Abstract: A method of manufacturing a tower structure includes providing an additive printing device having at least one printer head atop a support surface. The method also includes positioning a pre-fabricated component adjacent to the support surface. The pre-fabricated component is constructed of a composite material reinforced with a plurality of reinforcement members. Further, portions of the plurality of reinforcement members protrude from the composite material. Moreover, the method includes printing and depositing, via the at least one printer head, a cementitious material onto the support surface to build up the tower structure layer by layer around the pre-fabricated component. Thus, the portions of the plurality of reinforcement members that protrude from the composite material reinforce the cementitious material around the pre-fabricated component.

Abstract: The present disclosure is directed to an internal reinforcement assembly for a tower of a wind turbine. The reinforcement assembly includes a plurality of reinforcing rod members spaced circumferentially about the tower. Each of the plurality of reinforcing rod members includes a first end and a second end. The reinforcement assembly also includes an adjustable mounting component configured with each of the second ends of the plurality of reinforcing rod members. As such, the adjustable mounting components are mounted to an interior wall of the tower at a location to be reinforced. Thus, the reinforcing rod members interact with the tower to reinforce the tower at the location to be reinforced.

Abstract: A system and method are provided for manufacturing a tower structure. Accordingly, an interlocking form ring is additively manufactured with a first printhead assembly. The interlocking form ring defines a plurality of recesses in a radially inner or a radially outer face. A cementitious material is deposited within one or more of the recesses with a second printhead assembly. At least one reinforcing member is positioned within the recess with the second printhead assembly. The second printhead assembly is positioned adjacent to the cementitious material during the curing thereof so as to provide a slip form for the curing of the cementitious material.

Abstract: Methods of manufacturing a cementitious structure, such as a structure for supporting a wind turbine, include additively printing, via an additive printing device, one or more contours that include a cementitious material so as to form a cementitious structure in a layer by layer manner such that a first portion of the plurality of contours comprises a first plurality of contour coupling features that engage with a second plurality of contour coupling features of a second portion of the plurality of contours.

Abstract: A system and method are provided for manufacturing a tower structure. Accordingly, one or more layers of a wall element are deposited with a printhead assembly. At least one recess is defined in the wall element. The recess(es) has a single, circumferential opening positioned along an inner reference curve or an outer reference curve of the wall element. The recess(es) also has a depth which extends in a radial direction and intersects a midline reference curve. A reinforcing element is placed entirely within the recess(es) at the midline reference curve.

Abstract: A method of manufacturing a tower structure includes providing an additive printing device having at least one printer head atop a support surface. The method also includes positioning a pre-fabricated component adjacent to the support surface. The pre-fabricated component is constructed of a composite material reinforced with a plurality of reinforcement members. Further, portions of the plurality of reinforcement members protrude from the composite material. Moreover, the method includes printing and depositing, via the at least one printer head, a cementitious material onto the support surface to build up the tower structure layer by layer around the pre-fabricated component. Thus, the portions of the plurality of reinforcement members that protrude from the composite material reinforce the cementitious material around the pre-fabricated component.

Abstract: A method for manufacturing a tower structure of a wind turbine includes additively printing at least a portion of a frame shape of the tower structure of the wind turbine of a first material on a foundation of the tower structure. Further, the first material has a first cure rate. The method also includes allowing the portion of the frame shape to at least partially solidify. The method includes providing a second material around and/or within the portion of the frame shape such that the portion of the frame shape provides support for the second material. The second material includes a cementitious material having a second cure rate that is slower than the first cure rate, with the different cure rates reducing the net printing time for the overall structure. Moreover, the method includes allowing the second material to at least partially solidify so as to form the tower structure.

Abstract: A method for manufacturing a tower structure of a wind turbine at a wind turbine site. The method includes determining an optimized shape of the tower structure based on one or more site parameters. Further, the optimized shape of the tower structure is non-symmetrical. In a further step, the method include printing, via an additive printing device, the optimized shape of the tower structure of the wind turbine at the wind turbine site, at least in part, of a cementitious material. In addition, the method includes allowing the cementitious material to cure so as to form the tower structure of the wind turbine.

Abstract: A tower structure of a wind turbine includes a plurality of tower sections stacked atop each other in an end-to-end configuration along a vertical axis to form the tower structure of the wind turbine at a wind turbine site. Each of the tower sections is formed of at least one first tubular portion and at least one second tubular portion. Further, the first and second tubular portions of each of the plurality of tower sections are concentric with each other. Moreover, the first tubular portion is formed at least in part, of a cementitious material and the second tubular portion is formed of a perforated material having a plurality of holes.

Abstract: A method for manufacturing a tower structure of a wind turbine includes printing, via an additive printing device, the tower structure of the wind turbine of a cementitious material. During printing, the method includes embedding one or more reinforcement sensing elements at least partially within the cementitious material at one or more locations. Thus, the reinforcement sensing element(s) are configured for sensing structural health of the tower structure, sensing temperature of the cementitious material, heating to control cure time of the cementitious material, and/or reinforcing the cementitious material. In addition, the method includes curing the cementitious material so as to form the tower structure.

Abstract: An additive printing device and a method for using the same to manufacture a tower structure of a wind turbine is provided. The additive printing device includes a vertical support structure, a support ring suspended from the vertical support structure, and a printer head movably coupled to the support ring for selectively depositing cementitious material. A drive mechanism, such as a rack and pinion, moves the printer head around the support ring while selectively depositing cementitious material. The vertical support structure may be raised and/or the relative position between the vertical support structure and the printer head may be adjusted to raise the printer head to print subsequent layers. This process may be repeated to print the tower structure layer-by-layer from the ground up.

Abstract: Methods of manufacturing a cementitious structure, such as a structure for supporting a wind turbine, include additively printing, via an additive printing device, one or more contours that include a cementitious material so as to form a cementitious structure in a layer by layer manner such that a first portion of the plurality of contours comprises a first plurality of contour coupling features that engage with a second plurality of contour coupling features of a second portion of the plurality of contours.

Abstract: A method for manufacturing a tower structure of a wind turbine includes printing, via an additive printing device, a plurality of concentric sections of the tower structure of the wind turbine. The concentric sections may be printed simultaneously from concrete, may include tensioning cables or other structural supports, and may define other support flanges or overhangs. After curing, the method may include raising an inner section of the plurality of concentric sections to a top of an adjacent outer section and joining the two sections. This process may be repeated to telescope the concentric sections and raise the tower structure.

Abstract: A method for manufacturing a tower structure of a wind turbine includes printing, via an additive printing device, the tower structure of the wind turbine of a cementitious material. The method also includes printing, via the additive printing device, one or more additional airflow modifying features on an outer surface the tower structure of the wind turbine so as to reduce and/or prevent vortex shedding, excitation, and/or drag of the tower structure. Further, the method includes curing the cementitious material so as to form the tower structure.

Abstract: A wind turbine system includes a wind turbine generator having a rotor and a nacelle mounted atop a tower structure. The tower structure is mounted to a foundation structure and includes a plurality of tower sections, each including one or more tower section flanges. The wind turbine system further includes one or more connector rings. Each of the one or more connector rings is disposed proximate two adjacent tower section flanges and includes a plurality of pad eye adaptors each having an opening formed therein. The wind turbine system further includes a plurality of tensioned cables, with each coupled to one of the pad eye adaptors at a first end and the foundation structure at a second end. The plurality of tensioned cables are coupled to the tower structure at different or multiple connector ring heights based on site conditions to yield the desired lateral stability.

Abstract: A reinforcement assembly for a tower of a wind turbine is disclosed as having at least one generally cylindrical tower section with an exterior wall and an interior wall defining a height and a thickness therebetween. At least one generally cylindrical tower flange is coupled to the tower section, the tower flange having at least one vertical flange portion and at least one horizontal flange portion. At least one adjustable generally cylindrical reinforcing member has, at least one vertical member portion with at least one flexible portion coupled to the exterior wall of the tower section, and at least one horizontal member portion adjustably engaged with at least one adjusting spacer. Adjustment of the adjusting spacer aligns the reinforcing member with an adjacent tower flange.

Abstract: A multi-material tower section for a tower mast. The tower mast comprised of at least one multi-material tower section and a method for manufacturing the section. The section comprises at least one additively manufactured wall structure comprised of at least one first material and a plurality of additively manufactured internal reinforcement structures comprised of at least one additional material and disposed therewith the at least one additively manufactured wall structure.

Abstract: A wind turbine system includes a wind turbine generator having a rotor and a nacelle mounted atop a tower structure. The tower structure is mounted to a foundation structure and includes a plurality of tower sections, each including one or more tower section flanges. The wind turbine system further includes one or more connector rings. Each of the one or more connector rings is disposed proximate two adjacent tower section flanges and includes a plurality of pad eye adaptors each having an opening formed therein. The wind turbine system further includes a plurality of tensioned cables, with each coupled to one of the pad eye adaptors at a first end and the foundation structure at a second end. The plurality of tensioned cables are coupled to the tower structure at different or multiple connector ring heights based on site conditions to yield the desired lateral stability.

Abstract: The present disclosure is directed to an internal reinforcement assembly for a tower of a wind turbine. The reinforcement assembly includes a plurality of reinforcing rod members spaced circumferentially about the tower. Each of the plurality of reinforcing rod members includes a first end and a second end. The reinforcement assembly also includes an adjustable mounting component configured with each of the second ends of the plurality of reinforcing rod members. As such, the adjustable mounting components are mounted to an interior wall of the tower at a location to be reinforced. Thus, the reinforcing rod members interact with the tower to reinforce the tower at the location to be reinforced.

Abstract: A reinforcement assembly for a tower of a wind turbine is disclosed as having at least one generally cylindrical tower section with an exterior wall and an interior wall defining a height and a thickness therebetween. At least one generally cylindrical tower flange is coupled to the tower section, the tower flange having at least one vertical flange portion and at least one horizontal flange portion. At least one adjustable generally cylindrical reinforcing member has, at least one vertical member portion with at least one flexible portion coupled to the exterior wall of the tower section, and at least one horizontal member portion adjustably engaged with at least one adjusting spacer. Adjustment of the adjusting spacer aligns the reinforcing member with an adjacent tower flange.