A set of units for manufacturing a wind turbine nacelle

Abstract

A set of units for assembling to form a wind turbine nacelle. The nacelle includes a rotor support assembly, a generator, and an energy conversion assembly, and the set of units includes: a main unit arranged to be connected to a wind turbine tower and to house the rotor support assembly and the generator; and at least two different auxiliary units, each auxiliary unit housing operating components forming part of the energy conversion assembly. To allow for different wind turbine configurations, one of the auxiliary units can be selected from the at least two auxiliary units and assembled with the main unit to form the nacelle.

Description

[0001] introduction

[0002] The present disclosure relates to a set of units for manufacturing a nacelle for a wind turbine. The nacelle comprises a rotor support assembly and an energy conversion assembly. The set of units comprises a main unit arranged to be connected to a wind turbine tower and accommodating the rotor support assembly. The set of units also comprises at least two different auxiliary units, each of which accommodates an operating component forming part of the energy conversion assembly.

[0003] The present disclosure also relates to a method for manufacturing a nacelle by using the set of units. Background Art

[0004] In the past few years, there has been a trend towards increasing the size of wind turbines in terms of nominal power output and in terms of the physical dimensions of the various parts of the wind turbine. Furthermore, adapting a wind turbine to specific requirements related to rated power, desired output or other variables complicates design and manufacturing. Summary of the invention

[0005] An object of embodiments of the present disclosure is to facilitate further modularity, ease of design and manufacture, and to allow improved maintenance of wind turbines. Another object of embodiments of the present disclosure is to provide a nacelle that can be transported using common transport vehicles and to reduce transport and handling costs without limiting the possible size of the nacelle.

[0006] For these and other purposes, the present disclosure provides a set of units for assembling to form a nacelle of a wind turbine. The set of units comprises at least two different auxiliary units, each auxiliary unit housing an operating component forming part of an energy conversion assembly, wherein one of the auxiliary units can be selected from the at least two auxiliary units and assembled with a main unit to form the nacelle.

[0007] The at least two different auxiliary units have the same interface, each interface being configured to mate with the same complementary interface of the primary unit to allow selective connection of one of the at least two different auxiliary units to the same location on the primary unit. This can be achieved, for example, by two auxiliary units having the same interface, or by one single interface on the primary unit that can be connected to several different interfaces of different auxiliary units.

[0008] Thus, the wind turbine can be configured differently by selecting one or the other of the at least two auxiliary units, which enables a quick adaptation to specific needs.Since by using a configuration of individual units, the transport and assembly processes can be optimized and reconfiguration can be an option.

[0009] At least one of the at least two auxiliary units may not form part of the nacelle, thereby acting as an auxiliary unit which may be used to reconfigure the nacelle by replacing one auxiliary unit with a different auxiliary unit.

[0010] The wind turbine may comprise a generator which may be operated individually with operating components in each auxiliary unit, which means that the wind turbine may deliver electricity from the generator in a converted form without using a different auxiliary unit attached as an alternative.

[0011] Thus, the set of units facilitates modularity of the generic wind turbine structure and easy adaptation to different specific needs. During the design phase, the designer can choose between different auxiliary units and create a wind turbine based on specific requirements.

[0012] As an example, a first auxiliary unit of the at least two auxiliary units may provide a specific performance, e.g. with respect to a wind turbine characteristic (e.g. with respect to power production or power storage), and a second auxiliary unit of the at least two units may provide a different performance with respect to the wind turbine characteristic.

[0013] Thus, one of the at least two auxiliary units may accommodate one type of operating component selected from the group consisting of: transformers, converters, batteries, electrolytic cells and switchgear, and the other of the at least two auxiliary units may accommodate different operating components selected from the group consisting of: transformers, converters, batteries, electrolytic cells and switchgear.

[0014] Both auxiliary units may accommodate operating components of the same type (eg with different power ratings or different configurations), for example in order to match the connected power grid or the like.

[0015] Alternatively, the auxiliary units may house different types of operating components, such as a transformer in one auxiliary unit and an electrolytic cell in another auxiliary unit.

[0016] Each of the auxiliary unit and the main unit can have the size and / or shape of a freight container. Therefore, each unit inherits the advantages of freight containers in terms of handling, transportation and storage. Freight containers can be handled, for example, by ships, trains, trucks, etc. anywhere in the world, and are less expensive than bulk transportation. By transporting freight containers that constitute units, the cost savings are even more significant. Freight containers are also called intermodal containers, standard freight containers, box containers, sea containers or ISO containers, and generally refer to containers used for storing and transporting materials and products for intercontinental traffic in a global containerized intermodal freight system. Freight containers can follow the dimensions and structural specifications in the ISO standard of ISO668:2013 for Series 1 freight containers.

[0017] In one embodiment, the set of units comprises two auxiliary units, each of which has half the size of a freight container following the dimensional and structural specifications in the ISO standard ISO 668:2013 for Series 1 freight containers, and is arranged so that the two halves of the container can be assembled onto one container during transport and divided into the two auxiliary units so as to be arranged, for example, on opposite sides of the main unit. The container can in particular be split at an interface extending in the longitudinal direction of the container.

[0018] The nacelle may be configured to be mounted on a wind turbine tower such that it is carried by the wind turbine tower directly or indirectly via an intermediate tower structure. If the wind turbine is of a conventional horizontal axis type, the nacelle is typically carried by a yaw assembly located directly between the tower top and the nacelle. However, the present disclosure may also relate to a multi-rotor wind turbine wherein more than one nacelle is carried by a cross beam structure which in turn is carried by the tower, for example via a yaw assembly.

[0019] The present disclosure may relate to upwind wind turbines or downwind wind turbines.

[0020] The set of units comprises a main unit. The main unit may be the part that connects the nacelle to the tower directly or indirectly via the one or more intermediate tower structures. The main unit may in particular be considered to be a central part of the nacelle and houses components of the drive train, such as at least a part of the rotor shaft.

[0021] The wind turbine may be a direct drive wind turbine, where the generator is typically placed outside the nacelle, or the wind turbine may be, for example, where the generator is located in the main unit. The main unit supports the rotor via a rotor shaft.

[0022] Depending on the type of wind turbine, the main unit may comprise further components, such as a gearbox, a bearing system and different kinds of peripheral equipment, e.g. for lubrication, cooling and control purposes. The main unit may in particular comprise a main frame connecting the drive train and the tower or an intermediate tower structure, e.g. via a yaw assembly. The main frame may in particular be a cast component.

[0023] The primary unit and at least two different auxiliary units may be configured such that both auxiliary units may be attached to the same location on the primary unit.The primary unit may define a first interface allowing selective connection of one of the at least two different auxiliary units.

[0024] The main unit may also define a second interface, which is on an opposite side of the main unit and allows selective connection of one of the at least two different auxiliary units. This allows the auxiliary unit to be attached to both sides of the main unit, for example to opposite sides of a vertical plane passing through the rotor support assembly.

[0025] At least one of the at least two auxiliary units may be configured for the first interface, and at least one of the at least two auxiliary units may be configured for the second interface.

[0026] The set of units may include at least two different auxiliary units configured for a first interface and / or at least two auxiliary units configured for a second interface. In this embodiment, each auxiliary unit configured for the same interface on the primary unit may have the same interface to allow selective connection of one of the at least two different auxiliary units to the interface of the primary unit.

[0027] The energy conversion assembly converts the electricity from the generator into a desired energy form. The energy conversion assembly can be configured to deliver electricity, for example, in the form of AC or DC. The first auxiliary unit can accommodate a first operating component that forms part of the energy conversion assembly, and the second auxiliary unit can accommodate a second operating component that forms part of the energy conversion assembly.

[0028] In one embodiment, the first and second operating components have identically operating components, meaning that they have substantially the same functionality, but have different internal configurations, different ratings, or they may be produced by different manufacturers. This allows energy conversion to be shared between the two components, or allows the wind turbine to continue operating at a reduced capacity if one component fails.

[0029] In the case of electrical energy, the energy conversion assembly can be configured to connect the generator to, for example, an external power grid. In this case, the energy conversion assembly can, for example, be composed of a converter, a transformer and / or a switchgear. Any such components can be included in the energy conversion assembly.

[0030] Therefore, the operating component can be formed by a converter and / or a transformer or the like.

[0031] As an example, the first and second operating components may both be transformers, but with different sizes and capacities. In another example, the first and second operating components may both be converters, but with different sizes and capacities.

[0032] In one embodiment, the nacelle comprises a main unit and an auxiliary unit on one side of the main unit. On the other side of the main unit, one of at least two different units is selected so that the resulting nacelle comprises a main unit and at least two auxiliary units, one of which is selected between two different auxiliary units. Thus the two auxiliary units forming part of the nacelle may house the same components or different components. In one example, the resulting nacelle comprises a main unit with a generator and two auxiliary units, each of which houses the same operating components or houses different operating components.

[0033] As an example, the generator may be an asynchronous or synchronous generator, such as an asynchronous or synchronous generator, and the converter voltage may be in the same range as the generator voltage (sometimes referred to as the stator voltage).

[0034] In another example, the generator may be a doubly fed induction generator (DFIG). In this case, the voltage on the converter may be different from the generator stator voltage. The converter is connected to the generator rotor and typically has the same voltage as the stator voltage or a lower voltage than the stator voltage.

[0035] Low voltage may be considered, for example, as voltages up to 1000 V. Medium voltage may be considered as voltages from 1 KV to about 60 kV. The generator voltage may be low voltage or medium voltage.

[0036] In alternative embodiments, the first and second operating components have different functions in the energy conversion assembly. The first unit may, for example, be configured to convert electricity from the generator into electricity having characteristics matching the receiving grid, and the second unit may be configured to convert electricity from the generator into chemicals such as hydrogen, methanol or ammonia.

[0037] Each of the at least two auxiliary units may include a universal interface to the primary unit, the universal interface allowing universal connection of the generator in the primary unit to the operating components in the auxiliary unit. A universal interface is considered to be an interface on two different auxiliary units that both mate with the same interface on the primary unit, thereby allowing easy and quick selection of one auxiliary unit to be combined with the primary unit. Such an interface may, for example, include a standard electrical connector interface, and / or a standard interface for lubrication fluids, cooling, and other necessary interactions between the operating components in the primary and auxiliary units.

[0038] Each of the at least two auxiliary units can be defined in pairs of two auxiliary units, which are configured to match each other on the main unit. In particular, the auxiliary units in a pair of auxiliary units can be configured to be placed on opposite sides of the main unit. This means that the auxiliary units of a pair of auxiliary units match each other with respect to weight to provide an acceptable balance on the entire main unit, and they can also match each other with respect to the interaction between the operating components in the auxiliary units of a pair of auxiliary units. An example of such interaction can be that one auxiliary unit contains an energy conversion capability that matches the electrolytic cell in another auxiliary unit, and the two auxiliary units have a weight within a predetermined limit to provide an acceptable balance.

[0039] In particular, the auxiliary units may be rated with respect to specific characteristics of the auxiliary units, in particular specific characteristics of the operating components in the auxiliary units. The classification may for example define at least one of the following variables:

[0040] - input capacity relative to the electricity generated;

[0041] - Output capacity relative to the energy type defined for the auxiliary unit.

[0042] In one embodiment, the set of units comprises at least two main units, each main unit being configured such that a wind turbine nacelle can be manufactured by selecting one of the two main units and combining it with the selected auxiliary unit. In particular, each main unit can be arranged to be connected to a wind turbine tower and to house a rotor support assembly and a generator.

[0043] The main unit and the auxiliary unit may be arranged side by side in a direction away from the axis of rotation. This means that the auxiliary unit is laterally moved away from the axis of rotation relative to the main unit. The auxiliary unit may for example be in a direction perpendicular to the axis of rotation of the wind turbine rotor. This provides an advantageous modularity of the nacelle with an advantageous distribution of the main wind turbine components, such that the main bearing system and the drive train system are assembled in the main unit, while the other components are assembled in the auxiliary unit. Thus, the interface between the main unit and the auxiliary unit may in particular extend in the direction of the axis of rotation.

[0044] In one embodiment, the energy conversion assembly is configured to convert the electricity from the generator into energy in a chemical storage form, such as hydrogen, ammonia or methanol. Thus, the operating components may consist of an electrolysis cell stack or a battery, etc. Such components may be suitably housed in the auxiliary unit and advantageously carried directly by the main unit, as they are relatively heavy components.

[0045] Two different auxiliary units with the same interface towards the main unit can facilitate attachment to at least two different locations on the main unit, such as locations on the right and left sides of the main unit, i.e., locations on opposite sides of the rotor support assembly. In one embodiment, the auxiliary unit can be attached on the right side with the side surface against the right outer surface of the main unit, and can be rotated 180 degrees to attach to the left outer surface of the main unit with the same side surface.

[0046] In a second aspect, the present disclosure provides a wind turbine comprising a nacelle as described above.

[0047] In a third aspect, the present disclosure provides a method of manufacturing a nacelle by using a set of units as described herein.

[0048] The method may comprise the steps of assembling the main unit and the selected auxiliary unit, and completing the wind turbine by connecting the nacelle to the wind turbine tower.

[0049] The method may include leaving at least one of the at least two auxiliary units in place to allow replacement of the auxiliary unit with a different auxiliary unit, thereby allowing reconfiguration of the nacelle.

[0050] For each auxiliary unit, constraints may be defined to pre-specify which auxiliary units may interact with each other and / or to specify auxiliary units that may not interact with each other.

[0051] The method comprises the step of defining a desired nacelle configuration. The nacelle configuration may be, for example, a desired grid frequency or output power rating, or specific desired climatic conditions, such as average wind speed or turbulence conditions, air density or air temperature, for which the nacelle should be configured.

[0052] Subsequently, different combinations of primary and secondary units may be defined, and for each of these combinations, a design configuration is determined. The design configuration specifies the conditions that a combination is considered to satisfy.

[0053] Based on the desired configuration and the configurations achievable through different combinations, a particular combination is selected and the nacelle is constructed from those units selected.

[0054] The method may further comprise the following steps, namely defining:

[0055] - the desired output from the wind turbine;

[0056] - determining a plurality of combinations between at least one primary unit and different secondary units;

[0057] - defining for each combination the predictive capability of the nacelle derived from that combination; and

[0058] - Select combinations based on comparison of expected output and predictive ability.

[0059] Numbered List of Examples

[0060] 1. A set of units for assembling to form a nacelle of a wind turbine, the nacelle comprising a rotor support assembly and a generator and energy conversion assembly, the set of units comprising:

[0061] a main unit arranged to be connected to a wind turbine tower and to house said rotor support assembly and said generator; and

[0062] - at least two different auxiliary units, each housing operating components forming part of the energy conversion assembly, wherein one of the auxiliary units can be selected from the at least two auxiliary units and assembled with the main unit to form the nacelle.

[0063] 2. A set of units according to embodiment 1, wherein the primary unit defines a first interface that allows selective connection of one of the at least two different secondary units.

[0064] 3. A set of units according to embodiment 2, wherein the main unit defines a second interface, which is on the opposite side of the main unit and allows selective connection of one of the at least two different auxiliary units.

[0065] 4. The set of units according to embodiment 3, wherein at least one of the at least two auxiliary units is configured for the first interface and at least one of the at least two auxiliary units is configured for the second interface.

[0066] 5. The set of units according to embodiment 4, comprising at least two different auxiliary units configured for the first interface and / or at least two auxiliary units configured for the second interface.

[0067] 6. The set of units of embodiment 5, wherein the at least two different auxiliary units configured for the first interface have a same interface to allow selective connection of one of the at least two different auxiliary units to the first interface.

[0068] 7. A set of units according to embodiment 5 or 6, wherein the at least two different auxiliary units configured for the second interface have the same interface to allow selective connection of one of the at least two different auxiliary units to the second interface.

[0069] 8. A set of units according to any one of the preceding embodiments, wherein two auxiliary units of the at least two different auxiliary units have operating components that operate identically.

[0070] 9. A set of units according to any one of the preceding embodiments 5 to 8, wherein two auxiliary units of the at least two different auxiliary units configured for the first interface have operating components that operate in the same manner.

[0071] 10. A set of units according to any one of the preceding embodiments 5 to 9, wherein two auxiliary units of the at least two different auxiliary units configured for the second interface have operating components that operate in the same manner.

[0072] 11. A set of units according to any one of the preceding embodiments, wherein two of the at least two different auxiliary units have operating components that operate differently.

[0073] 12. A set of units according to any one of the preceding embodiments 5 to 11, wherein two of the at least two different auxiliary units configured for the first interface have operating components with different operations.

[0074] 13. A set of units according to any one of the preceding embodiments 5 to 12, wherein two of the at least two different auxiliary units configured for the second interface have operating components with different operations.

[0075] 14. A group of units according to embodiment 6, wherein a first one of the operating components is selected from the group consisting of: transformers, converters, batteries, electrolytic cells and switchgear, and wherein a second one of the operating components is different from the first operating component and is selected from the group consisting of: transformers, converters, batteries, electrolytic cells and switchgear.

[0076] 15. A method of manufacturing a nacelle by using a set of units according to any one of the preceding embodiments, the method comprising:

[0077] - selecting a primary unit and at least one of the at least two different secondary units; and

[0078] - Manufacturing the nacelle by connecting the selected auxiliary unit to the main unit.

[0079] 16. The method according to embodiment 15, comprising the step of attaching the nacelle to the wind turbine tower by assembling the main unit and the wind turbine tower.

[0080] 17. The method of embodiment 16, comprising, after attaching the main unit to the wind turbine tower, the subsequent step of assembling the auxiliary unit and the main unit.

[0081] 18. A method according to any one of embodiments 15 to 17, the method comprising defining constraints for each auxiliary unit, wherein the constraints define other auxiliary units configured to interact with the auxiliary unit in question, or define other auxiliary units that cannot interact with the auxiliary unit in question.

[0082] 19. The method of embodiments 16 to 18, comprising defining:

[0083] - Desired cabin configuration;

[0084] - determining a plurality of combinations between at least one primary unit and different secondary units;

[0085] - define the resulting cabin configuration for each combination; and

[0086] - selecting a combination based on a comparison of said obtained cabin configuration with said desired cabin configuration.

[0087] 20. The method of embodiment 19, wherein the defined desired nacelle configuration and the defined resulting nacelle configuration include at least one of a desired grid frequency, an output power rating, and certain desired climate conditions.

[0088] 21. The method according to any one of embodiments 15 to 20, comprising: selecting a combination between the main unit and the auxiliary unit based on the generator power and average wind speed defined for the main unit and the total rated power of the conversion assembly defined for the auxiliary unit.

[0089] 22. The method of any one of embodiments 15 to 21, wherein the primary unit and the secondary unit are selected to provide a nacelle that produces chemicals based on electricity from the generator.

[0090] 23. The method of embodiment 22, wherein the primary unit and the auxiliary unit are selected to provide a nacelle that generates electricity for a grid in addition to the chemicals generated based on electricity from the generator.

[0091] 24. The method of any one of embodiments 15 to 23, wherein the primary unit and the secondary unit are selected to provide a nacelle based airborne unit generated electrical power.

[0092] 25. The method of any one of embodiments 15 to 24, comprising defining a plurality of combinations of a primary unit and different secondary units for a left side of the primary unit.

[0093] 26. The method of any one of embodiments 15 to 26, comprising defining a plurality of combinations of a primary unit and different secondary units for use to the right of the primary unit.

[0094] 27. The method of any one of embodiments 15 to 26, comprising defining a plurality of combinations of different primary units and one or more secondary units for use to the right of the primary unit.

[0095] 28. The method of any one of embodiments 15 to 28, comprising defining a plurality of combinations of different primary units and one or more secondary units for use to the left of the primary unit.

[0096] List of Figures

[0097] Hereinafter, embodiments of the present disclosure will be described in more detail with reference to the accompanying drawings, in which:

[0098] Figure 1a and Figure 1b A wind turbine is shown;

[0099] Figure 2 A nacelle of a wind turbine is shown;

[0100] Figure 3 Shows Figure 2 A perspective view of the cabin 2;

[0101] Figure 4 Shows Figure 3 of the cabin, but as seen from above;

[0102] Figure 5 An embodiment is shown where the left and right auxiliary units contain identical components;

[0103] Figure 6 An embodiment is shown in which two auxiliary units 61, 62 are located one above the other;

[0104] Figure 7a and Figure 7b Several units forming a set of units are shown for assembly to form a wind turbine nacelle by selecting one of at least two units;

[0105] Figure 8 and Fig. 9 An embodiment is shown in which the first fixing structure is constituted by a bolt-shaped fixing pin;

[0106] Fig.10 , Fig.11 Another embodiment of the first and second fixing structures is shown in more detail;

[0107] Figures 12 to 15Four different embodiments of the interface between the primary unit and the secondary unit are shown.

[0108] Figures 16 to 18 An embodiment in which the main unit and the auxiliary unit are assembled by a hinge structure is shown;

[0109] Fig.19 , Fig. 20 Further details of the hooks used to attach the auxiliary unit to the main unit are shown;

[0110] Fig.21 The hook is shown in an open position, with the auxiliary unit freely lowered to the ground;

[0111] Fig. 22 shows a cutaway view with two bolt holes for attaching the auxiliary unit to the main unit;

[0112] Fig.23 , Fig.24 , FIG. 25 shows an embodiment in which the hook is slidably suspended; and

[0113] Figure 26 to Figure 28 An embodiment of a crane on a main unit for lifting an auxiliary unit is shown. DETAILED DESCRIPTION

[0114] The detailed description and specific examples (while indicating embodiments) are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this detailed description.

[0115] Figure 1a and Figure 1b A wind turbine 1 is shown with a nacelle 2 mounted on a tower 3. A hub 4 carrying three rotor blades 5 forms the rotor and is carried by a rotor support assembly in the nacelle 2. Typically, the rotor support assembly includes a rotor shaft connecting a gear arrangement and a generator to the hub. However, gears are not always required, as the generator can be driven directly by the shaft. Figure 1b A direct drive wind turbine is shown with the generator 6 being located outside the nacelle.

[0116] Figure 2 The nacelle is shown to include a main unit 20 and two auxiliary units 21, 22. A cooling area 23 is arranged on top of the nacelle. The cooling area is formed by a heat exchanger which may form part of the main unit and / or any of the auxiliary units. The main unit 20 is mounted on a tower 3 by a yaw device (not shown) allowing the nacelle 2 to rotate in order to direct the rotor into the wind.

[0117] Figure 3 Shows Figure 2 A perspective view of the cabin 2. Figure 3, the outer wall of the nacelle 2 is transparent (for illustration), thereby revealing the internal parts of the nacelle 2 and the wind turbine components housed in the nacelle. The main unit 20 houses a main bearing unit 31, a gear device 32 and a generator 33, which are arranged sequentially behind the hub 4 along the direction defined by the rotation axis of the hub 4. The components in the main unit mainly form part of the drive train.

[0118] The auxiliary unit 22 accommodates a transformer unit 34 and a converter unit 35, which here constitute two different operating components accommodated in the auxiliary unit. In an alternative embodiment, the operating component may be an electrolytic cell stack or battery.

[0119] Each auxiliary unit 21, 22 is mounted via an interface along one side of the main unit 20. In the disclosed embodiment, they are mounted in such a way that one auxiliary unit 21 is mounted along the right side of the main unit 20, while the other auxiliary unit 22 is mounted along the left side of the main unit 20, as seen from the hub 4 towards the rear wall of the main unit 20 along the axis of rotation of the hub 4.

[0120] Figure 5 An embodiment is shown in which the left and right auxiliary units contain at least one identical component, which creates a weight balance and a dual functionality. Dual functionality means that the wind turbine comprises two functionally identical components, one for each auxiliary unit. In the event of a malfunction, the wind turbine can continue to operate at reduced power while replacing an operating component in one of the auxiliary units.

[0121] Figure 4 and Figure 5 A transport system is shown comprising tracks 42 which extend from the primary unit into the secondary unit and allow easy loading and unloading of spare parts etc.

[0122] exist Figures 2 to 5 In the embodiment, the auxiliary unit is composed of elements having the shape and dimensions of a standardized freight container in general, such as a 40-foot freight container having dimensions and structural specifications as provided by the ISO standard ISO 668:2013 for series 1 freight containers. The auxiliary unit is connected to the main unit by means of ISO corner lifting structures, which are usually formed from steel and constitute a particularly strong interface with the container. In this embodiment, one side of the main unit has an auxiliary unit selected between two different auxiliary units, so that the resulting nacelle comprises a main unit with a generator and two auxiliary units, each of which accommodates the same operating components. The two auxiliary units may not only contain the same operating components, but may be identical, i.e. identical with respect to the interface towards the main unit and with respect to other components except the operating components.

[0123] Figure 6 An embodiment is shown of two auxiliary units 61, 62 located one above the other. In this embodiment, the upper auxiliary unit 61 consists of a unit having the size and shape of a 40-foot freight container, while the lower auxiliary unit 62 consists of a unit having the size and shape of a 20-foot freight container. Both containers have the size and structural specifications provided by ISO standard ISO 668:2013, and the auxiliary units are attached to each other mainly by the corner fittings of the 20-foot container and partly by the corner lifting fittings of the 40-foot container.

[0124] Figure 7a Several units forming a set of units for assembly to form a nacelle of a wind turbine are shown. In this illustration, it can be seen that the set comprises a plurality of different auxiliary units which can be selected individually. The set contains more units than are required to manufacture the nacelle, thus allowing different configurations based on the units selected for the nacelle. The unit numbered 71 is a main unit. The unit numbered 72 is a left auxiliary unit for attachment to the left side of the main unit and the unit numbered 73 is a right auxiliary unit for attachment to the right side of the main unit.

[0125] The set of units further comprises a plurality of drive trains 74 configured differently, eg with respect to main bearings, drive shafts or gearboxes etc., eg to provide a required nacelle configuration, eg for specific climatic conditions etc., ie eg to match specific wind conditions.

[0126] The set of units also comprises several hubs 75 matched to rotors of different sizes, for example to match different power requirements or climatic conditions. The set further comprises different heat exchangers 76 for matching different cooling needs and / or different climatic conditions.

[0127] By way of example, the following units and combinations of units can be defined:

[0128] Rx = auxiliary unit number X installed on the right side, example: R1 is for the auxiliary unit installed on the right side of the main unit and has identification number 1 in the group of units.

[0129] Lx = auxiliary unit number X installed on the left side, example: L3 is for the auxiliary unit installed on the left side of the main unit and has the identification number 3 auxiliary in the group of units.

[0130] Primary / secondary configuration examples with asynchronous or synchronous generator and full converter AC / DC to DC / AC

[0131]

[0132] Example of a main unit / auxiliary unit configuration with a doubly fed induction generator (DFIG) generator and partial power converter AC / DC DC / AC:

[0133]

[0134] Example of a master / slave unit configuration with AD / DC() converter (generator side) and hydrogen

[0135]

[0136] Example of a master / slave unit configuration with AD / DC () converter (generator side) and storage device

[0137]

[0138] Examples of master / auxiliary configurations with asynchronous or synchronous generators and full converter AC / DC to DC / AC and kite units

[0139]

[0140] Module L9 is an auxiliary module that houses an aerial unit as an energy harvesting system, wherein the aerial unit (eg a kite or foil) can harvest energy while in the air, for example connected to the auxiliary unit via a cable.

[0141] Figure 7b A main unit 20 is shown, wherein an auxiliary unit 73 is attached to the right side of the main unit. The auxiliary unit contains a transformer and a converter. On the opposite left side, the nacelle is made of either of the auxiliary units 72', 72", which have the same interface towards the main unit. Thus, the wind turbine can be configured differently by selecting one or the other of these two auxiliary units 72', 72".

[0142] At least one of the two auxiliary units 72 ′ is an auxiliary unit that does not form part of the nacelle but allows replacement with a different auxiliary unit.

[0143] Each of the two auxiliary units 72', 72" enables the main unit to operate and thus provides two alternative configurations. The upper auxiliary unit 72' includes components that are essentially the same as those contained in the auxiliary unit 73 and can therefore be used to change the rated power. The lower auxiliary unit 72" contains different energy conversion modules, such as a fuel cell for converting electrical energy from the generator into other forms of energy (such as hydrogen, etc.). Figures 8 to 11 In different embodiments it is shown how the operating components can be attached to one or both of the primary unit and the secondary unit.

[0144] exist Figure 8In the embodiment of the present invention, a bolt-shaped fixing pin 78 engages into a reinforcing feature 79. The bolt-shaped fixing pin carries the operating component directly to the main unit and forms a load path from the operating component to the tower.

[0145] Fig. 9 An embodiment is shown in which the operating component is supported by support legs 91 between the bottom of the operating component and the bottom of the auxiliary unit.

[0146] Fig.10 Another embodiment is shown in more detail, in which the operating components 104 are carried by a support frame 105 supported on the bottom of the auxiliary unit 102 and are suspended directly from a main frame 106 inside the main unit 101. The main frame thus forms part of the load path from the operating components to the tower.

[0147] At least 50% of the weight of the transformer 104 is thereby carried by the main unit 101, while the remaining weight is carried by the auxiliary unit 102, which in turn is carried by the main unit 101. Therefore, the remaining part of the weight is not carried by the main unit 101 directly.

[0148] Fig.11 Shown with Fig.10 An embodiment comparable to the embodiment in , but in which the support frame 111 is suspended via brackets 1102, which are placed on the main frame 106 inside the main unit 101. The main frame thus forms a load path from the operating components to the tower.

[0149] Figures 12 to 15 Four different embodiments of the unit fixing structure forming the interface between the primary unit and the secondary unit are shown. In each of the four illustrations, the primary unit 121 and the secondary unit 122 are connected by a mating structure forming the unit fixing structure and described in further detail below.

[0150] exist Fig.12 In the embodiment, the matching structure is composed of a bracket 123, and the main unit and the auxiliary unit are connected by bolts through the bracket 123.

[0151] exist Fig.13 In the example, the coordination structure consists of Fig.12 The auxiliary unit is formed of a lower bracket 123 of the bracket used in the embodiment of the present invention. At the upper edge, the main unit and the auxiliary unit are assembled by a hook 131 pivotally engaged to the main unit at a hinge point 132. When in the illustrated position, the hook can be rotated as shown by arrow 133 and engage an edge bracket 134 of the auxiliary unit. When the lower bracket 123 is removed and the hook 131 is rotated into the main unit, the auxiliary unit can be lowered to the ground.

[0152] Fig.14 The examples in Fig.13The embodiment in is equivalent, but wherein the lower bracket is replaced by an upper bracket 141 and the hook is placed at the lower edge.

[0153] exist Fig.15 In the embodiment, the lower and upper brackets are used to bolt the auxiliary unit to the main unit, and the slidable support 151 supports the lower surface of the auxiliary unit when bolted. If it is desired to lower the auxiliary unit to the ground, for example in order to replace the operating component with a different operating component, the slidable support can be slid to the left and the auxiliary unit can be lowered, for example by using a crane built into the main unit.

[0154] exist Figures 12 to 15 In any of the embodiments shown, the bracket or hook directs the load from the auxiliary unit into a rigid portion of the main unit, such as into a load carrying column, such as a corner column of the main unit. Various structural features can connect the bracket or hook carrying the auxiliary unit directly to the main frame in the main unit, thereby establishing a load path to the tower.

[0155] Apart from Figures 12 to 15 In addition to the hook and bracket interface shown, a first fixing structure (not shown) directly connects the operating component (not shown) to the main frame within the main unit.

[0156] Figures 16 to 18 An embodiment is shown in which the primary unit and the secondary unit are assembled by a hinge structure comprising hinge elements 163, 164, 165 having holes for receiving hinge pins 166 extending through the hinge elements. Fig.16 Also shown is that the interface forms a gap 167 that allows air to pass through it, for example from below the nacelle to above the nacelle. The gap is held open at the bottom by a spacing element 168 that may consist of a number of pins or an open structure that allows air to pass between the units.

[0157] This gap can increase heat convection, thereby increasing cooling of the space within the primary unit and the secondary unit.

[0158] The gap is not limited to the embodiment with the hinge structure, but can be combined with any other assembly method.

[0159] Fig.17 and Fig.18 Hinge elements 163, 164, 165 and hinge pin 166 are shown. Fig.17 In the embodiment of the present invention, the hinge elements are correctly positioned relative to each other so that the hinge pin can slide into the hinge element. Fig.18 In the embodiment of the present invention, the hinge pin is inserted through the hole of the hinge element.

[0160] Fig.19Further details of the hook used to attach the auxiliary unit 191 to the main unit 192 are shown. The hook 193 is rotatably suspended at a hinge 194 in the main unit. The hook can be rotated through an opening 195 in the auxiliary unit and catch a groove or edge 196 in the auxiliary unit. The hook can also be attached in the auxiliary unit and catch a groove or edge in the main unit, in which case the hook can be attached in reverse, i.e. as shown in FIG. Fig. 20 shown.

[0161] Fig.21 The hook is shown in an open position, with the auxiliary unit freely dropping to the ground.

[0162] Fig. 22 A cross section is shown in which two bolt holes 221 can be seen. The bolt holes facilitate the connection of the auxiliary unit to the main unit by using bolts for secure fixing. In this embodiment, the hook is mainly used to position the auxiliary unit at the correct height relative to the main unit, while the bolts are used to connect the units.

[0163] exist Fig.19 , Fig.21 and Fig. 22 In the embodiment, the hook is preferably supported by the main frame of the main unit, for example via a post or support rod arranged along the inner surface of the main unit. Fig.19 In the embodiment, the post 197 extends along the inner surface of the main unit and supports the hook on the main frame in the bottom of the main unit.

[0164] exist Fig. 20 In the case where the hook forms part of the auxiliary unit, the edge in the main unit that the hook engages may preferably be carried by the main frame in the main unit. Equally, this can be achieved via a rod or column arranged along the inner surface of the main unit.

[0165] The hook may be moved in the open position ( Fig.21 ) and closed position ( Fig.19 , Fig. 20 , Fig. 22 )

[0166] Fig.23 , Fig.24 FIG. 25 shows an embodiment in which the hook is not swivel-suspended but slidably suspended. Figures 19 to 22 In the embodiment of Fig.23 and Fig.24 In the cross-sectional view, bolt holes 231 are shown, which can be used for secure bolting of the auxiliary unit to the main unit. Fig.23 The hook is attached to the main unit, and Fig.24 The hook in the attachment is attached to the auxiliary unit.

[0167] exist Fig.25a In the embodiment of the present invention, hook 251 slides to the left, thereby disengaging the edge of the auxiliary unit and allowing the auxiliary unit to be lowered to the ground. Fig.25b In the embodiment of the present invention, the hook 251 slides to the right, thereby engaging the edge of the auxiliary unit and keeping the two units fixed to each other. The hook can slide by a power drive, for example by a hydraulic actuator.

[0168] In the above description, Figure 19 to Figure 2 5 is interpreted as a part of the unit fixing structure for fixing the auxiliary unit to the main unit. A similar structure can constitute a first fixing structure by which the operating part is releasably fixed to the main unit. A similar structure can also constitute a second fixing structure by which the operating part is releasably fixed to the auxiliary unit, and a similar structure can constitute a third fixing structure by which the two auxiliary units are fixed to each other.

[0169] Fig.26 The auxiliary unit is shown being raised or lowered during replacement for the purpose of reconfiguration. The auxiliary unit is raised and lowered by using a crane 261 forming part of the main unit. The movement is substantially only in the vertical plane, as shown by arrow 263, and the attachment of the auxiliary unit to the main unit may be facilitated by a unit securing structure as described above, which includes a movable securing feature, such as an articulated or slidable hook or the like.

[0170] Fig. 27 An internal crane 261 is shown in an enlarged view. The crane is attached to the top of the primary unit and through its position it can lift the auxiliary unit in a vertical direction to a position where the unit fixing structure can form a joint between the primary unit and the auxiliary unit. This process may not require movement in other directions than the vertical direction and thus facilitates a simple assembly process while reducing the need for external crane assistance. For adjustment in the horizontal plane, the crane 261 may have the option of horizontal movement, for example as shown by arrow 262.

[0171] Fig.28 Another crane structure is schematically shown with a double cantilever beam 281 on top of a main unit 282. The cantilever beam 281 can be extended laterally in a telescoping section 283. The cantilever beam facilitates lifting and attaching the auxiliary unit 284 to the main unit 282. Although the unit securing structure disclosed herein including a pivotable or slidable hook generally facilitates attaching the auxiliary unit by lifting and lowering the auxiliary unit in the vertical direction only, the in-and-out movement facilitates fine adjustment of the horizontal distance between the main unit and the auxiliary unit.

[0172] definition

[0173] In this document, the term "nacelle" refers to the commonly accepted term describing the machine room of a wind turbine, ie the part that carries the rotor and the drive train and is carried by the wind turbine tower.

[0174] In this document, the terms "primary unit" and "secondary unit" refer to units that are transportable separately and that can be assembled with one or more other units to form a cabin.

[0175] In this document, the term "rotor support assembly" refers to those parts of the nacelle that carry the rotor, typically the drive train, main bearings and main frame. Depending on the type of wind turbine, the drive train may include different components, such as a rotor shaft, a generator and optionally a gearbox between the rotor shaft and the generator.

Claims

1. A set of units for assembling to form a nacelle (2) for a wind turbine, the nacelle including a rotor support assembly and an energy conversion assembly, the set of units comprises: - a main unit (20, 71), the main unit being arranged to be connected to a wind turbine tower and to house the rotor support assembly; and at least two different auxiliary units (21, 22, 61, 62, 72, 73), each auxiliary unit housing operating components forming part of the energy conversion assembly, wherein the at least two different auxiliary units have the same interface towards the main unit, whereby one of the auxiliary units can be selected from the at least two auxiliary units and assembled with the main unit to form the nacelle, wherein one of the at least two auxiliary units houses a type of operating component selected from the group consisting of a transformer, an inverter, a battery, an electrolytic cell, and switchgear, and wherein the other of the at least two auxiliary units houses a different type of operating component selected from the group consisting of a transformer, an inverter, a battery, an electrolytic cell, and switchgear.

2. The set of units according to claim 1, wherein, at least one of the at least two auxiliary units does not form part of the nacelle.

3. The set of units according to claim 2, wherein, the generator of the wind turbine operates with the operating components in each auxiliary unit to deliver the power from the generator in a converted form without using the auxiliary unit that does not form part of the nacelle.

4. The set of units according to claim 1, wherein, the main unit defines a first interface that allows selective connection of one of the at least two different auxiliary units such that each auxiliary unit can be attached to the same position on the main unit.

5. The set of units according to claim 4, wherein, the main unit defines a second interface on the opposite side of the main unit and allows selective connection of one or the other of the at least two different auxiliary units.

6. The set of units according to claim 5, wherein, the same interface of the at least two different auxiliary units can be assembled with the first interface and the second interface.

7. The set of units according to claim 5 or 6, the set of units including at least two different auxiliary units configured for the first interface and / or at least two auxiliary units configured for the second interface.

8. The set of units according to claim 1, wherein, two auxiliary units house the same type of operating components.

9. The set of units according to claim 8, wherein, the two operating components of the same type have different rated powers.

10. The set of units according to claim 1, wherein, the auxiliary units house different types of operating components.

11. The set of units according to claim 10, wherein, The set of units includes a first series of auxiliary units, each auxiliary unit of the first series accommodating an operating component of a first type and each operating component having a different capacity, and wherein the set of units includes a second series of auxiliary units, the second series of auxiliary units accommodating operating components of a second type, the operating components of the second type interacting with the operating components of the first type during operation of the wind turbine nacelle, and each operating component of the second type having a capacity matching the capacity of one of the operating components of the first type accommodated in one of the auxiliary units of the first series.

12. The set of units according to any one of claims 1 to 6, wherein, the two different auxiliary units having the same interface towards the main unit facilitate attachment to at least two different positions on the main unit.

13. The set of units according to claim 12, wherein, the at least two different positions on the main unit are a right-hand position and a left-hand position on opposite sides of the rotor support assembly.

14. The set of units according to any one of claims 1 to 6, wherein, the wind turbine includes a generator located outside the nacelle.

15. The set of units according to any one of claims 1 to 6, wherein, the nacelle further accommodates a generator (33).

16. A wind turbine comprising a nacelle formed by a set of units according to any one of the preceding claims.

17. A method of manufacturing a nacelle by using a set of units according to any one of the preceding claims, the method comprising: - selecting a main unit and one of the at least two different auxiliary units; and - manufacturing the nacelle by connecting the selected auxiliary unit to the main unit.

18. The method according to claim 17, the method comprising using at least one of the at least two auxiliary units as an auxiliary unit that does not form part of the nacelle.

19. The method according to claim 17 or 18, the method comprising the step of attaching the nacelle to a wind turbine tower by assembling the main unit and the wind turbine tower.

20. The method according to claim 19, the method comprising the following subsequent steps after attaching the main unit to the wind turbine tower: assembling the auxiliary unit and the main unit.

21. The method according to claim 17 or 18, the method comprising defining a constraint for each auxiliary unit, the constraint defining other auxiliary units configured to interact with the auxiliary unit under discussion or defining other auxiliary units that cannot interact with the auxiliary unit under discussion.

22. The method according to claim 17 or 18, the method comprising defining: - a desired nacelle configuration; - determining a plurality of combinations between at least one main unit and different auxiliary units; - defining the resulting nacelle configuration for each combination; and - selecting a combination based on a comparison of the resulting nacelle configuration with the desired nacelle configuration.

23. The method according to claim 22, wherein, the defined desired nacelle configuration and the defined resulting nacelle configuration include at least one of a desired grid frequency, an output rated power, and a specific desired climate condition.

24. The method according to claim 17 or 18, the method comprising: selecting a combination between the main unit and the auxiliary unit based on the generator power defined for the main unit, the average wind speed, and the total rated power of the conversion components defined for the auxiliary unit.

25. The method according to claim 17 or 18, wherein, the main unit and the auxiliary unit are selected to provide a nacelle that generates a chemical substance based on the electricity from the generator.

26. The method according to claim 25, wherein, the main unit and the auxiliary unit are selected to provide a nacelle that generates electricity for the grid in addition to the chemical substance generated based on the electricity from the generator.

27. The method according to claim 17 or 18, wherein, the main unit and the auxiliary unit are selected to provide a nacelle that generates electricity based on an airborne unit.

28. The method according to claim 17 or 18, the method comprising defining a plurality of combinations of a main unit and different auxiliary units for the left side of the main unit.

29. The method according to claim 17 or 18, the method comprising defining a plurality of combinations of a main unit and different auxiliary units for the right side of the main unit.

30. The method according to claim 17 or 18, the method comprising defining a plurality of combinations of different main units and one or more auxiliary units for the right side of the main unit.

31. The method according to claim 17 or 18, the method comprising defining a plurality of combinations of different main units and one or more auxiliary units for the left side of the main unit.

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