METHOD FOR PRODUCING A CONCRETE FORMWORK FOR A TOWER SEGMENT, AND METHOD FOR PRODUCING A TOWER SEGMENT FOR A TOWER OF A WIND TURBINE

Abstract

A method for producing a concrete formwork for a component, in particular a tower segment for a tower, preferably a tower of a wind turbine, to a method for producing a component, in particular a tower segment for a tower, preferably a tower of a wind turbine, to a concrete formwork for a component, in particular a tower segment for a tower, preferably a tower of a wind turbine, to a component, in particular a tower segment for a tower, preferably a tower of a wind turbine, and to a pattern of a component, in particular a tower segment for a tower, preferably a tower of a wind turbine.

Claims

1. A method comprising: producing a concrete formwork for a component for a tower of a wind turbine, the producing comprising: providing a pattern of the component; erecting a production formwork around the pattern at a distance from the pattern, wherein a cavity is produced between the production formwork and the pattern and corresponds to dimensions of the concrete formwork to be produced; filling the cavity with liquid concrete; and hardening the concrete to the form the concrete formwork.

2. The method as claimed in claim 1, comprising: removing the production formwork; and removing the pattern.

3. The method as claimed in claim 1, comprising: coating surfaces of the concrete formwork facing the pattern with an anti-adhesion coating; or coating surfaces of the concrete formwork facing the pattern with a primer coating and an anti-adhesion coating.

4. The method as claimed in claim 1, wherein: the dimensions of the pattern are increased in comparison with the component to be produced with the concrete formwork by a shrinkage allowance for the hardening of the concrete; or dimensions of the pattern are increased in comparison with the component to be produced with the concrete formwork by an amount that takes into account shrinkage allowances for the hardening of the concrete both of the concrete formwork and of the component to be produced with the concrete formwork.

5. The method as claimed in claim 1, comprising: reinforcing the cavity with a reinforcement; and/or introducing auxiliary means for the use or transport of the concrete formwork to be produced.

6. The method as claimed in claim 1, wherein the concrete formwork comprises an inner portion and an outer portion that are produced simultaneously.

7. The method as claimed in claim 1, comprising: separating the concrete formwork into two or more partial concrete formworks.

8. The method as claimed in claim 1, wherein: the production formwork is at least one of: a concrete formwork, a fixed formwork, a timber formwork, a girder formwork, a panel formwork, a permanent formwork, a single-face formwork, a double-face formwork, a freeform formwork, or a round formwork; and the production formwork has dimensions that are suitable for road transport.

9. A method comprising: producing first and second concrete formworks for at least two different components for a tower of a wind turbine the producing comprising: producing a first concrete formwork by the method as claimed in claim 1, wherein the pattern is a first pattern; providing a second pattern of a second component, wherein the second pattern is different from the first pattern; erecting the production formwork, previously used for the production of the first concrete formwork, around the second pattern at a distance from the second pattern, wherein a cavity is produced between the production formwork and the second pattern and corresponds to dimensions of the second concrete formwork to be produced; filling the cavity with liquid concrete; and hardening the concrete to produce the second concrete formwork.

10. A method comprising: producing a component for a tower of a wind turbine, the producing comprising: providing a concrete formwork produced by the method as claimed claim 1; filling a cavity formed by the concrete formwork with liquid concrete; and hardening the concrete to produce the component.

11. The method for producing a component as claimed in claim 10, comprising: removing the concrete formwork; reinforcing the cavity with a reinforcement; introducing guides for tensioning wires, lines, or cables into the cavity; and finishing by at least one of: grinding or coating the component.

12. A concrete formwork for a component for a tower of a wind turbine, wherein the concrete formwork was produced in the method as claimed in claim 1.

13. A component for a tower of a wind turbine wherein the component was produced by the method as claimed in claim 10.

14. A pattern of a component for a tower of a wind turbine, dimensions of the pattern are increased in comparison with the component to be produced with the concrete formwork by a shrinkage allowance for the concrete; and dimensions of the pattern are increased in comparison with the component to be produced with the concrete formwork by an amount that takes into account shrinkage allowances for the concrete both of the concrete formwork and of the component to be produced with the concrete formwork.

15. (canceled)

16. The concrete formwork as claimed in claim 12, wherein the component is a tower segment for the tower of the wind turbine.

17. The method as claimed in claim 10, wherein the component is a tower segment of a wind turbine.

18. The method as claimed in claim 1, wherein the component is a tower segment of a wind turbine.

19. The method as claimed in claim 1, wherein the concrete formwork comprises an inner portion and an outer portion that are produced one after the other.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0053] Preferred embodiments of the invention are described by way of example on the basis of the accompanying figures, in which:

[0054] FIG. 1 shows a schematic representation of a wind turbine with a tower with components produced according to an embodiment of the invention;

[0055] FIG. 2 shows a schematic representation of an embodiment, given by way of example, of the method according to an embodiment of the invention for producing a concrete formwork for a component, in particular a tower segment for a tower of a wind turbine;

[0056] FIG. 3 shows a schematic cross section through an embodiment, given by way of example, of a production formwork and a pattern for a component;

[0057] FIG. 4 shows the cross section as shown in FIG. 3 with concrete formwork;

[0058] FIG. 5 shows a formwork according to the prior art, which can be used as production formwork;

[0059] FIG. 6 shows a schematic cross section through an embodiment, given by way of example, of a concrete formwork;

[0060] FIG. 7 shows the cross section as shown in FIG. 3 with a component.

DETAILED DESCRIPTION

[0061] FIG. 1 shows a wind turbine 100 with a tower 102 and a nacelle 104. Arranged on the nacelle 104 is a rotor 106 with three rotor blades 108 and a spinner 110. During operation, the rotor 106 is set in a rotary motion by the wind, and thereby drives a generator in the nacelle 104. The tower 102 has components that were produced by the method described here.

[0062] The schematic representation of an embodiment, given by way of example, of the method according to the invention for producing a concrete formwork for a component, in particular a tower segment for a tower of a wind turbine according to FIG. 2, comprises the following steps: S1: providing a pattern of the component; S2: erecting a production formwork around the pattern at a distance from the pattern, wherein a cavity produced between the production formwork and the pattern corresponds to the dimensions of the concrete formwork to be produced; S3: filling the cavity with liquid concrete; S4: hardening the concrete; S5: removing the production formwork; S6: removing the pattern; S7: coating the surfaces facing the pattern in the production of the concrete formwork with an anti-adhesion coating.

[0063] FIG. 3 shows a schematic cross section through an embodiment, given by way of example, of a production formwork 300 and a pattern 200 for a component; FIG. 4 shows the cross section as shown in FIG. 3 with the concrete formwork 501, 502. According to FIG. 3, a pattern 200 of a component can be seen, arranged on a base or formwork table 310. It is indicated by the broken line 201 that the pattern 200 is increased in size by a shrinkage allowance for the concrete that is used for the component to be produced. The broken line 201 schematically represents the geometry of the component to be produced, smaller by the shrinkage allowance for the concrete. In FIG. 3, parts 301, 302 of the production formwork 300 are arranged alongside the pattern 200, at a distance from it, to the right and left. Formed between the part 301 of the production formwork 300 and the component 200 is a cavity 401, between the part 302 of the production formwork 300 and the component 201 a further cavity 402. Arranged on the component 200 is a further part 303 of the production formwork 300. The parts 301, 302 of the production formwork are supported by bracings 304. Alternatively or in addition, the parts 301, 302 may also be connected, in particular bolted, to the formwork table 310. The part 303 of the production formwork 300 is supported with respect to the parts 301, 302 of the production formwork 300 by way of struts 305. The cavities 401, 402 are delimited in the downward direction by the floor or formwork table 310 and are open in the upward direction, so that the liquid concrete can be introduced into the cavities 401, 402 from above. To the sides, the cavities 401, 402 are delimited by the pattern 200 and the parts 301, 302 of the production formwork 300. The cavities 401, 402 are preferably also delimited at the end faces, which cannot be seen in FIG. 3. The delimitation may be realized by a further formwork part (not represented).

[0064] As can be seen in FIG. 4, the cavities 401, 402 according to FIG. 3 have been filled with liquid concrete and the concrete has been hardened, so that the two portions 501, 502 of the concrete formwork 500 have been created. The two portions 501, 502 of the concrete formwork 500 may also be referred to as the inner portion and outer portion, in particular if the component to be produced is a component in the form of a circular ring or a component with the form of a segment of a circular ring.

[0065] In the production of the concrete formwork 500, the surfaces 501a, 502a are facing the pattern 200 and, in the production of the component 800, facing the component 800 or previously the cavity 700 (see FIGS. 6 and 7). These surfaces 501a, 502a are preferably coated with an anti-adhesion coating, in order to avoid or reduce adhesive attachment of the component 800 to the concrete formwork 500. Oils or epoxides may be used for example as the anti-adhesion coating.

[0066] FIG. 6 shows a schematic cross section through an embodiment, given by way of example, of a concrete formwork 501, 502; FIG. 7 shows the cross section as shown in FIG. 3 with the component 800. After the removal of the pattern 200 and the production formwork 300, the concrete formwork 500 produced can be used on a base or formwork table 310 for producing a component. For this purpose, the cavity 700 between the portions 501, 502 of the concrete formwork 500 is filled with liquid concrete, which after hardening forms the component 800.

[0067] The dimensional stability of the component 800 to be produced with the concrete formwork 500 is influenced by the surfaces 501a, 502a facing the pattern 200 in the production of the concrete formwork 500, not by the surfaces facing the production formwork 300 in the production of the concrete formwork 500. Therefore, a simple formwork that meets lower requirements for precision can be used for the production formwork 300. By contrast, the pattern 200, which is produced with the greatest possible dimensional stability, can preferably be reused for producing any number of concrete formworks 500, and on account of the transport dimensions can preferably be transported even over relatively long distances.

[0068] Shown in FIG. 5 is a round formwork 600 according to the prior art, which can be used as production formwork. The round formwork 600 according to FIG. 5 has an outer formwork part 601 and an inner formwork part 602, formed between which is a cavity 650, which can be filled with liquid concrete in order to produce a component in the form of a ring. The supporting struts 604, by which the outer formwork part 601 is supported, can be seen. At the upper end, the inner formwork part 602 has a railing 611. Formed at the upper end of the outer formwork part 601 is a peripheral walkway 610, likewise with a railing. Such round formworks 600 are known in the prior art and can be used flexibly, including for different radii. However, for changing geometries of tower segments, in particular tapering tower segments and/or other particular geometries in the tower segments, considerable adaptations are required and cannot be realized with existing formwork, or only with great effort and special quality control with regard to precision. It is therefore also possible to use such flexibly usable formworks as the round formwork 600 as production formwork, in order to enclose the sides of the concrete formwork that are facing away from the patternand consequently the component to be produced later. In this way, for example, even special geometries, such as for example tapering components, can be produced with concrete formworks for which the same or only a slightly modified production formwork was used.