WO2005028781A2

WO2005028781A2 - Composite tower for a wind turbine and method of assembly

Info

Publication number: WO2005028781A2
Application number: PCT/US2004/030271
Authority: WO
Inventors: Clement Hiel; George Korzeniowski
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-09-16
Filing date: 2004-09-16
Publication date: 2005-03-31
Anticipated expiration: 2006-03-16
Also published as: WO2005028781A3

Abstract

The invention includes a new composite tower (102) for a wind turbine (104). The tower (102) comprises several nested tower sections (108) that can telescope to increased heights. Each section may be formed from two or more composite panels (302) connected by two or more connectors (304), the sections (108) comprising any of a plurality of polygonal shapes. The panels (302) may further comprise tufted, foam core (306) panels (302) that have a great strength properties. The invention also includes a method for installing and erecting the tower (102) and wind turbine (104).

Description

COMPOSITE TOWER FOR A WIND TURBINE AND METHOD OF ASSEMBLY

CLAIM TO PRIORITY In relation to this International Application, applicants claim priority of earlier US provisional application Serial No. 60/540,115 filed in the United States Patent and Trademark Office on 29 January 2004 and US provisional application Serial No. 60/503,427 filed in the United States Patent and Trademark Office on 16 September 2003, the entire disclosure of each provisional application is incorporated by reference herein. TECHNICAL FIELD The present invention relates to a composite structure. More particularly, the invention relates to a composite tower for mounting and holding a wind turbine used in the generation of electricity. The invention also relates to the method for assembling the composite tower. BACKGROUND ART Harnessing the power of the wind has been an ambition of mankind since early times.

Past attempts included the windmills of Northern Europe that use wind movements to power mills and pumps used to irrigate and move water. Later electrical advancements have allowed utility companies to transform the movement of the winds into electrical power. As a source of energy, wind generated power is non-polluting and abundant. The Earth's environment provides wind in every comer of the world. Unfortunately, wind energy can be less cost effective than other forms of energy generation. Certain wind velocities are required to turn the large rotor wind generators. Only a few places on Earth exist where the wind is strong enough and consistent enough near the surface of the Earth to create the drive large wind turbine generators. However, wind velocities are nearly always strong enough when the winds are measured higher in elevation, away from the surface of the Earth. The required wind velocities to help power a 5MW wind generator exist usually above 250 feet. Thus, wind turbine towers must position the generator in the wind flow at the requisite elevation. A general rule of thumb is that doubling the tower height would enable the turbines to harness 45% more energy for any size turbine wherein one Megawatt of wind-generating capacity typically will satisfy the electricity needs of 350 households in an industrial society, or roughly 1000 people. To achieve the required height for the tower, some prior art patents have resorted to large steel and concrete towers. These towers are extremely massive and are cost prohibitive. In addition, these towers are very hard to build to the heights required. Indeed, these towers require special transport logistics for hardware, special handling equipment and the need to build temporary roads. Moreover, these towers require erection by very tall and expensive cranes. To add to the complexity of erection, some cranes require up to 15 semi-trucks to transport the crane alone to the site. DISCLOSURE OF INVENTION The invention includes a new composite tower for a wind turbine. The tower includes several nested tower sections that can telescope to increased heights. Each section may be formed from two or more composite panels. These panels may comprise tufted, foam core sandwich panels that have great stiffness and strength properties. The invention also includes a method for installing and erecting the tower. In one embodiment of the invention, a composite tower is used to support a wind turbine. The composite tower comprises two or more composite tower sections comprising two or more composite panels and two or more connecting devices to connect the panels together to form an enclosed polygonal structure wherein, the composite tower sections are telescoped to a full height of the tower. In a further embodiment, the composite tower comprises two or more composite tower sections. A first section having a polygonal structure of four or more sides is deposited into a hole in the ground. A second section comprises the same polygonal structure as the first section and further comprises a diameter that enables the second section to fit within the diameter of the first section. Each successive section comprises a smaller diameter such that each successive section may fit within the sections below it. The tower may then be telescoped to a full height. In yet another embodiment, the composite tower is used to support a wind turbine. The invention further includes a method of assembling a telescoping composite tower with an outer section and at least one nested section, comprising: presenting the tower in a horizontal position; elevating the tower to a vertical position; lowering the tower to a mounting assembly; and extending the nested section of the tower. In another embodiment, the outer section or one or more nested sections of the tower may be built on-site. In yet another embodiment, a method is disclosed to elevate the tower, the method comprising: attaching a set of cabling from an elevator to an upper end of the tower and pulling the upper end of the tower upwardly until the tower is in the vertical position. In this embodiment, pulling the upper end of the tower includes one of reeling in the cable to a pre- positioned elevator, changing the position of the elevator that is attached to the tower with fixed cables, or reeling in the cables while changing the position of the elevator. In a further embodiment, lowering the tower includes placing the lower end of the tower into a pre-dug hole; and, anchoring the tower to a mounting bracket inside the hole. Alternatively, lowering the tower includes anchoring the tower to a mounting bracket anchored to the ground. In another embodiment, extending the nested section includes raising the nested section such that the upper end of the nested section is above the upper end of the outer section; and, securing the nested section in-place once the nested section is raised. In a further embodiment, a wind turbine may be placed on the upper end of the nested section before extending the nested section. A method is further disclosed to attach the blades to the wind turbine. In this embodiment, the steps may comprise for example: attaching a first turbine blade to the wind turbine; extending the nested section of the tower; rotating the wind turbine until the first turbine blade is positioned in a non- vertical position; lowering the nested section of the tower; and attaching a second turbine blade. A method is further disclosed to assemble a telescoping tower on-site. The method comprises pultruding two or more first elongated composite panels on-site; attaching first panels together to form a first base composite tower section; pultruding two or more second elongated composite panels on-site; attaching second panels together to form a second composite tower section, wherein the second composite tower section has a circumference smaller than the first base composite tower section; and nesting the second composite tower section within the first base composite tower section. The method further comprises pultruding two or more elongated panels on site; and attaching the panels together to form a third composite tower section; wherein, the third composite tower section comprises a circumference smaller than the second and first base composite tower sections. In an alternate embodiment of the invention, a pulley system may be used to telescope the tower sections. According to this embodiment, a pulley system may comprise a cable attached to the bottom of a telescoping section, wherein said cable is fed around a pulley connected to a winch type element at the other end of the telescoping section; a collar around the edge of a lower tower section; a bracket attached to the collar to hold the pulley; and a set of guide wheels to guide the telescoping section; wherein, the pulley system to raises or lowers the telescoping section between a fully extended position and a position nested within a lower tower section. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a three-dimensional view of one embodiment of an erected wind turbine tower according to the present invention. FIG. 2 shows a two-dimensional view of one embodiment of an erected wind tower according to the present invention. FIG. 3A shows an embodiment of a cross section of a tower section according to the present invention. FIG. 3B shows another embodiment of a cross section of a tower section according to the present invention. FIG. 3C shows another embodiment of a cross section of a tower section according to the present invention. FIG. 4 shows an embodiment of a connector and two panels used to form a tower section according to the present invention. FIG.4A shows an embodiment of a connector and two panels used to form a tower section according to the present invention. FIG. 5 shows an embodiment of a cross section of a panel used to form a tower section according to the present invention. FIG. 6 shows cross sectional views of embodiments of different tower sections that may be nested according to the present invention. FIG. 6A shows cross sectional views of embodiments of different tower sections for an eight sided tower that may be nested according to the present invention. FIG. 7 shows cross sectional views of embodiments of different tower sections that may be nested according to the present invention. FIG. 8 shows an embodiment of a tower using nested and telescoping tower sections according to the present invention. FIG. 9 shows an embodiment of a telescoping tower that is not fully extended showing two tower sections with embodiments of the pulley system and mounting hardware according to the present invention. FIG. 10 shows an embodiment of a telescoping tower that is fully extended showing two tower sections with embodiments of the pulley system and mounting hardware according to the present invention. FIG. 11 shows a closer view an embodiment the pulley system and mounting hardware according to the present invention. FIG. 12 shows a closer view an embodiment the pulley system and mounting hardware according to the present invention. FIG. 13A shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 13B shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 13C shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 13D shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 13E shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 13F shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 13G shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 13H shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 131 shows a part of an embodiment of a process to raise and erect a telescoping tower according to the present invention. FIG. 14A shows a part of an embodiment of a process to install blades on a turbine set atop a telescoping tower according to the present invention. FIG. 14B shows a part of an embodiment of a process to install blades on a turbine set atop a telescoping tower according to the present invention. FIG. 14C shows a part of an embodiment of a process to install blades on a turbine set atop a telescoping tower according to the present invention. FIG. 14D shows a part of an embodiment of a process to install blades on a turbine set atop a telescoping tower according to the present invention. FIG. 15A shows another embodiment of a telescoping tower before it is fully extended according to the present invention. FIG. 15B shows another embodiment of a telescoping tower after it is fully extended according to the present invention. To clarify, each drawing includes reference numerals. These reference numerals follow a common nomenclature. The reference numeral will have three or four digits. The first digits represent the drawing number where the reference numeral was first used. For example, a reference numeral used first in FIG. 1 will have a number like 1XX while a number first used in FIG. 5 will have a number like 5XX. The second two numbers represent a specific item within a drawing. One item in FIG. 1 will be 101 while another item will be 102. Like reference numerals used in later drawing represent the same item. For example, reference numeral 102 in FIG. 3 is the same item as shown in FIG. 1. MODES FOR CARRYING OUT THE INVENTION The present invention includes tall tubular structures (towers) used for wind turbine towers. As used herein, the terms "tall tubular structures" and "tower" may be used interchangeably. These towers can achieve heights not possible by most of the prior art towers (in excess of 200' (60.9 m)). These towers can be made from composite materials, nested, and telescoped. The wind turbine tower 100 is shown generally in FIG. 1. The wind turbine tower 100 consists of a tower 102 and a turbine generator 104. A turbine generator 104 is any electric generator that can convert the kinetic energy of the wind movement into electrical energy. Any generator may be used. Stronger winds that have higher velocities may allow for the use of the more powerful generators. Thus, strong, upper elevation winds, may allow the use of 5MW or even more powerful generators. However, one skilled in the art will recognize that the type or power rating of the generator 104 is immaterial to the invention. Generally, the generator 104 is attached to a set of blades 106a, 106b, and 106c or instruments that capture the wind energy and use it to m the electric generator 104. Several designs of blades are possible. The present invention has three propeller-type blades 106a, 106b, and 106c. These blades 106a, 106b, and 106c can be specially shaped to convert the inflow energy of the wind (linear movement of the wind) into rotational energy of the blades (movement in the blades) 106a, 106b, and 106c and the generator 104. One skilled in the art will recognize other blade arrangements that may be used with the present invention. The present invention focuses on the tower 102. The tower 102 is a composite structure. Several embodiments of the structure may exist. The tower 102 may be made from one or more tower sections 108a, 108b, and 108c, sometimes referred to herein more generally as 108 where it does not indicate any one section in particular. In the embodiment shown in FIG. 1, the tower 102 has three tower sections 108a, 108b, and 108c. While the embodiment shown includes three tower sections 108a, 108b, and 108c, one skilled in the art will recognize, after reviewing this description, the tower 102 can be made from one or more tower sections. The tower 102 also demonstrates that the tower sections 108a, 108b, and 108c may be nested, and the tower 102 may be telescoped into a fully extended height. Again, this embodiment is only exemplary, and the tower 102 may not be nested or telescoped but can be arranged as one or two or more sections of equal diameter that are connected together. However, to reach the heights suggested (over 200 feet (60.9 m)), the tower 102 may require a telescoped and nested configuration for ease of erection and installation. The embodiment shown includes sections 108a, 108b, and 108c that are hexagonal in cross section. This shape is exemplary. Each section 108a, 108b, or 108c may adopt one of numerous choices for cross sections. These cross sections may include, but are not limited to, any polygon, a circle, or an ellipse (oval). In addition, each section 108a, 108b, and 108c of the tower 102 may have a unique and different cross section from the other sections or may have a similar or the same cross section as the other sections. One skilled in the art will recognize other embodiments of the cross sections. A tower 102 may employ and be anchored by one or more sets of guy wires. The embodiment shown has two sets of guy wires 110 and 112. Each set of guy wires 110 and 112 may have a plurality of wires that brace the tower 100. The embodiment shown includes three guy wires in each set. While it may be possible to use fewer than three wires, it is preferred that each set of guy wires 110 or 112 include three or more wires to brace the tower against deflection in any direction. The guy wires may be made of any material strong enough and rigid enough to brace the tower 100. In the exemplary embodiment, the guy wires 110 or 112 are a steel cable. The guy wires 110 or 112 may be attached to one or more connectors (shown later) on the tower 102. An exemplary embodiment of a connector will be described below. Also, the guy wires 110 or 112 should be connected to an anchor point (not shown) set on or in the ground. The anchor can be a concrete post or footing with a clevis or eye to connect the wire. Two or more guy wires may share a connection to the tower 102 or an anchor point. Each guy wire can have a certain angular relationship to the tower 102 and the ground. These relationships must provide the adequate bracing for the tower 100 from deflection in the tower 102. One skilled in the art will be capable of determining the appropriate angle for the guy wires 110 or 112 in accordance with the present invention. One skilled in the art will recognize other embodiments of the guy wires 110 or 112 that are included in the present invention. Hereinafter, the embodiment provided in FIG. 1 will be used to describe the present invention. However, the invention is not limited to that one embodiment, and one skilled in the art will recognize contemplated changes to the invention. in an alternate embodiment, guy wires 110 or 112 are not required for the support of a tower 100. Indeed, as the towers get increasingly larger, the influence of guy wires diminishes due to the large moments of inertia of the different telescoping sections, which make up the tower. This embodiment would be attractive for the emerging offshore tower installations because creating the attachment points for connecting the guy wires in an offshore environment is very difficult to do and also expensive and time consuming. Referring to FIG. 2, a cross-section of the embodiment of the tower 100 is shown. The tower 102 includes the three sections 108a, 108b, and 108c, the wind turbine generator 104, and two sets of guy wires 110 or 112. The tower sections 108a, 108b, and 108c are shown nested into each other before and after the tower 102 is fully extended. One embodiment, according to the invention and as shown in FIG 2 may have, for example, the following dimensions. Referring to FIG. 2, the tower 100 is constructed by depositing base section 108a into a hole. As an example, the height 120 from the ground surface 122 to the center of the wind turbine 102 may be 88.7 m. Breaking out various height portions, the height 124 from the bottom of the hole to the top of the base section 108a may be 29 m, the height 126 from the ground surface to the top of tower section 108b may be 58 m. The height 128 from the ground surface to the top of the tower may be 86.8 m. The hole 130 stabilizing the tower section 108a may comprise a height of about 10 m. Similarly each telescoped tower section 108b and 108c may sit within the previous tower section by a distance 136b and 136c of about 10 m. External guy wires in this example, may be extended and secured away from tower 102 achieving a diameter 134 of about 24.5 m. Continuing this particular example the wind turbine 104 blade diameter may achieve a diameter 138 of about 64 m. Accordingly, in this example, the composite tower 102 reaches an exemplary height of about 90 m and supports a wind turbine 104 having a blade diameter of about 64 m. It is noted that this is only an example of measurements and one skilled in the art may scale the values either proportionately or variably up or down accordingly. While a tower section may be made from a single piece of composite material, the preferred embodiment includes two or more panels that connect together to form the composite tower section. As explained above, the tower section may have a hexagonal cross- section, such as that shown in FIG. 3A. While this hexagonal shape may be made from one piece as shown in FIG. 3A, the preferred embodiment uses panels and connectors as shown in FIG. 3B. The exemplary embodiment in FIG. 3B uses six panels 302 and six connectors 304, but one skilled in the art will recognize that more or fewer panels or connectors may be used to form the hexagonal cross section. In addition, the exemplary embodiment presented uses flat panels 302 with connectors 304 placed in the corners of the hexagon. Again, one skilled in the art will recognize that shaped panels (having more than one side in more than one plane) may comprise the panels 302 and the connectors 304 may connect the panels 302 along the flat sides of the hexagon. One skilled in the art will also recognize how the connectors 304 and panels 302 can be modified to create other polygonal or other patterned cross sections. An alternate embodiment of a tower 310 in accordance with the invention is illustrated in FIG. 3C. As illustrated, the tower section may have an octagonal cross-section, such as that shown in FIG. 3C. While this octagonal shape may be made from one piece, the preferred embodiment uses panels and connectors as shown in FIG. 3C. The exemplary embodiment in FIG. 3C uses eight panels 302 and eight connectors 322. As used herein, panel 302 refers to any shape and configuration panel used to construct a polygonal tower. One skilled in the art will recognize that panel 302 encompasses a plurality of configurations depending on the shape of the tower 102. It is noted that one skilled in the art could construct an eight sided tower using more than eight panels and more than eight connectors. In addition, this exemplary embodiment uses flat panels 302 with connectors 322 placed in the comers of the octagon. Again, one skilled in the art will recognize that shaped panels (having more than one side in more than one plane) may comprise the panels 302 and the connectors 322 may connect the panels 302 along the flat sides of the octagon. One skilled in the art will also recognize how the connectors 322 and panels 302 can be modified to create other polygonal or other patterned cross sections. An embodiment of a connector 304 as depicted in FIG. 3, is shown in FIG. 4. A connector 304 can include an outer wall 402 and an inner wall 404. The outer walls 402 can parallel the sides of the panel and form a comer 406 that may determine the shape (a hexagon in this embodiment) of the paneled tower 300. Similarly, the inner walls 404 can parallel the sides of the panels 302 and form a corner 408. In most embodiments, the comers 406 and 408 are the same angle. The inner 404 and outer 402 walls can be connected by a cross brace 410. A cross brace 410 can join the two walls 402 and 404 together and provide structural strength to the connector 304. The arrangement of the inner wall 404, the outer wall 402, and the brace 410 may form a cavity 414 that may accept the panel 302. As shown in FIG. 4, the panel 302 can be inserted into the cavity 414. Adhesive or a mechanical connector may attach the panel 302 to the connector 304. The walls 402 and 404 and braces 410 of the connector 304 may be formed for any sufficiently rigid and strong material. In an exemplary embodiment, the connectors 304 are a composite formed from one or more plies of a fibrous material and resin. The embodiment shown is only exemplary and one skilled in the art will recognize other connectors 304 that may be used and how those connectors 304 may have a different arrangement. Another example of an embodiment of a connector 322 as depicted in FIG. 3C, is shown in FIG. 4A. A connector 322 can include an outer wall 420 and an inner wall 422. The outer walls 420 can parallel the sides of the panel 302 and form a comer 424 that may determine the shape (an octagon in this embodiment) of the paneled tower 310. Similarly, the inner walls 422 can parallel the sides of the panels 302 and form a comer 426. In most embodiments, the comers 424 and 426 are the same angle. The inner 422 and outer 420 walls can be connected by a cross brace 428. A cross brace 428 can join the two walls 420 and 422 together and provide structural strength to the connector 322. The arrangement of the inner wall 420, the outer wall 422, and the brace 428 may form a cavity 430 that may accept the panel 302. In one embodiment, panel 302 comprises a notched end 432. The thickness of the end notch portion 432 is slightly less than the thickness of the panel 302. As shown in FIG. 4A, the notch 432, enables the panel 302 to be inserted into the cavity 430. Adhesive or a mechanical connector may attach the panel 302 to the connector 322. The walls 420 and 422 and brace 428 of the connector 322 may be formed for any sufficiently rigid and strong material. In an exemplary embodiment, the connectors 322 are a composite formed from one or more plies of a fibrous material and resin. The embodiment shown is only exemplary and one skilled in the art will recognize other connectors 322 that may be used and how those connectors 322 may have a different arrangement. In various embodiments, the panels 302 may have several configurations. The panels 302 may be made from any sufficiently stiff and strong material including, but not limited to, steel, aluminum, or other metals, also wood panels and laminated wood panels such as "Glulam" could be used. However, in a preferred embodiment, the tower 102 is constructed from a composite. Composites have great strength and stiffness, but are much lighter than steel and other metals. An exemplary composite construction is described in Provisional U.S. Patent Application titled, "Composite Utility Pole with Reinforced Panel Construction and Method and Apparatus To Build Panel-Type Pole" filed January 13, 2004, Serial No. 60/536,164, which is incorporated by reference herein. A simple embodiment of the exemplary panel 302 is shown in FIG. 5B. FIG 5 A depicts tower 102 comprising nested tower sections 108a, 108b and 108c. FIG. 5B is a detailed view of portion A of FIG 5 A showing one embodiment of panel 302. In this example, the panel 302 comprises two skins 502, a foam core 504, and a plurality of fiber reinforcing rovings 506. This embodiment of the panel 302 is very rigid, very strong, very light, and easily constructed. One skilled in the art will recognize other embodiments of the panel 302 by reviewing the incorporated patent application and the succeeding description. As explained above, the tower 102 may be constructed from two or more sections 108a, 108b, and 108c. To make the sections 108a, 108b, and 108c, panels 302 of either similar size or different dimensions are connected together to create the sections 108a, 108b, and 108c. The sections 108a, 108b, and 108c may have different heights depending on the length of the panels 302 that form the section 108a, 108b, or 108c. For the telescoping and nesting embodiment shown in FIG. 1 and FIG. 2, the sections 108a, 108b, and 108c have different cross-sectional diameters. Referring to FIG. 6, three sections 108a, 108b, and 108c of the tower 102 are provided. As can be seen, each section 108a, 108b, and 108c has a different diameter, and the sections 108a, 108b, and 108c can fit within the other successively larger section. In an alternate embodiment illustrated in FIG. 6A, three sections 108a, 108b, and 108c of an octagonal pole 310, are provided. In FIG. 7, the three sections 108a, 108b, and 108c are shown separately. The dimensions provided are exemplary but show that the different sections 108a, 108b, and 108c can be created by using panels 302 of greater or lesser width. Prior art towers were unable to achieve great heights where wind velocities are faster and more sustained. Assembling the larger prior art towers is also increasingly difficult as towers get increasingly taller. The present invention provides towers 100 of great height (above 200' (61m)) and makes it easy to install the tower 100 because of the telescoping design. Referring to FIG. 8, the tower sections 108a, 108b, and 108c can be nested together. After the tower sections 108a, 108b, and 108c are nested, the wind turbine 104 can be attached to the upper most section 108c of the tower 102. Then, the sections 108a, 108b, and 108c can be telescoped to the final height of the tower 100. The dimensions shown in FIG. 8 are only exemplary. However, using the dimensions for explanation purposes, a tower 100 of nearly 300' can be constructed from the telescoping sections 108a, 108b, and 108c. The installation of the wind turbine 104 can be completed before telescoping. Thus, the wind turbine 104 and the blades 106a, 106b, and 106c may be installed at a height of less than 100' (30.5m). This difference is important because some standard equipment used to create current 100' (30.5m) towers can be used to create the 300' (91.5 m) telescoping tower 100. To telescope the tower sections 108a, 108b, and 108c, a set of hardware and mechanical implements must be used. This invention contemplates several embodiments of mechanical systems that can extend the tower sections 108a, 108b, and 108c. For instance, a hydraulic lift may be provided that can push the tower sections 108a, 108b, and 108c into their final configuration. In another embodiment, a motorized wheel may ride a track inside the tower sections 108a, 108b, and 108c that can push the tower 102 to its extended configuration. One skilled in the art will recognize other possible embodiments. In the exemplary embodiment, a pulley and winch system 900 can be used to extend the telescoped sections 108a, 108b, and 108c. Referring to FIG. 9, the nested sections 108a and 108b may be equipped with one or more pulleys 902 atop the sections. A cable 904, at one end, can be attached by a mechanical attachment to the bottom 906 of the telescoping section 108b or 108c. The cable 904 can be fed around the pulley 902 and connected to a winch (not shown) at the other end (not shown) of the cable 904. To extend the telescoped sections 108b and 108c, the winch can draw in the cable 904 and force the bottom 906 of telescoped section 108b or 108c to be pulled upward towards the pulley 902. Referring to both FIG. 9 and FIG. 10, both figures show close-up views of an embodiment of the pulley system 900 and some mounting hardware. In FIG. 9, the upper tower section 108b is not fully extended, and in FIG. 10, the upper tower section 108b is fully extended. A collar or ring 1002 is placed around the top edge of the lower tower section 108a. The collar 1002 helps guide the upper section 108b as it is extended. The pulley 902 may be mounted to the collar 1002. In some embodiments, the pulley 902 and the collar 1002 may be a single integrated piece. The embodiments shown in FIG. 9 provide a bracket 1004 that holds the pulley 902 and is attached to the collar 1002. The collar 1002 also includes a hole or lumen 1006 that allows the cable 904 to pass through it. The collar 1002 may be made of any sufficiently strong and rigid material. In the instant embodiment, the collar 1002 may be made from steel or aluminum. The collar 1002 is explained in more detail below. The cable 904 can be anchored to a bottom ring 1008. This bottom ring 1008 may also be made of any sufficiently strong and rigid material. In the instant embodiment, the bottom ring 1008 may be made from steel or aluminum. In some embodiments, the bottom ring 1008 may ride against the inside surface of the bottom tower section 108a. The embodiment shown includes a bottom ring 1008 that does not ride along the bottom tower section 108a, and the ring 1008 has a slanted edge that can contact a stop block 1012 mounted on the bottom section 108a of the tower 102. The bottom ring 1008 is explained in more detail below. As illustrated in FIG. 10, in one embodiment an anchor attachment or ring 1014 can be attached to the cable 904 or to the top section 108b of the tower 102. This anchor attachment 1014 can ride on the cable 904 or the upper tower section 108b until the upper section 108b reaches its fully extended position. A bolt may then be set through the collar 1002 and screwed or attached into the anchor attachment 1014. With the bolt in place, the upper tower section 108b and the lower tower section 108a are anchored in place and will remain extended. In the embodiment shown, a set of guide wheels 1016 help ensure that the upper section 108b is extended upwards evenly without tilting. Other guides that may be used instead of the wheels 1016 may include, but are not limited to, a set of bearings or a shoe. The wheels 1016 may also be unnecessary. One skilled in the art will recognize other devices that may accomplish the task of helping guide the upper section 108b. These embodiments of the pulleys and attachment hardware are explained in more detail below. Referring to FIG. 11, a close up view of the pulley embodiment 902 is shown. In this embodiment, the upper tower section 108b is fully extended. The attachment ring 1014 is set against the collar 1002. A bolt 1202 has been set through the collar 1002 and into the attachment ring 1014. Other attachment devices including, but not limited to, rivets, nails, screws, adhesives, or staples are contemplated. The cable 904 can be seen going around the pulley 902, through the collar 1002, through the attachment ring 1014 and down toward the bottom ring 1008. In FIG. 12, a close up of the embodiment of the bottom ring 1008 is shown. A lumen or through hole 1302 for the cable 904 is shown. On the underneath side of the bottom ring 1008, a bolt or attachment 1304 for the end of the cable 904 is provided. The cable 904 can be terminated on either the top or underneath side of the bottom ring 1008. If the cable 904 is connected to the top of the bottom ring 1008, an eye or clevis may be provided to attach the cable 904 with screws, bolts, hooks, or other attachment devices. One skilled in the art will recognize various ways of attaching the cable 904 that are included with this invention. The bottom ring 1008 may hold the panel 302 of the tower section 108b in a groove 1306 formed around the ring 1008. In other embodiments, the panel 302 may be held by a sleeve or inner wall that can be reinforced with gussets. The connection between the bottom ring 1008 and the panel 302 may have other various embodiments that one skilled in the art will recognize. A floor 1308 may be included with the bottom ring 1008. This floor 1308 may be separately attached or formed with the bottom ring 1008. To reduce weight, the floor 1308 may be formed from a panel similar to the panel sections 302. However, the floor 1308 may be formed from any rigid material. The guide wheels 1016 are shown attached to the bottom ring 1008 and set against the inner wall of the bottom tower section 108a. Again, the wheels 1016 may allow the bottom of the upper tower section 108b to rise smoothly without tilting within the bottom tower section 108a. FIG. 12 shows the top tower section 108b in a fully telescoped position. The wheels 1016 guided the bottom ring 1008 into contact with the stop block 1012 mounted on the bottom tower section 108a. Both the bottom ring 1008 and the stop block 1012 may have a slanted edge 1310. This slanted edge 1310 helps center the bottom of the top tower section 108b. In addition, as the collar 1002 is bolted or screwed tightly in position, the slanted edge 1310 slips into tight contact. Thus, the bottom of the upper tower section 108b becomes firmly secured against the bottom tower section 108a without the need for further bolts or attaching hardware. This embodiment makes unnecessary the need for personnel to get access to the bottom of the lower tower section 108a, which would be very difficult in the current design. All of the preceding attachment hardware and telescoping hardware is exemplary. One skilled in the art will recognize variations to the hardware that are included in the present invention. An embodiment of a method 1400 of installing or erecting the wind turbine tower 100 is shown in FIG. 13A through FIG. 131. In preparation for the installation of the tower 100, the panel sections 302 of the tower 102 may be constructed on site. Using machinery and processes described in the incorporated patent, lengthy, tufted panels 302 may be made, milled, and connected together to form the tower sections 108a, 108b, and 108c. Constructing the tower sections 108a, 108b, and 108c on site alleviates the need to ship the very large tower sections 108a, 108b, and 108c via truck or helicopter or other cumbersome and costly means. The hardware for the tower sections 108a, 108b, and 108c may be attached on site and the tower sections 108a, 108b, and 108c may be nested together. To prepare for installation, a hole 1402 may be set into the ground that can receive the tower 102. This hole 1402 may be lined with a concrete lining 1404 that may be preformed or poured on site. Other materials may also be used to form the lining 1404 including, but not limited to, diatomaceous earth, composite materials, wood, elastomers, steel, other rigid materials, or other vibration dampening materials. The hole 1402 functions as a footing for the tower 102. In other embodiments, the tower 102 may not be placed in a hole 102 in the ground but mounted to a footing poured in the earth. The attachment of the tower 102 to the mounting may be done by a series of bolts or other attachment devices. The tower 102 may also be slipped over a housing that projects from the ground. In other words, a rigid structure may be formed with which the tower 102 mates. One skilled in the art will recognize other methods of mounting or placing the tower 102 on, above, or in the ground, but the invention will hereinafter be described as being set in a hole 1402. The invention is not limited to that one embodiment. A gantry and scaffolding system 1406 may then be built over the mounting structure. The scaffolding 1406 may be a steel truss structure formed from several towers or several walls of interlocking steel members. These scaffolding systems are well known in the art and are currently in use to construct smaller towers. Therefore, the scaffolding system will not be explained further. An elevator 1408 may be attached to the scaffolding 1406. The elevator 1408 may raise and lower the tower 102 or other parts of the wind turbine tower 100 from the ground to the top or near the top of the scaffolding 1406. A crane system 1410 may be placed on the elevator 1408 to move the tower 102 or other parts of the tower 100 horizontally a short distance. Again, these systems are well known and are currently in use in the art. Therefore, these devices will not be explained further. In other embodiments, a crane may be used to raise the tower 100 and the other parts of the tower 100. A helicopter may also be used to raise the tower 100. One skilled in the art will recognize other methods or machines that can help raise the tower 100. Once the tower sections 108a, 108b, and 108c are built, the hardware installed, and the tower sections 108a, 108b, and 108c nested, the tower 102 may be pre-positioned atop two or more moving cars 1412. The cars 1412 may be some type of truck bed or specially designed moving car. One skilled in the art will recognize other cars 1412 that may be used. In the embodiment shown, the cars 1412 are similar to railroad flatbed cars. These flatbed cars 1412 move along a set of laid tracks (not shown). Referring to FIG. 13A, FIG. 13B, and FIG. 13C, the cars 1412 allow the bottom of the tower 102 to slide smoothly under the top of the tower 102 as the elevator 1408 raises the tower 102 to a vertical position. Without the cars 1412, the bottom of the tower 102 may swing in a pendulum motion while being raised, which could create a dangerous situation for the workers and the installation equipment. The car 1412 that holds the bottom of the tower 102 can have a sleeve 1414 that holds the bottom of the tower 102. A pivot 1416 placed at the bottom of the sleeve 1414 can help the tower 102 transition from a horizontal orientation to a vertical orientation. Once vertical (see FIG. 13B), the sleeve 1414 may lay flat against the bed of the car 1412. A sleeve, collar, or other attachment 1418 may be placed around the top of the tower 102. The collar 1418 may be connected to the crane 1410 by a set of cables, wires, or hoists 1420. In other embodiments, the hoists 1420 may be attached to some hardware permanently affixed to the tower 102. The hoists 1420 will help pivot the tower 102 and lower it into the hole 1402. Referring to FIG. 13D, once the bottom of the tower 102 is over the hole 1402 and vertical, the hoist 1410 can lift the tower 102 enough to extract the flatbed car 1412 from underneath the tower 102. At this point, the tower 102 is suspended in midair over the hole 1402. As shown in FIG. 13E, the tower 102 may then be lowered by the hoist 1410 into the hole 1402. Another layer of material or materials 1422 may then be placed around the tower 102 between the tower 102 and the lining 1404 of the hole 1402. These materials may be different, similar, or the same as those that may be used for the lining 1404. Again, these materials may include, but are not limited to, diatomaceous earth, composite materials, wood, elastomers, steel, other rigid materials, or other vibration dampening materials. A door or passageway 1424 may be created in the tower 102 before or after placement of the tower in the hole 1402. This door 1424 can provide access to the interior of the tower 102 to personnel installing the tower 102. Thus, any hardware attachments, electrical connections, or other installation requirements may be completed before the tower 102 is telescoped. In other embodiments, the door 1424 may provide access to the bottom of the hole 1402, where the personnel may scale the tower 102 from that point. This embodiment may be preferred because it does not lessen the structural strength of the tower 102. Once the tower 102 is set in the ground, the collar 1418 may be detached from the tower 102, as shown in FIG. 13F. The mrbine generator 104 may be placed on the flatbed car 1412. The flat bed car 1412 allows the turbine 104 to be rolled or placed next to the tower 102 but under the scaffolding 1406. The elevator 1408 can be lowered and the hoists 1410 connected to the mrbine generator 104. Referring to FIG. 13G, the mrbine generator 104 can be raised by the elevator 1408 to a height above the tower 102. The flatbed car 1412 can be moved away from the tower. Using the crane, the turbine generator 104 can be positioned over the top of the tower 102 as shown in FIG. 13H. One of the persons 1426 installing the turbine 104 may enter the mrbine 104, to help guide the mrbine 104 onto the tower 102 as it is lowered. In other embodiments, the mrbine 104 may be set atop the tower 102 using a separate crane or a helicopter. The mrbine 104 may also be set atop the tower 102 before the tower 102 is pivoted to a vertical orientation and lowered into the hole 1402. One skilled in the art will recognize other methods of installing the mrbine 104 that are included in the present invention. The hoists 1410 and the elevator 1408 may be used to lower the mrbine 104 onto the tower 102. As shown in FIG. 131, the mrbine 104 is set onto the top of the uppermost tower section 108c. Once set in place, the turbine generator 104 may be attached to the tower section 108c using some type of mating hardware. This hardware may include, but is not limited to, bolts and nuts, screws, rivets, adhesive, or welded steel collars. In many embodiments, the mrbine 104 will not have the blades 106a, 106b, and 106c installed before the mrbine 104 is placed on the tower 102. The blades 106a, 106b, and 106c tend to be very long in high power generators and may not fit under or around the scaffolding 1406. Thus, it may be necessary to install the blades 106a, 106b, and 106c onto the turbine 104 after the mrbine 104 is set onto the tower 102. An embodiment of a method 1500 to install the turbine blades 106a, 106b, and 106c is shown in FIG. 14A through FIG. 14D. The first blade 106c may be attached to the hoist 1410 and raised to the mrbine 104 using the elevator 1408. The first blade 106c can be attached or mated to the turbine 104 using methods known in the art. Once mated, the cables 1 12 and 110 can be attached to winches (not shown) placed around the tower 102 and anchored to the ground. The winches can draw in the cables 112 for the first tower section 108c. This process forces the tower section 108c to telescope upward as shown in FIG. 14A. The first section 108c of the tower 102 may be partially extended, fully extended, or nearly fully extended. The cables 110 for the second tower section 108b may then be drawn in by the winches. This process telescopes the second tower section 108b upward, as shown in FIG. 15B. While the second tower section 108b may be fully extended, nearly fully extended, or partially extended, the exemplary embodiment requires the tower section 108b to be extended only far enough to allow the bottom 1502 of the blade 106c to clear the top 1504 of the scaffolding 1406. At this point, the first blade 106c may be rotated, by turning the mrbine 104, the required number of degrees, to install the next blade 106b. For instance, if the mrbine 104 had four blades, the blade would be rotated 90°, and if the turbine 104 had six blades, the mrbine would be rotated 60°. In the exemplary embodiment, the mrbine 104 has three blades a 106a, 106b, and 106c, and therefore, the first blade 106c should be rotated 120°, as shown in FIG. 14B. The blade 106c and the mrbine 104 may be rotated in the clockwise or counterclockwise direction. In preparation for the second blade installation, the tower sections 108b and 108c are lowered again by letting out the cables 112 and 110 from the winches. Referring to FIG. 14C, the second blade 106b is raised and attached to the mrbine 104 similar to the process used for the first blade 106c. The tower sections 108b and 108c are again telescoped upward using the cables 110 and 112 attached to the winches. Once the second blade 106b clears the scaffolding 1406, the mrbine 104 and the two blades 106c and 106b are rotated 120°. The tower sections 108b and 108c are then lowered for installation of the third and final blade 106a. As shown in FIG. 14D, the installation of the third blade 106a is similar. The third blade 106a is raised to the turbine 104 and attached. The tower sections 108b and 108c are telescoped, and the turbine 104 and the blades 106a, 106b, and 106c are rotated 60°. Once the third blade 106c is installed, the tower 100 is ready for the final installation steps. If the tower sections 108a, 108b, and 108c are not already fully extended, the winches are used to fully extend the tower sections 108a, 108b, and 108c. The installation personnel may then use the elevator 1408 and scaffolding 1406 to install the bolts 1202 or the other mating hardware. The mating hardware attaches the tower sections 108a, 108b, and 108c together mechanically. Once the tower sections 108a, 108b, and 108c are attached, the pulleys 902 or other telescoping device may be pinned or fixed in position. This fixation may be done by placing a pin through the pulley 902 and into the arm 1004 holding the pulley 902. The cables 904, used to telescope the tower sections 108a, 108b, and 108c, can then be unhooked from the winches and attached to some footings. These cables 904 can now act as the guy wires 110 and 112 for the tower 100. Thus, the same cables 904 used to telescope the tower 102 now stabilize the tower 100. If the tower 100 ever requires maintenance or disassembly, these guy wires 110 and 112 may be attached again to winches and used to lower the tower 102. An arrangement can also be created where the cables are detached. This would fit in with the embodiment that does not use guy wires. If one needs to bring the tower down, then new wires can be attached. All electrical and other connections may be made, and the tower 100 may be operated. Another embodiment of the tower 100 invention is shown in FIG. 15A and FIG. 15B. Here, the tower 100 has four tower sections 108a, 108b, 108c, and 108d, three sets of pulleys and telescoping hardware, three sets of guy wires, and is installed using a similar process to the one described above. FIG. 15A shows the tower ready to be telescoped into final position. FIG. 15B shows one embodiment of the tower fully extended with the guy wires attached to footings (not shown). This embodiment of the tower may be used for 5MW mrbine generators installed on a tower that is over 500' (156m) in height. One skilled in the art will recognize that by adding additional or larger tower sections, ever increasing heights may be achieved by the present invention. In this example, a first tower section 108a comprising a diameter of about 9m is deposited into a hole in the ground and extends from within the hole upward. The first tower section 108a comprises a diameter greater than the diameter of sections 108b, 108c and 108d and functions to support additional tower sections. A second section 108b having a diameter of about 7.5m sits partially within the first section 108a and telescopes upward. A third section 108c having a diameter of about 6m sits within the second section 108b and telescopes upward. A fourth section 108d having a diameter of about 4.5m sits within the third section 108c and telescopes upward. In this embodiment, the total height of the fully telescoped tower 102 is about 156m. The diameter of the blades of the wind mrbine is about 120m. These values are exemplary only and not meant to be limiting. In this embodiment, a wind mrbine 104 is supported by the fully telescoped tower 102. A tower 102 as illustrated in FIG. 15B may support a wind mrbine 104 comprising blades spanning at least 120m. In an alternate embodiment, the tower may be adapted to comprise smaller diameter tower section measurements to support smaller wind turbine engines. Accordingly, in a further embodiment, the tower may support a wind mrbine having a significantly smaller wind mrbine comprising a significantly smaller blade diameter.

Claims

We Claim:

1. A composite tower used to support a wind mrbine, comprising: a. two or more composite tower sections, comprising i. two or more composite panels; and ii. two or more connecting devices to connect the panels together to form an enclosed polygonal structure; b. wherein, the composite tower sections are telescoped to a full height of the tower.

2. A composite tower used to support a wind mrbine, comprising: a. a first section deposited into a hole in the ground; b. a second section comprising a diameter less than the first section that enables the second section to fit within the first section; c. a third section comprising a diameter less than the first and second sections said diameter enabling the third section to fit within the first and second sections; d. a fourth section comprising a diameter less than the first, second and third sections, said diameter enabling the fourth section to fit within the first, second and third sections; wherein, each of the first, second, third and fourth sections further comprise four or more panels comprised of a composite material connected by four or more connecting devices to form a polygonal shape; and wherein the composite tower sections are telescoped to a full height of the tower.

3. The composite tower sections as claimed in claim 1 comprising sections of equal diameter.

4. The composite tower as claimed in claim 1 comprising two or more composite sections that telescope upward from a first base section, wherein the two or more sections incrementally decrease in diameter proportionate with each increase in distance from the base section to enable nesting of the composite sections.

5. The composite tower sections as claimed in claim 1, wherein four or more panels are connected by four or more connecting devices to form a tubular structure.

6. The composite panels as claimed in claim 1 and 2, wherein said composite panels further comprise one or more of steel, aluminum, metals, wood or laminated wood.

7. The composite panels as claimed in claim 1 and 2, wherein said composite panels comprise a sandwich structure further comprising two or more skins surrounding a foam core having a plurality of reinforcing rovings stitched through the sandwich structure.

8. The composite tower as claimed in claim 1 and 2, wherein said composite tower is further supported by one or more guy wires.

9. The composite tower as claimed in claim 1 and 2, wherein said composite tower is not supported by guy wires.

10. The composite tower as claimed in claim 1 and 2 comprising: a. a composite tower portion; and b. a wind mrbine portion.

11. The connecting device as claimed in claim 1 and 2 comprising: a. an inner wall; b. an outer wall; and c. one or more brace pieces connecting the inner and the outer wall; wherein the inner and outer walls form one or more cavities to accept one or more panels.

12. The connecting device as claimed in claim 11 comprising a comer configured to form the final shape of the structure.

13. An octagonal composite tower used to support a wind turbine, comprising: a. two or more composite tower sections, comprising i. eight composite panels; and ii. eight or more connecting devices to connect the panels together and to form an enclosed octagonal structure; b. wherein, the composite tower sections are telescoped to a full height of the tower.

14. The composite tower as claimed in claim 13 further comprising tower sections of equal diameter.

15. The composite tower as claimed in claim 13 comprising two or more composite sections that telescope upward from a first base section, wherein the two or more sections incrementally decrease in diameter proportionate with each increase in distance from the base section to enable nesting of the composite sections.

16. The composite tower sections as claimed in claim 13, wherein eight panels are connected by eight or more connecting devices to form a tubular structure.

17. The composite panels as claimed in claim 13, wherein said composite panels further comprise one or more of steel, aluminum, metals, wood or laminated wood.

18. The composite panels as claimed in claim 13, comprising: c. two or more panel skins; d. a foam core; and e. a plurality of reinforcing rovings; wherein, the panel skins form a sandwich stmcmre surrounding a foam core further reinforced by a plurality of reinforcing rovings stitched through the sandwich stmcmre.

19. The composite tower as claimed in claim 13, wherein said composite tower is further supported by one or more guy wires.

20. The composite tower as claimed in claim 13, wherein said composite tower is not supported by guy wires.

21. The composite tower as claimed in claim 13 comprising: a. a composite tower portion; and b. a wind mrbine portion.

22. The connecting device as claimed in claim 12 comprising: a. an inner wall; b. an outer wall; and c. one or more brace pieces connecting the inner and the outer wall; wherein the inner and outer walls form one or more cavities to accept one or more panels.

23. The connecting device as claimed in claim 22 wherein the inner and outer walls comprise a corner configuration depending on the shape of the final tower.

24. A method of assembling a telescoping composite tower with an outer section and at least one nested section, comprising: a. presenting the tower in a horizontal position; b. elevating the tower to a vertical position; c. lowering the tower to a mounting assembly; and d. extending the nested section of the tower.

25. A method according to claim 24, wherein presenting the tower includes: a. building either the outer section or one or more nested sections of the tower on- site; and b. nesting the outer section of the tower with one or more of the nested sections.

26. A method according to claim 24, wherein elevating the tower includes: a. attaching a set of cabling from an elevator to an upper end of the tower; b. pulling the upper end of the tower upwardly until the tower is in the vertical position.

27. A method according to claim 26, wherein pulling the upper end of the tower includes one of reeling in the cable to a pre-positioned elevator, changing the position of the elevator that is attached to the tower with fixed cables, or reeling in the cables while changing the position of the elevator.

28. A method according to claim 24, wherein lowering the tower includes placing the lower end of the tower into a pre-dug hole; and, anchoring the tower to a mounting bracket inside the hole.

29. A method according to claim 24, wherein lowering the tower includes anchoring the tower to a mounting bracket anchored to the ground.

30. A method according to claim 24, wherein extending the nested section includes raising the nested section such that the upper end of the nested section is above the upper end of the outer section; and, securing the nested section in-place once the nested section is raised.

31. A method according to claim 24, further comprising placing a wind mrbine on the upper end of the nested section before extending the nested section.

32. A method according to claim 31 , further comprising a. attaching a first mrbine blade to the wind mrbine; b. extending the nested section of the tower; c. rotating the wind mrbine until the first mrbine blade is positioned in a non- vertical position; d. lowering the nested section of the tower; and, e. attaching a second mrbine blade.

33. A method of assembling a telescoping composite tower, comprising: a. pultruding two or more first elongated composite panels on-site; b. attaching first panels together to form a first base composite tower section; c. pultruding two or more second elongated composite panels on-site; d. attaching second panels together to form a second composite tower section, wherein the second composite tower section has a circumference smaller than the first base composite tower section; and e. nesting the second composite tower section within the first base composite tower section.

34. The method as claimed in claim 33, further comprising: a. Pultruding two or more elongated panels on site; b. Attaching the panels together to form a third composite tower section; wherein, the third composite tower section comprises a circumference smaller than the second and first base composite tower sections.

35. The method as claimed in claim 33, further comprising a pulley system comprising: a. a cable attached to the bottom of a telescoping section, wherein said cable is fed around a pulley connected to a winch type element at the other end of the telescoping section; b. a collar around the edge of a lower tower section; c. a bracket attached to the collar to hold the pulley; and d. a set of guide wheels to guide the telescoping section; wherein, the pulley system to raises or lowers the telescoping section between a fully extended position and a position nested within a lower tower section.