WO2019234488A2

WO2019234488A2 - Casting mold for an annular concrete module, method for producing a concrete module using said casting mold and assembly system for producing a floating substructure of a floating wind turbine, which substructure is composed of said concrete module

Info

Publication number: WO2019234488A2
Application number: PCT/IB2019/000453
Authority: WO
Inventors: Sönke Siegfriedsen
Original assignee: Aerodyn Consulting Singapore Pte Ltd
Priority date: 2018-06-06
Filing date: 2019-05-29
Publication date: 2019-12-12
Also published as: DE102018113467A1; WO2019234488A3; TW202001082A

Abstract

The invention relates to a casting mold (100) for producing an annular concrete module (10), comprising a matrix (110, 120) and a core (134), characterized in that the matrix (110, 120) is formed by a lower half-shell (110) and a respective upper mold element (120A, 120B) hingedly connected to one side of the lower half-shell (110), a wall (130, 140) at each side of the matrix (110, 120), which delimits the cavity formed by the matrix (110, 120) and the core (134), and the core (134) can be releasably connected to at least one of the two walls (130, 140) for the purpose of positioning inside the matrix (110, 120).

Description

Casting mold for an annular concrete module, method for producing a concrete module with the casting mold and assembly system for producing a floating foundation of a floating wind turbine consisting of the concrete modules

The invention relates to a mold for producing an annular concrete module, with a die and a core. The invention also relates to a method for manufacturing a concrete module with this casting mold. Finally, the invention relates to a mounting system for producing a foundation of a floating wind turbine, wherein the foundation consists of three connected to a connecting element, formed from a plurality of concrete modules each arms.

The manufacture of concrete modules for the manufacture of components of a wind turbine is known from prior public use. In particular, vertical molds are used for the manufacture of constructions made of concrete towers of wind turbines, which allow the production of concrete modules that can be assembled into a tower. For this purpose, a steel reinforcement is typically placed between a die and a core received by the die, and the concrete is filled from above into the cavity to a predetermined level.

After hardening of the concrete, the connection surfaces of the concrete modules still have to be ground flat.

In addition to the production of towers made of concrete, EP 3 019 740 B1 and DE 10 2016 1 18 078 Alauch also disclose a floating foundation made of concrete of a floating wind energy plant. The foundation is - like the known towers - formed from a plurality of interconnected by means of prestressing strands concrete modules, the concrete modules in particular as known from WO 2017/206977 A l can be made known. These concrete modules are ring-shaped and have a substantially oval cross-section, the structure of which is specifically described in detail in WO 2017/206977 A l.

Although the method known from the tower production basically also for the production of concrete modules for producing a foundation of a floating Wind energy plant, this has the disadvantage that the additional steps for reworking the abutment surfaces are very time-consuming and labor-intensive. In addition, the vertical formation of a plurality of molds is very space-intensive.

A first object of the invention is therefore to provide a casting mold with which a concrete module suitable in particular for use as a component of a floating foundation of a floating wind energy plant can be manufactured, without this having to be reworked. The casting mold should be as compact as possible and not very space-consuming.

A second object of the invention is accordingly to provide a method by which the aforementioned concrete module can be manufactured with relatively little time and effort.

Finally, it is a third object of the invention, a mounting system for manufacturing a floating foundation of a wind turbine from the aforementioned

Concrete modules to create.

These objects are achieved according to the invention by the mold having the features of claim 1, the method having the features of claim 14 and the mounting system having the features of claim 16. The dependent claims give each advantageous embodiments of the invention.

According to the invention, therefore, a casting mold for producing an annular concrete module, with a die and a core is proposed, in which the die is formed from a lower half shell and one hinged to one side of the lower half shell upper formwork, one on each side of the die the wall defining the cavity formed by the die and the core is provided, and in which the core is detachably connected to at least one of the two walls for positioning within the die. Due to the horizontal orientation of the casting mold and the walls defining the cavity formed by the die and the core, a concrete module with predefined abutment surfaces is created which does not require post-processing.

For easy positioning of the core in the die, the core is preferably integrally formed with the one wall. If one wall is sealingly brought to the die, the position of the core within the die is also predetermined. For exact positioning of the wall to the die and especially of the core relative to the die, it is advisable to provide lead structures, which determines the spatial orientation of the elements relative to each other.

According to a further preferred embodiment, the formwork forms are designed such that when the die is closed, a gap remains between the upper formworks.

The gap remaining between the two upper formwork forms has the advantage on the one hand that with the concrete supplied with the cavity, entrained air bubbles can outgas through the gap and leave the cavity, and thus can not be trapped in the concrete.

On the other hand, the gap is used during its filling up to the upper edge of the upper

Shuttering forms for the formation of a plateau which, with skids formed correspondingly on the underside of the concrete module, effects a secure stacking of the concrete modules one above the other (see below).

For easy demolding of the concrete part, the molds are hinged to the lower half-shell such that the upper molds completely release the lower half-shell in a first position and at least partially cover in a second position.

Thus, it is in the first position readily possible to lift a cured concrete part vertically from the lower half-shell, without the upper formwork forms are a hindrance.

Specifically, this is a respective form of a form pivoting first linear actuator is provided, which is connected at one end to a formwork and at its other end to the lower half-shell. This first linear drive can

be formed for example as a hydraulic cylinder. If the core is integrally formed with the one wall, the one wall is particularly preferably on a linear guide extending from the lower half shell

slidably mounted. This makes it possible, in particular by means of a wall on the linear guide sliding second linear drive simply possible to insert the core into the die and held there by one wall to position. It is particularly provided that the second linear drive is designed as a hydraulic cylinder.

According to a further preferred embodiment, the mold which is sealed in this way can be sealed in that means arranged on the two walls for bracing the walls are provided with one another.

A material-saving embodiment of the Gießfonn is obtained by the fact that the other wall is annular and is formed substantially only slightly wider than the cavity formed by the die and the core.

According to a further preferred embodiment, a plurality of cylinders arranged in at least one of the walls are provided, which are drawn into the wall in a first position and extended into the cavity in a second position for forming a cavity to be formed in the concrete module to be manufactured. The cylinders may for example be provided in the fixed other wall, wherein the

slidably fitted a wall on the side facing the cavity of the shape of the cylinder has corresponding immovable form elements. Preferably, however, the one wall and the other wall corresponding cylinder. These are in particular (also) designed as a hydraulic cylinder.

The arranged in two walls cylinder or on the one wall

arranged mold elements and arranged in the other wall cylinder are inserted into a reinforcement of the concrete module by pulling pipes through

Production of the concrete module - as known from EP 3 019 740 B l - tensioning strands are to be pulled. The cylinders and the mold elements thus seal the pipes against

Fill with concrete. In this case, the cylinders and possibly the form elements at preferably conical design a cavity in the concrete module, in each of which one half of a connecting element for connecting two concrete modules can be used. The connecting element also assumes a sealing function that protects the pipes from the ingress of water.

Furthermore, the casting mold preferably has two grooves arranged parallel to one another in the lower half-shell for the formation of runners arranged on the concrete module to be manufactured. The distance between the skids to one another corresponds particularly preferably to the width of the gap between the upper formwork forms. By this configuration, the concrete modules can be stored by stacking and moved during assembly on their runners on a conveyor line.

Finally, a feed opening into the lower half-shell, which supplies liquid to the cavity, is preferably provided. Particularly preferably, the feed opens at the lowest point of the half shell. The filling of the mold with concrete from the bottom of the mold, in particular when forming a gap between the upper molds has the advantage that with the concrete introduced into the cavity air can easily escape through the gap.

According to the invention, a method for manufacturing a concrete module with the described casting mold is claimed in which at least the following steps are carried out:

a. Placing a reinforcement on the core,

b. Inserting the core into the opened die and closing the die by folding the molds or closing the die by folding the molds and inserting the core into the closed die, c. Pouring concrete into the cavity formed by die and core,

d. Curing the concrete,

e. Demoulding the concrete module by unfolding the formwork,

Pulling out the core and removing the concrete module from the lower half shell. As mentioned above, the method is particularly preferred for the case that the reinforcement has a plurality of tubes extending between the walls, wherein the cylinders arranged to form a cavity to be formed in the concrete module to be manufactured have, prior to step c. out of the walls into the cavity and inserted into the tubes and at step e. be fed into the walls.

The reinforcement is made of steel in particular. Alternatively, the reinforcement can also be made of other materials, which is effective against impact, bending and pressure loads.

In particular, the reinforcement is formed by an outer reinforcement cage and an inner reinforcement cage accommodated by the latter, which are separated by a plurality of

Spacers are interconnected. The spacers extend outwards over the outer reinforcing cage and inwards beyond the inner reinforcing cage. This configuration provides for a positioning of the reinforcement within the mold spaced from the die and the core. The spacers hold the

Reinforcement during the concrete pouring process in the central position and ensure a minimum distance of the reinforcement to the surfaces of the concrete module.

The spacers each have an opening for receiving in each case one arranged between the reinforcing cages tube, wherein a plurality of successively arranged spacers support a tube.

In this case, the particular conical cylinder are extended into the cavity in the direction of the open pipe ends, so that the cylinders close the tubes and center within the reinforcement.

Finally, a mounting system for producing a foundation of a floating wind turbine is proposed, the foundation of three with a

Connecting element connected, each consisting of a plurality of concrete modules formed arms, wherein the mounting system designed as a platform central

Connecting part for receiving the connecting element and three on the central In particular, a casting mold is arranged at the free ends of the conveyor sections, so that the concrete modules are ready for assembly directly after removal from the mold.

The conveyor lines of the mounting system are preferably designed as roller conveyors and allow - especially if the underside of the concrete modules is formed with runners - a simple movement of the concrete modules on the mounting system.

During assembly, the alignment of two concrete modules relative to each other is preferably accomplished by having at least one adjacent two pipes

Concrete modules connecting, designed as Flohlkörper connecting element is provided, which is specially designed as a double cone. This connecting element is used in addition to the centering as a sealing element to protect the cavity formed by the pipes from ingress of water.

The invention will be explained in more detail below with reference to exemplary embodiments illustrated in the attached drawings and particularly preferred embodiments. Show it:

Fig. 1 is a perspective view of one by means of the most preferred

designed mold to be manufactured concrete module;

Fig. 2, designed as a steel reinforcement, provided with pipes reinforcement of the concrete module of Figure 1 in a perspective view.

3 shows a cross section through the concrete module of FIG. 1;

4 shows a longitudinal section through the concrete module from FIG. 1;

5 shows a longitudinal section through two concrete modules assembled to form a foundation; 6 is a sectional view (a) in the longitudinal direction and a perspective view (b) of the two concrete modules aligned with each other positioning and sealing element;

7 is a perspective view of a particularly preferred designed mold for manufacturing the previously illustrated concrete module.

Fig. 8 is a perspective view of the mold of Fig. 7 in a first

Process step for the production of a concrete module;

9 shows a perspective view of the casting mold from FIG. 7 in a second method step for producing a concrete module;

Fig. 10 is a perspective view of the mold of Fig. 7 in a third

Verfahrensschrit for the production of a concrete module;

1 1 is a perspective view of the mold of Figure 7 in a fourth Verfahrensschrit for producing a concrete module.

FIG. 12 shows a detail view from FIG. 11 cut in the longitudinal direction of the casting mold; FIG.

13 shows a perspective view of the casting mold from FIG. 7 in a fifth method step for producing a concrete module;

14 shows a perspective view of the casting mold from FIG. 7 in a sixth method step for producing a concrete module;

FIG. 15 shows a perspective view of the casting mold from FIG. 7 in a seventh process step for producing a concrete module; FIG.

FIG. 16 is a perspective view of the underside of the mold of FIG. 7; FIG. 17 shows a perspective view of a mounting system for producing a foundation of a floating wind turbine in a first assembly stage; and

Fig. 1 8 is a perspective view of the mounting system of FIG. 17 in a

second assembly stage.

Fig. 1 shows the perspective view of the finished concrete module 10 with preferably designed lower runners 50 and an upper plateau 70. Further, the conical end holes 60 of the inner guide tubes 40 are seen for the tensioning strands 230 on the side surfaces.

Fig. 2 shows the perspective view of the complete (steel) reinforcement 20 and the guide tubes 40 between the inner reinforcing cage 22 and the inner

Reinforcing cage 24 are positioned.

Fig. 3 shows the cross section through a portion of the concrete segments 10 with the inner 22 and outer reinforcement 24, the guide tubes 40 positioned centrally therebetween and the positioning plates 30 which hold all parts in the desired position during the casting and curing process Reinforcing baskets 22, 24 held at a designated distance to the outer walls of the concrete module to ensure sufficient coverage.

Fig. 4 shows a longitudinal section through a concrete module 10, in which the entire reinforcement 20 can be seen and in the middle of the guide tubes 40. Furthermore, to recognize the

Positioning plates 30, in this case four pieces over the total length. At the two ends of the guide tubes 40, the conical, cast-in openings 60 can be seen, which will later accommodate the positioning elements 70.

Fig. 5 shows two concrete modules 10, which are brought together and brought about the positioning elements 70 in alignment. Furthermore, one recognizes the aligned to these positioning elements 70 guide tubes 40 for the subsequent recording of the tensioning strands 230th Fig. 6 shows a Doppelkonisches Positionierlement 70 in half-section and in one

perspective view. This component is made of an elastic and sealing material.

FIG. 7 shows the overall view of the casting mold 100 for producing a concrete module 10. Essentially, the casting mold 100 consists of the lower half shell 110, the upper one

Shuttering form 120 consisting of the two individual formworks 120A, 120B, the front wall 130, the core 134 and the rear wall 140. The components together limit the contour of the concrete module to be cast therefrom 10. For extending and retracting the core 134 guide elements 150 are present on which the inner molding can be moved axially. This is done by means of the linear motors 160 which can move the core 134 into and out of the die 1 10, 120. On the outside of the front wall 130 are hydraulic cylinders for actuating the conical shaped bolt 132 can be seen. These provide for the conical end holes 60 in the concrete module 10.

In order to be able to lift the concrete module 10 out of the mold, the two upper individual formworks 120 A, 120 B must be able to be driven by means of linear motors 170.

FIG. 8 shows the first manufacturing step for producing a concrete module 10. The entire mold 100 has been moved apart and the reinforcement 20 with inner reinforcement 22 and outer reinforcement 24 and guide tubes 40 is pushed onto the core 134 as an assembly.

Fig. 9 shows the second step, in which the core 134 with the mounted thereon

Reinforcement 20 by means of the linear guides 150 and the linear motors 160 in the die 1 10, 120 retracted.

10 shows the third step, in which the two upper individual shuttering forms 120A, 120B are fed in with the aid of the linear motors 170. The mold is now ready for filling with concrete. Fig. 1 1 shows the fourth step of the production in which all the cylinders are initially driven with the conical pin 132 into the mold and thereby the guide tubes 40 are brought into the final position. Then the concrete is preferably pressed from below into the closed mold 100 by means of a (not shown) concrete pump, so that the air can escape from the mold upwards and no air bubbles remain in the concrete.

A filling from above through the gap between the two upper individual formations 120A, 120B is also possible, if it can be ensured that the concrete is very fluid and the air can escape upwards.

Fig. 12 shows a longitudinal section through the core 134, the concrete module 10, the guide tubes 40 and the front wall 130. Further, a cylinder 132 can be seen with the conical end and the centering.

Fig. 13 shows the fifth manufacturing step after curing of the concrete. In this case, the two upper individual shuttering forms 120A, 120B are driven by means of the linear motors 170. The cylinders 132 are extended so that the conical ends of the concrete module 10 are completely removed.

Fig. 14 shows the sixth manufacturing step in which the core 134 with the front

Sidewall 130, which are formed together as a component, with the aid of the linear guide 150 and the linear actuators 180 from the die 100, 120 is moved out.

Fig. 15 shows the seventh and last manufacturing step, in which the concrete module 10 is lifted out of the lower half-shell. Thereafter, the system is pre-cleaned and prepared for the production of the next concrete module 10. This entire process can usually be repeated every 24 hours.

Fig. 16 shows the mold from below, where the concrete supply system 1 15 is located. This consists of an unspecified concrete pump, Zuführrohrleitungen, a

Shut-off valve and a cleaning system for rinsing with water throughout

Concrete feed after completion of filling the mold with concrete. 17 shows a mounting system 200 for assembling a foundation for a floating wind energy plant from a plurality of the concrete modules manufactured using the casting mold 100. On three conveyor lines 210 with rollers or a track system, the concrete modules 10 can be placed with the molded on the bottom skids 50. By these runners 50, the concrete modules 10 are already properly aligned with each other and can then be moved axially until they come together. In this case, the biconical guide elements 70 are inserted into the conical holes 60 of the concrete modules 10.

Fig. 18 shows the final step of the foundation assembly. When all the concrete modules 10 are constructed on the guideways 210, the tensioning strands 230 are passed through the guide tubes 40 and fixed to the central part 240. At the outer ends of the outer concrete modules, a steel plate 220 is arranged, on which the tensioning strands 230 are supported and the preload loads are distributed in the concrete. Via a clamping system, the bias voltage is then applied to all strands according to a predetermined flow scheme.

Claims

Mold (100) for producing an annular concrete module (10), with a die (1 10, 120) and a core (134), characterized in that

- The die (1 10, 120) from a lower half-shell (1 10) and one with one side of the lower half-shell (1 10) hingedly connected upper formwork (120 A, 120 B) is formed,

- One each on both sides of the die (1 10, 120) of the die (1 10, 120) and the core (134) formed cavity bounding wall (130, 140) is provided, and

the core (134) is releasably connected to at least one of the two walls (130, 140) for positioning within the die (110, 120).

2. casting mold (100) according to claim 1, characterized in that the core (134) with the one wall (130) is integrally formed.

3. Mold (100) according to one of the preceding claims, characterized in that a gap remains between the upper formworks (120A, 120B) when the die is closed.

4. The mold (100) according to any one of the preceding claims, characterized in that the upper formwork forms (120A, 120B), the lower half shell (1 10) completely release in a first position and at least partially cover in a second position.

5. casting mold (100) according to any one of the preceding claims, characterized by a respective a formwork (120A, 120B) pivoting first

Linear drive (170) with one end with a formwork (120A,

120B) and connected at its other end to the lower half shell (1 10).

6. casting mold (100) according to claim 2, characterized in that the one wall (130) on a from the lower half-shell (1 10) extending linear guide (150) is slidably mounted.

7. casting mold (100) according to claim 6, characterized by a wall (130) on the linear guide (150) displaceable second linear drive (160).

8. casting mold (100) according to any one of the preceding claims, characterized by on the two walls (130, 140) arranged means for bracing the

Walls (130, 140) with each other.

9. casting mold (100) according to any one of the preceding claims, characterized in that the other wall (140) is annular.

10. A mold (100) according to any one of the preceding claims, characterized by a plurality of in at least one of the walls (130, 140) arranged cylinders (132), the drawn in a first position in the wall (130, 140) and in a second position for forming a in the concrete to be produced module (10) trainees cavity (60) are extended into the cavity.

1 1. A mold (100) according to claim 10, characterized in that the cylinders (132) are conical.

12. A mold (100) according to any one of the preceding claims, characterized by two mutually parallel in the lower half-shell (1 10) arranged grooves for the formation of concrete to be manufactured on the module (10) runners (50).

13. A mold (100) according to any one of the preceding claims, in the lower half-shell (1 10) opening, the liquid concrete feeding inlet (1 15).

14. A method for manufacturing a concrete module (10) with the mold (100) according to any one of the preceding claims, characterized by the steps:

a. Placing a reinforcement (20) on the core (134),

b. Inserting the core (134) in the opened die (1 10, 120) and closing the die (1 10, 120) by folding the formwork (120A, 1 20B) or closing the die (1 10, 120) by folding the molds (120A, 120B) and inserting the core (134) into the closed die (110, 120), c. Pouring concrete into the cavity formed by die (1 10, 120) and core (134),

d. Curing the concrete,

e. Unfolding the concrete module by unfolding the formwork (120A, 120B), pulling out the core (134) and removing the concrete module (10) from the lower half-shell (1 10).

15. The method according to claim 14, characterized in that the reinforcement (20) has a plurality of between the walls (130, 140) extending tubes (40), wherein to form a cavity to be formed in the concrete module to be produced (10) (60) equipped cylinder (132) before step c. from the walls (130, 140) are extended into the cavity and inserted into the tubes (40) and at step e. be pulled into the walls (130, 140).

16. Mounting system (200) for producing a foundation of a floating wind turbine, wherein the foundation consists of three with a connecting element (240) connected, each of a plurality of concrete modules (10) formed arms, wherein the mounting system (200) has a central connecting part to

Receiving the connecting element (240) and three on the central connecting part star-shaped converging conveyor lines (210) for transporting the modules (10) in the direction of the central connecting part.

17. Mounting system (200) according to claim 16, characterized in that the

Conveying sections (210) are designed as roller conveyors.