Nacelles for wind turbines

Abstract

A wind turbine nacelle is configured for mounting on a wind turbine tower and for supporting a rotor support assembly. The nacelle includes a main unit and at least one auxiliary unit. To increase flexibility and improve wind turbine assembly and maintenance procedures, the auxiliary unit includes at least two sub-units, each sub-unit housing at least one wind turbine component, such as an inverter or transformer. These sub-units are attached individually to the main unit or they are joined together and attached to the main unit as a single component.

Description

Technical Field

[0001] The present disclosure relates to a nacelle for a wind turbine, the nacelle comprising a main unit and at least one auxiliary unit mounted on one side of the main unit. The nacelle of the present invention is particularly suitable for large wind turbines. The present disclosure further relates to a method for erecting a wind turbine comprising such a nacelle. Background Art

[0002] The size of wind turbines is constantly increasing, both in terms of rated power output and in terms of the physical size of the individual components of the wind turbine. As a result, the size of the nacelle must also increase in order to accommodate the required wind turbine components. The wind turbine is typically transported from the manufacturing location or locations of the individual components to the work site where the wind turbine is erected. Summary of the invention

[0003] An object of embodiments of the present disclosure is to promote further modularity, ease of design and manufacture and 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 means and to reduce transport and handling costs without limiting the possible size of the nacelle.

[0004] In accordance with these and other objects, the present disclosure provides a wind turbine nacelle configured for mounting on a wind turbine tower and for supporting a rotor support assembly defining an axis of rotation, the nacelle comprising:

[0005] a main unit arranged to be connected to a wind turbine tower and to house a rotor support assembly, and

[0006] At least one auxiliary unit.

[0007] The main unit and the auxiliary unit are independent units, for example, arranged side by side in a direction away from the rotation axis and assembled in a first interface, and at least one of the auxiliary units includes at least two sub-units, for example, assembled in a second interface or at least two sub-units that are separately attached to the main unit without being engaged with each other.

[0008] The main unit may be considered as the central part of the nacelle. The main unit may be arranged to be connected to the wind turbine tower via the yaw device. Thus, it may comprise at least a part of the yaw device. Furthermore, it may house the rotor support assembly. In particular, the main unit may comprise a main frame to allow forces from the rotor and the drive train to be directed downwards into the tower via the yaw device.

[0009] In a wind turbine in which the main unit accommodates the rotor support assembly, the auxiliary unit or units may typically accommodate a plurality of different wind turbine components. Splitting the auxiliary unit into at least two subunits allows different suppliers to supply different independent units. This allows the packaging and logistics during the transport of the at least one component to be performed by separate suppliers and at the construction site of the wind turbine each subunit supplied with its at least one component may be assembled and used directly to form the auxiliary unit of the nacelle. During the entire shipping and assembly process the at least one component may remain encapsulated in the subunit and thus optimal protection of the at least one component may be provided during the entire shipping and assembly process.

[0010] In particular, continuous packaging and use of the at least one component in a subunit forming part of the final nacelle potentially provides increased life and reduced store functionality in areas where the at least one component may become soiled by dirt, rain, water or sand etc. The number of liability transfers may also be reduced, as the supplier may remain responsible for the at least one component and the subunit, e.g. throughout the shipping and assembly process, until the seal into the subunit is broken and the at least one component is connected to other wind turbine components housed in other subunits or in the main unit.

[0011] In particular, different wind turbine components may be delivered in sealed containers forming a plurality of subunits, and the seals may remain intact until the subunits are assembled to form a portion of the nacelle. In a final assembly state, e.g., in which all wind turbine components are installed in the nacelle and the nacelle is in position on the tower, the sealed container may be opened and connections between the different wind turbine components may be established. Until this point, the packaging of at least one component in the subunit is in a state provided by the supplier.

[0012] The secondary unit and / or the primary unit may be formed to have a size and / or shape comparable or equal to that of a shipping container. Each unit thus inherits the advantages of a shipping container with respect to handling, transportation and storage. A shipping container can be transported anywhere in the world, for example by ship, train, truck, etc., and at a lower cost than bulk transportation.

[0013] The cost savings are even more significant with the shipping freight containers that make up these units. Shipping freight containers are also known as intermodal containers, standard freight containers, box containers, ocean containers, or ISO containers, and generally refer to containers used to store and move materials and products in the global containerized intermodal transportation system for intercontinental traffic. Shipping freight containers may follow the dimensional and structural specifications in the ISO standard ISO 668:2013 for Series 1 freight containers.

[0014] In one embodiment, the nacelle comprises two secondary units, each of which has half the size of a shipping freight container conforming to 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 into one container during transport and divided into two secondary units to be arranged on opposite sides of the main unit. The container can be divided in particular in an interface extending along the longitudinal direction of the container (i.e. the longest dimension of the container).

[0015] The nacelle may be carried directly by the tower or indirectly via an intermediate tower structure. If the wind turbine is of a conventional horizontal axis type, the nacelle is usually carried by a yaw device between the tower top and the nacelle. However, the present disclosure may also relate to a multi-rotor wind turbine of the type in which more than one nacelle is carried by a crossbeam structure which is again carried by the tower.

[0016] The present disclosure may relate to upwind wind turbines or to downwind wind turbines.

[0017] The main unit is the component connecting the nacelle to the tower directly or indirectly via said intermediate tower structure or structures.The main unit may in particular be a central part of the nacelle and accommodate parts of the drive train, eg at least a part of the rotor shaft.

[0018] 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 where the generator is located, for example, in the main unit.The main unit supports the rotor via a rotor shaft.

[0019] 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, which connects the drive train with the tower or an intermediate tower structure, e.g. via a yaw device. The main frame may in particular be a cast component.

[0020] The main frame can rotate relative to the tower via the yaw device. This can be facilitated by connecting the main frame to the tower via the yaw device or by connecting at least two main frames of a separate nacelle structure to the tower via the intermediate tower structure, which is again coupled to the tower via the yaw device.

[0021] The main unit and the auxiliary unit are assembled in a first interface. The first interface may be particularly suitable for allowing the auxiliary unit to be released from the main unit after the main unit is assembled on the top of the tower. For this purpose, the first interface may include interlocking structural features located on the main unit and the auxiliary unit. Examples of such interlocking features may be protrusions on one of the main unit and the auxiliary unit and recesses or holes on the other of the main unit and the auxiliary unit, the first interface may be a bolt interface that allows the main unit and the auxiliary unit to releasably engage, or the auxiliary unit may be held in place on the main unit by a cable, through which the auxiliary unit may be lowered to the ground for maintenance, replacement of components, or for transportation of components and personnel between the ground and the cabin. In one embodiment, the first interface is configured so that the auxiliary unit can be received by the main unit when the auxiliary unit is lowered close to the main unit. Such an interface may be composed of a hook or an upwardly protruding rail on at least one of the main unit and the auxiliary unit.

[0022] In one embodiment, these subunits are attached to the main unit separately. In this embodiment, the first interface interacts with each subunit separately. In another embodiment, these subunits are assembled in the second interface. The second interface can be particularly suitable for allowing a subunit to be released from another subunit. For this purpose, the second interface can include interlocking structural features located on each subunit. An example of such interlocking features can be a protrusion on one of the subunits and a notch or hole on another subunit in each subunit. The second interface can be a bolt interface that allows each subunit to releasably engage with each other, or each subunit can be engaged by a cable, through which a subunit can be lowered to the ground for the maintenance, replacement of components or for the transportation of components and personnel between the ground and the cabin. In one embodiment, the second interface is configured so that when a subunit is lowered close to another subunit, the subunit can be received by the other subunit. Such an interface can be composed of a hook or a guide rail protruding upward and outward on at least one of the subunits or two subunits located in the subunit.

[0023] One subunit may form an upper unit, and another of the subunits may form a lower unit. The upper unit and the lower unit are aligned in a vertical row. In this embodiment, the lower unit may be particularly considered for at least one component that requires frequent maintenance or replacement, and the second interface may include a plurality of cables, through which the upper subunit can be lowered to the ground for maintenance, replacement of the component, or for transportation of the component and personnel between the ground and the cabin.

[0024] In one embodiment, the upper unit is located at a height above the main unit. In this case, the upper unit can also be considered for at least one component imposing a higher safety risk, and by the higher position, fire and heat can be more easily isolated in the upper unit.

[0025] The lower unit may also be considered for at least one component imposing a higher safety risk and, through the lower position, the lower unit may be released and sent to the surface in case of a fire or the like.

[0026] The upper unit may form the top of the lower unit, which means that the upper surface of the lower unit is covered by the lower surface of the upper unit. For this purpose, the lower unit and the upper unit may have almost the same shape and / or size when seen in a horizontal section. The lower unit and the upper unit may be almost the same unit and they may have substantially the same content. For example, they may house a transformer and an inverter.

[0027] In one embodiment, the secondary unit formed by the upper sub-unit and the lower sub-unit has a height substantially equal to the height of the primary unit, for example, 80-120% of the height of the primary unit.

[0028] In one embodiment, the main unit defines a side wall extending between a bottom and a top. In this embodiment, both the lower unit and the upper unit can be suspended from the same side wall of the main unit.

[0029] If the subunits are engaged in the second interface, it may specifically extend transversely to the first interface, e.g. perpendicularly to the first interface. In one embodiment, the first interface is substantially planar and follows the side surfaces of the primary and secondary units. The interface may extend in a plane parallel to the axis of rotation and having a surface normal perpendicular to the axis of rotation.

[0030] Both the main unit and the sub-unit may have wall portions facing each other to provide a double-sided wall structure.

[0031] A gap may be defined between a subunit and the main unit and / or between two subunits. Thus, at least one of the first interface and the second interface may define a gap between the walls, ie, between the main unit and the auxiliary unit or between subunits of the auxiliary unit.

[0032] In one embodiment, two subunits have gaps with the main unit, in one embodiment, only one subunit has a gap with the main unit, in one embodiment, two subunits have a gap, and in one embodiment, there are gaps between subunits and between subunits and the main unit. The gaps may allow air to pass between the main unit and the auxiliary unit or between the subunits of the auxiliary unit, and thus may increase safety by preventing the spread of fire or heat convection between units with gaps therebetween. The gaps may further increase cooling in the unit.

[0033] Inlet may be defined from the main unit to at least one of the subunits, and / or from one subunit to another subunit.The nacelle may include a gasket sealingly engaging the two subunits or a subunit and the main unit to form a sealed engagement between the engaged components.

[0034] The gasket around the inlet from the main unit to the sub-unit may specifically engage the walls of both the main unit and the sub-unit, and the gasket around the inlet from sub-unit to sub-unit may specifically engage the walls of both sub-units.

[0035] Each subunit may form an interior space which may be completely separate from the space in the main unit and / or from the space in another subunit. For this purpose, the subunits may include suitable sealing means for sealing any openings, such as openings around cables or pipes extending from the main unit into the subunit or between two subunits.

[0036] One of the subunits may form a front unit and another of the subunits may form a rear unit, and the front unit and the rear unit are aligned in a horizontal row. In this embodiment, the rear unit may in particular be considered to be rearwards in the direction from the hub of the wind turbine and downwards in the direction of the rotor. In a typical upwind turbine, the wind turbine control will keep the hub in the upwind direction when the wind turbine is running. The rear unit may in particular include at least one component that imposes a higher safety risk, and with the rear position, the wind carries dangerous pollutants and fires etc. out of the wind turbine and increases the safety of personnel involved in maintenance or assembly etc.

[0037] The secondary unit may house at least one component that interacts with a wind turbine component in the primary unit. The interaction may include electrical communication of signals or power or communication via cooling or lubrication fluids.

[0038] The power conversion assembly converts the power from the generator into a desired energy form. The power conversion assembly can be configured to deliver electricity (e.g., in AC or DC) or to convert the electricity from the generator into other forms of energy, such as hydrogen, ammonia, or methanol.

[0039] In the case of electrical energy, the power conversion assembly can be configured to connect the generator to, for example, an external power grid. In this case, the power conversion assembly can be composed of, for example, an inverter, a transformer, and a switch gear. Any such components can be included in the power conversion assembly.

[0040] As an example, the generator may be an asynchronous or synchronous generator, eg, an asynchronous or synchronous generator, and the inverter voltage may be in the same range as the generator voltage (sometimes referred to as the stator voltage).

[0041] In another example, the generator may be a doubly fed induction generator (DFIG). In this case, the voltage on the inverter may be different from the generator stator voltage. The inverter is connected to the generator rotor and is typically the same voltage as the stator voltage or lower.

[0042] 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 a low voltage or a medium voltage.

[0043] In a wind turbine configured to produce hydrogen, ammonia, or methanol, the power conversion assembly may include an electrolytic cell configured to produce the substance based on electricity from the generator.

[0044] In other embodiments, the wind turbine may store energy and the power conversion assembly may include a battery.

[0045] The working component may for example be selected from the group consisting of a transformer, an inverter, a battery and a fuel cell.Thus, the secondary unit may comprise an outer surface facing the primary unit and comprising an interface for electrical or fluid communication facilitating such working components.

[0046] In a corresponding manner, one or each of these subunits may house working components that interact with wind turbine components in another subunit. The working components in one subunit may, for example, be selected from the group consisting of a transformer, an inverter, a battery and a fuel cell. Thus, a subunit may include an outer surface that faces another subunit and includes interfaces for electrical or fluid communication and facilitating these specific components.

[0047] A working component in one subunit may have the same function as a working component in another subunit. This provides dual functionality in the case where different components are dedicated to the same function. One of the two components of the same function may be housed in one of the subunits, while the other component may be housed in the other subunit.

[0048] In the event of a fault, the wind turbine may continue to operate at reduced power while replacing an operating component in one of the subunits, for example by replacing the entire subunit.

[0049] At least one sub-unit may house a working component that is suspended directly from the main unit.

[0050] The subunit may be sealed and the electronic alarm structure may sense theft or intrusion of water, moisture or undesirable temperatures etc. The subunit may include a climate control device, for example in the form of a dehumidifier, air conditioning device or heater.

[0051] The subunit may in particular be self-sustaining via its own power source in the form of batteries or solar cells etc. so as to allow the alarm structure or climate control device to remain operational during transport and assembly.

[0052] The subunit may include an identification structure with identification data (e.g., a tag) to identify the working part and the location of the subunit on the nacelle. The identification tag may, for example, identify which auxiliary unit the subunit belongs to, and it may identify the most recent repair or replacement of the working part or the entire subunit.

[0053] The identification structure may include an electronic radio communication of the identification data.

[0054] At least one of the sub-units may have a size or shape corresponding to the size or shape of a shipping container of, for example, 10, 20, 40, or 45 ft. In particular, the primary unit may be 40 ft. or 45 ft. long, and the sub-units constituting at least one of the secondary units may be two 20 ft. containers.

[0055] At least one of the subunits may be configured for high current components, while another subunit may be configured for high voltage components.The units may form differently classified safety areas.

[0056] One subunit may, for example, include a gas-based fire extinguishing system for achieving a specific classification with respect to a fire.

[0057] The nacelle may include a system for automatically releasing at least one of the subunits. This feature may be used, for example, in the event of a fire, where one unit may be released to prevent the spread of the fire. The released unit may be lowered to the ground in a controlled manner, for example, by a cable structure comprising an automatic braking mechanism to prevent high lowering speeds. In one embodiment, one or more of the subunits are fixed to other subunits or the main unit by bolts, the bolts comprising an explosion-based release mechanism and fixed to a winch by a cable, the winch having a braking coupling to prevent the winding speed from exceeding a certain limit. In the event of a fire in the subunit, the bolts are broken and the subunit falls to the ground controlled by the cable. Thus, the automatic release device may include various devices for automatically releasing the unit, including a power-driven hook, an explosive bolt, a deceleration cable for lowering the unit, and the like.

[0058] In particular, one subunit may include an inverter and another of the subunits may include a transformer. The two subunits may in particular be directly adjacent and form one of the auxiliary units. Alternatively, at least one subunit may include an inverter and another of the subunits may include a battery or a fuel cell.

[0059] At least one of the subunits may be separated from another of the subunits and lowered individually.

[0060] In one embodiment, the primary unit and the secondary unit are joined in an interface forming a gap that allows air to pass from below the nacelle through the gap to above the nacelle. Such a gap can increase heat convection and thus increase cooling of the space within the primary unit and the secondary unit.

[0061] In one embodiment, the vibration-damping material is arranged between the primary unit and the secondary unit. Rubber or foam materials, or materials with similar elastic deformability and vibration-damping effects, may be used. The vibration-damping material may be particularly compressed between the primary unit and the secondary unit, and it may be particularly arranged where the primary unit and the secondary unit are fixed by nails, rivets, bolts or any similar mechanical attachments.

[0062] In one embodiment, the primary unit is wider than the secondary unit. By "wider" the primary unit is meant that its dimension in the horizontal plane and perpendicular to the axis of rotation is larger than the same dimension of the secondary unit. The primary unit may specifically be wider than a shipping cargo container that follows the dimensional and structural specifications in the ISO standard ISO 668:2013 for Series 1 cargo containers, while the secondary unit may have dimensions specified for those ISO standards (ISO 668:2013) Series 1 cargo containers or less.

[0063] In one embodiment, the primary unit comprises a cantilever beam structure movable between a suspended configuration and a retracted configuration. In the suspended configuration, the cantilever beam structure forms at least one and optionally several outwardly protruding cantilevers, which are configured to carry the secondary unit and can be used to hoist the secondary unit towards and away from the primary unit. The outwardly protruding cantilever beam structure can be specifically attached to a top part of the primary unit.

[0064] The nacelle may include a crane structure attached to the main unit and configured to lift the auxiliary unit from the ground in a vertical direction to a position where the unit fixing structure can connect the auxiliary unit to the main unit. This means that the crane structure is configured to lift the auxiliary unit vertically without having to move the auxiliary unit in other directions. This lifting process is particularly suitable for combination with the unit fixing structure including a rotatable or slidable hook, thereby facilitating attachment without requiring relative movement between the main unit and the auxiliary unit in directions other than the vertical direction.

[0065] In a second aspect, a method of manufacturing a nacelle for a wind turbine is provided. The method comprises: receiving at least two wind turbine components, each located in a container. The two containers are joined while the components are located in the containers. The secondary unit formed by the joining is attached to the primary unit, and the primary unit is attached to the wind turbine tower. The primary unit may be attached to the wind turbine tower before or after the secondary unit is attached to the primary unit, and the containers may be joined to the primary unit one by one, or they may be joined before they are assembled with the primary unit into a single secondary unit.

[0066] In particular, it may be advantageous to deliver the two components into separate subunits, assemble the subunits at or near the location where the wind turbine is erected to define the secondary unit, and assemble the main unit and the secondary unit, for example on top of a tower.

[0067] The container may be sealed and may provide electronic alarms, ie, based on unexpected intrusion or undesirable temperature, water or humidity.

[0068] The container may be arranged to isolate one of the two wind turbine components from the other of the two wind turbine components in a gas-tight manner. Such a gas-tight isolation in a selected sub-unit may have several advantages. One sub-unit may be gas-tight, while an adjacent sub-unit may be open, thereby allowing for example a rapid pressure reduction in the event of a fire. By dividing the auxiliary unit into several sub-units, each sub-unit may be gas-tight or open, depending on the risk of fire etc.

[0069] The sub-unit may be arranged to hermetically isolate at least one of the two wind turbine components from wind turbine components in the main unit and / or wind turbine components in other containers.

[0070] A sub-unit may be released from another container and from the main unit in response to an incident such as a fire.

[0071] List of numbered implementations

[0072] 1. A wind turbine nacelle configured for mounting on a wind turbine tower and housing a rotor support assembly defining a rotation axis, the nacelle comprising:

[0073] a main unit arranged to be connected to a wind turbine tower and to house a rotor support assembly, and

[0074] at least one auxiliary unit,

[0075] Wherein, the main unit and the auxiliary units are independent units assembled at a first interface, and at least one of the auxiliary units includes at least two sub-units assembled at a second interface.

[0076] 2. The nacelle of embodiment 1, wherein one of the subunits forms a front unit and another of the subunits forms a rear unit.

[0077] 3. The nacelle of embodiment 2, wherein the front unit and the rear unit are aligned in a horizontal row.

[0078] 4. A nacelle according to any of the preceding embodiments, wherein one of the subunits forms an upper unit and another of the subunits forms a lower unit.

[0079] 5. The nacelle of embodiment 4, wherein the upper unit and the lower unit are aligned in a vertical row.

[0080] 6. The nacelle according to embodiment 5, wherein the upper unit forms a top of the lower unit.

[0081] 7. A nacelle according to any of the preceding embodiments, wherein the second interface extends transversely to the first interface.

[0082] 8. A nacelle according to any of the preceding embodiments, wherein the secondary unit houses working components that interact with wind turbine components in the primary unit.

[0083] 9. A nacelle according to any of the preceding embodiments, wherein at least one subunit houses working components that interact with wind turbine components in another subunit.

[0084] 10. A nacelle according to any preceding embodiment, housing a power conversion assembly and wherein the component is a working component forming part of the power conversion assembly.

[0085] 11. A nacelle according to embodiment 10, wherein a working component in one subunit has the same function as a working component in another subunit.

[0086] 12. A nacelle according to any of the preceding embodiments, wherein at least one subunit houses working components that are directly suspended from the main unit.

[0087] 13. A nacelle according to any preceding embodiment, wherein at least one of the subunits is the size or shape of a 10, 20, 40 or 45 foot sized shipping container.

[0088] 14. A nacelle according to any of the preceding embodiments, wherein at least one of the subunits forms a safety area which is categorized differently than another of the subunits with respect to safety regulations.

[0089] 15. A nacelle according to any of the preceding embodiments, wherein one subunit comprises a gas based fire extinguishing system.

[0090] 16. A nacelle according to any of the preceding embodiments, comprising an automatic release of at least one of the subunits.

[0091] 17. A nacelle according to any of the preceding embodiments, wherein at least one subunit comprises a first working component and another of the subunits comprises a second working component, the first and second working components forming parts of the same power conversion assembly.

[0092] 18. A nacelle according to any of the preceding embodiments, wherein at least one subunit comprises an inverter and another of the subunits comprises a battery.

[0093] 19. A nacelle according to any of the preceding embodiments, wherein at least one subunit can be separated from another of the subunits and lowered individually.

[0094] 20. A nacelle according to any preceding embodiment, wherein the primary unit and the secondary unit are arranged side by side in a direction away from the rotation axis.

[0095] 21. A method of manufacturing a nacelle for a wind turbine, the method comprising: receiving at least two wind turbine components each packaged in a container, and attaching two containers with the packaged components to a main unit of the nacelle.

[0096] 22. The method of embodiment 21, wherein the main unit is attached to a wind turbine tower, and wherein the two wind turbine components remain packaged in the container until the main unit is attached to the tower. BRIEF DESCRIPTION OF THE DRAWINGS

[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 The cabin seen from above;

[0102] Figure 5 An embodiment in which the left auxiliary unit and the right auxiliary unit accommodate the same components is shown;

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

[0104] Figure 7 schematically showing details of the interface between the main unit and one of the sub-units;

[0105] Figures 8 to 9 shows the primary and secondary units in an embodiment in which the sub-units are arranged in vertical rows;

[0106] Figure 10 to Figure 11 Details of different layouts with gaps between cells are shown;

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

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

[0109] Fig.19a Figure 19 Fig.19c and Fig. 20 Further details of the hooks used to attach the secondary unit to the primary unit are shown;

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

[0111] Fig. 22 A cross section is shown with two bolt holes for attaching the secondary unit to the primary unit;

[0112] Figures 23, 24, 25a and 25b show 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 a secondary unit is shown. DETAILED DESCRIPTION

[0114] While the detailed description and specific examples indicate certain implementations, they 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 a generator 6 located outside the nacelle.

[0116] Figure 2 The nacelle is shown to comprise a main unit 20 and two auxiliary units 21, 22. A cooling area 23 is arranged on the top of the nacelle. The cooling area is formed by a heat exchanger, which may form part of the main unit and / or any auxiliary unit. The main unit 20 is mounted on the tower 3 via a yaw device (not shown), thereby allowing the nacelle 2 to rotate so as to guide the rotor blades carried by the hub 4 into the wind. The auxiliary unit 22 is divided into two independent subunits 24, 25, both of which are joined to the main unit as two independent subunits. In addition, the subunits can be joined along a second interface 26 to form an auxiliary unit as an assembled entity.

[0117] Figure 3 Shows Figure 2 A perspective view of the cabin 2. Figure 3 In the embodiment, the outer wall of the nacelle 2 is transparent, thereby revealing the inner part of the nacelle 2 and the wind turbine components accommodated therein. The main unit 20 accommodates a main bearing unit 31, a gear device 32 and a generator 33 sequentially arranged behind the hub 4 along the direction defined by the rotation axis of the hub 4.

[0118] The auxiliary unit 21 houses a transformer unit 34 in a rear subunit 36 ​​and an inverter unit 35 in a front subunit 37. The division between the subunits is shown by a transverse partition 38. The rear unit and the front unit are independent units that can be separated from each other and from the main unit individually.

[0119] Each secondary unit 21, 22 is mounted along the side of the primary unit 20 via a first interface. In the disclosed embodiment, the secondary units are mounted such that one secondary unit 21 is mounted along the right side of the primary unit 20 and the other secondary unit 22 is mounted along the left side of the primary unit 20, as viewed from the hub 4 toward the rear wall of the primary unit 20 in the direction along the axis of rotation of the hub 4. The subunits are joined along a second interface. As shown by the bulkhead 38, the second interface may extend perpendicular to the first interface.

[0120] The main unit and the auxiliary unit include a cooperating opening 39, which allows a person to enter the auxiliary space in the auxiliary unit from the main space in the main unit. In a similar manner, the sub-units may include a cooperating opening, thereby allowing a person to enter an adjacent sub-unit from one sub-unit.

[0121] Figure 4 Shows Figure 3 The cabin is seen from above. The subunits 42, 43 of the auxiliary unit 22 each have a wall portion that abuts against the wall of the main unit. The partition 44 is placed between the inverter unit 35 and the transformer unit 34 and represents a second interface, dividing between the two subunits that make up the auxiliary unit 22.

[0122] Figure 5 An embodiment is shown in which the left and right auxiliary units contain at least one identical component establishing weight balance and dual functionality. Dual functionality means that the wind turbine comprises two components of the same function, one component being housed in each auxiliary unit. In the event of a fault, the wind turbine can continue to operate at half power while the working component in one of the auxiliary units is replaced. Figure 5 In FIG. 5 , it is further shown that both auxiliary units 21, 22 comprise two subunits separated by a partition 51. Thus, each dual-function component (ie, transformer or inverter) can be replaced individually in each of the two auxiliary units.

[0123] Figure 6An embodiment is shown in which two subunits 61, 62 are positioned one above the other. Subunit 61 is an upper subunit consisting of a 40-foot container and subunit 62 is a lower subunit consisting of a 20-foot container.

[0124] Figure 7 Details of a first interface are shown. The interface engages the main unit 20 with the subunit 71 in a releasable manner and allows, for example, replacement of one of the subunits of the auxiliary unit during maintenance. The interface consists of an inward guide or rail 73 in one of the subunits 72. The rail 73 is shown in dotted lines and defines a recess into the outer surface 75. The rail has a C-shaped profile in a horizontal cross-section (i.e., when viewed from above). The rail is configured to receive a protrusion 74 provided on the subunit, and in particular, the rail is capable of receiving the protrusion 74 in a very simple process in which the subunit 71 is lowered along the outer surface 75 of the main unit 20. This is shown by arrow 76. This very simple process allows easy replacement of the subunit without having to separate the entire auxiliary unit from the main unit.

[0125] Figures 8 to 9 An embodiment is shown in which the cabin comprises a main unit 20 and three auxiliary units, each of which is composed of two subunits 61, 62. In the embodiment shown, each subunit is directly attached to the main unit, but they can also be attached to another subunit. The upper subunit 61 and the lower subunit 62 are units arranged in the same vertical row. Because the upper unit and the lower unit have the same shape and size when seen in horizontal section, the upper unit forms the top above the lower unit.

[0126] In this embodiment, the auxiliary unit (ie, two stacked sub-units) has almost the height of the main unit, and the two sub-units are suspended at the same side wall of the main unit. The auxiliary unit is arranged on the rear end of the main unit and on the opposite side of the main unit 20.

[0127] Even if these auxiliary units are attached at the side wall on the right, left or rear side of the main unit, the load of these auxiliary units can be carried by a more rigid structure located at the side wall or inside the main unit, for example, by the main frame of the nacelle, which is arranged to carry the rotor assembly and transfer the load of the rotor assembly to the tower.

[0128] Fig. 9 The same nacelle is shown but with the sides of the sub-units removed to show that the upper unit 61 is identical to the lower unit 62, ie they house the same components, in this case a transformer and inverter.

[0129] Figure 10 to Figure 11Different layouts provided by the first interface and the second interface, respectively, are shown.

[0130] exist Fig.10 In the embodiment of the present invention, the first interface provides a gap between the primary unit and the secondary unit. The gap allows air to pass between the primary unit and the secondary unit, thereby supporting effective cooling by convection. In addition, the gap increases safety, for example by preventing the spread of fire.

[0131] exist Fig.11 In the embodiment of the present invention, a gap is defined between the subunits of the auxiliary unit. In addition, the gap allows air to pass between the subunits of the auxiliary unit, thereby supporting effective cooling by convection and increasing safety.

[0132] Figures 12 to 15 Four different embodiments of the unit fixing structure forming part of the second interface, ie the embodiment of the interface between two subunits of the auxiliary unit, are shown. In each of the four illustrations, the first subunit 121 and the second subunit 122 are connected by a cooperating structure described below.

[0133] exist Fig.12 In the embodiment, the cooperating structure is constituted by a bracket 123, by means of which the first subunit and the second subunit are joined by bolts.

[0134] exist Fig.13 In the collaboration structure, Fig.12 The first and second subunits are assembled at the upper edge by means of a hook 131 pivotally engaged to the first subunit at a hinge point 132. The hook can be rotated as indicated by arrow 133 and engages an edge bracket 134 of the second subunit when in the position shown. When the lower bracket 123 is removed and the hook 131 is rotated into the first subunit, the second subunit can be lowered to the ground.

[0135] Fig.14 The implementation method in Fig.13 The embodiment in is comparable, but wherein the lower bracket is replaced by an upper bracket 141 and the hook is placed at the lower edge.

[0136] exist Fig.15 In the embodiment, the lower bracket and the upper bracket are used to bolt the second subunit to the first subunit, and the slidable support 151 supports the lower surface of the second subunit in the state where the bolts have been attached. If the second subunit needs to be lowered to the ground, for example, for replacement or maintenance of working parts, the slidable support can be slid to the left, and the second subunit can be lowered, for example, by using a crane built into the first subunit. Figures 12 to 15In any of the embodiments shown, the brackets or hooks direct the load from the secondary unit into a rigid portion of the primary unit, for example, into a load carrying column such as a corner column of the primary unit. Various structural features can connect the brackets or hooks carrying the secondary unit directly to the main frame in the primary unit, thereby establishing a load path into the tower.

[0137] Figures 16 to 18 An embodiment is shown in which the first and second subunits 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 a gap 167 forming the interface, allowing air to pass through it, for example from below the nacelle to above the nacelle. The gap is kept open at the bottom by a distance element 168, which may consist of a number of pins or an open structure allowing air to pass between the units.

[0138] Such a gap can increase heat convection and thus increase cooling of the space within the first subunit and the second subunit.The gap is not limited to the embodiment with a hinged structure, but can be combined with any other assembly method.

[0139] 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.

[0140] Fig.19a , Fig.19b and Fig.19c Further details of hooks for attaching one unit 191 to another unit 192 are shown, for example, a subunit to a main unit or a subunit to another subunit, referred to herein simply as a first unit and a second unit. A hook 193 is rotatably suspended at a hinge 194 in the first unit and catches a notch or edge 195 in the second unit.

[0141] The hook may also be attached in the second unit and catch a notch or edge in the first unit, in which case the hook may be attached in reverse, i.e., as Fig. 20 The hook can be positioned by using an actuator.

[0142] Fig.21 The hook is shown in an open position, in which the second unit is free to be lowered to the ground.

[0143] Fig. 22A cross section is shown in which two bolt holes 221 are visible. The bolt holes help attach the second subunit to the first subunit by using bolts for secure fixing. In this embodiment, the hook is mainly used to position the second subunit at the correct height relative to the first subunit, and the bolts are used to join the units.

[0144] In Figure 19, Fig.21 and Fig. 22 In the embodiment, the hook is preferably supported by a rigid frame structure, for example, via a column or support rod arranged along the inner surface of the unit that holds the hook. In Figure 19, a column 197 extends along the inner surface of the unit and supports the hook on the main frame in the bottom portion of the unit.

[0145] The hook can be moved in the open position ( Fig.21 ) and closed position (Figure 19, Fig. 20 , Fig. 22 )

[0146] Figures 23, 24, 25a and 25b show an embodiment in which the hook is not suspended rotatably but slidably. This function is similar to that of Figures 19 to 25. Fig. 22 In Figures 23 and 24, the cross-sectional views show bolt holes 231 which can be used for secure bolting of the units.

[0147] In Figure 25a, the 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. In Figure 25b, 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 powered drive (e.g., by a hydraulic actuator).

[0148] In the above description, FIGS. 19 to 25 b are explained as parts of the unit fixing structure for coupling the units.

[0149] Fig.26 The unit is shown being lifted up or down during maintenance or replacement. The unit is lifted using a crane 261 forming part of the main unit or forming part of one of the sub-units. Movement is substantially only in the vertical plane shown by arrow 263 and attachment of the auxiliary unit or one of the sub-units may be assisted by a unit securing structure as previously described, including moveable securing features such as hinged or slidable hooks or the like.

[0150] Fig. 27An internal crane 261 is shown in an enlarged view. The crane is attached to the top portion of the main unit or one of the subunits and, through its position, the crane can lift other units in a vertical direction to a position where the unit fixing structure can form a joint between the units. This process may not require movement in directions other than the vertical direction and thus facilitates a simple assembly process, 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.

[0151] Fig.28 Another crane structure is schematically shown with a double cantilever beam 281 on top of the main unit 282 or on top of one of the sub-units. The cantilever beam 281 can be extended laterally in a telescopic section 283. The cantilever beam facilitates the lifting and connection of another unit 284. Even though the unit fixing structure disclosed herein (including pivotable or slidable hooks) generally facilitates the attachment of the auxiliary unit or sub-unit by lifting only in the vertical direction, the in-and-out movement can also facilitate the fine adjustment of the horizontal distance between the main unit and the auxiliary unit.

[0152] definition

[0153] Herein, the term "nacelle" refers to the commonly accepted term describing the machine room for a wind turbine, ie the part that carries the rotor and drive train and is carried by the wind turbine tower.

[0154] The terms "primary unit" and "secondary unit" herein refer to units that can be transported separately and that can be assembled with one or more other units to form a cabin.

[0155] Herein, the term "rotor support assembly" refers to those parts of the nacelle that carry the rotor, typically the drive train, the main bearings and the 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 wind turbine nacelle configured for mounting on a wind turbine tower and housing a rotor support assembly defining a rotation axis, the nacelle comprising: a main unit arranged to be connected to a wind turbine tower and to house the rotor support assembly, and at least one auxiliary unit, wherein the primary unit and the at least one secondary unit are independent units assembled at a first interface, and Wherein, the at least one auxiliary unit comprises at least two sub-units, and the at least two sub-units are individually attached to the main unit at the first interface.

2. The nacelle according to claim 1, wherein: One of the at least two sub-units forms an upper unit, and another of the at least two sub-units forms a lower unit, the lower unit being arranged below the upper unit and aligned in a vertical row with the upper unit.

3. The nacelle according to claim 2, wherein: The upper unit forms a top portion of the lower unit.

4. The nacelle according to claim 2, wherein: When viewed in horizontal cross-section, the lower unit and the upper unit have substantially the same shape and / or size.

5. The nacelle according to claim 2, wherein: The at least one auxiliary unit formed by the upper sub-unit and the lower sub-unit has a height between 80% and 120% of the height of the main unit.

6. The nacelle according to claim 2, wherein: The main unit defines a side wall extending between a bottom and a top, and wherein the lower unit and the upper unit are suspended from the main unit at a same side wall of the main unit.

7. The nacelle according to claim 1, wherein: The at least two subunits are identical units.

8. The nacelle of claim 1, wherein: A gap is defined between the main unit and the at least one auxiliary unit and / or between the at least two sub-units of the at least one auxiliary unit, and the gap allows air to pass between the main unit and the at least one auxiliary unit and / or between the at least two sub-units of the at least one auxiliary unit.

9. The nacelle according to claim 8, wherein: The gap is defined between the main unit and the at least one auxiliary unit and between the at least two subunits of the at least one auxiliary unit.

10. The nacelle according to claim 9, wherein: Gaps between the at least two sub-units and between the at least one auxiliary unit and the main unit are connected to each other.

11. The nacelle of claim 1 , comprising an entrance from the main unit to at least one of the at least two subunits.

12. The nacelle of claim 1, comprising an inlet from one of the at least two subunits to another of the at least two subunits.

13. A nacelle according to claim 11 or 12, comprising a gasket sealingly engaging two sub-units or a sub-unit and a main unit to form a sealing joint between the engaging parts.

14. The nacelle of claim 1, wherein: Each of the at least two subunits is formed to be airtightly separated from a space in the main unit, and / or each of the at least two subunits is airtightly separated from a space in another of the at least two subunits.

15. The nacelle of claim 1, wherein: At least one of the at least two sub-units forms a security area that is classified differently from another of the at least two sub-units with respect to security rules.

16. The nacelle of claim 1, wherein: One of the at least two subunits comprises a gas based fire extinguishing system.

17. The nacelle of claim 1, comprising an automatic release of at least one of the at least two subunits, the automatic release allowing the at least one subunit to be removed from the main unit and from another of the at least two subunits.

18. The nacelle of claim 1, wherein: One of the at least two sub-units forms a front unit, wherein another of the at least two sub-units forms a rear unit, and wherein the front unit and the rear unit are aligned in a horizontal row.

19. The nacelle of claim 1, wherein: At least one of the at least two subunits is sized or shaped like a 10, 20, 40 or 45 foot sized shipping container.

20. The nacelle of claim 1, the at least two subunits of the at least one auxiliary unit being assembled in a second interface.

21. A wind turbine comprising a nacelle according to any of the preceding claims.

22. A method of manufacturing a nacelle for a wind turbine, the nacelle comprising a main unit and at least one auxiliary unit, the at least one auxiliary unit comprising at least two subunits, the method comprising: receiving at least two wind turbine components each packaged in a container forming a respective one of the at least two subunits; as well as attaching the at least two sub-units with the components enclosed therein to the main unit of the nacelle at a first interface, Wherein, attaching the at least two sub-units comprises individually attaching each of the at least two sub-units to the main unit at the first interface.

23. The method of claim 22, further comprising attaching the main unit to a wind turbine tower, wherein: The two wind turbine components remain packaged in the respective containers of the at least two sub-units until the main unit is attached to the tower.

24. The method of claim 22 or 23, further comprising hermetically isolating one of the at least two wind turbine components from another of the at least two wind turbine components.

25. The method of claim 22 or 23, further comprising hermetically isolating at least one of the at least two wind turbine components from a wind turbine component in the main unit.

26. The method according to claim 22 or 23, further comprising: In response to an event, one container of the at least two subunits is released from another container of the at least two subunits and from the main unit.

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