to establish the length of the reinforcement assembly's midline circumference based on the actual midline circumference; receiving the actual midline circumference from the controller of the additive printing system via the controller of the jig table; and establishing the magnitude of the overlap between adjacent prefabricated reinforcement segments of the plurality of prefabricated reinforcement segments via the controller of the jig table. An additive printing system according to any of the preceding embodiments, comprising the steps of: determining the required position of each of a plurality of movable stoppers; generating a setpoint for at least one servo of the fixture table, calculated via the controller of the fixture table to position each of the movable stoppers at the required position, wherein the at least one servo is operably coupled to the plurality of movable stoppers of the fixture table to position the plurality of movable stoppers based on the length around the midline of the reinforcing assembly; acting on the at least one servo according to the setpoint; positioning a portion of the plurality of prefabricated reinforcing segments via the plurality of movable stoppers to establish the overlap between each adjacent segment of the plurality of prefabricated reinforcing segments; and coupling the first segment end of each of the plurality of prefabricated reinforcing segments with the second segment end of each adjacent segment of the plurality of prefabricated reinforcing segments. [Explanation of Symbols]

[0069] 100: Wind turbine 104: Support surface 106: Nacelle 108: Rotor 110: Hub 112: Rotor blade 200: Controller 202: Processor 204: Memory device 206: Communication module 208: Sensor interface 300: Add-on printing system 302: Print head assembly 304: Support structure 306: Vertical support component 308: Horizontal support component 310: Support arm 311: Sensor 312: Print nozzle 316: Fixture table 318: Movable stopper 320: Servo 322: Linkage 324: Support surface 326: Lifting element 328: Separation 330: Material processing device 332: Print path 334: Optical scanner 336: 3D map 338: Laser emitter 340: Movable roller 342: Groover 344: Grooving element 346: Retaining groove 500: Tower structure 502: Wall element 504: Hollow interior 506: Cement-based material 508: Outer surface 510: Inner surface 512: First printed layer 514: Horizontal reinforcement assembly 516: Second printed layer 518: Inner rail 520: Outer rail 522: Lateral member 524: First end 526: Second end 528: Prefabricated reinforcement segment 530: Inner rail segment 532: Outer rail segment 534: First segment end 536: Second segment end 538: Overlap 540: Coupler unit 542: First channel 544: Second channel 546: Plate structure 548: Guide orifice 550: Lifting interface 552: Inner rail radius 554: Outer rail radius 556: Rail stock

Claims

1. A method for manufacturing a tower structure, wherein the method is A step of depositing a first print layer of wall elements with a printhead assembly via an additive printing system, wherein the wall elements surround the vertical axis of a tower structure, The steps include determining the actual midline perimeter length of the first printed layer via the controller of the additive printing system, The steps include forming a horizontal reinforcement assembly based at least partially on the actual midline perimeter, The steps include: positioning a horizontal reinforcing assembly horizontally on the first printing layer, and aligning it with the vertical axis and the axial direction; The steps include: depositing a second printed layer of wall elements on a horizontal reinforcement assembly using a print head assembly via an additive printing system; A method that includes this.

2. The horizontal reinforcement assembly, An inner rail having a length shorter than the actual circumference of the midline, An outer rail having a length greater than the actual circumference of the midline, wherein the inner rail and the outer rail have a shape corresponding to the horizontal shape of the first printed layer, A plurality of lateral members, each of which has a first end connected to an inner rail and a second end connected to an outer rail, and The method according to claim 1, including the method described in claim 1.

3. The step of forming a horizontal reinforcement assembly is A step of receiving a plurality of prefabricated reinforcing segments, wherein each of the plurality of prefabricated reinforcing segments includes an inner rail segment connected to an outer rail segment via a portion of a plurality of lateral members, and each of the plurality of prefabricated reinforcing segments has a first segment end and a second segment end defined by the inner rail segment and the outer rail segment, A step of determining the magnitude of the overlap between adjacent prefabricated reinforcing segments of a plurality of prefabricated reinforcing segments configured to establish the midline perimeter of the reinforcing assembly based on the actual midline perimeter, The method according to claim 2, further comprising the step of joining the end of a first segment of each of the plurality of prefabricated reinforcing segments with the end of a second segment of each adjacent segment of the plurality of prefabricated reinforcing segments to establish an overlap between them based on a determined overlap size.

4. The step of establishing overlap is The steps include positioning multiple movable stoppers on the fixture table based on the midline circumference of the reinforcement assembly, The steps include: positioning portions of multiple prefabricated reinforcing segments via multiple movable stoppers to establish overlap between each adjacent segment of multiple prefabricated reinforcing segments; The method according to claim 3, further comprising:

5. The step of arranging multiple movable stoppers on the jig table is, The steps include: activating at least one servo operably coupled to multiple movable stoppers, A step of changing the position of at least one of the multiple movable stoppers relative to the support surface of the jig table, and The method according to claim 4, further comprising:

6. The step of activating at least one servo is, The steps include determining the required position of each of several movable stoppers via a controller in order to establish the magnitude of the overlap between adjacent prefabricated reinforcing segments of several prefabricated reinforcing segments, The steps include generating a setpoint for at least one servo, calculated via the controller, to position each movable stopper in the desired location, and The method according to claim 5, further comprising:

7. The step of forming a horizontal reinforcement assembly is A step of receiving multiple prefabricated reinforcing segments, wherein each of the multiple prefabricated reinforcing segments comprises an inner rail segment connected to an outer rail segment via a portion of multiple lateral members, The steps include connecting adjacent prefabricated reinforcing segments of each pair of multiple prefabricated reinforcing segments via a coupler unit, and The method according to any one of claims 2 to 6, further comprising the coupler unit being configured to establish the midline perimeter of the reinforcement assembly based on the actual midline perimeter.

8. The step of positioning the horizontal reinforcement assembly is Steps to operably connect at least one lifting element to the lifting interface of the coupler unit. The method according to claim 7, further comprising:

9. The step of forming a horizontal reinforcement assembly is The steps include determining the required midline perimeter of the reinforcement assembly based on the actual midline perimeter, The steps include determining the required inner rail radius based on the length of the midline circumference of the required reinforcement assembly, The steps include: applying a bend to a first portion of the rail stock corresponding to the required inner rail radius via a material processing device; The steps include determining the required outer rail radius based on the length of the midline circumference of the required reinforcement assembly, A step of applying a bend to a second portion of a rail stock via a material processing device, wherein the second portion of the rail stock has a length corresponding to the length of the outer rail, The steps include connecting multiple lateral members between the inner rail and the outer rail via a material processing device, The method according to any one of claims 2 to 8, further comprising:

10. A horizontal reinforcing assembly is positioned horizontally on the first printed layer. A step of establishing a movable coupling between at least one lifting element and a horizontal reinforcing assembly, wherein the horizontal reinforcing assembly is positioned such that a separation distance is established between at least one lifting element and the first printing layer when the horizontal reinforcing assembly is placed on the first printing layer, A step of separating at least one lifting element from the horizontal reinforcing assembly while maintaining a separation distance between at least one lifting element and the first printing layer, the step of placing a horizontal reinforcing assembly on a first printing layer, wherein maintaining at least one separation distance prevents contact between the at least one lifting element and the first printing layer. The method according to any one of claims 2 to 9, further comprising:

11. The step of determining the actual midline perimeter of the first printed layer is: The steps include recording the actual print path of the print head assembly during the deposition of the first print layer via the controller of the additive printing system, The steps include determining the actual midline perimeter length of the first print layer based on the actual print path of the print head assembly, and The method according to any one of claims 1 to 10, further comprising:

12. The step of determining the actual midline perimeter of the first printed layer is: The process involves the deposition of the first printed layer, followed by the optical scanning of the first printed layer via an optical scanner of the additive printing system. The process involves generating a three-dimensional map of the first printed layer based on an optical scan via the controller of the additive printing system, The process involves determining the actual midline perimeter of the first printed layer based on a three-dimensional map of the first printed layer, via the controller of the additive printing system. The method according to any one of claims 1 to 10, further comprising:

13. The additive manufacturing system further includes at least one laser emitter, and the method is The method according to any one of claims 1 to 12, further comprising the step of projecting at least one placement guide onto a first printed layer via at least one laser emitter, wherein the at least one placement guide is configured to guide the placement of a horizontal reinforcement assembly on the first printed layer.

14. The print head assembly further comprises an operable roller positioned to precede the print nozzle during the deposition operation, and the method The steps include: positioning a horizontal reinforcing assembly on a first printing layer, applying a downward force to the horizontal reinforcing assembly via an operable roller; Steps include: embedding the horizontal reinforcement assembly at least partially within the first printed layer in response to a downward force; The method according to any one of claims 1 to 13, further comprising:

15. An additive printing system for manufacturing tower structures, The tower structure includes wall elements that surround the vertical axis of the tower structure. The additional printing system Support structure and, Optical scanner and A print head assembly operably coupled to a support structure, A controller that is communicatively coupled to the print head assembly and optical scanner, It includes, The controller The steps include: depositing a first print layer on the wall element with the print head assembly, The steps include optically scanning a first printed layer via an optical scanner, A step of generating a three-dimensional map of the first printed layer based on an optical scan, The steps include determining the actual midline perimeter length of the first printed layer based on a three-dimensional map of the first printed layer, A step of forming a horizontal reinforcement assembly based at least partially on the actual midline perimeter, wherein the horizontal reinforcement assembly comprises an inner rail having a length shorter than the actual midline perimeter, an outer rail having a length longer than the actual midline perimeter, and a plurality of lateral members, each lateral member having a first end connected to the inner rail and a second end connected to the outer rail, and the inner rail and the outer rail having a shape corresponding to the horizontal shape of the first printed layer, The steps include: positioning a horizontal reinforcing assembly horizontally on the first printing layer, and aligning it with the vertical axis and the axial direction; The steps include: depositing a second printed layer of the wall element on a horizontal reinforcement layer using a print head assembly; An additive printing system comprising at least one processor configured to perform or instruct multiple operations, including the following.

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