Adapter for wind turbine retrofit and related methods

Abstract

The present disclosure relates to a wind turbine. The wind turbine includes a tower, a head having a generator, and a rotor mechanically coupled to the generator. The rotor includes a hub and a plurality of rotor blades coupled to the hub and extending outwardly from the hub. The wind turbine also includes an adapter coupled between the tower and the head, wherein the adapter defines an inner cavity. In addition, the wind turbine includes one or more electrical components electrically coupled to the generator, wherein the one or more electrical components are positioned within the inner cavity defined by the adapter.

Description

Technical Field

[0001] The present disclosure relates generally to wind turbines. More particularly, the present disclosure relates to adapters and related methods for facilitating retrofitting of wind turbines. Background Art

[0002] Wind energy is considered to be one of the cleanest and most environmentally friendly energy sources currently available, and wind turbines are receiving increasing attention in this regard. Modern wind turbines typically include a tower and a machine head mounted on the tower. The machine head may include a generator and one or more rotor blades. The rotor blades convert the kinetic energy of the wind into mechanical energy using the known airfoil principle. The drivetrain transfers the mechanical energy from the rotor blades to the generator, which in turn converts the mechanical energy into electrical power. Thereafter, electrical components of the wind turbine, such as power converters and transformers, transmit the electrical power from the generator to the utility grid.

[0003] Wind turbine technology is rapidly evolving. In this regard, it may be desirable to refurbish a used wind turbine when the technology therein becomes obsolete and / or the used wind turbine approaches the end of its design life. Generally, refurbishment may provide various advantages, such as implementing newer, more efficient technology and components. In many cases, during refurbishment, a used head may be removed from a used tower and replaced with a new, more technologically advanced head.

[0004] During such renovation, the power converters and / or transformers may also be upgraded. Typically, these electrical components are quite large and therefore need to be installed in the lower portion of the tower. Removing and replacing the used power converters and / or transformers from the lower portion of the tower is difficult, time-consuming and expensive. Therefore, the used power converters and transformers are electrically disconnected from the generator and the grid and remain in the lower portion of the tower during such renovation. In this regard, new power converters and transformers are positioned in a building or other structure constructed near the wind turbine tower and are electrically connected to the generator and the grid. However, the construction of the structure for accommodating the new transformer and power converters increases the overall cost of the renovation.

[0005] Therefore, improved apparatus and methods for retrofitting wind turbines would be welcome in the art. Summary of the invention

[0006] Aspects and advantages of the technology will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the technology.

[0007] In one aspect, the present disclosure is directed to a wind turbine. The wind turbine includes a tower, a head having a generator, and a rotor mechanically coupled to the generator. The rotor includes a hub and at least one rotor blade coupled to the hub and extending outwardly from the hub. The wind turbine also includes an adapter coupled between the tower and the head, wherein the adapter defines an inner cavity. In addition, the wind turbine includes one or more electrical components electrically coupled to the generator, wherein the one or more electrical components are positioned within the inner cavity defined by the adapter.

[0008] On the other hand, the present invention is directed to a wind turbine, comprising a tower having a top flange, a head having a generator and a bedplate, and a rotor mechanically coupled to the generator. The rotor comprises a hub and at least one rotor blade coupled to the hub and extending outwardly from the hub. The wind turbine also comprises a yaw bearing having a first race and a second race. The wind turbine also comprises an adapter coupled between the yaw bearing and one of the tower or the head. The adapter defines an inner cavity. The adapter also comprises a top flange and a bottom flange, wherein the top flange of the adapter is coupled to one of the bedplate or the yaw bearing of the head, and the bottom flange is coupled to one of the top flange or the yaw bearing of the tower. In addition, the wind turbine comprises one or more electrical components electrically coupled to the generator, wherein the one or more electrical components are positioned within the inner cavity defined by the adapter.

[0009] In another aspect, the present disclosure is directed to a method for refurbishing a wind turbine. The method includes removing a used head from a used tower of the wind turbine. The method also includes coupling an adapter to a new head, wherein the adapter defines an interior cavity and one or more electrical components positioned within the interior cavity. Additionally, the method includes coupling the adapter to the used tower and electrically coupling the one or more electrical components positioned within the interior cavity of the adapter to a power grid.

[0010] These and other features, aspects and advantages of the present technology will be better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present technology and, together with the description, serve to explain the principles of the present technology.

[0011] Embodiment 1. A wind turbine comprising:

[0012] Tower;

[0013] a nose including a generator;

[0014] a rotor mechanically coupled to the generator, the rotor comprising a hub and at least one rotor blade coupled to and extending outwardly from the hub;

[0015] an adapter coupled between the tower and the nose, the adapter defining an interior cavity; and

[0016] One or more electrical components are electrically coupled to the generator, the one or more electrical components being positioned within the interior cavity defined by the adapter.

[0017] Embodiment 2. The wind turbine of Embodiment 1, wherein the one or more electrical components include a transformer.

[0018] Embodiment 3. The wind turbine of Embodiment 2, wherein the transformer comprises a plurality of single-phase transformers.

[0019] Embodiment 4. A wind turbine according to Embodiment 2, wherein the inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, and the transformer includes a first single-phase transformer positioned in the first horizontal plane of the inner cavity, a second single-phase transformer positioned in the second horizontal plane of the inner cavity, and a third single-phase transformer positioned in the third horizontal plane of the inner cavity.

[0020] Embodiment 5. The wind turbine of Embodiment 1, wherein the one or more electrical components include a power converter.

[0021] Embodiment 6. A wind turbine according to Embodiment 5, wherein the inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, and the power converter includes a first power converter portion positioned within the first horizontal plane of the inner cavity, a second power converter portion positioned within the second horizontal plane of the inner cavity, and a third power converter portion positioned within the third horizontal plane of the inner cavity.

[0022] Embodiment 7 The wind turbine of Embodiment 1, wherein the one or more electrical components include a power converter and a transformer, a portion of the power converter being vertically aligned with a portion of the transformer.

[0023] Embodiment 8. A wind turbine comprising:

[0024] a tower including a top flange;

[0025] a nose, which includes a generator and a base plate;

[0026] a rotor mechanically coupled to the generator, the rotor comprising a hub and at least one rotor blade coupled to and extending outwardly from the hub;

[0027] a yaw bearing comprising a first raceway and a second raceway;

[0028] an adapter coupled between the yaw bearing and one of the tower or the nose, the adapter defining an inner cavity, the adapter further comprising a top flange and a bottom flange, the top flange of the adapter coupled to a bottom plate of the nose or one of the yaw bearings, the bottom flange coupled to a top flange of the tower or one of the yaw bearings; and

[0029] One or more electrical components are electrically coupled to the generator, the one or more electrical components being positioned within the interior cavity defined by the adapter.

[0030] Embodiment 9. The wind turbine of Embodiment 8, wherein the one or more electrical components include a transformer.

[0031] Embodiment 10. The wind turbine of Embodiment 9, wherein the transformer comprises a plurality of single-phase transformers.

[0032] Embodiment 11. A wind turbine according to Embodiment 9, wherein the inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, and the transformer includes a first single-phase transformer positioned in the first horizontal plane of the inner cavity, a second single-phase transformer positioned in the second horizontal plane of the inner cavity, and a third single-phase transformer positioned in the third horizontal plane of the inner cavity.

[0033] Embodiment 12. The wind turbine of Embodiment 8, wherein the one or more electrical components include a power converter.

[0034] Embodiment 13. A wind turbine according to Embodiment 12, wherein the inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, and the power converter includes a first power converter portion positioned within the first horizontal plane of the inner cavity, a second power converter portion positioned within the second horizontal plane of the inner cavity, and a third power converter portion positioned within the third horizontal plane of the inner cavity.

[0035] Embodiment 14 The wind turbine of Embodiment 8, wherein the one or more electrical components include a power converter and a transformer, a portion of the power converter being vertically aligned with a portion of the transformer.

[0036] Embodiment 15. A method for refurbishing a wind turbine, the method comprising:

[0037] removing a used nose from a used tower of the wind turbine;

[0038] coupling an adapter to a new handpiece, the adapter defining an interior cavity and one or more electrical components positioned within the interior cavity;

[0039] coupling the adapter to the used tower; and

[0040] The one or more electrical components positioned within the interior cavity of the adapter are electrically coupled to an electrical grid.

[0041] Embodiment 16. The method according to embodiment 15 further comprises:

[0042] removing a used yaw bearing from the wind turbine; and

[0043] A new yaw bearing is coupled to the adapter and either a new nose or a used tower.

[0044] Embodiment 17. The method of Embodiment 15, wherein the one or more electrical components include a transformer and a power converter.

[0045] Embodiment 18. The method according to Embodiment 17, wherein the transformer includes a plurality of single-phase transformers.

[0046] Embodiment 19. The method of Embodiment 17, wherein a portion of the power converter is vertically aligned with a portion of the transformer.

[0047] Embodiment 20. A method according to Embodiment 17, wherein the inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, the transformer includes a first single-phase transformer positioned in the first horizontal plane of the inner cavity, a second single-phase transformer positioned in the second horizontal plane of the inner cavity, and a third single-phase transformer positioned in the third horizontal plane of the inner cavity, and the power converter includes a first power converter part positioned in the first horizontal plane of the inner cavity, a second power converter part positioned in the second horizontal plane of the inner cavity, and a third power converter part positioned in the third horizontal plane of the inner cavity. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] A complete and enabling disclosure of the present technology, including the best mode thereof, is set forth in this specification, which refers to the accompanying drawings, in which:

[0049] Figure 1 is a perspective view of one embodiment of a used wind turbine according to aspects of the present disclosure;

[0050] Figure 2 is a perspective interior view of one embodiment of a spent handpiece according to aspects of the present disclosure;

[0051] Figure 3 is a cross-sectional view of one embodiment of a used wind turbine according to aspects of the present disclosure, showing components for coupling a used nose of the used wind turbine to a used tower of the used wind turbine;

[0052] Figure 4 is a schematic diagram of one embodiment of a used electrical system of a used wind turbine according to aspects of the present disclosure;

[0053] Figure 5 is a cross-sectional view of one embodiment of a refurbished wind turbine according to aspects of the present disclosure showing an adapter coupled between a used tower and a yaw bearing;

[0054] Figure 6 is a cross-sectional view of one embodiment of a refurbished wind turbine according to aspects of the present disclosure showing an adapter coupled between a new nose and a yaw bearing;

[0055] Figure 7 is a schematic diagram of one embodiment of a new electrical system installed within an adapter of a retrofitted wind turbine according to aspects of the present disclosure;

[0056] Figure 8 According to aspects of the present disclosure Figure 7 A schematic diagram of one embodiment of a new transformer for a new electrical system shown in;

[0057] Fig. 9 is a cross-sectional view of one embodiment of an adapter for retrofitting a used wind turbine according to aspects of the present disclosure, showing one or more new electrical components positioned within the adapter; and

[0058] Fig.10 is a flow chart illustrating one embodiment of a method for retrofitting a wind turbine according to aspects of the present disclosure.

[0059] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the technology. DETAILED DESCRIPTION

[0060] Reference will now be made in detail to embodiments of the present technology, one or more examples of which are shown in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. The same or similar names in the drawings and description have been used to refer to the same or similar parts of the technology. As used herein, the terms "first", "second", and "third" are used interchangeably to distinguish one component from another, and are not intended to indicate the location or importance of the various components.

[0061] Each example is provided by way of explanation rather than limitation of the technique. In fact, it will be apparent to those skilled in the art that modifications and variations may be made in the present technology without departing from its scope or spirit. For example, a feature shown or described as part of one embodiment may be used on another embodiment to produce yet another embodiment. Therefore, it is intended that the present disclosure covers such modifications and variations within the scope of the appended claims and their equivalents.

[0062] The wind turbines disclosed herein and various components of these wind turbines are described below as "used", "new" or "refurbished". In general, a used wind turbine is any wind turbine before refurbishment, regardless of whether such wind turbine has actually been used to generate electricity. A used component (e.g., a head, a power converter, a transformer, etc.) is any component that is replaced, upgraded and / or changed during refurbishment. Thus, a used component can be removed from a used wind turbine and a corresponding new component replaced in its place (e.g., the head). Alternatively, a used component can be operably separated from a used wind turbine, but physically remains present within the used wind turbine (e.g., various electrical components). In this case, the corresponding new component is installed at another location within the wind turbine. A new component is any component installed within a used wind turbine as part of a refurbishment, regardless of whether the component is actually unused. Therefore, a used component removed from a first wind turbine and installed in a second wind turbine as part of a refurbishment operation is still a new component in the context of the second wind turbine. In addition, a new part may generally be technically superior to a corresponding used part. However, in some cases, a new part may be the same as a new part or technically inferior (e.g., reduced cost, weight, complexity, etc.) to a new part. In this regard, a used part is any part that existed in a wind turbine prior to refurbishment, and a new part is any part that did not exist prior to refurbishment but exists in a wind turbine after refurbishment. In addition, a refurbished wind turbine refers to any wind turbine after a refurbishment operation is completed.

[0063] Reference is now made to the drawings. Figure 1 1 is a perspective view of one embodiment of a used wind turbine 10. As shown, used wind turbine 10 generally includes a used tower 12 extending outwardly from a support surface 14 in a vertical direction 15 and a used head 16 mounted on used tower 12. Used head 16 may include a rotor 18 having a rotor hub 20 and at least one rotor blade 22 coupled to and extending outwardly from hub 20. For example, in Figure 1 In the embodiment shown in FIG. 1 , the rotor 18 includes three rotor blades 22. However, in alternative embodiments, the rotor 18 may include more or less than three rotor blades 22. Each rotor blade 22 may be spaced around the hub 20 to facilitate the rotation of the rotor 18 to convert kinetic energy from the wind into usable rotational mechanical energy. The used head 16 may also include an electrical generator 24 that is configured to generate electrical power from the rotational energy of the rotor 18.

[0064] Reference now Figure 2 , the used head 16 may include a drivetrain 26 that couples the rotor 18 to the generator 24. As shown, the drivetrain 26 may include a rotor shaft 28 that couples the rotor hub 20 to a gearbox 30. The gearbox 30 may be supported by and coupled to a base plate 32 of the used head 16. The drivetrain 26 also includes a generator shaft 34 that couples the gearbox 30 to the generator 24. In this regard, the rotation of the rotor 18 drives the generator 24. More specifically, the rotor shaft 28 may provide a low-speed, high-torque input to the gearbox 30 in response to the rotation of the rotor blades 22 and the hub 20. The gearbox 30 may then convert the low-speed, high-torque input into a high-speed, low-torque output to drive the generator shaft 34 and thereby drive the generator 24.

[0065] The used wind turbine 10 may include a used yaw drive 36 for adjusting the yaw angle of the used nose 16 (i.e., the angular orientation of the used nose 16 relative to the used tower 12). In particular, the used nose 16 may be rotatably coupled to the tower 12 via a used yaw bearing 38 ( Figure 3 Thus, a used yaw drive 36 may include one or more used yaw adjustment mechanisms 40 that are oriented about a yaw axis 42 ( Figure 1 ) Rotate the used nose 16 relative to the used tower 12 to adjust the yaw angle of the used nose 16. Figure 2While two used yaw adjustment mechanisms 40 are shown, the used wind turbine 10 may include any suitable number of used yaw adjustment mechanisms 40, such as a single used yaw adjustment mechanism 40 or more than two used yaw adjustment mechanisms 40. For example, some embodiments of the used yaw drive 36 may include four used yaw adjustment mechanisms 40.

[0066] Figure 2 1 shows an exemplary embodiment of a used yaw adjustment mechanism 40. More specifically, each used yaw adjustment mechanism 40 may include an electric motor 44 mounted to and / or passing through the base plate 32. Each electric motor 44 may include a pinion gear 46 coupled thereto that engages a used yaw bearing 38 ( Figure 3 ) fixed raceway. During operation of the used yaw adjustment mechanism 40, the motor 44 rotates the corresponding pinion 46, which rotates the used yaw bearing 38. The rotation of the pinion 46 relative to the used yaw bearing 38 causes the used nose 16 to rotate about the yaw axis 42 ( Figure 1 In alternative embodiments, the used yaw adjustment mechanism 40 may include any suitable type of actuator and / or any suitable structure or mechanism for transmitting motion between the used tower 12 and the used nose 16 .

[0067] The used yaw drive 36 may also include one or more brake assemblies 50 for controlling the rotation of the used nose 16 about the yaw axis 42 ( Figure 1 ). For example, as shown in the illustrated embodiment, the brake assemblies 50 can be mounted to and / or pass through the base plate 32. Thus, each brake assembly 50 can frictionally engage a fixed raceway of a used yaw bearing 38 or another suitable friction surface of a used wind turbine 10 to stop, slow, and / or otherwise control rotation of the used nose 16 about the yaw axis 42. The used wind turbine 10 can include any suitable number of brake assemblies 50. For example, in one exemplary embodiment, the used wind turbine 10 can include between twelve and twenty brake assemblies 50. However, in other embodiments, the used wind turbine 10 can include less than twelve brake assemblies 50 or more than twenty brake assemblies 50.

[0068] Additionally, the spent airframe 16 may include a nacelle 52 that surrounds and encloses various components of the spent airframe 16 (eg, the generator 24 , the drivetrain 26 , etc.) Generally, the floor 32 and nacelle 52 may form one or more exterior surfaces of the spent airframe 16 .

[0069] Figure 3Various aspects of the used yaw drive 36 are shown in greater detail. As mentioned above, the used yaw drive 36 may include a used yaw bearing 38 coupled between the used tower 12 and the used nose 16. More specifically, the used yaw bearing 38 may include a first or inner race 54, a second or outer race 56 positioned about the inner race 54, and a plurality of rolling elements 58 (e.g., rollers, balls, cones, needles, etc.) positioned between the inner race 54 and the outer race 56. As shown, in one embodiment, the inner race 54 may be coupled to a top flange 60 of the used tower 12 via suitable fasteners 62. Similarly, the outer race 56 may be coupled to a bottom plate 32 of the used nose 16 via suitable fasteners 64. However, in alternative embodiments, the inner race 54 may be coupled to the bottom plate 32 of the used nose 16, and the outer race 56 may be coupled to a top flange 60 of the used tower 12. Furthermore, in other embodiments, used yaw bearing 38 may have any other suitable configuration.

[0070] Reference now Figure 4 , the used wind turbine 10 includes a used electrical system 100 that supplies electrical power generated by the generator 24 to a utility grid 102. As shown, the used electrical system 100 may include various electrical components (e.g., power converters, transformers, etc.) positioned within the used tower 12. For example, in one embodiment, the various electrical components are positioned within the lower portion 66 of the used tower 12. Figure 1 , the lower portion 66 of the used tower 12 corresponds to the portion of the used tower 12 that is located proximate to the support surface 14. For example, in one embodiment, the lower portion 66 of the used tower 12 may be the bottom thirty percent of the used tower 12. However, in alternative embodiments, the lower portion 66 of the used tower 12 may be less than the bottom thirty percent of the used tower 12, such as the bottom twenty percent of the used tower 12, or greater than the bottom thirty percent of the used tower 12, such as the bottom forty percent of the used tower 12. In other embodiments, the various components of the electrical system 100 may be located at any other suitable location within the used wind turbine 10 or remote from the used wind turbine 10.

[0071] As shown, the used electrical system 100 can be configured to provide AC power (alternating current power) to the utility grid 102 via a dual path. More specifically, in the illustrated embodiment, the generator 24 corresponds to a doubly-fedinduction generator, which is configured to generate, for example, three-phase AC power. In this regard, the stator 68 of the generator 24 can be coupled to the used transformer 104 via a stator bus 106. The rotor 70 of the generator 24 can be coupled to the used power converter 108 via a rotor bus 110. The used power converter 108 can in turn be coupled to the used transformer 104 via a grid-side bus 112. The used transformer 104 can in turn be coupled to the utility grid 102. However, in alternative embodiments, the generator 24 can be coupled to the grid 102 in any other suitable manner so that the power generated by the generator 24 is supplied to the grid 102.

[0072] exist Figure 4 In the embodiment shown in , the used transformer 104 corresponds to a three-phase three-winding transformer. Thus, the used transformer 104 includes a high voltage (e.g., greater than 12 kVAC) primary winding 114 coupled to the utility grid 102, a medium voltage (e.g., 6 kVAC) secondary winding 116 coupled to the stator bus 106, and a low voltage (e.g., 690 VAC) auxiliary winding 118 coupled to the grid-side bus 112. Alternatively, the used transformer 104 may have only two windings (e.g., primary winding 114 and secondary winding 116), four windings (e.g., primary winding 114, secondary winding 116, auxiliary winding 118, and additional windings), or any other suitable number of windings.

[0073] like Figure 4As shown in , the used power converter 108 generally includes a rotor-side converter 120 coupled to the rotor-side bus 110 and a grid-side converter 122 coupled to the grid-side bus 112. The used power converter 108 also includes a DC link (direct current link) 124 coupled between the rotor-side and grid-side converters 120, 122. In one embodiment, the rotor-side converter 120 corresponds to an AC-DC converter (alternating current-to-direct current converter) configured to convert AC power from the rotor 70 of the generator 24 into DC power for delivery to the DC link 124. In addition, the grid-side converter 122 corresponds to a DC-AC converter configured to convert DC power from the DC link 124 into AC power suitable for delivery to the utility grid 102. The rotor side converter 120 and the grid side converter 122 may include various switching devices 126, such as insulated gate bipolar transistors, insulated gate commutated thyristors, metal oxide semiconductor field effect transistors, and / or silicon controlled rectifiers. In general, the switching devices 126 may be modulated to adjust or otherwise modify various parameters of the power generated by the generator 24 (e.g., changing the frequency, converting AC to DC, converting DC to AC, etc.) so that the power is suitable for consumption in the grid 102. However, in alternative embodiments, the used power converter 108 may have any other suitable topology.

[0074] Additionally, the used electrical system 100 may include various circuit breakers, switches, fuses, contactors, and / or the like to selectively electrically couple and / or disconnect various components from the generator 24 and / or the grid 102. For example, in Figure 4 In the embodiment shown in FIG. 1 , the used electrical system 100 may include a switch 128, a stator bus breaker 130, a grid-side bus breaker 132, and a grid breaker 134. However, in alternative embodiments, the used electrical system 100 may include other breakers, switches, fuses, and / or contactors instead of or in addition to the components 128, 130, 132, 134.

[0075] Figure 5 and 6 An embodiment of a retrofitted wind turbine 200 according to aspects of the present disclosure is shown. Specifically, Figure 5An embodiment of a refurbished wind turbine 200 is shown in which an adapter 202 is located between a used tower 12 and a new yaw bearing 204 of a new yaw drive 210. In contrast, Figure 6 Another embodiment of a retrofitted wind turbine 200 is shown, wherein an adapter 202 is located between a new yaw bearing 204 and a new nose 206 .

[0076] Typically, a refurbished wind turbine 200 is formed by upgrading, replacing, or otherwise modifying one or more components of a used wind turbine 10. For example, Figure 5 and 6 In the embodiment shown in FIG. 1 , the used head 16 is removed from the used tower 12 of the used wind turbine 10 and the new head 206 is coupled to the used tower 12 via the adapter 202 to form a refurbished wind turbine 200. In addition, as described below with reference to Figure 7 As will be described, retrofitted wind turbine 200 also includes a new electrical system 300 having one or more components positioned within adapter 202 .

[0077] As mentioned above, in Figure 5 In the embodiment shown in , the refurbished wind turbine 200 includes an adapter 202 coupled between the used tower 12 and the new yaw bearing 204 (e.g., along the vertical direction 15). More specifically, the adapter 202 includes a bottom flange 212 that is coupled to the top flange 60 of the used tower 12, for example, via suitable fasteners 214. The adapter 202 also includes a top flange 216 that is coupled to the new yaw bearing 204, for example, via suitable fasteners 218. As shown, the new yaw bearing 204 can include an inner race 220, an outer race 222 positioned around the inner race 220, and a plurality of rolling elements 224 (e.g., rollers, balls, cones, needles, etc.) positioned between the inner race 220 and the outer race 222. For example, in one embodiment, the inner race 220 can be coupled to the top flange 216 of the adapter 202 via fasteners 218. Similarly, the outer raceway 222 can be coupled to the base plate 226 of the new nose 206 by suitable fasteners 228. However, in alternative embodiments, the inner raceway 220 can be coupled to the base plate 226 of the new nose 206, and the outer raceway 222 can be coupled to the top flange 216 of the adapter 202. Moreover, the new yaw bearing 204 can have any other suitable configuration. In addition, the new yaw drive 210 can include a new yaw adjustment mechanism 230. Moreover, in another embodiment, the top flange 214 of the adapter 202 can be coupled to the used yaw bearing 38 ( Figure 3 ), for example when a used yaw bearing 38 and / or a used yaw drive 36 ( Figure 3 ) is reused.

[0078] like Figure 6 As shown in FIG. 1 , in one embodiment, the adapter 202 of the refurbished wind turbine 200 is coupled between the new nose 206 and the new yaw bearing 204. More specifically, the top flange 216 of the adapter 202 may be coupled to the bottom plate 226 of the new nose 206, for example, via suitable fasteners 234. Additionally, the bottom flange 212 of the adapter 202 may be coupled to the new yaw bearing 204, for example, via suitable fasteners 236. For example, as shown, the outer race 222 of the new yaw bearing 204 may be coupled to the bottom flange 212 of the adapter 202 via fasteners 236. Similarly, the inner race 220 may be coupled to the top flange 60 of the used tower 12 via suitable fasteners 238. However, in alternative embodiments, the outer race 222 may be coupled to the top flange 60 of the used tower 12, and the inner race 220 may be coupled to the bottom flange 212 of the adapter 202. Furthermore, in another embodiment, the bottom flange 212 of the adapter 202 may be coupled to a used yaw bearing 38 ( Figure 3 ), for example when a used yaw bearing 38 and / or a used yaw drive 36 ( Figure 3 ) is reused.

[0079] Reference now Figure 7 , the new wind turbine 10 includes a new electrical system 300 that supplies electrical power generated by the generator 240 positioned within the new head 206 to the utility grid 102. As shown, the new electrical system 300 may include one or more new electrical components (e.g., power converters, transformers, etc.) positioned within the adapter 202. In this regard, and as will be described in more detail below, the various electrical components may be located within the adapter 202 at different levels or locations along the vertical direction 15. In other embodiments, some of the components of the new electrical system 300 may be located within the adapter 202, while other components of the new electrical system 300 may be located at one or more other suitable locations within the retrofitted wind turbine 200 or remote from the retrofitted wind turbine 200.

[0080] As shown, the new electrical system 300 can be configured to provide AC power to the utility grid 102 via a dual path. More specifically, in the illustrated embodiment, the generator 240 corresponds to a doubly fed induction generator, which is configured to generate, for example, three-phase AC power. In this regard, the stator 242 of the generator 240 can be coupled to the new transformer 304 via a stator bus 306. The rotor 244 of the generator 240 can be coupled to the new power converter 308 via a rotor bus 310. The new power converter 308 can in turn be coupled to the new transformer 304 via a grid-side bus 312. The new transformer 304 can in turn be coupled to the utility grid 102. However, in alternative embodiments, the generator 240 can be coupled to the grid 102 in any other suitable manner so that the power generated by the generator 240 is supplied to the grid 102.

[0081] exist Figure 8 In the embodiment shown in , the new transformer 304 corresponds to three different single-phase transformers 314, 316, 318, which are wired or otherwise electrically coupled together to form a single three-phase transformer. More specifically, the new transformer 304 may include a first single-phase transformer 314, and a second single-phase transformer 316 electrically coupled to the first single-phase transformer 314, and a third single-phase transformer 316 electrically coupled to the first single-phase transformer 314 and the second single-phase transformer 316. As will be described below, the three single-phase transformers 314, 316, 318 electrically coupled together may be narrower than a single three-phase transformer (e.g., the used transformer 104). However, in alternative embodiments, the new transformer 304 may have any other suitable configuration, such as a single three-phase transformer.

[0082] Reference Figure 7, the new power converter 108 generally includes a rotor side converter 320 coupled to the rotor side bus 310 and a grid side converter 322 coupled to the grid side bus 312. The new power converter 308 also includes a DC link 324 coupled between the rotor side converter 320 and the grid side converter 322. In one embodiment, the rotor side converter 320 corresponds to an AC-DC converter configured to convert AC power from the rotor 244 of the generator 240 into DC power for delivery to the DC link 324. In addition, the grid side converter 322 corresponds to a DC-AC converter configured to convert DC power from the DC link 324 into AC power suitable for delivery to the utility grid 102. The rotor side converter 320 and the grid side converter 322 may include various switching devices 326, such as insulated gate bipolar transistors, insulated gate commutated thyristors, metal oxide semiconductor field effect transistors, and / or silicon controlled rectifiers. Generally, switchgear 326 may be modulated to regulate or otherwise modify various parameters of the power generated by generator 240 (e.g., changing frequency, converting AC to DC, converting DC to AC, etc.) so that the power is suitable for consumption in grid 102. However, in alternative embodiments, new power converter 308 may have any other suitable topology.

[0083] In addition, the new electrical system 300 may include various circuit breakers, switches, fuses, contactors, and / or the like to selectively electrically couple and / or disconnect various components from the generator 240 and / or the grid 102. For example, in Figure 7 In the embodiment shown in FIG. 3 , the new electrical system 300 may include a switch 328, a stator bus breaker 330, a grid-side bus breaker 332, and a grid breaker 334. However, in alternative embodiments, the new electrical system 300 may include other breakers, switches, fuses, and / or contactors instead of or in addition to the components 328, 330, 332, 334.

[0084] As mentioned above, one or more of the electrical components of the new electrical system 300 are positioned within the adapter 202 of the retrofitted wind turbine 200. For example, in Fig. 9In the embodiment shown in FIG. 1 , the new power converter 308 and the new transformer 304 are positioned within the adapter 202. More specifically, the adapter 202 includes a sidewall 246 extending between the bottom flange 212 and the top flange 214 in the vertical direction 15. In this regard, the sidewall 246 of the adapter 202 defines an interior cavity 248 within the adapter 202. As shown, the new power converter 308 and the new transformer 304 are positioned within the interior cavity 248. For example, in one embodiment, the new power converter 308 and / or the new transformer 304 can be coupled to the sidewall 246. In another embodiment, the new power converter 308 and the new transformer 304 can be positioned on a platform (not shown) within the interior cavity 248 of the adapter 202. In other embodiments, in addition to or in place of the new power converter 308 and the new transformer 304, other electrical components of the new electrical system 300 (e.g., various buses, switches, circuit breakers, etc.) can be positioned within the adapter 202.

[0085] In addition, the inner cavity 248 of the adapter 202 can define a plurality of levels, wherein each level occupies a different portion of the inner cavity 248 along the vertical direction 15. For example, as shown, the inner cavity 248 can include a first level 250 extending between the bottom flange 212 of the adapter and a dashed line 252. The inner cavity 248 also includes a second level 254 positioned above the first level 250 along the vertical direction 15, wherein the second level 254 extends between the dashed line 254 and the dashed line 256. In addition, the inner cavity 248 also includes a third level 258 positioned above the second level 254 along the vertical direction 15, wherein the third level 258 extends between the dashed line 256 and the top flange 214 of the adapter 202. However, the inner cavity 248 of the adapter 202 can include more or fewer levels, such as two levels or four or more levels.

[0086] In several embodiments, components of the new power converter 308 and / or the new transformer 304 may be located at different vertical locations within the adapter 202. Positioning portions of the new power converter 308 and / or the new transformer 304 at different vertical locations may reduce the foot print of these components 304, 308 as compared to the used power converter and transformer 108, 104, thereby minimizing the diameter of the adapter 202. More specifically, in one embodiment, the new power converter 308 may include a first power converter portion 336 positioned within the first horizontal plane 250 of the internal cavity 248, a second power converter portion 338 positioned within the second horizontal plane 254 of the internal cavity 248, and a third power converter portion 340 positioned within the third horizontal plane 258 of the internal cavity 248. In one exemplary embodiment, the first, second, and third power converter portions 336, 338, 340 may correspond to the grid-side converter 322, the rotor-side converter 320, and a power cabinet (not shown), respectively. In another exemplary embodiment, the first, second, and third power converter portions 336, 338, 340 may correspond to both converters 320, 322, respectively; a control cabinet (not shown); and a power cabinet. However, in alternative embodiments, new power converter 308 may include more or fewer portions, and / or the portions of power converter 308 may correspond to any other suitable power converter components or combinations of power converter components. Similarly, new transformer 304 may include a first transformer portion 342 positioned within first horizontal plane 250 of cavity 248, a second transformer portion 344 positioned within second horizontal plane 254 of cavity 248, and a third transformer portion 346 positioned within third horizontal plane 258 of cavity 248. For example, in one embodiment, as Figure 8 As shown, first transformer portion 342 may correspond to first single-phase transformer 314, second transformer portion 344 may correspond to second single-phase transformer 316, and third transformer portion 346 may correspond to third single-phase transformer 318. However, in alternative embodiments, new transformer 304 may include more or fewer portions, and / or portions of transformer 304 may correspond to any other suitable transformer components or combinations of transformer components.

[0087] In addition, if Fig. 9As shown in , one or more portions of new power converter 308 may be aligned with one or more portions of new transformer 304 along vertical direction 15. For example, first power converter and transformer portions 336, 342 may be aligned along vertical direction 15, second power converter and transformer portions 338, 344 may be aligned along vertical direction 15, and / or third power converter and transformer portions 340, 346 may be aligned along vertical direction 15. However, in alternative embodiments, new power converter 308 and / or new transformer 304 may include any other suitable number of components or portions, and these components or portions may be positioned at any other suitable location within adapter 202.

[0088] Fig.10 One embodiment of a method 400 for refurbishing a wind turbine according to aspects of the present subject matter is shown. Fig.10 The steps performed in a specific order are depicted for the purpose of illustration and discussion, and the methods discussed herein are not limited to any specific order or arrangement. Therefore, the various steps of the methods disclosed herein may be omitted, rearranged, combined and / or adjusted in various ways without departing from the scope of the present disclosure.

[0089] like Fig.10 As shown in FIG. 4 , at ( 402 ), method 400 may include removing a used head from a used tower of a wind turbine. For example, as described above, a used head 16 of a used wind turbine 10 may be removed from a used tower 12 of a used wind turbine 10 .

[0090] At (404), method 400 may include coupling the adapter to the new handpiece. For example, as described above, top flange 216 of adapter 202 may be coupled to new handpiece 206. In one embodiment, top flange 216 of adapter 202 may be coupled to new yaw bearing 204 or a used yaw bearing 38, which in turn may be coupled to bottom plate 226 of new handpiece 16, such as Figure 5 In another embodiment, the top flange 216 of the adapter 202 can be directly coupled to the bottom plate 226 of the new head 16, such as Figure 6 as shown in .

[0091] Additionally, at (406), the method 400 may include coupling the adapter to the used tower. For example, as described above, the bottom flange 212 of the adapter 202 may be coupled to the used tower 12. In one embodiment, the bottom flange 212 of the adapter 202 may be coupled directly to the top flange 60 of the used tower 12, such as Figure 5In another embodiment, the bottom flange 212 of the adapter 202 may be coupled to a new yaw bearing 204 or a used yaw bearing 38, which in turn is coupled to the top flange 60 of a used tower 12, as shown in FIG. Figure 6 as shown in .

[0092] In addition, if Fig.10 As shown in , at (408), method 400 may include electrically coupling one or more electrical components positioned within the interior cavity of the adapter to the grid. For example, as described above, one or more electrical components of new electrical system 300, such as new power converter 308 and / or new transformer 304, may be positioned within interior cavity 248 defined by adapter 202. Thus, these components may be electrically coupled to grid 102 via various buses, switches, and / or breakers, such as stator bus 306, rotor bus 310, grid-side bus 312, switch 328, stator bus breaker 330, grid-side breaker 332, and / or grid breaker 334.

[0093] As described in more detail above, the retrofitted wind turbine 200 includes an adapter 202 in which one or more components of the new electrical system 300 (e.g., a new power converter 308 and / or a new transformer 304) are positioned. In this regard, and unlike conventional wind turbines, the retrofitted wind turbine 200 does not require removal of a used power converter and / or transformer or construction of structures to accommodate a new power converter and / or transformer, thereby reducing the overall cost of the retrofit operation.

[0094] This written description uses examples to disclose the present technology, including the best mode, and also to enable any person skilled in the art to practice the technology, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the present technology is defined by the claims, and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the written language of the claims, or if such other examples include equivalent structural elements with insubstantial differences from the literal language of the claims, it is intended that such other examples are within the scope of the claims.

Claims

1. A wind turbine comprising: Tower; a nose including a generator; a rotor mechanically coupled to the generator, the rotor comprising a hub and at least one rotor blade coupled to and extending outwardly from the hub; one or more spent electrical components electrically separated from the generator, the one or more spent electrical components positioned within the tower; an adapter coupled between the tower and the nose, the adapter defining an interior cavity; and One or more new electrical components are electrically coupled to the generator, the one or more new electrical components being positioned within the interior cavity defined by the adapter.

2. The wind turbine according to claim 1, wherein: The one or more new electrical components include a transformer.

3. The wind turbine according to claim 2, wherein: The transformer includes a plurality of single-phase transformers.

4. The wind turbine according to claim 2, wherein: The inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, and the transformer includes a first single-phase transformer positioned in the first horizontal plane of the inner cavity, a second single-phase transformer positioned in the second horizontal plane of the inner cavity, and a third single-phase transformer positioned in the third horizontal plane of the inner cavity.

5. The wind turbine of claim 1, wherein: The one or more new electrical components include a power converter.

6. The wind turbine according to claim 5, wherein: The inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, and the power converter includes a first power converter part positioned in the first horizontal plane of the inner cavity, a second power converter part positioned in the second horizontal plane of the inner cavity, and a third power converter part positioned in the third horizontal plane of the inner cavity.

7. The wind turbine of claim 1, wherein: The one or more novel electrical components include a power converter and a transformer, with a portion of the power converter vertically aligned with a portion of the transformer.

8. A wind turbine comprising: a tower including a top flange; a nose, which includes a generator and a base plate; a rotor mechanically coupled to the generator, the rotor comprising a hub and at least one rotor blade coupled to and extending outwardly from the hub; a yaw bearing comprising a first raceway and a second raceway; one or more spent electrical components electrically separated from the generator, the one or more spent electrical components positioned within the tower; an adapter coupled between the yaw bearing and one of the tower or the nose, the adapter defining an inner cavity, the adapter further comprising a top flange and a bottom flange, the top flange of the adapter coupled to a bottom plate of the nose or one of the yaw bearings, the bottom flange coupled to a top flange of the tower or one of the yaw bearings; and One or more new electrical components are electrically coupled to the generator, the one or more new electrical components being positioned within the interior cavity defined by the adapter.

9. The wind turbine according to claim 8, wherein: The one or more new electrical components include a transformer.

10. The wind turbine according to claim 9, wherein: The transformer includes a plurality of single-phase transformers.

11. The wind turbine of claim 9, wherein: The inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, and the transformer includes a first single-phase transformer positioned in the first horizontal plane of the inner cavity, a second single-phase transformer positioned in the second horizontal plane of the inner cavity, and a third single-phase transformer positioned in the third horizontal plane of the inner cavity.

12. The wind turbine of claim 8, wherein: The one or more new electrical components include a power converter.

13. The wind turbine of claim 12, wherein: The inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane, and the power converter includes a first power converter part positioned in the first horizontal plane of the inner cavity, a second power converter part positioned in the second horizontal plane of the inner cavity, and a third power converter part positioned in the third horizontal plane of the inner cavity.

14. The wind turbine of claim 8, wherein: The one or more novel electrical components include a power converter and a transformer, with a portion of the power converter vertically aligned with a portion of the transformer.

15. A method for refurbishing a wind turbine, the method comprising: removing a used nose from a used tower of the wind turbine; coupling an adapter to a new handpiece, the adapter defining an interior cavity and one or more new electrical components positioned within the interior cavity, the one or more new electrical components electrically coupled to a generator of the new handpiece; coupling the adapter to the used tower, the used tower including one or more used electrical components electrically separated from the generator; and The one or more new electrical components positioned within the interior cavity of the adapter are electrically coupled to an electrical grid.

16. The method according to claim 15, further comprising: removing a used yaw bearing from the wind turbine; and A new yaw bearing is coupled to the adapter and either a new nose or a used tower.

17. The method according to claim 15, wherein: The one or more new electrical components include transformers and power converters.

18. The method according to claim 17, wherein: The transformer includes a plurality of single-phase transformers.

19. The method according to claim 17, wherein: A portion of the power converter is vertically aligned with a portion of the transformer.

20. The method according to claim 17, wherein: The inner cavity defined by the adapter includes a first horizontal plane, a second horizontal plane positioned above the first horizontal plane, and a third horizontal plane positioned above the second horizontal plane. The transformer includes a first single-phase transformer positioned in the first horizontal plane of the inner cavity, a second single-phase transformer positioned in the second horizontal plane of the inner cavity, and a third single-phase transformer positioned in the third horizontal plane of the inner cavity. The power converter includes a first power converter part positioned in the first horizontal plane of the inner cavity, a second power converter part positioned in the second horizontal plane of the inner cavity, and a third power converter part positioned in the third horizontal plane of the inner cavity.

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