Patent Description:
This invention was made with Government support under Contract No. DE-EE0009059 awarded by the U. Department of Energy (DOE). The Government has certain rights in the invention.

Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The rotor blades capture kinetic energy of wind using known foil principles. The rotor blades transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.

Tower structures, and in particular wind turbine towers, are often constructed of steel tubes, pre-fabricated concrete sections, or combinations thereof. Further, the tubes and/or concrete sections are typically formed off-site, shipped onsite, and then arranged together to erect the tower. For example, certain conventional manufacturing method include forming pre-cast concrete rings, shipping the rings to the site, arranging the rings atop one another, and then securing the rings together. As tower heights increase, however, conventional manufacturing methods are limited by transportation regulations that prohibit shipping of tower sections having a diameter greater than about <NUM> to <NUM> meters. Thus, certain tower manufacturing methods include forming a plurality of arc segments and securing the segments together on site to form the diameter of the tower, e.g., via bolting and/or welding. Such methods, however, require extensive labor and can be time-consuming.

In view of the foregoing, the art is continually seeking improved methods for manufacturing wind turbine towers. For example, more recently, progress has been made in the construction of wind turbine towers, at least in part, using additive manufacturing techniques. Such methods allow for the tower structures to be erected on site and also allows the structures to be built to taller heights.

Accurate placement of reinforcement members in additively-printed concrete structures is an important factor in assuring structural integrity. In addition, a record of rebar placement is necessary for code compliance. In printed concrete structures, the reinforcement member placement is completed in conjunction with the printing process, with reinforcement member placement alternating with the printing of the concrete layers (which differs from a poured concrete structure, wherein the entire rebar cage is in place relative to formwork). Thus, placement of the reinforcement members during the additive manufacturing process in a fast, reliable, and efficient manner has proven to be a difficult task. Therefore, precise tracking of rebar placement is not easy or feasible in the art. In addition, reinforcement member placement is difficult to automate and to track, as the reinforcement members (e.g., rebar, tension cables, etc.) are usually placed in opposing orientations and positions due to the geometry and structure of the rebar cages. <CIT> describes a system and method for manufacturing a tower structure.

Accordingly, the present disclosure is directed to a method for tracking reinforcement member placement in an additively manufactured structure that addresses the aforementioned issues, and more particularly to a method for tracking reinforcement member placement when additively manufacturing a tower base or tower of a wind turbine.

Aspects and advantages of the present disclosure will be set forth in part in the following description, or may be obvious from the description.

In an aspect, the present disclosure is directed to a method of manufacturing a tower structure. The method includes depositing, via a printhead assembly of an additive printing system, one or more first printed layers of a wall of a tower structure. The method also includes positioning a first reinforcement member with respect to the one or more first printed layers of the wall. The method also includes determining, via an optical sensor of the additive printing system, a position for placing a second reinforcement member based on a position of the first reinforcement member with respect to the one or more first printed layers.

In another aspect, the present disclosure is directed to a method of manufacturing a tower structure. The method includes depositing, via an additive printing system, a first printed layer of a wall with a printhead assembly, the wall at least partially circumscribing a vertical axis of the tower structure. The method also includes positioning a first reinforcement member on the first printed layer. The method includes depositing, via the additive printing system, a second printed layer of the wall with the printhead assembly on the first reinforcement member. The method further includes placing a second reinforcement member on the second printed layer. The method also includes determining, via a controller of the additive printing system, a position for placing the second reinforcement member based on the first reinforcement member positioning. Further, the method includes positioning the second reinforcement member on the second printed layer in the determined position. In addition, the method includes depositing, via the additive printing system, a third printed layer of the wall with the printhead assembly on the second reinforcement member.

In still another aspect, the present disclosure is directed to an additive printing system for manufacturing a tower structure. The additive printing system includes a support structure, an optical sensor, a printhead assembly operably coupled to the support structure, and a controller communicatively coupled to the printhead assembly and the optical sensor. The controller includes at least one processor configured to perform or direct a plurality of operations. The plurality of operations include, but are not limited to, depositing a first printed layer of the wall with the printhead assembly. In addition, the plurality of operations also include optically scanning the first printed layer, via the optical sensor, during depositing of the first printed layer by the printhead assembly. The plurality of operations further include depositing a second printed layer of the wall with the printhead assembly atop the first printed layer, the first printed layer including a first horizontal reinforcement assembly positioned in a horizontal orientation, the second printed layer configured to hold a second horizontal reinforcement assembly thereon. The plurality of operations also include generating a three-dimensional map of the first printed layer based on the optical scan. Further, the plurality of operations include determining a position for placing the second horizontal reinforcement assembly based on the three-dimensional map of the first printed layer.

Reference now will be made in detail to embodiments of the present disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the present disclosure, not limitation of the present disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope of the invention. For instance, features illustrated or described as part of an embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims.

Generally, the present disclosure is directed to additively manufactured structures, additive manufacturing systems, and additive manufacturing methods for manufacturing a tower structure, such as a wind turbine tower. "Additively manufactured structures" as used herein refers to structures formed using automated deposition of sequential layers (e.g., print layers) of cementitious material, such as concrete, and/or other construction materials, via "additive manufacturing" technologies such as additive manufacturing, <NUM>-D printing, spray deposition, extrusion additive manufacturing, concrete printing, automated fiber deposition, as well as other techniques that utilize computer numerical control and multiple degrees of freedom to deposit material.

"Additive manufacturing" as used herein refers to processes used to synthesize three-dimensional objects in which successive layers of material are formed under computer control to create the objects. As such, objects of almost any size and/or shape can be produced from digital model data. It should further be understood that the additive manufacturing methods of the present disclosure may encompass three degrees of freedom, as well as more than three degrees of freedom such that the printing techniques are not limited to printing stacked two-dimensional layers but are also capable of printing curved and/or irregular shapes.

In order to achieve the requisite structural strength for modern large-scale construction, additively manufactured structures generally require reinforcement. Known methods for reinforcing wind turbine towers often utilize vertical rebar and/or a rebar cage. For example, a common construction practice is to manually place a prefabricated rebar cage in the desired location prior to pouring concrete. While such approaches may reinforce the tower structure, they are often labor intensive and costly, and may not be compatible with construction via additive manufacturing. Additionally, known methods of reinforcing an additively manufactured structure may not accurately place the reinforcing elements in an optimal position within the structure. Accordingly, the present application presents novel systems and methods for tracking reinforcement member placement in an additively manufactured structure that are simple, accurate, non-labor-intensive, and cost-effective.

For example, in an embodiment, the present disclosure is directed to a novel method of manufacturing a tower structure that includes depositing, via a printhead assembly of an additive printing system, one or more first printed layers of a wall of the tower structure, positioning a first reinforcement member with respect to the one or more first printed layers of the wall, and determining, via an optical sensor of the additive printing system, a position for placing a second reinforcement member based on a position of the first reinforcement member with respect to the one or more first printed layers. In particular, the actual physical dimensions and the particular placement, positioning, and/or orientation of the first reinforcement member(s) may be optically scanned, tracked, and/or mapped. This information may be used to generate a visual representation or a three-dimensional map, for example, of the placement, positioning, and/or orientation of the reinforcement member(s).

In an embodiment, the determined, tracked, and mapped position of the first reinforcement member(s), with respect to the first printed layer(s) of the wall of the tower structure, may then be used to screen and select from amongst various reinforcement members for the best fit or most applicable second reinforcement member(s). The determined, tracked, and mapped position of the first reinforcement member(s) may also be used to custom form or design (digitally or physically) the second reinforcement member(s). Moreover, the determined, tracked, and mapped position of the first reinforcement member(s) also may be used to place or position the second reinforcement member(s) relative to the first reinforcement member(s), or relative the first printed layer(s), before additional printed layer(s) are added thereon. In other words, the dimensions, placement, and position of the second reinforcement member(s) may be tailored to the determined, tracked, and mapped position of the first reinforcement member(s).

Referring now to the drawings, <FIG> illustrates a perspective view of an embodiment of a tower structure <NUM> according to the present disclosure. As depicted in <FIG>, the tower structure may be a component of a wind turbine <NUM>. As shown, the wind turbine <NUM> generally includes a tower structure <NUM> extending from a support surface <NUM>, a nacelle <NUM>, mounted on the tower structure <NUM>, and a rotor <NUM> coupled to the nacelle <NUM>. The rotor <NUM> includes a rotatable hub <NUM> and at least one rotor blade <NUM> coupled to and extending outwardly from the hub <NUM>. For example, in the illustrated embodiment, the rotor <NUM> includes three rotor blades <NUM>. However, in an alternative embodiment, the rotor <NUM> may include more or less than three rotor blades <NUM>. Each rotor blade <NUM> may be spaced about the hub <NUM> to facilitate rotating the rotor <NUM> to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy. For instance, the hub <NUM> may be rotatably coupled to an electric generator (not shown) positioned within the nacelle <NUM> to permit electrical energy to be produced.

It should be appreciated that while discussed herein in reference to a wind turbine tower, the present disclosure is not limited to wind turbine towers but may be utilized in any application having concrete construction and/or tall tower structures. For example, the present disclosure may be utilized in the additive manufacturing of homes, buildings, portions of buildings, bridges, towers, poles, and other aspects of the concrete industry. Further, the methods described herein may also apply to manufacturing any similar structure that benefits from the advantages described herein, e.g., a wind turbine support tower, a cooling tower, a communications tower, a bridge pylon, a smokestack, a transmission tower, an observation tower, a dwelling, an office, an ornamental tower, a water tower, and/or other similar structures.

Referring now to <FIG>, the tower structure <NUM> of the wind turbine <NUM> of <FIG> is described in more detail according to an embodiment of the present disclosure. Specifically, <FIG> illustrates a partial, cross-sectional view of an embodiment of the tower structure <NUM> of the wind turbine <NUM> according to the present disclosure. As shown, the tower structure <NUM> defines a generally circumferential tower wall <NUM> having an outer surface <NUM> and an inner surface <NUM>. Further, as shown, the circumferential tower wall <NUM> generally defines a hollow interior <NUM> that is commonly used to house various turbine components (e.g., a power converter, transformer, etc.). Moreover, in an embodiment, the tower structure <NUM> is formed using additive manufacturing.

Furthermore, as shown, the tower structure <NUM> may be formed of one or more cementitious materials <NUM> reinforced with one or more reinforcement members <NUM>, such as elongated cables or wires, helical cables or wires, reinforcing bars (also referred to as rebar), mesh reinforcing fibers (metallic or polymeric), reinforcing metallic rings (circular, oval, spiral and others as may be relevant), and/or couplings. According to an embodiment, the cementitious material <NUM> may be provided through any suitable supply system <NUM> (see, e.g., <FIG>). Further, the reinforcement members <NUM> may be precisely placed, tracked, mapped, and embedded in the cementitious material <NUM> during the printing process, as described in detail herein. As used herein, the cementitious materials <NUM> may include any suitable workable paste that is configured to bind together after curing to form a structure. Suitable cementitious materials include, for example, concrete, pitch resin, asphalt, geopolymers, polymers, cement, mortar, cementitious compositions, or similar materials or compositions.

According to an embodiment of the present disclosure, an adhesive material (not shown), a cold joint primer (not shown), and/or steel/metal/alloy/ composite frame(s) or end cap(s) in the form of C-shaped frames, for example, (not shown) may also be provided between one or more of the cementitious materials <NUM> and the foundation <NUM>, the cementitious material <NUM> and reinforcement members <NUM>, or multiple layers of the cementitious material <NUM> and reinforcement members <NUM>. Thus, these materials may further supplement or complement interlayer bonding between materials, facilitate integration or use of pre-fabricated components or formwork, or simply provide aesthetic benefits (e.g., capping off the rough edges of an additively manufactured wall of cementitious material <NUM> in a tower structure <NUM>).

"Adhesive material" as used herein refers to cementitious material such as mortar, polymeric materials, and/or admixtures of cementitious material and polymeric material. Adhesive formulations that include cementitious material are referred to herein as "cementitious mortar. " "Cementitious mortar" as used herein refers to any cementitious material that may be combined with fine aggregate. Cementitious mortar made using Portland cement and fine aggregate is sometimes referred to as "Portland cement mortar," or "OPC. " Adhesive formulations that include an admixture of cementitious material and polymeric material are referred to herein as "polymeric mortar. " Any cementitious material may be included in an admixture with a polymeric material, and optionally, fine aggregate. Adhesive formulations that include a polymeric material are referred to herein as "polymeric adhesive.

Polymeric materials that may be utilized in an adhesive formulation include any thermoplastic or thermosetting polymeric material, such as acrylic resins, polyepoxides, vinyl polymers (e.g., polyvinyl acetate (PVA), ethylene-vinyl acetate (EVA)), styrenes (e.g., styrene butadine), as well as copolymers or terpolymers thereof. Characteristics of certain polymeric materials are described in ASTM C1059 / C1059M-<NUM>, Standard Specification for Latex Agents for Bonding Fresh to Hardened Concrete.

Referring now to <FIG>, an additive printing system <NUM> is illustrated according to an embodiment of the present disclosure. Notably, all or part of tower structure <NUM> of <FIG> may be printed, layer-by-layer, using the additive printing system <NUM>, which may use any suitable mechanisms for depositing layers of additive material, such as concrete, to form the tower structure <NUM>. The additive printing system <NUM> has one or more nozzles for depositing material onto the surface <NUM>. The nozzles are controlled by a controller to form an object programmed within the controller processor (such as a CAD file; described in detail herein). More specifically, as shown in <FIG> and described herein, the additive printing system <NUM> includes one or more printer heads <NUM> having any suitable number of nozzles <NUM> and being independently movable to simultaneously print layers of the tower structure <NUM>.

More specifically, and again referring to <FIG>, the additive printing system <NUM> may include a vertical support structure <NUM> which is generally configured for suspending one or more of the printer heads <NUM> above the tower structure <NUM> during the printing process. In this regard, the vertical support structure <NUM> may extend from the ground or from foundation <NUM> upwards substantially along a vertical direction V to a position at least partially above a top <NUM> of the tower structure <NUM> (e.g., and also above foundation <NUM> before the first layer is printed).

As illustrated, the vertical support structure <NUM> may include a plurality of support towers <NUM> and one or more gantry beams <NUM> that extend between at least two of the support towers <NUM>. Although two support towers <NUM> and a single gantry beam <NUM> are illustrated in the <FIG>, it should be appreciated that any suitable number and position of support towers <NUM> may be used according to alternative embodiments. In addition, the support towers <NUM> and the gantry beams <NUM> are illustrated as being truss-like structures (e.g., similar to a tower crane), but could be formed in any other suitable manner or have any other configuration according to alternative embodiments.

In addition, although the vertical support structure <NUM> is illustrated as being positioned on the outside of the tower structure <NUM>, it should be appreciated that according to alternative embodiments, the vertical support structure <NUM> may be positioned inside the tower structure <NUM>. According to still other embodiments, the vertical support structure <NUM> may include the support towers <NUM> positioned both inside and outside of the tower structure <NUM>. In addition, the additive printing system <NUM> may be suspended from the vertical support structure <NUM> using any other suitable system or mechanism.

Notably, during the additive printing process, the top <NUM> of tower structure <NUM> is built layer-by-layer, rising along the vertical direction V. Therefore, the vertical support structure <NUM> may be an expandable support structure which may be raised along with the height of tower structure <NUM>. In this regard, the vertical support structure <NUM> may be formed from a plurality of stacked segments <NUM> which are positioned adjacent each other along the vertical direction V and joined to form the rigid vertical support structure <NUM>. Thus, when the tower structure <NUM> approaches the top <NUM> of the vertical support structure <NUM>, additional segments <NUM> may be added to stacked segments <NUM> to raise the overall height of vertical support structure <NUM>.

Referring specifically to <FIG>, additional segments <NUM> may be combined with stacked segments <NUM> to raise the vertical support structure <NUM> using a jacking system <NUM>. In general, as shown, the jacking system <NUM> may be positioned proximate foundation <NUM> and is configured for raising the vertical support structure <NUM> (e.g., including the stacked segments <NUM> and the gantry beams <NUM>) and inserting additional segments <NUM>. Specifically, a separate jacking system <NUM> may be positioned at a bottom of each support tower <NUM>.

According to an embodiment, the jacking system <NUM> may include a jacking frame <NUM> and a jacking mechanism <NUM> which are positioned at the bottom of stacked segments <NUM>. The jacking mechanism <NUM> described herein may generally be any suitable hydraulically, pneumatically, or other mechanically actuated system for raising the vertical support structure <NUM>. Accordingly, when additional segments <NUM> need to be added, a dedicated jacking mechanism <NUM> simultaneously raises each of the support towers <NUM> such that additional segments <NUM> may be inserted. Specifically, the jacking frame <NUM> may support the weight of the vertical support structure <NUM> as additional segments <NUM> are positioned below the lowermost stacked segments <NUM>. Additional segments <NUM> are joined to stacked segments <NUM> using any suitable mechanical fasteners, welding, etc. This process may be repeated as needed to raise the total height of the vertical support structure <NUM>.

In certain situations, it may be desirable to protect the tower structure <NUM> and components of the additive printing system <NUM> from the external environment in which they are being used. In such embodiments, the tower cover <NUM> may generally be any suitable material positioned around the vertical support structure <NUM>. For example, the tower cover <NUM> may be a fabric-like material draped over or attached to the vertical support structure <NUM> (e.g., over the support towers <NUM> and/or the gantry beams <NUM>).

As mentioned above, the vertical support structure <NUM> is generally configured for supporting one or more of the printer heads <NUM> and or other modules which facilitate the formation of the tower structure <NUM>. Referring specifically to <FIG>, the additive printing system <NUM> may further include one or more support members, such as support rings <NUM>, that are suspended from the vertical support structure <NUM>, or more specifically from gantry beams <NUM>, above the tower structure <NUM>. For example, as illustrated, the support ring <NUM> is mounted to the gantry beam <NUM> using a vertical positioning mechanism <NUM>. In general, the vertical positioning mechanism <NUM> is configured for adjusting a height or vertical distance <NUM> measured between the gantry beam <NUM> and a top of support ring <NUM> along the vertical direction V. For example, the vertical positioning mechanism <NUM> may include one or more hydraulic actuators <NUM> extending between gantry beam <NUM> and support ring <NUM> for moving support ring <NUM> and printer heads <NUM> along the vertical direction V as tower structure <NUM> is built up layer-by-layer.

As illustrated, the hydraulic actuators <NUM> are configured for adjusting the vertical distance <NUM> to precisely position nozzles <NUM> of the printer heads <NUM> immediately above top <NUM> of the tower structure <NUM>. In this manner, the additive printing process may be precisely controlled. However, it should be appreciated that according to alternative embodiments, the vertical motion of the printer heads <NUM> may be adjusted in any other suitable manner. For example, according to an embodiment, the support ring <NUM> may be rigidly fixed to the gantry beam <NUM> while the support ring <NUM> and/or the printer heads <NUM> are used to facilitate vertical motion to precisely position nozzles <NUM>. For example, the printer heads <NUM> may be slidably mounted to the support ring <NUM> using a vertical rail and positioning mechanism to adjust the vertical position relative to the support ring <NUM> and the tower structure <NUM>.

According to the illustrated embodiment, the printer head(s) <NUM> is movably coupled to the support ring <NUM> such that the nozzles <NUM> may deposit cementitious material <NUM> around a perimeter of tower structure <NUM> while the support ring <NUM> remains rotationally fixed relative to gantry beam <NUM>. In this regard, for example, a drive mechanism <NUM> may operably couple the printer head(s) <NUM> to the support ring <NUM> such that printer head(s) <NUM> may be configured for moving around a perimeter <NUM> of the support ring <NUM> (e.g., about a circumferential direction C) while selectively depositing the cementitious material <NUM>. One exemplary drive mechanism <NUM> is described below and illustrated in the figures, but it should be appreciated that other drive mechanisms are contemplated and within the scope of the present disclosure.

As best shown in <FIG>, for example, the drive mechanism <NUM> may include a ring gear <NUM> that is positioned on the support ring <NUM> and a drive gear <NUM> that is rotatably mounted to printer head <NUM>. Specifically, as illustrated, the ring gear <NUM> is defined on a bottom <NUM> of the support ring <NUM>. Thus, when printer head(s) <NUM><NUM> is mounted on the bottom <NUM> of support ring <NUM>, drive gear <NUM> engages ring gear <NUM>. The drive mechanism <NUM> may further include a drive motor <NUM> that is mechanically coupled to the drive gear <NUM> for selectively rotating the drive gear <NUM> to move printer head(s) <NUM> around a perimeter <NUM> of the support ring <NUM>. In this manner, the support ring <NUM> may remain stationary while printer head(s) <NUM> moves around the support ring <NUM> while depositing the cementitious material <NUM> to form a cross-sectional layer of tower structure <NUM>.

Although the drive mechanism <NUM> is illustrated herein as a rack and pinion geared arrangement using drive gear <NUM> and ring gear <NUM>, it should be appreciated that any other suitable drive mechanism <NUM> may be used according to alternative embodiments. For example, the drive mechanism <NUM> may include a magnetic drive system, a belt drive system, a frictional roller drive system, or any other mechanical coupling between printer head(s) <NUM> and support ring <NUM> which permits and facilitates selective motion between the two.

In addition, in an embodiment, the support ring <NUM> may generally have a diameter that is substantially equivalent to a diameter of the tower structure <NUM>. However, it may be desirable to print the tower structure <NUM> having a non-fixed diameter or a tapered profile. In addition, as illustrated for example in <FIG>, the tower structure <NUM> may include an outer tower wall <NUM> spaced apart along a radial direction R from an inner tower wall <NUM>. For example, the outer tower wall <NUM> may be printed to define a mold for receiving poured concrete, e.g., to decrease printing time and total construction time.

Thus, as shown in <FIG>, the additive printing system <NUM> may include a plurality of concentric support rings <NUM> and printer heads <NUM> for simultaneously printing each of the outer tower wall <NUM> and the inner tower wall <NUM>. Specifically, as illustrated, an outer support ring <NUM> may be positioned above the outer tower wall <NUM> and have a substantially equivalent diameter to the outer tower wall <NUM>. Similarly, the inner support ring <NUM> may be positioned above the inner tower wall <NUM> and have a substantially equivalent diameter to the inner tower wall <NUM>. According to this embodiment, each of outer support ring <NUM> and inner support ring <NUM> may include dedicated printer heads <NUM> and/or other modules for facilitating the printing process of outer tower wall <NUM> and inner tower wall <NUM>, respectively.

Referring again to <FIG>, the printer head(s) <NUM> may include mechanisms for adjusting the position of nozzles <NUM> on printer head(s) <NUM>. For example, printer head(s) <NUM> may include a radial adjustment mechanism <NUM> that is configured for moving print nozzle <NUM> along the radial direction R. Specifically, according to the illustrated embodiment, radial adjustment mechanism <NUM> includes a slide rail <NUM> mounted to a bottom <NUM> of printer head <NUM>. The slide rail <NUM> extends substantially along the radial direction and is configured for slidably receiving the nozzle <NUM>.

The radial adjustment mechanism <NUM> may further include an actuating mechanism <NUM> that moves print nozzle <NUM> along the radial direction R within the slide rail <NUM>. For example, the actuating mechanism <NUM> may include any suitable actuator or positioning mechanism for moving nozzle <NUM> within the slide rail <NUM>. In this regard, for example, the actuating mechanism <NUM> may include one or more of a plurality of linear actuators, servomotors, track conveyor systems, rack and pinion mechanisms, ball screw linear slides, etc..

Referring still to <FIG> and <FIG>, the additive printing system <NUM> may include any other suitable number of subsystems or modules to facilitate and improved printing process or improved finishing of tower structure <NUM>. For example, as illustrated in <FIG>, the additive printing system <NUM> may include a reinforcement module <NUM> which is movably coupled to the support ring <NUM> and is configured for embedding one or more reinforcement members <NUM> at least partially within tower structure <NUM>. In this regard, for example, the reinforcement module <NUM> may be similar to the printer head(s) <NUM> in that engages the support ring <NUM> and may move around a perimeter <NUM> of the support ring <NUM> while depositing the reinforcement members <NUM>.

For example, according to an embodiment, the reinforcement members <NUM> may be reinforcement bars (i.e., rebar), tensioning cables, or any other suitable structural reinforcement members, as explained briefly below. For example, as shown in <FIG>, the reinforcement module <NUM> may embed one or more reinforcement members <NUM> at least partially within one or more of portions of the tower structure <NUM>. In this regard, the reinforcement module <NUM> positions reinforcement members <NUM> at least partially within the tower structure <NUM>. It should be understood that such reinforcement members <NUM> may extend along the entire height of the tower structure <NUM> (e.g., as shown in <FIG>) or along only a portion of the tower height.

Similarly, referring still to <FIG> and <FIG>, the additive printing system <NUM> also may be configured to supply backfill material, for example, via a mechanism movably coupled to the support ring <NUM> and configured for depositing backfill material and/or any other material as described herein. In this regard, for example, such a mechanism may be similar to the printer head(s) <NUM> and/or reinforcement module <NUM> in that it engages the support ring <NUM> and may move around a perimeter <NUM> of the support ring <NUM> while depositing a backfill material. For example, according to an embodiment, the backfill material described herein may include any suitable workable paste that is configured to bind together after curing to form a structure. Suitable materials include, for example, concrete, pitch resin, asphalt, clay, cement, mortar, cementitious compositions, geopolymer materials, polymer materials, or similar materials or compositions.

Referring now to <FIG>, various views of another embodiment of a tower structure <NUM> and another embodiment of an additive printing system <NUM> are illustrated. As shown, the tower structure <NUM> may be formed by depositing one or more layers of a wall <NUM> with a printhead assembly <NUM> of the additive printing system <NUM>. In an embodiment, as shown, the wall <NUM> may circumscribe or at least partially circumscribe (for example, to accommodate an access opening) a vertical axis (VA) of the tower structure <NUM>. Each wall <NUM> may for example, be one of a plurality of print layers in an axially aligned arrangement to form the tower structure <NUM>. In addition, as is described herein, the tower structure <NUM> may be formed using at least one cementitious material <NUM>.

As depicted in the partial overhead view of the tower <NUM> illustrated in <FIG>, the wall <NUM> may, in an embodiment, have an outer circumferential face <NUM> corresponding to each layer of the wall <NUM>. The outer circumferential face <NUM> may have a maximal radial distance from the vertical axis (VA). The outer circumferential face <NUM> may, for example, be generally circular, circumscribing the vertical axis (VA).

In an embodiment, the wall <NUM> may have an inner circumferential face <NUM> corresponding to each layer of the wall <NUM>. The inner circumferential face <NUM> may have a minimal radial distance from the vertical axis. The inner circumferential face <NUM> may, for example, be generally circular, circumscribing the vertical axis.

As depicted in the overhead view (e.g., layer view) of the tower <NUM> illustrated in <FIG>, an embodiment of a reinforcement member <NUM> in the form of a reinforcement assembly may be positioned on the first printed layer <NUM> (as depicted by arrow A<NUM>). <FIG>, therefore, illustrates the process of forming the tower <NUM> following placement and/or positioning of the reinforcement member <NUM> on the first printed layer <NUM>. <FIG> also illustrates a portion of the second printed layer <NUM> deposited on the reinforcement member <NUM>.

The reinforcement member <NUM> may, in an embodiment, include an inner rail <NUM>, an outer rail <NUM>, and/or a plurality of transverse members <NUM>. Each transverse member <NUM> may have a first end <NUM> coupled to the inner rail <NUM>. In an embodiment, each transverse member <NUM> may have a second end <NUM> coupled to the outer rail <NUM>. It should be appreciated that the inner rail <NUM> and/or the outer rail <NUM> may have a shape corresponding to a horizontal shape of the first printed layer. For example, in an embodiment wherein the tower structure <NUM> has a generally cylindrical or conical shape, the inner rail <NUM> and/or the outer rail <NUM> may be generally circular. By way of an additional example, in an embodiment wherein the tower structure <NUM> has a generally polygonal shape, the inner rail <NUM> and/or the outer rail <NUM> may include a plurality of angles/corners joined by a plurality of straight and/or curved sections. In such an embodiment, the inner rail <NUM> and/or the outer rail <NUM> may have a shape which mirrors the plurality of angles/corners joined by the plurality of straight and/or curved sections.

As particularly depicted in <FIG>, in an embodiment, a midline reference curve (CM) may be defined for each layer of the tower structure <NUM>. The midline reference curve (CM) may be equidistant between the outer circumferential face <NUM> and the inner circumferential face <NUM> for the layer. Accordingly, the midline reference curve (CM) may be generally circular, and at least partially circumscribing the vertical axis. It should be appreciated that the midline reference curve (CM) may represent a radial neutral point corresponding to the width/thickness (W) of the wall <NUM>.

It also should be appreciated that the midline reference curves (CM) of the print layers of the wall <NUM> may have different actual midline perimeter lengths at various heights of the tower structure <NUM>. For example, the tower structure <NUM> may taper with an increase in height. As a result, a midline reference curve (CM) of a print layer near the support surface <NUM> may have a greater actual midline perimeter length than the actual midline perimeter length of a midline reference curve (CM) adjacent the ultimate height of the tower structure <NUM>.

As particularly depicted in <FIG>, in an embodiment, the reinforcement member <NUM> may include a plurality of prefabricated reinforcement segments <NUM>. For example, in an embodiment, the reinforcement member <NUM> may include three prefabricated reinforcement segments <NUM>, with each prefabricated reinforcement segment <NUM> covering a <NUM>-degree arc of the midline reference curve (CM). In an additional embodiment, the reinforcement member <NUM> may include four prefabricated reinforcement segments <NUM>, with each prefabricated reinforcement segment <NUM> covering a <NUM>-degree arc of the midline reference curve (CM). In a further embodiment, the reinforcement member <NUM> may include six prefabricated reinforcement segments <NUM>, with each prefabricated reinforcement segment <NUM> covering a <NUM>-degree arc of the midline reference curve (CM). It should, therefore, be appreciated that in an embodiment, forming the reinforcement member <NUM> may include receiving the plurality of prefabricated reinforcement segments <NUM>.

Each of the plurality of prefabricated reinforcement segments <NUM> may, in an embodiment, include an inner rail segment <NUM> coupled to an outer rail segment <NUM> via a portion of the plurality of transverse members <NUM>. Each of the plurality of prefabricated reinforcement segments <NUM> may have a first segment end <NUM> and a second segment end <NUM> opposite thereof. The first segment end <NUM> and the second segment end <NUM> may be defined by the inner and outer rail segments <NUM>, <NUM>. In another embodiment, each of the plurality of prefabricated reinforcement segments <NUM> of the tower structure <NUM> may be pre-formed with/manufactured to a fixed length (e.g., arc length).

In an embodiment, each of the plurality of prefabricated reinforcement segments <NUM> or the reinforcement member <NUM> generally may include a lifting interface. The lifting interface may be configured to couple to at least one lifting element in order to facilitate the positioning of the fully assembled reinforcement member <NUM> on the first printed layer <NUM>. The lifting interface may be a flexible element configured to translate from a generally vertical orientation to a generally horizontal orientation or anywhere in between when the reinforcement member <NUM> is positioned on the first printed layer <NUM> and the lifting element(s) is decoupled. For example, in an embodiment, the lifting interface may be a cable, a hinged element, and/or a deformable plate element.

In another embodiment, the lifting element(s) may operate to establish a separation or gap between the reinforcement member(s) <NUM> or the prefabricated reinforcement segments <NUM> relative to the first printed layer <NUM> when the reinforcement members <NUM> or components are being placed or positioned thereon. Following the placement or positioning of the reinforcement members <NUM> or components on the first printed layer <NUM>, the lifting element(s) may be released or release may be delayed to allow for hardening or curing of the cementitious material, for example. Accordingly, the lifting element(s) may be separated from the reinforcement member(s) <NUM> or the prefabricated reinforcement segments <NUM> while the separation or gap is maintained relative to the first printed layer <NUM>. The lifting element(s) also may remain engaged to and holding the reinforcement member(s) <NUM> or the prefabricated reinforcement segments <NUM> while the separation or gap is maintained relative to the first printed layer <NUM> as a new print layer is being deposited.

By at least maintaining the separation or gap between the reinforcement member(s) <NUM> or the prefabricated reinforcement segments <NUM> and the first printed layer <NUM>, premature damage to recently printed layers may be precluded. Precluding contact between the reinforcement member(s) <NUM> or the prefabricated reinforcement segments <NUM> and the cementitious material <NUM> of the first printed layer <NUM>, which may remain soft/uncured during the positioning of the reinforcement members or components, may mitigate/preclude damage to the first printed layer <NUM>, while allowing the reinforcement members or components to be precisely placed and positioned within a new printer layer. It should be appreciated that precluding damage to the first printed layer <NUM> may increase the structural integrity of the tower structure <NUM> relative to that obtainable in the presence of a damaged first printed layer <NUM>.

Returning to <FIG>, in an embodiment, the additive printing system <NUM> may include a support structure <NUM>. The support structure <NUM> may extend from the ground and/or from the support surface <NUM> along a generally vertical direction (V). In an embodiment, the support structure <NUM> may include at least one vertical support component <NUM>. As depicted, in an embodiment, the vertical support component(s) <NUM> may be located radially outward of the tower structure <NUM>. However, in an additional embodiment, the vertical support component(s) <NUM> may be located radially inward of the wall <NUM> or supported above and over the wall (as shown in the embodiment of <FIG>, for example).

The vertical support component(s) <NUM> may, in an embodiment, support a horizontal support component <NUM>. The vertical support component(s) <NUM> and the horizontal support component <NUM> may, in an embodiment, be a truss-like structure (e.g., similar to a tower crane). However, the vertical support component(s) <NUM> and the horizontal support component <NUM> may be formed in the other suitable manner or have any other configuration according to alternative embodiments. The horizontal support component <NUM> may, in an embodiment, be rotatable about the vertical support component(s) <NUM>. In an additional embodiment, the horizontal support component <NUM> may be movably coupled to the vertical support component(s) <NUM> so as to permit the horizontal support component <NUM> to move in the vertical direction (V).

In at least one embodiment, the vertical support component(s) <NUM> may be configured to have a height that increases in step with the tower structure <NUM> during the manufacturing thereof. In such an embodiment, additional segments may be combined with the vertical support component(s) <NUM> to raise the vertical support structure using a jacking system (for example, similar to that shown in the embodiment of <FIG>). In general, the jacking system may be positioned proximate the support surface <NUM> and may be configured for raising the vertical support component(s) <NUM> and inserting additional segments.

The support structure <NUM> may be configured to support at least one support arm <NUM> movably coupled thereto. The support arm(s) <NUM> may be configured to position at least one component of the additive printing system <NUM> adjacent to the tower structure <NUM>. The support arm(s) <NUM> may also be configured to deliver power, air, cementitious material, form material, or other resources to the supported component. In an additional embodiment, the support arm(s) <NUM> may also be equipped with at least one optical sensor <NUM> (see <FIG>) for detecting a position of the support arm(s) <NUM> relative to the tower structure <NUM>.

The additive printing system <NUM> may include the printhead assembly <NUM> supported by the support structure <NUM>. The printhead assembly <NUM> may be positioned over the support surface <NUM> or preceding layers of the wall <NUM> by at least one of the horizontal support component <NUM> and/or the support arm(s) <NUM>. The printhead assembly <NUM> may include a print nozzle <NUM>. The print nozzle <NUM> may be configured to direct and/or shape a flow of cementitious material <NUM> during the additive printing of the tower structure <NUM>.

As particularly depicted in <FIG>, the optical sensor(s) <NUM> may be a three dimensional scanner. In another embodiment, the optical sensor(s) <NUM> may be a non-contact scanner that utilizes cameras (e.g., a stereoscopic system) and/or lasers (e.g., a triangulation-based 3D laser scanner) to capture physical characteristics of the tower structure <NUM>. In another embodiment, the optical sensor(s) <NUM> may comprise an image sensor (e.g., a camera or video sensor) and may be configured to leverage processor-based algorithmic models, machine learning, or convolutional neural networks to derive information from digital images, videos, and other visual inputs and to take actions or make recommendations based on that information. Moreover, the at least one optical sensor <NUM> may be integrated with the printhead assembly <NUM>. However, in an additional embodiment, the optical sensor(s) <NUM> may be an independent element supported by the support structure <NUM>.

Following the deposition of the first printed layer <NUM> and placement and positioning of the reinforcement member(s) <NUM>, the optical sensor(s) <NUM> may, in an embodiment, be employed to optically scan the printed layer being deposited over the reinforcement member(s) <NUM>. Thus, in an embodiment, a controller <NUM> (see <FIG>) may then generate (as depicted by arrow A<NUM>) a three-dimensional map <NUM> of the printed layer being deposited, based on the optical scan. In addition, the controller <NUM> may, in an embodiment, determine the actual midline perimeter length of the first printed layer <NUM> based on the three-dimensional map <NUM> of the first printed layer <NUM>.

In another embodiment, the controller <NUM> may, in an embodiment, record the actual physical dimensions and the particular placement, positioning, and orientation of the first reinforcement member(s) before and during an actual print path <NUM> of the printhead assembly <NUM>. The actual print path <NUM> may be recorded by the controller <NUM> during deposition of a second printed layer <NUM> going over the first printed layer <NUM>. For example, in an embodiment, the sensor(s) <NUM> may be utilized to continuously monitor the placement and positioning of the first reinforcement member(s) and the second printed layer <NUM>. In an embodiment, a midline perimeter length needed for the second reinforcement member(s) may be determined. The second reinforcement member(s) may then be formed based, at least in part, on the actual midline perimeter which itself is based on the determined, tracked, and mapped position of the first reinforcement member(s).

As depicted in <FIG>, in an embodiment, the additive printing system <NUM> may include a jig table <NUM>. The jig table <NUM> may be positioned on the ground/support surface <NUM> at the installation location of the tower structure <NUM>. For example, the jig table <NUM> may be positioned adjacent to the tower structure <NUM>. The jig table <NUM> may be configured to receive the plurality of prefabricated reinforcement segments <NUM>. In an embodiment, the jig table <NUM> may be sized to support the reinforcement member <NUM> when fully formed.

The jig table <NUM> may, in an embodiment, include a plurality of movable stops <NUM>. The plurality of movable stops <NUM> may, for example, be configured to orient/position the plurality of prefabricated reinforcement segments <NUM> in order to form the reinforcement member(s) <NUM> used throughout the tower structure <NUM>. Accordingly, in an embodiment, the plurality of movable stops <NUM> may be positioned based on the reinforcement member midline perimeter length. At least a portion of the plurality of prefabricated reinforcement segments <NUM> may be positioned via the plurality of movable stops <NUM>.

In an embodiment, the jig table <NUM> may include at least one servo <NUM>. The servo(s) <NUM> may be operably coupled to a portion of the plurality of movable stops <NUM>, such as via a linkage <NUM>. In such an embodiment, the servo(s) <NUM> may be actuated in order to alter a location of at least one of the plurality of movable stops <NUM> relative to a support surface <NUM> of the jig table <NUM>. The jig table <NUM> may be communicatively coupled to the controller <NUM> in an embodiment. In such an embodiment, the controller <NUM> of the additive printing system <NUM> may determine a required position for each of the plurality of movable stops <NUM>.

Referring now to <FIG> and <FIG>, in an embodiment, the additive printing system <NUM> may include at least one laser emitter <NUM>. The laser emitter(s) <NUM> may be supported by the support structure <NUM> and/or the support arm(s) <NUM>. In an embodiment, the laser emitter(s) <NUM> may project at least one placement guide onto the first printed layer <NUM> or the second printer layer. The placement guide(s) may be configured to facilitate the positioning of the reinforcement member <NUM> on the first printed layer <NUM> or the second printed layer <NUM>. The placement guide(s) may, for example, be an illuminated ring, a plurality of alignment marks, an orientation point, and/or other similar features.

Referring now to <FIG>, in an embodiment, the printhead assembly <NUM> may include an actuatable roller <NUM>. The actuatable roller <NUM> may be positioned to precede the print nozzle <NUM> during a deposition operation. In other words, the actuatable roller <NUM> may proceed along the print path <NUM> in advance of the print nozzle <NUM>.

Following the positioning of the reinforcement member <NUM> on the first printed layer <NUM>, the actuatable roller <NUM> may, in an embodiment, be utilized to exert a downward force (F) on the reinforcement member <NUM>. In response to the downward force (F), the reinforcement member <NUM> may be embedded at least partially within the first printed layer <NUM>. It should be appreciated that embedding the reinforcement member <NUM> at least partially within the first printed layer <NUM> while the cementitious material <NUM> remains soft/uncured may mitigate an impact of the reinforcement member <NUM> on the second printed layer <NUM>, and any subsequent print layers of the wall <NUM>.

Referring to <FIG> and <FIG>, in an embodiment, the printhead assembly <NUM> may include an actuatable groover <NUM>. The actuatable groover <NUM> may be positioned to trail the print nozzle <NUM>. In an embodiment, the actuatable groover <NUM> may include at least one grooving element <NUM>. The grooving element(s) <NUM> may be configured to form at least one depression/recess in an upper surface of the first printed layer <NUM> or the second printed layer <NUM>. Accordingly, in an embodiment, the actuatable groover <NUM> may be positioned in contact with a portion of the wet cementitious material <NUM> of the first printed layer <NUM>. In an embodiment, the actuatable groover <NUM> may be utilized to develop the depression/recess in the portion of the wet cementitious material <NUM> of the first printed layer <NUM>.

In an embodiment, the actuatable groover <NUM> may be utilized to form a positioning line (L) in the portion of the wet cementitious material <NUM>. The positioning line (L) may be configured to facilitate the accurate placement of the reinforcement member <NUM> on the first printed layer <NUM>. Accordingly, the positioning line (L) may have a cross-sectional depth (D<NUM>) that is less than a cross-sectional maximal width (W<NUM>). The cross-sectional maximal width (W<NUM>) may, for example, correspond to the maximal diameter of the inner and/or outer rail <NUM>, <NUM>. It should be appreciated that the cross-sectional depth (D<NUM>) being less than a cross-sectional maximal width (W<NUM>) may facilitate the positioning of a majority of the reinforcement member <NUM> above an upper surface of the first printed layer <NUM>.

As depicted in <FIG>, in an embodiment, the actuatable groover <NUM> may include at least two grooving elements <NUM>. The grooving elements <NUM> may be utilized by the additive printing system <NUM> to form at least two parallel receiving grooves <NUM> (a single receiving groove <NUM> is depicted in <FIG> for purposes of illustration) in the first printed layer <NUM>. The parallel receiving grooves <NUM> may be configured to receive at least the inner and outer rail <NUM>, <NUM> of the reinforcement member <NUM>. In an embodiment, each of the receiving grooves <NUM> may have a cross-sectional width (W<NUM>) that corresponds to a cross-sectional width of the respective inner and outer rails <NUM>, <NUM>. Each of the receiving grooves <NUM> may, in an embodiment, have a cross-sectional depth (D<NUM>) configured to at least partially embed the reinforcement member <NUM> in the first printed layer <NUM>.

As depicted particularly in <FIG>, in an embodiment, the additive printing system <NUM> may include both the actuatable roller <NUM> and the actuatable groover <NUM>. In such an embodiment, the actuatable groover <NUM> may be positioned to engage the first printed layer <NUM> during the deposition thereof (as depicted in <FIG>). Following the deposition of the first printed layer <NUM>, a separation may be established (as depicted in <FIG>) between the grooving element(s) <NUM> and the wet cementitious material <NUM>. The reinforcement member <NUM> may then be positioned in contact with the resultant positioning line (L) or parallel receiving grooves <NUM>. With the reinforcement member <NUM> accurately positioned on the first printed layer <NUM>, the actuatable roller <NUM> may be positioned in contact with the reinforcement member <NUM> in order to at least partially embed the reinforcement member <NUM> in the first printed layer <NUM>. In conjunction with the exertion of the downward force (F) by the actuatable roller <NUM>, the printhead assembly may deposit a portion of cementitious material <NUM> to print the second printed layer <NUM>.

Referring now to <FIG>, a schematic diagram of an embodiment of suitable components of the controller <NUM> that may control the additive printing system <NUM> according to the present disclosure is illustrated. For example, as shown, the controller <NUM> may include one or more processor(s) <NUM> and associated memory device(s) <NUM> configured to perform a variety of computer-implemented functions (e.g., performing the methods, steps, calculations and the like and storing relevant data as disclosed herein). Additionally, the controller <NUM> may also include a communications module <NUM> to facilitate communications between the controller <NUM> and the various components of the additive printing system <NUM>. Further, the communications module <NUM> may include a sensor interface <NUM> (e.g., one or more analog-to-digital converters) to permit signals transmitted from one or more sensors to be converted into signals that can be understood and processed by the processors <NUM>. It should be appreciated that the sensor(s) may be communicatively coupled to the communications module <NUM> using any suitable means, such as a wired or a wireless connection. Additionally, the communications module <NUM> may also be operably coupled to a component of the additive printing system <NUM> so as to orchestrate the formation of the tower structure <NUM>.

As used herein, the term "processor" refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits. Additionally, the memory device(s) <NUM> may generally comprise memory element(s) including, but not limited to, computer readable medium (e.g., random access memory (RAM)), computer readable non-volatile medium (e.g., a flash memory), a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD) and/or other suitable memory elements. Such memory device(s) <NUM> may generally be configured to store suitable computer-readable instructions that, when implemented by the processor(s) <NUM>, configure the controller <NUM> to perform various functions including, but not limited to, manufacturing a tower structure, as described herein, as well as various other suitable computer-implemented functions.

In particular, in an embodiment, the communications module <NUM> may include a sensor interface <NUM> comprising one or more analog-to-digital converters to permit signals transmitted from one or more sensors or feedback devices to be converted into signals that can be understood and processed by the processor(s) <NUM>. It should be appreciated that these sensors may be communicatively coupled to the communications module <NUM> using any suitable means, e.g., via a wired or wireless connection using any suitable wireless communications protocol known in the art. The processor <NUM> may also be configured to compute advanced control algorithms and communicate to a variety of Ethernet or serial-based protocols (Modbus, OPC, CAN, etc.).

Referring now to <FIG>, a flow diagram of an embodiment of a method <NUM> of manufacturing a tower structure is provided. In particular, the method <NUM> can be used to form the tower structure <NUM> of <FIG> using the additive printing system <NUM> of <FIG> or the additive printing system <NUM> of <FIG>, or to form any other suitable structure, tower, or tall structure using any other suitable additive printing device. In this regard, for example, the controller <NUM> of <FIG> may be configured for implementing the method <NUM>. However, it should be appreciated that the method <NUM> is discussed herein only to describe aspects of the present disclosure and is not intended to be limiting.

Further, though <FIG> depicts a control method having steps performed in a particular order for purposes of illustration and discussion, those of ordinary skill in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein can be adapted, rearranged, expanded, omitted, or modified in various ways without deviating from the scope of the present disclosure. Moreover, although aspects of the methods are explained with respect to the tower structure <NUM> and the additive printing device <NUM>, <NUM> as an example, it should be appreciated that these methods may be applied to the operation of additive printing device to form any suitable tower structure.

In particular, as shown at (<NUM>), the method <NUM> includes depositing, via a printhead assembly <NUM> of an additive printing system <NUM>, one or more first printed layers <NUM> of a wall <NUM> of a tower structure <NUM>. The one or more first printed layers <NUM> may at least partially circumscribing a vertical axis VA of the tower structure <NUM>.

As shown at (<NUM>), the method <NUM> also includes positioning a first reinforcement member <NUM> with respect to the one or more first printed layers <NUM> of the wall <NUM>. In certain embodiments, the method <NUM> may include depositing, via the additive printing system <NUM>, a second printed layer <NUM> of the wall <NUM> with the printhead assembly <NUM> on the first reinforcement member <NUM>, the second printed layer configured to hold a second reinforcement member thereon. In certain embodiments, the method <NUM> also may include placing (distinguished from "positioning" herein) a second reinforcement member on the second printed layer.

As shown at (<NUM>), the method <NUM> also includes determining, via an optical sensor <NUM> of the additive printing system <NUM>, a position for placing a second reinforcement member based on a position of the first reinforcement member <NUM> with respect to the one or more first printed layers <NUM>. In certain embodiments, the method <NUM> may include optically scanning, via the optical sensor <NUM>, the physical dimensions and the particular, placement, positioning, and orientation of the reinforcement member(s) <NUM>. In certain embodiments, the method <NUM> may include tracking and mapping the physical dimensions and the particular, placement, positioning, and orientation of the reinforcement member(s) <NUM>.

Moreover, in certain embodiments, the method <NUM> may include screening and selecting from amongst various reinforcement members for the best fit or most applicable second reinforcement member(s), with respect to the one or more first printed layers <NUM> of the wall <NUM> of the tower structure <NUM>. In certain embodiments, the method <NUM> also may include custom forming or designing (digitally, using a digital twin, for example, or physically) the second reinforcement member(s). In certain embodiments, the method <NUM> also may include placing or positioning the second reinforcement member(s) relative to the first reinforcement member(s) <NUM>, or relative the one or more first printed layers <NUM>, before additional printed layer(s) are added on top.

Optionally, as shown at (<NUM>), the method <NUM> may also include positioning the second reinforcement member on the second printed layer <NUM> in the determined position. In certain embodiments and optionally as shown at (<NUM>), the method <NUM> also may include depositing, via the additive printing system, a third printed layer of the wall with the printhead assembly on the second reinforcement member.

Claim 1:
A method (<NUM>) of manufacturing a tower structure, the method comprising:
depositing (<NUM>), via a printhead assembly of an additive printing system, one or more first printed layers of a wall of the tower structure;
positioning (<NUM>) a first reinforcement member with respect to the one or more first printed layers of the wall; characterized by:
determining (<NUM>), via an optical sensor of the additive printing system, a position for placing a second reinforcement member based on a position of the first reinforcement member with respect to the one or more first printed layers.