EP4294987A1 - Mold part set for wind turbine ground foundation and wind turbine ground foundation - Google Patents

Mold part set for wind turbine ground foundation and wind turbine ground foundation

Info

Publication number
EP4294987A1
EP4294987A1 EP21707222.2A EP21707222A EP4294987A1 EP 4294987 A1 EP4294987 A1 EP 4294987A1 EP 21707222 A EP21707222 A EP 21707222A EP 4294987 A1 EP4294987 A1 EP 4294987A1
Authority
EP
European Patent Office
Prior art keywords
mold part
mold
joining surface
face
parts
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21707222.2A
Other languages
German (de)
French (fr)
Inventor
Marta CARROZA DIAZ
Rüdiger Marquardt
Ali Mohammadi MOHAGHEGH
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
RWE Renewables Europe and Australia GmbH
Original Assignee
RWE Renewables Europe and Australia GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by RWE Renewables Europe and Australia GmbH filed Critical RWE Renewables Europe and Australia GmbH
Publication of EP4294987A1 publication Critical patent/EP4294987A1/en
Pending legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/01—Flat foundations
    • E02D27/016—Flat foundations made mainly from prefabricated concrete elements
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/32—Foundations for special purposes
    • E02D27/42—Foundations for poles, masts or chimneys
    • E02D27/425—Foundations for poles, masts or chimneys specially adapted for wind motors masts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/20—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors
    • F03D13/22—Foundations specially adapted for wind motors
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/01—Flat foundations
    • E02D27/02—Flat foundations without substantial excavation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction

Definitions

  • the subject matter relates to a set of mold parts for a wind turbine foundation and a wind turbine foundation.
  • Wind turbines are regularly founded with a concrete foundation.
  • a concrete foundation is built on-site as part of engineering work.
  • a formwork is built and then filled with concrete and reinforced by rebars to form a reinforced concrete structure.
  • the engineering work, formwork and pouring on-site are costly and take a long time.
  • transporting liquid concrete to the construction site is technically challenging and expensive, especially in impassable terrain.
  • the conditions under which the poured concrete can harden are on-site weather-dependent and thus cannot be standardized, which can lead to different compressive and tensile strengths of the components.
  • due to the on-site formwork the dimensional accuracy of the structures is often worse than desired by the designer and necessary for a safe stand.
  • the subject matter was based on the object of providing mold parts for a wind turbine ground foundation as well as a wind turbine ground foundation which provides great Stability with low material input and can be produced with high constructional, in particular dimensional accuracy.
  • a set of mold parts is to be understood as a set, group, plurality or multiplicity of mutually compatible mold parts.
  • a set of mold parts is formed from at least two separate mold parts that can be joined to form a mold part assembly.
  • at least two separate mold parts of the mold part set can be compatible with each other and can be joined to form a mold part assembly.
  • Joining to build the mold part assembly is preferably carried out by means of a form fit on corresponding joining surfaces of the mold parts.
  • the mold parts can engage in form fit with each other via the respective joining surfaces.
  • the foundation can be a shallow foundation, slab foundation and/or ground foundation.
  • ground the term shallow or slab is also meant.
  • the term torque can be used as general description of a moment, e.g. a bending moment.
  • the foundation requires a sufficiently dimension and sufficiently high axial moment of inertia for stability.
  • Sufficient dimensions of the foundation are required for stability reasons, in particular to avoid overturning and to transfer the loads to the ground whilst the bearing capacity of the ground is not exceeded.
  • Sufficient moment of inertia is required for stiffness reasons. Stability and stiffness is achieved in particular if the spatial extension of the foundation parallel to the longitudinal axis of the tower mounted on the ground foundation is large.
  • a first mold part of the set of mold parts is wall-shaped.
  • a wall is characterized by its length and height being many times greater than its width.
  • the wall-shaped mold part can be a single mold of made from multiple mold assembled after curing of the mold.
  • the wall-shaped mold part is preferably arranged on the ground foundation in such a way that its height extension direction is essentially parallel to the longitudinal axis of the tower to be mounted on the foundation. In this way, the axial moment of inertia of the wall-shaped mold part applied to the vertical axis can absorb the bending moments/torques of the tower.
  • the wall-shaped mold provides stiffness and rigidity to the system It has been recognized that wall-shaped elements can be sufficient to absorb the bending moments /torques /bending loads. It has been recognized that it is not necessary to have the height extension of the ground foundation equal all around the tower. Rather, three or more first wall-shaped mold parts may be provided to accommodate the beding moments/torques/bending loads. It should be noted that in the following, in particular four wall-shaped mold parts are described, however, three or more than four wall-shaped mold are possible, which preferably are arranged around the central pedestral in equal angles.
  • a second mold part is provided to prevent the wall-shaped mold parts from shifting relative to each other.
  • the second mold part is beam-shaped.
  • a beam is characterized by its length being many times greater than its height and width.
  • the beam-shaped mold part is preferably arranged at the wall-shaped mold parts to fix them to each other.
  • a beam-shaped mold part can be used to increase the bearing surface of the foundation on the ground, in particular at a distance from the tower, in particular by the dimension of the length extension of the wall-shaped mold part.
  • At least one wall face of the wall-shaped mold part has in its region of at least one longitudinal edge a first joining surface for the beam-shaped mold part. That is, a beam-shaped mold part can be engaged with the wall face at the first joining surface.
  • a beam-shaped mold part is preferably arranged with its longitudinal axis parallel to the surface normal of the joining surface of the wall-shaped mold part.
  • a first front face of the beam-shaped mold part has a second joining surface corresponding to the first joining surface.
  • the surface normal of the front face with its second joining surface preferably runs essentially parallel to the longitudinal axis of the beam-shaped mold part.
  • the beam-shaped, second mold part has a first and second front face.
  • the respective front faces can be formed with a corresponding second joining surface.
  • the joining surfaces arranged on the two front faces are in particular complementary to one another.
  • a joining surface may also be provided on the beam-shaped mold part along a side face for receiving a fourth mold part, as will be described further below.
  • the side face may be a side wall extending from a first front face toward a second front face.
  • the joining surface on the side face may extend along the entire height extension. This also applies to the joining surfaces on the front faces.
  • a third joining surface is arranged on a first front face of a third mold part.
  • the third mold part is substantially similar in geometric shape to the second mold part, and may also be described as beam-shaped.
  • the above explanations apply substantially accordingly. Only the arrangement of the third joining surfaces on the third mold part may be different from the arrangement of the second joining surfaces on the second mold part, in particular, only one front face on the third mold part may be provided with a third joining surface.
  • a third joining surface can be provided on a side face of the third mold part.
  • the mold part set is formed from several mold parts.
  • the respective joining surfaces on the mold parts to be joined together are shaped complementarily to one another.
  • the joining surfaces are profiled with a relief-shaped surface.
  • the relief-shaped profiling is formed as shear keys.
  • a shear key can ensure a Form fit in at least one spatial direction. This is in particular the direction of the height extension of the first mold part. In the installed state, this regularly corresponds to the longitudinal axis of the tower to be erected on the foundation. In particular, this can be a direction of a center axis of the ground foundation. A form fit between the mold parts can take place in this direction.
  • the first joining surface is preferably formed on the wall-shaped mold part on its wall face only in an edge region of the longitudinal edge of the wall face.
  • the height extension of the first mold part preferably runs essentially parallel to a direction of a center axis of the foundation and thus preferably parallel to a direction of a longitudinal axis of a tower to be erected on the foundation.
  • a longitudinal edge can extend in a radially outward direction, and in the region of this longitudinal edge, but on the wall face and not on a side face, the first joining surface can extend.
  • the joining surfaces are formed in particular in the form of shear keys, in particular in the form of projections and recesses, in particular in the form of grooves and tongues.
  • the projections and recesses can extend longitudinally in a plane that is essentially parallel to the ground in the installed state of the mold parts. In particular, this is a plane whose surface normal is substantially parallel to a center axis of the foundation and/or a longitudinal extension of the tower to be built on the foundation.
  • the shear key may also be relief-shaped, along two directions.
  • the shear key may be formed in pyramidal, or it may be formed in the shape of conical.
  • a first joining surface is arranged on respective opposing wall faces. These joining surfaces/which are arranged on wall faces facing away from each other, can be shaped congruently or complementary to each other.
  • a fourth mold part can be provided in addition to the first, second and third mold parts.
  • the fourth mold part is in particular wall-shaped.
  • the fourth mold part can be pre-fabricated or alternative cast in situ.
  • the fourth mold part can be a single mold or assembled from multiple pre-cast molds after curing.
  • the wall face of the fourth mold part in preferably runs essentially perpendicular to the wall face of the first mold part.
  • the fourth mold part lies in particular in a bottom region.
  • the fourth mold part can rest against the first joining surface extending along the edge region in the longitudinal direction of the wall face of the first mold part.
  • the fourth mold part may also be referred to as being disc-shaped or slab shaped, wherein wall-shaped, disc- shaped and slab-shaped may be regarded as interchangeable terms.
  • Fourth joining surfaces corresponding to the first joining surface may be provided on each two adjacent side walls of the fourth mold part. These fourth joining surfaces can be complementary to the first joining surfaces, so that the fourth mold part with the fourth joining surfaces can form a form fit with the first joining surfaces of the first mold part.
  • the fourth mold part can also be shaped in such a way that it can be connected in form fit to side faces of one or both beam-shaped mold parts, in particular to the joining surfaces of the beam-shaped mold parts extending along the side faces.
  • a fourth joining surface corresponding to the second joining surface is provided on a side wall of the fourth mold part and a fourth joining surface corresponding to the third joining surface is provided on a side wall adjacent to this side wall.
  • These fourth joining surfaces can be complementary to the second and/or third joining surfaces so that they can be joined together in a form-fitting manner.
  • fourth joining surfaces can be arranged, where these fourth joining surfaces can be different from each other, for instance on two adjacent side faces the fourth joining surfaces can be complementary to the first joining surfaces and on a third side face a fourth joining surface can be complementary to the second joining surface and on a fourth side face a fourth joining surface can be complementary to the first joining surface.
  • at least three first mold parts can be connected to each other via at least one respective beam-shaped mold part.
  • the at least three first mold parts, but preferably four first mold parts extend with their longitudinal edge radially away from a center axis of the ground foundation.
  • the first mold parts are preferably distributed in equidistant angular sections around the center axis of the foundation.
  • first mold parts In order to fix the position of the first mold parts relative to one another, in particular the angular position of the first mold parts relative to one another around the center axis, they can be connected to one another via at least one respective beam-shaped mold part.
  • the beam-shaped mold parts rest against the first mold parts and preferably form a closed ring around the center axis of the ground foundation.
  • the first mold parts are connected to each other via a connection of a second and a third mold part.
  • the mold parts form a quadrangular structure of four quadrants around the center axis of the ground foundation, each quadrant being bounded by two perpendicular first mold parts and two perpendicular second and third mold parts connected to each other and to the first mold parts. That is, starting from a central axis, a quadrant is formed by a first mold part, a second mold part, a third mold part, and again a first mold part.
  • the mold parts are preferably connected to one another at their abutting joint surfaces in a form fit by shear keys.
  • the ground foundation is composed of interconnected mold part assemblies, wherein a mold part assembly according to an embodiment is composed of a mold part set as described above, at least one wall-shaped mold part and at least one beam-shaped mold part are provided in a mold part assembly.
  • the beam-shaped mold part rests with its end-face joining surface against the first joining surface of the wall-shaped mold part.
  • the beam-shaped mold part rests against the first joining surface in a region of the wall face of the wall-shaped mold part that is located radially on the outside of the center axis of the ground foundation.
  • the mold part assembly has a third mold part.
  • This third mold part rests with its end third joining surface against the first joining surface of at least one of the two first mold parts.
  • the third mold part rests with its front face against the first joining surface radially outwardly of the center axis of the ground foundation in the region of the wall face of the wall-shaped mold part.
  • the second mold part is in contact with the first joining surface on its first front face and in contact with the third joining surface of the third mold part on its second front face opposite the first front face.
  • the second mold part lies between the first mold part and the third mold part and is interlocked in form fit With these respectively via an front face.
  • a fourth mold part may occupy a space formed between the first, second, and third mold parts. This can be done by a pre-cast mold or preferably by casting in situ.
  • the first, second and third mold parts can be perpendicular to each other.
  • the second and third mold parts are provided in a bottom region of the foundation in the installed state.
  • the fourth mold part may be located between the first and second mold parts in the bottom region.
  • the fourth mold part may be interlocked with its fourth joining surfaces with the second and third joining surfaces.
  • the fourth mold part can be interlocked with its fourth joining surfaces with the first joining surfaces of two first mold parts that are perpendicular to each other.
  • the mold parts are formed as precast parts, in particular as precast concrete parts.
  • the mold parts are in particular prefabricated precast parts that can be delivered to the construction site in a prefabricated state.
  • the mold parts are preferably formed from a mineral building material, in particular from concrete.
  • the concrete is in particular an ultra-high-strength concrete.
  • a fiber reinforcement is provided in the concrete, in particular a synthetic fiber reinforcement. This can be a basalt fiber or a carbon fiber.
  • metal fibers are also possible.
  • the precast elements are made of fiber-reinforced concrete (FRC). FRP fibers, basalt fibers, metallic fibers or metallic rebars can be used.
  • FRC fiber-reinforced concrete
  • the tensile strength of the finished parts can be increased by using fibers, in particular glass fibers, carbon fibers, basalt fibers or the like.
  • a fiber content of at least 10%, preferably at least 20%, is advantageous in order to achieve a sufficiently high tensile strength.
  • a further increase in tensile strength results from post tensioning of the mold parts by means of the tendons.
  • Sufficient compressive strength results from the use of the mineral building material, in particular concrete.
  • At least one through opening may be provided in the first mold part. This through-opening can extend in particular along the longitudinal axis of the first mold part.
  • the through opening is provided for receiving a tendon or a bar.
  • through-openings can be provided which extend transversely, in particular perpendicularly, to the longitudinal axis of these mold parts.
  • these through-openings run parallel to the respective front faces.
  • These through-openings are also provided to accommodate tendons.
  • through-openings can be provided running inside the wall face, these through-openings preferably running in the longitudinal direction as well as in the transverse direction crossing, but not overlapping, one another in the fourth mold part. These through-openings can also be provided to accommodate tendons.
  • the through openings of the fourth mold part can be aligned with the through openings of the second and third mold parts in the installed state, so that tendons can be tensioned through the second mold part and the fourth mold part as well as through the third mold part and the fourth mold part.
  • Through-openings extending in the width direction of the mold part can be provided in the first mold parts in the area of the first joining surface. In the installed state, these can be aligned with the through- openings of the fourth mold part.
  • tendons can clamp together through a first mold part, two opposing fourth mold parts and third mold parts, and two opposing fourth mold parts and second mold parts.
  • the tendons are suitable for bracing the mold parts of a mold part assembly against each other.
  • the tendons are suitable for bracing at least two adjacent mold part assemblies.
  • the tendons can also post tension (overpress, compress) the mold parts, which means that the mold parts are given a mechanical tension by the tendons. This increases the tensile strength against tensile stress of the mold part, especially if it is formed from a mineral building material, such as concrete.
  • a tendon is in particular a post tensioning steel. The tendon can be inserted in the form of a bar through suitable through- openings running in the mold parts and tensioned at the outer outlets of the mold parts joined together or of the mold part assemblies joined together, in particular by means of bolting.
  • a wind turbine ground foundation includes a central foundation body having an upper face, a lower face, and at least one side face extending between the upper face and the lower face.
  • This foundation body serves as a support for a junction console for a tower of the wind turbine at the upper face.
  • This foundation body may also be understood as pedestral.
  • the central foundation body can take up the tendons, bolts, or bars.
  • the central foundation can be cast on site.
  • the junction console can be a standard anchor cage.
  • the junction console can be made from tendons trough an adapter plate, which is closed by the side faces and which can be cast on site. At least one mold part assembly having at least one set of mold parts as described is disposed on a side face.
  • the central foundation body can be manufactured on site, in particular formed and cast. In this context, it is possible in particular for tendons to be guided through the formwork mold and to be integrated into the foundation body during casting. It is also possible, in particular, that receptacles for tendons are provided in the formwork for the foundation body and are integrated into the foundation body during casting. It is also possible that the foundation body is a prefabricated concrete component and in particular has a receptacle for the tendons or integrated tendons.
  • the foundation body is polygonal, in particular rectangular, preferably square.
  • a mold part assembly can be arranged on each of the side faces, in particular four side faces.
  • a first mold part with its respective outer side wall can abut against each of two further mutually opposite side faces of the foundation body.
  • side walls of the first mold parts may be arranged on the side walls of the central foundation body.
  • At least three, preferably four, mold part assemblies as previously described are arranged circumferentially around the foundation body.
  • the first mold parts face radially outwardly away from the side faces of the central body.
  • the first mold parts extend longitudinally in a radial direction away from the side faces.
  • the second and third mold parts abut with their front faces against the first joining surfaces, respectively, and are interlocked with the first joining surfaces via the shear keys.
  • a second and a third and preferably a fourth mold part are provided on both sides of a first mold part.
  • the wind turbine ground foundation is preferably point-symmetrical with respect to the center axis, but can also be at least axial symmetrically with respect to at least one longitudinal ⁇ axis of a first mold part in the installed state,
  • First mold parts extending at an angle to one another with respect to their longitudinal axis are connected to one another via respective at least second and preferably third mold parts, in which case a second mold part is perpendicular to a wall face of a first mold part and a third mold part is perpendicular to a wall face of a further first mold part, and the second and third mold parts are connected to one another at their ends remote from the first mold parts via their second and third joining- surfaces.
  • Fig. 1a, b a first mold part according to an embodiment
  • Fig. 2 a second mold part according to an embodiment
  • Fig. 3 a third mold part according to an embodiment
  • Fig. 4 a fourth mold part according to an embodiment
  • Fig. 5 a wind turbine foundation according to a first embodiment
  • Fig. 6 a plan view of a wind turbine foundation according to Fig. 5a;
  • Fig. 7 a cross-section through a wind turbine foundation according to Fig. 5a.
  • Fig. la shows a first mold part 2.
  • the first mold part 2 is wall-shaped, as can be seen in Fig. la.
  • the first mold part 2 is preferably cuboid-shaped with a rectangular wall face, but can also be formed trapezoidal, as shown in Fig. 1b, in particular with a wall tapered in the vertical direction along a longitudinal extension.
  • the first mold part 2 has opposing wall faces 2a.
  • the wall faces are spanned by the longitudinal direction 4a and the vertical direction 4b.
  • the first mold part 2 has two opposing side faces 2b extending in the upward direction 4b and two opposing side faces 2c extending in the longitudinal direction 4a.
  • the side faces 2b may also be referred to as front faces.
  • the extent of the first mold part 2 in the longitudinal direction 4a and in the upward direction 4b is considerably greater than in a transverse direction 4c.
  • a first joining surface 8 is provided on the wall faces 2a in the region of a longitudinal edge 6 on the wall face 2.
  • the joining surface 8 comprises grooves and projections extending in the longitudinal direction 4a.
  • the through openings 10a, b serve to receive tendons, as will be described below.
  • Fig. 2 shows a second mold part 12.
  • the second mold part 12 is preferably cuboid- shaped and has a longitudinal extension in a transverse direction 4c, a width extension in a longitudinal direction 4a and a height extension in a height direction 4b.
  • the second mold part 12 has two opposing side faces 12a, b and two opposing front faces 12c, respectively.
  • a second joining surface 18 may be provided on the second mold part 12 on one front face 12c, but preferably on both front faces 12c.
  • the second joining surface 18 can also extend along a side face 12b.
  • through openings 20 extending in the longitudinal direction 4a are provided in the second mold part 12.
  • the through openings 20 serve to receive tendons, as will be described below.
  • Fig. 3 shows a third mold part 22.
  • the third mold part 22 is preferably cuboid-shaped and has a longitudinal extension in a transverse direction 4c, a width extension in a longitudinal direction 4a and a height extension in a height direction 4b.
  • the third mold part 22 has two opposing side faces 22a, b and two opposing front faces 22c, respectively.
  • a third joining surface 28 may be provided on the third mold part 22 at one front face 22c only.
  • the third joining surface 28 may further extend along a side face 22b.
  • Fig. 3 it can be seen that through openings 30 extending in the longitudinal direction 4a are provided in the second mold part 22.
  • the through openings 30 serve to receive tendons, as will be described below.
  • Fig. 4 shows a fourth mold part 32.
  • the fourth mold part 32 is slab-shaped.
  • the fourth mold part 32 has two slab surfaces 32a that face each other.
  • the slab surfaces 32a extend along the longitudinal direction 4a and the transverse direction 4c.
  • the fourth mold part 32 has side faces 32b, 32c.
  • Fourth joining surfaces 38 extend along the side faces 32b, 32c.
  • Through-openings 40 extend through the fourth mold part 32 parallel to the slab surface 32a in each of the longitudinal direction 4a and the transverse direction 4c.
  • the mold parts 2, 12, 22 and 32 are in particular precast concrete parts. In particular, they can be prefabricated and then transported to the construction site.
  • the mold parts 2, 12, 22, 32 can be joined together via their respective joining surfaces 8, 18, 28, 38 in such a way that they form a form fit, in particular with respect to the vertical direction 4b.
  • mold part 32 can also be cast in situ. Then, for instance, the first three mold parts 2, 12, 22 are assembled as shown in Fig. 5 and mold part 32 will be cast in between.
  • bars, bolts or tendons can already be applied in the through holes 10, 20, 30 and can be overmolded by the material of the fourth mold part 32.
  • the mold parts 2, 12, 22, 32, in particular the first mold parts 2 and the fourth mold parts 32, can abut a central foundation body (pedestral) 42.
  • a central foundation body (pedestral) 42 This is shown by way of example in Fig. 5.
  • the central foundation body 42 is formed with a junction console 44 for a tower of a wind turbine.
  • the junction console 44 is conventionally formed and is therefore not explained in detail.
  • the foundation body 42 is constructed on site as a cast-in-place concrete member.
  • Through-openings 50 penetrate the central foundation body 42 in the longitudinal direction 4a and the transverse direction 4c, as can be seen by way of example in Fig. 6 and Fig. 7.
  • four first mold parts 2 can abut with their side faces 2b in a star shape, the arrangement being such that the through openings 10a are aligned with the through openings 50.
  • a fourth mold part 32 can be placed or cast in situ between each of two first mold parts 2, whereby the first joining surfaces 8 of the first mold parts 2 form a form fit with the fourth joining surfaces 38 of the fourth mold parts 32.
  • This form fit is at least with respect to the vertical axis 4b.
  • the fourth mold part 32 is arranged on the first mold parts 2 such that the through openings 40 are aligned with the through openings 10b.
  • the first mold parts 2 can be fixed relative to one another via a second mold part 12 and a third mold part 22, respectively.
  • a second mold part 12 is placed against the first joining surface 8 of a first mold part 2 at a front face 2c with a second joining surface 18.
  • the through openings 20 are aligned with the through openings 40 and the through openings 10b.
  • a third mold part 22 is placed with its third joining surface 28 against a second joining surface 18.
  • the third mold part 22 is placed with its third joining surface 28 against a first joining surface 8 of a first mold part 2.
  • the through openings 30 are aligned with the through openings 40 and the through openings 10b.
  • a structure just described is formed circumferentially around the central foundation body 42. Subsequently, a tendon is guided through each of the through openings 10a, the through openings 20, 40, 10b, as well as the through openings 30, 40, 10b. This allows the mold parts to be pressed against each other.
  • the tendons are in particular steel tendons which cause the mold parts to be post tensioned as well. This gives the mold parts increased tensile strength compared with blank mold parts.
  • the foundation component manufactured in this way is used to support a tower of a wind turbine at the junction console 44.
  • the junction can be dimensioned depending on the type (concrete, steel, etc.) and size of the tower.
  • FIG. 6 The plan view of such a structure can be seen in Fig. 6. It can be seen that the mold parts 2 are arranged in a star shape around the central foundation body 42. It can also be seen that the second mold parts 12 and the third mold parts 22 are arranged on the first mold parts 2. It can be seen that the mold parts 12, 22 are intermittently arranged circumferentially around the central foundation body 42 on the respective first mold parts 2. It can further be seen how tendons 50, are arranged penetrating the mold parts 2, 12, 22 to brace the mold parts.
  • fourth mold parts 32 are respectively received enclosed by the first mold parts 2, second mold parts 12 and third mold parts 22.
  • the cross-section through such a wind turbine ground foundation can be seen in Fig.
  • the through openings 50 and 20 can be seen. Furthermore, it can be seen that in an upward direction 4b the second mold parts 12 and the third mold parts 22 are arranged in a floor region. It can also be seen how the mold parts 12, 22 interlock with each other at their joining surfaces 18, 28. It can also be seen that the mold parts can be filled with backfill, e.g excavated material 60 or imported from a quarry in order to realize a further surcharge load on the ground foundation and to increase its stability.
  • backfill e.g excavated material 60 or imported from a quarry in order to realize a further surcharge load on the ground foundation and to increase its stability.

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  • Wind Motors (AREA)

Abstract

Mold part set for a wind turbine ground foundation with at least two mold parts, wherein a first mold part (2) is wall-shaped and, at least second mold part (12) is beam-shaped, wherein at least one wall face (2a) of the first mold part has, in the region of at least one longitudinal edge (6), a first joining surface (8) for the second mold part (12), and a first front face of the second mold part has a second joining surface (18) corresponding to the first joining surface.

Description

Mold part set for wind turbine ground foundation and wind turbine ground foundation
The subject matter relates to a set of mold parts for a wind turbine foundation and a wind turbine foundation.
Wind turbines, especially onshore wind turbines, are regularly founded with a concrete foundation. Such a concrete foundation is built on-site as part of engineering work. First, a formwork is built and then filled with concrete and reinforced by rebars to form a reinforced concrete structure. However, the engineering work, formwork and pouring on-site are costly and take a long time. In addition, transporting liquid concrete to the construction site is technically challenging and expensive, especially in impassable terrain. The conditions under which the poured concrete can harden are on-site weather-dependent and thus cannot be standardized, which can lead to different compressive and tensile strengths of the components. In addition, due to the on-site formwork, the dimensional accuracy of the structures is often worse than desired by the designer and necessary for a safe stand.
Due to these disadvantages of on-site construction, the subject matter was based on the object of providing mold parts for a wind turbine ground foundation as well as a wind turbine ground foundation which provides great Stability with low material input and can be produced with high constructional, in particular dimensional accuracy.
This object is solved by a set of mold parts according to claim 1, a mold part assembly according to claim 10 and a wind turbine foundation according to claim 14.
A set of mold parts is to be understood as a set, group, plurality or multiplicity of mutually compatible mold parts. A set of mold parts is formed from at least two separate mold parts that can be joined to form a mold part assembly. In this case, at least two separate mold parts of the mold part set can be compatible with each other and can be joined to form a mold part assembly. Joining to build the mold part assembly is preferably carried out by means of a form fit on corresponding joining surfaces of the mold parts. The mold parts can engage in form fit with each other via the respective joining surfaces.
The foundation can be a shallow foundation, slab foundation and/or ground foundation. When the term ground is used, the term shallow or slab is also meant.
It has been recognized that considerable high moments, e.g. moment arms, bending moments etc. s act on the foundation of a wind turbine when it is operated. In the following, the term torque can be used as general description of a moment, e.g. a bending moment. In order to be able to absorb these torques, whose vectors point in a direction radial to the tower, the foundation requires a sufficiently dimension and sufficiently high axial moment of inertia for stability. Sufficient dimensions of the foundation are required for stability reasons, in particular to avoid overturning and to transfer the loads to the ground whilst the bearing capacity of the ground is not exceeded. Sufficient moment of inertia is required for stiffness reasons. Stability and stiffness is achieved in particular if the spatial extension of the foundation parallel to the longitudinal axis of the tower mounted on the ground foundation is large.
It is therefore proposed that a first mold part of the set of mold parts is wall-shaped. A wall is characterized by its length and height being many times greater than its width. The wall-shaped mold part can be a single mold of made from multiple mold assembled after curing of the mold. The wall-shaped mold part is preferably arranged on the ground foundation in such a way that its height extension direction is essentially parallel to the longitudinal axis of the tower to be mounted on the foundation. In this way, the axial moment of inertia of the wall-shaped mold part applied to the vertical axis can absorb the bending moments/torques of the tower.
The wall-shaped mold provides stiffness and rigidity to the system It has been recognized that wall-shaped elements can be sufficient to absorb the bending moments /torques /bending loads. It has been recognized that it is not necessary to have the height extension of the ground foundation equal all around the tower. Rather, three or more first wall-shaped mold parts may be provided to accommodate the beding moments/torques/bending loads. It should be noted that in the following, in particular four wall-shaped mold parts are described, however, three or more than four wall-shaped mold are possible, which preferably are arranged around the central pedestral in equal angles.
A second mold part is provided to prevent the wall-shaped mold parts from shifting relative to each other. The second mold part is beam-shaped. A beam is characterized by its length being many times greater than its height and width. The beam-shaped mold part is preferably arranged at the wall-shaped mold parts to fix them to each other. In addition, a beam-shaped mold part can be used to increase the bearing surface of the foundation on the ground, in particular at a distance from the tower, in particular by the dimension of the length extension of the wall-shaped mold part.
In order to now mechanically engage the mold parts to one another, it is proposed that at least one wall face of the wall-shaped mold part has in its region of at least one longitudinal edge a first joining surface for the beam-shaped mold part. That is, a beam-shaped mold part can be engaged with the wall face at the first joining surface.
A beam-shaped mold part is preferably arranged with its longitudinal axis parallel to the surface normal of the joining surface of the wall-shaped mold part. For arranging the beam-shaped mold part on the wall-shaped mold part, in particular on its first joining surface, it is proposed that a first front face of the beam-shaped mold part has a second joining surface corresponding to the first joining surface. The surface normal of the front face with its second joining surface preferably runs essentially parallel to the longitudinal axis of the beam-shaped mold part. The two mold parts can preferably be joined together in a form fit via the mutually corresponding joining surfaces.
The beam-shaped, second mold part has a first and second front face. For joining, in particular for form-fit joining the beam-shaped mold part to two wall-shaped mold parts or to one wall-shaped mold part and to one third mold part described below, the respective front faces can be formed with a corresponding second joining surface. The joining surfaces arranged on the two front faces are in particular complementary to one another.
A joining surface may also be provided on the beam-shaped mold part along a side face for receiving a fourth mold part, as will be described further below. The side face may be a side wall extending from a first front face toward a second front face. The joining surface on the side face may extend along the entire height extension. This also applies to the joining surfaces on the front faces.
According to one embodiment, it is proposed that a third joining surface is arranged on a first front face of a third mold part. The third mold part is substantially similar in geometric shape to the second mold part, and may also be described as beam-shaped. The above explanations apply substantially accordingly. Only the arrangement of the third joining surfaces on the third mold part may be different from the arrangement of the second joining surfaces on the second mold part, in particular, only one front face on the third mold part may be provided with a third joining surface. In addition, as with the second mold part, a third joining surface can be provided on a side face of the third mold part.
As already explained above, the mold part set is formed from several mold parts.
These can be engaged with each other in a form-fit manner. For this purpose, the respective joining surfaces on the mold parts to be joined together are shaped complementarily to one another. The joining surfaces are profiled with a relief-shaped surface. In particular, the relief-shaped profiling is formed as shear keys. Here, in particular, a shear key can ensure a Form fit in at least one spatial direction. This is in particular the direction of the height extension of the first mold part. In the installed state, this regularly corresponds to the longitudinal axis of the tower to be erected on the foundation. In particular, this can be a direction of a center axis of the ground foundation. A form fit between the mold parts can take place in this direction.
For a connection of the wall-shaped mold part to at least one of the beam-shaped mold parts and/or a fourth mold part, the first joining surface is preferably formed on the wall-shaped mold part on its wall face only in an edge region of the longitudinal edge of the wall face. In the installed state, the height extension of the first mold part preferably runs essentially parallel to a direction of a center axis of the foundation and thus preferably parallel to a direction of a longitudinal axis of a tower to be erected on the foundation. In a bottom region of the wall face, in particular in the region in which the wall face in the installed state extends vertically from the tower to be erected, a longitudinal edge can extend in a radially outward direction, and in the region of this longitudinal edge, but on the wall face and not on a side face, the first joining surface can extend.
The joining surfaces are formed in particular in the form of shear keys, in particular in the form of projections and recesses, in particular in the form of grooves and tongues. In this case, the projections and recesses can extend longitudinally in a plane that is essentially parallel to the ground in the installed state of the mold parts. In particular, this is a plane whose surface normal is substantially parallel to a center axis of the foundation and/or a longitudinal extension of the tower to be built on the foundation. However, the shear key may also be relief-shaped, along two directions. The shear key may be formed in pyramidal, or it may be formed in the shape of conical.
According to one embodiment, it is proposed that a first joining surface is arranged on respective opposing wall faces. These joining surfaces/which are arranged on wall faces facing away from each other, can be shaped congruently or complementary to each other. As explained above, a fourth mold part can be provided in addition to the first, second and third mold parts. The fourth mold part is in particular wall-shaped. The fourth mold part can be pre-fabricated or alternative cast in situ. Like the first mold part, the fourth mold part can be a single mold or assembled from multiple pre-cast molds after curing.
In the installed state, the wall face of the fourth mold part in preferably runs essentially perpendicular to the wall face of the first mold part. In the installed state, the fourth mold part lies in particular in a bottom region. In this case, the fourth mold part can rest against the first joining surface extending along the edge region in the longitudinal direction of the wall face of the first mold part. The fourth mold part may also be referred to as being disc-shaped or slab shaped, wherein wall-shaped, disc- shaped and slab-shaped may be regarded as interchangeable terms. Fourth joining surfaces corresponding to the first joining surface may be provided on each two adjacent side walls of the fourth mold part. These fourth joining surfaces can be complementary to the first joining surfaces, so that the fourth mold part with the fourth joining surfaces can form a form fit with the first joining surfaces of the first mold part.
The fourth mold part can also be shaped in such a way that it can be connected in form fit to side faces of one or both beam-shaped mold parts, in particular to the joining surfaces of the beam-shaped mold parts extending along the side faces. For this purpose, it is proposed that a fourth joining surface corresponding to the second joining surface is provided on a side wall of the fourth mold part and a fourth joining surface corresponding to the third joining surface is provided on a side wall adjacent to this side wall. These fourth joining surfaces can be complementary to the second and/or third joining surfaces so that they can be joined together in a form-fitting manner. To be clear, on the side faces of the fourth mold part, fourth joining surfaces can be arranged, where these fourth joining surfaces can be different from each other, for instance on two adjacent side faces the fourth joining surfaces can be complementary to the first joining surfaces and on a third side face a fourth joining surface can be complementary to the second joining surface and on a fourth side face a fourth joining surface can be complementary to the first joining surface. According to an embodiment, it is proposed that at least three first mold parts can be connected to each other via at least one respective beam-shaped mold part. The at least three first mold parts, but preferably four first mold parts, extend with their longitudinal edge radially away from a center axis of the ground foundation. The first mold parts are preferably distributed in equidistant angular sections around the center axis of the foundation. In order to fix the position of the first mold parts relative to one another, in particular the angular position of the first mold parts relative to one another around the center axis, they can be connected to one another via at least one respective beam-shaped mold part. The beam-shaped mold parts rest against the first mold parts and preferably form a closed ring around the center axis of the ground foundation. Preferably, the first mold parts are connected to each other via a connection of a second and a third mold part.
According to an embodiment, the mold parts form a quadrangular structure of four quadrants around the center axis of the ground foundation, each quadrant being bounded by two perpendicular first mold parts and two perpendicular second and third mold parts connected to each other and to the first mold parts. That is, starting from a central axis, a quadrant is formed by a first mold part, a second mold part, a third mold part, and again a first mold part. The mold parts are preferably connected to one another at their abutting joint surfaces in a form fit by shear keys.
The ground foundation is composed of interconnected mold part assemblies, wherein a mold part assembly according to an embodiment is composed of a mold part set as described above, at least one wall-shaped mold part and at least one beam-shaped mold part are provided in a mold part assembly. The beam-shaped mold part rests with its end-face joining surface against the first joining surface of the wall-shaped mold part. In this case, the beam-shaped mold part rests against the first joining surface in a region of the wall face of the wall-shaped mold part that is located radially on the outside of the center axis of the ground foundation.
According to an embodiment, it is proposed that the mold part assembly has a third mold part. This third mold part rests with its end third joining surface against the first joining surface of at least one of the two first mold parts. Like the second mold part, the third mold part rests with its front face against the first joining surface radially outwardly of the center axis of the ground foundation in the region of the wall face of the wall-shaped mold part.
According to an embodiment, it is proposed that the second mold part is in contact with the first joining surface on its first front face and in contact with the third joining surface of the third mold part on its second front face opposite the first front face. Thus, the second mold part lies between the first mold part and the third mold part and is interlocked in form fit With these respectively via an front face.
A fourth mold part may occupy a space formed between the first, second, and third mold parts. This can be done by a pre-cast mold or preferably by casting in situ. The first, second and third mold parts can be perpendicular to each other. In particular, the second and third mold parts are provided in a bottom region of the foundation in the installed state. The fourth mold part may be located between the first and second mold parts in the bottom region. In this case, the fourth mold part may be interlocked with its fourth joining surfaces with the second and third joining surfaces. On the other hand, the fourth mold part can be interlocked with its fourth joining surfaces with the first joining surfaces of two first mold parts that are perpendicular to each other.
According to one embodiment, the mold parts are formed as precast parts, in particular as precast concrete parts. The mold parts are in particular prefabricated precast parts that can be delivered to the construction site in a prefabricated state. The mold parts are preferably formed from a mineral building material, in particular from concrete. The concrete is in particular an ultra-high-strength concrete. Preferably, a fiber reinforcement is provided in the concrete, in particular a synthetic fiber reinforcement. This can be a basalt fiber or a carbon fiber. However, metal fibers are also possible. In particular, the precast elements are made of fiber-reinforced concrete (FRC). FRP fibers, basalt fibers, metallic fibers or metallic rebars can be used. The tensile strength of the finished parts can be increased by using fibers, in particular glass fibers, carbon fibers, basalt fibers or the like. Here, a fiber content of at least 10%, preferably at least 20%, is advantageous in order to achieve a sufficiently high tensile strength. A further increase in tensile strength results from post tensioning of the mold parts by means of the tendons. Sufficient compressive strength results from the use of the mineral building material, in particular concrete.
Parallel to the wall faces of the first mold part, at least one through opening (recess) may be provided in the first mold part. This through-opening can extend in particular along the longitudinal axis of the first mold part. The through opening is provided for receiving a tendon or a bar.
In the second and third mold parts, through-openings (recesses) can be provided which extend transversely, in particular perpendicularly, to the longitudinal axis of these mold parts. In particular, these through-openings run parallel to the respective front faces. These through-openings are also provided to accommodate tendons.
In the fourth mold part, through-openings (recesses) can be provided running inside the wall face, these through-openings preferably running in the longitudinal direction as well as in the transverse direction crossing, but not overlapping, one another in the fourth mold part. These through-openings can also be provided to accommodate tendons.
The through openings of the fourth mold part can be aligned with the through openings of the second and third mold parts in the installed state, so that tendons can be tensioned through the second mold part and the fourth mold part as well as through the third mold part and the fourth mold part. Through-openings extending in the width direction of the mold part can be provided in the first mold parts in the area of the first joining surface. In the installed state, these can be aligned with the through- openings of the fourth mold part. Thus, tendons can clamp together through a first mold part, two opposing fourth mold parts and third mold parts, and two opposing fourth mold parts and second mold parts.
On the one hand, the tendons are suitable for bracing the mold parts of a mold part assembly against each other. On the other hand, the tendons are suitable for bracing at least two adjacent mold part assemblies.
The tendons can also post tension (overpress, compress) the mold parts, which means that the mold parts are given a mechanical tension by the tendons. This increases the tensile strength against tensile stress of the mold part, especially if it is formed from a mineral building material, such as concrete. A tendon is in particular a post tensioning steel. The tendon can be inserted in the form of a bar through suitable through- openings running in the mold parts and tensioned at the outer outlets of the mold parts joined together or of the mold part assemblies joined together, in particular by means of bolting.
According to another aspect, a wind turbine ground foundation includes a central foundation body having an upper face, a lower face, and at least one side face extending between the upper face and the lower face. This foundation body serves as a support for a junction console for a tower of the wind turbine at the upper face. This foundation body may also be understood as pedestral.
The central foundation body can take up the tendons, bolts, or bars. The central foundation can be cast on site. The junction console can be a standard anchor cage.
The junction console can be made from tendons trough an adapter plate, which is closed by the side faces and which can be cast on site. At least one mold part assembly having at least one set of mold parts as described is disposed on a side face. The central foundation body can be manufactured on site, in particular formed and cast. In this context, it is possible in particular for tendons to be guided through the formwork mold and to be integrated into the foundation body during casting. It is also possible, in particular, that receptacles for tendons are provided in the formwork for the foundation body and are integrated into the foundation body during casting. It is also possible that the foundation body is a prefabricated concrete component and in particular has a receptacle for the tendons or integrated tendons.
In plan view, the foundation body is polygonal, in particular rectangular, preferably square. A mold part assembly can be arranged on each of the side faces, in particular four side faces. Thus, it is possible for one mold part assembly to bear against two mutually opposite side faces of the foundation body. A first mold part with its respective outer side wall can abut against each of two further mutually opposite side faces of the foundation body. In particular, side walls of the first mold parts may be arranged on the side walls of the central foundation body. Through the central foundation body, through-openings can be provided which, in the installed state, are aligned with the through-openings in the first mold parts. Tendons can be post tensioned through these through-openings in the manner described. The first mold parts can be tensioned with the central foundation body by means of the tendons.
According to one embodiment, it is proposed that at least three, preferably four, mold part assemblies as previously described are arranged circumferentially around the foundation body. The first mold parts face radially outwardly away from the side faces of the central body. The first mold parts extend longitudinally in a radial direction away from the side faces. At the radially outward outer edges of the first mold parts, the second and third mold parts abut with their front faces against the first joining surfaces, respectively, and are interlocked with the first joining surfaces via the shear keys. A second and a third and preferably a fourth mold part are provided on both sides of a first mold part. In plan view, the wind turbine ground foundation is preferably point-symmetrical with respect to the center axis, but can also be at least axial symmetrically with respect to at least one longitudinal· axis of a first mold part in the installed state,
First mold parts extending at an angle to one another with respect to their longitudinal axis, in particular first mold parts extending at right angles, are connected to one another via respective at least second and preferably third mold parts, in which case a second mold part is perpendicular to a wall face of a first mold part and a third mold part is perpendicular to a wall face of a further first mold part, and the second and third mold parts are connected to one another at their ends remote from the first mold parts via their second and third joining- surfaces.
The subject matter is explained in more detail below with reference to a drawing showing embodiments. In the drawing show:
Fig. 1a, b a first mold part according to an embodiment;
Fig. 2 a second mold part according to an embodiment;
Fig. 3 a third mold part according to an embodiment;
Fig. 4 a fourth mold part according to an embodiment;
Fig. 5 a wind turbine foundation according to a first embodiment;
Fig. 6 a plan view of a wind turbine foundation according to Fig. 5a;
Fig. 7 a cross-section through a wind turbine foundation according to Fig. 5a. Fig. la shows a first mold part 2. The first mold part 2 is wall-shaped, as can be seen in Fig. la. The first mold part 2 is preferably cuboid-shaped with a rectangular wall face, but can also be formed trapezoidal, as shown in Fig. 1b, in particular with a wall tapered in the vertical direction along a longitudinal extension.
The first mold part 2 has opposing wall faces 2a. The wall faces are spanned by the longitudinal direction 4a and the vertical direction 4b. Furthermore, the first mold part 2 has two opposing side faces 2b extending in the upward direction 4b and two opposing side faces 2c extending in the longitudinal direction 4a. The side faces 2b may also be referred to as front faces. The extent of the first mold part 2 in the longitudinal direction 4a and in the upward direction 4b is considerably greater than in a transverse direction 4c. A first joining surface 8 is provided on the wall faces 2a in the region of a longitudinal edge 6 on the wall face 2. The joining surface 8 comprises grooves and projections extending in the longitudinal direction 4a.
In Fig. la, b it can further be seen that through openings 10a extending parallel to the wall face 2a in the longitudinal direction 4a are provided in the first mold part 2. In Fig. la, b it can further be seen that through openings 10b extending perpendicular to the wall face 2a in the transverse direction 4c are provided in the first mold part 2.
The through openings 10a, b serve to receive tendons, as will be described below.
It is possible, that two mold parts 2 as shown in Fig. la are assembled at facing side faces 2b to establish one two piece mold part 2.
Fig. 2 shows a second mold part 12. The second mold part 12 is preferably cuboid- shaped and has a longitudinal extension in a transverse direction 4c, a width extension in a longitudinal direction 4a and a height extension in a height direction 4b. The second mold part 12 has two opposing side faces 12a, b and two opposing front faces 12c, respectively. A second joining surface 18 may be provided on the second mold part 12 on one front face 12c, but preferably on both front faces 12c. The second joining surface 18 can also extend along a side face 12b. In Fig. 2, it can be seen that through openings 20 extending in the longitudinal direction 4a are provided in the second mold part 12. The through openings 20 serve to receive tendons, as will be described below.
Fig. 3 shows a third mold part 22. The third mold part 22 is preferably cuboid-shaped and has a longitudinal extension in a transverse direction 4c, a width extension in a longitudinal direction 4a and a height extension in a height direction 4b. The third mold part 22 has two opposing side faces 22a, b and two opposing front faces 22c, respectively. A third joining surface 28 may be provided on the third mold part 22 at one front face 22c only. The third joining surface 28 may further extend along a side face 22b.
In Fig. 3, it can be seen that through openings 30 extending in the longitudinal direction 4a are provided in the second mold part 22. The through openings 30 serve to receive tendons, as will be described below.
Fig. 4 shows a fourth mold part 32. The fourth mold part 32 is slab-shaped. The fourth mold part 32 has two slab surfaces 32a that face each other. The slab surfaces 32a extend along the longitudinal direction 4a and the transverse direction 4c. Further, the fourth mold part 32 has side faces 32b, 32c. Fourth joining surfaces 38 extend along the side faces 32b, 32c. Through-openings 40 extend through the fourth mold part 32 parallel to the slab surface 32a in each of the longitudinal direction 4a and the transverse direction 4c. The mold parts 2, 12, 22 and 32 are in particular precast concrete parts. In particular, they can be prefabricated and then transported to the construction site. At the construction site, the mold parts 2, 12, 22, 32 can be joined together via their respective joining surfaces 8, 18, 28, 38 in such a way that they form a form fit, in particular with respect to the vertical direction 4b. However, mold part 32 can also be cast in situ. Then, for instance, the first three mold parts 2, 12, 22 are assembled as shown in Fig. 5 and mold part 32 will be cast in between. In this case, bars, bolts or tendons can already be applied in the through holes 10, 20, 30 and can be overmolded by the material of the fourth mold part 32.
The mold parts 2, 12, 22, 32, in particular the first mold parts 2 and the fourth mold parts 32, can abut a central foundation body (pedestral) 42. This is shown by way of example in Fig. 5. It can be seen that the central foundation body 42 is formed with a junction console 44 for a tower of a wind turbine. The junction console 44 is conventionally formed and is therefore not explained in detail. In particular, the foundation body 42 is constructed on site as a cast-in-place concrete member. Through-openings 50 penetrate the central foundation body 42 in the longitudinal direction 4a and the transverse direction 4c, as can be seen by way of example in Fig. 6 and Fig. 7. On the central foundation body 44, as shown in Fig. 5, four first mold parts 2 can abut with their side faces 2b in a star shape, the arrangement being such that the through openings 10a are aligned with the through openings 50.
Then, optionally, a fourth mold part 32 can be placed or cast in situ between each of two first mold parts 2, whereby the first joining surfaces 8 of the first mold parts 2 form a form fit with the fourth joining surfaces 38 of the fourth mold parts 32. This form fit is at least with respect to the vertical axis 4b. The fourth mold part 32 is arranged on the first mold parts 2 such that the through openings 40 are aligned with the through openings 10b.
The first mold parts 2 can be fixed relative to one another via a second mold part 12 and a third mold part 22, respectively. For this purpose, a second mold part 12 is placed against the first joining surface 8 of a first mold part 2 at a front face 2c with a second joining surface 18. When the second mold part 12 is in contact with the first joining surface 8, the through openings 20 are aligned with the through openings 40 and the through openings 10b.
A third mold part 22 is placed with its third joining surface 28 against a second joining surface 18. In addition, the third mold part 22 is placed with its third joining surface 28 against a first joining surface 8 of a first mold part 2. When the third mold part 22 is attached with its joining surface 28 to the first joining surface 8, the through openings 30 are aligned with the through openings 40 and the through openings 10b. A structure just described is formed circumferentially around the central foundation body 42. Subsequently, a tendon is guided through each of the through openings 10a, the through openings 20, 40, 10b, as well as the through openings 30, 40, 10b. This allows the mold parts to be pressed against each other. The tendons are in particular steel tendons which cause the mold parts to be post tensioned as well. This gives the mold parts increased tensile strength compared with blank mold parts.
The foundation component manufactured in this way is used to support a tower of a wind turbine at the junction console 44. Depending on the type (concrete, steel, etc.) and size of the tower, the junction can be dimensioned.
The plan view of such a structure can be seen in Fig. 6. It can be seen that the mold parts 2 are arranged in a star shape around the central foundation body 42. It can also be seen that the second mold parts 12 and the third mold parts 22 are arranged on the first mold parts 2. It can be seen that the mold parts 12, 22 are intermittently arranged circumferentially around the central foundation body 42 on the respective first mold parts 2. It can further be seen how tendons 50, are arranged penetrating the mold parts 2, 12, 22 to brace the mold parts. Here, it is preferred that fourth mold parts 32 are respectively received enclosed by the first mold parts 2, second mold parts 12 and third mold parts 22. The cross-section through such a wind turbine ground foundation can be seen in Fig.
7. Here, the through openings 50 and 20 can be seen. Furthermore, it can be seen that in an upward direction 4b the second mold parts 12 and the third mold parts 22 are arranged in a floor region. It can also be seen how the mold parts 12, 22 interlock with each other at their joining surfaces 18, 28. It can also be seen that the mold parts can be filled with backfill, e.g excavated material 60 or imported from a quarry in order to realize a further surcharge load on the ground foundation and to increase its stability.
List of reference signs
2 first mold part
2a wall face 2b, c side face 4a longitudinal direction 4b vertical direction 4c transverse direction 6 longitudinal edge 8 first joining surface
10a, b through opening 12 second mold part
12a, b, c side face 18 second joining surface 20 trough opening 22 third mold part
22a, b, c side face
38 third joining surface
40 through opening
42 foundation body
44 junction console
50 through opening
60 soil

Claims

C l a i m s
1. Mold part set for a wind turbine ground foundation with at least two mold parts, wherein a first mold part is wall-shaped and, at least second mold part is beam-shaped, characterized in that at least one wall face of the first mold part has, in the region of at least one longitudinal edge, a first joining surface for the second mold part, and a first front face of the second mold part has a second joining surface corresponding to the first joining surface.
2. Mold part set according to claim 1, characterized in that a second joining surface is arranged respectively on the first front face and on a second front face opposite the first front face, and/or the second joining surface additionally extends along a side face, preferably completely, between the first front face and a second front face, opposite the first front face, of the second mold part.
3. Mold part set according to any one of the preceding claims, characterized in that a third joining surface is arranged on a first front face of a third mold part, and/or the third joining surface additionally extends along a side face, preferably completely, between the first front face and a second front face, opposite the first front face, of the third mold part.
4. Mold part set according to any one of the preceding claims, characterized in that joining surfaces of mold parts which can be joined to one another are profiled in complementary relief, in particular in the form of shear keys.
5. Mold part set according to any one of the preceding claims, characterized in that the first joining surface extends only in an edge region of the longitudinal edge of the wall face.
6. Mold part set according to any one of the preceding claims, characterized in that that a first joining surface is arranged on respective opposite wall faces.
7. Mold part set according to any one of the preceding claims, characterized in that a fourth slab-shaped mold part has a fourth joining surface corresponding to the first joining surface on each of two adjacent side walls and/or the fourth slab-shaped mold part has on a side wall a fourth joining surface corresponding to the second joining surface and on a side wall adjacent to this side wall a fourth joining surface corresponding to the third joining surface.
8. Mold part set according to any one of the preceding claims, characterized in that - at least three first mold parts can be connected respectively to one another via at least one second mold part, so that a closed ring is formed around the joining surfaces of the first mold parts.
9. Mold part set according to any one of the preceding claims, characterized in that the joining surfaces of the mold parts are connected to each other in a form fit by the shear keys.
10. A mold part assembly comprising a mold part set according to any one of the preceding claims, having at least one first mold part and at least one second mold part, the second mold part abutting the first joining surface of the first mold part with its second joining surface.
11. The mold part assembly according to claim 10, wherein the third mold part abuts with its third joining surface against the first joining surface of at least one of the first two mold parts.
12. The mold part assembly of claim 10 or 11, wherein the second mold part abuts the third joining surface of the third mold part with the second joining surface at the second front face opposite the first front face.
13. The mold part assembly of any one of claims 10 to 12, wherein the fourth mold part is disposed between the first mold part, the second mold part, and the third mold part.
14. Wind turbine foundation with a central foundation body having an upper face, a lower face, and at least one side face extending between the upper face and the lower face, wherein at least one junction console for a tower of the wind turbine is disposed on the upper face, and at least one mold part assembly according to any one of the preceding claims is disposed on the side face.
15. A wind turbine foundation according to claim 14, characterized in that at least three mold part assemblies according to any one of the preceding claims are circumferentially arranged around the foundation body.
16. A wind turbine foundation according to claim 14, characterized in that two first mold parts are connected to one another via at least one second and/or one third mold part respectively, the second and/or third mold parts running annularly around the foundation body.
17. A wind turbine foundation according to any one of claims 14 to 16, characterized in that in an intermediate space between a respective first and second and/or third mold part, the fourth mold part is arranged.
18. A wind turbine foundation according to any one of claims 14 to 17, characterized in that the mold parts are post tensioned across the foundation body via tendons running in receptacles running through the mold parts.
EP21707222.2A 2021-02-19 2021-02-19 Mold part set for wind turbine ground foundation and wind turbine ground foundation Pending EP4294987A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2021/054126 WO2022174912A1 (en) 2021-02-19 2021-02-19 Mold part set for wind turbine ground foundation and wind turbine ground foundation

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EP4294987A1 true EP4294987A1 (en) 2023-12-27

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EP (1) EP4294987A1 (en)
AU (1) AU2021428899A1 (en)
MX (1) MX2023009393A (en)
WO (1) WO2022174912A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1400073B1 (en) * 2009-09-11 2013-05-17 Stefano Knisel IMPROVED FOUNDATION FOR WIND TOWER
US9938685B2 (en) * 2015-07-15 2018-04-10 Rute Foundation Systems, Inc. Beam and pile anchor foundation for towers
ES2701605A1 (en) * 2018-12-03 2019-02-25 Hws Concrete Towers S L FOUNDATION FOR WIND TOWERS (Machine-translation by Google Translate, not legally binding)

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AU2021428899A1 (en) 2023-08-31
WO2022174912A1 (en) 2022-08-25
MX2023009393A (en) 2023-08-23

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