A lightweight, high-strength structure for the casing of a large wind turbine generator

Abstract

This invention relates to the field of wind turbines, specifically to a lightweight, high-strength structure for a large wind turbine casing, comprising a bottom casing and a top casing. The invention utilizes external airflow entering through an inlet on the windward side, flowing through a duct, and accelerating under the guidance of a conical structure in a guide ring. The accelerated airflow continues along the duct, eventually exiting through an outlet, entering a connecting slot, and acting on a baffle plate, thereby driving a rotating plate to rotate. The rotation of the rotating plate is converted into tension force through a connecting arm, creating a continuous, dynamic compression between the bottom and top casings. This structure, by systematically arranging air ducts within the casing, achieves overall weight reduction and lightweight design while cleverly utilizing wind energy during operation to convert it into real-time strengthening force on the connecting structure. This mechanism fundamentally overcomes the drawbacks of traditional static hollowing weight reduction methods that lead to structural weakening, achieving a synergistic unity of lightweight design and high structural strength during dynamic operation.

Description

Technical Field

[0001] This invention relates to the field of wind turbines, and more specifically to a lightweight, high-strength structure for a large wind turbine housing. Background Technology

[0002] The wind turbine housing is a structural enclosure assembly that covers and protects the core equipment of a wind turbine generator set. It uses advanced composite materials and mechanical design to provide physical protection, environmental sealing, structural support, heat dissipation management, and maintenance accessibility for the expensive internal mechanical and electrical systems over a lifespan of 20-25 years.

[0003] In the invention patent application CN211874663U, published on 2020-11-06 and entitled "A Lightweight Wind Turbine Generator Housing," this invention discloses a lightweight wind turbine generator housing, including end plates on the front and rear sides, four bases, a U-shaped enclosure, two top beams, and two motor mounting cylinders. The end plates have openings. One end of each base is fixedly connected to the mounting plane of the end plate, and the other end is located between the two end plates. The top beams are fixedly connected to the tops of the front and rear end plates respectively. The two sides of the U-shaped enclosure are fixedly connected to the front and rear end plates respectively, and the top of the U-shaped enclosure is flush with the top of the end plates. The top of each wall of the U-shaped enclosure forms a concave channel beam with an opening located on the surface of the U-shaped enclosure. The motor mounting cylinders are parallel to the end plates and located between the two end plates. This invention solves the problem of excessive weight in current wind turbine generator housings.

[0004] In the aforementioned patents or prior art, wind turbine casings typically employ a split design, composed of upper and lower sections or multiple parts. Due to the large overall size and weight of the structure, lightweighting is usually necessary to reduce manufacturing costs and installation complexity. Currently, common lightweighting solutions often involve perforating the casing surface and adding reinforcing beams to achieve weight reduction while maintaining some structural strength. However, such methods often weaken the integrity of the connections between components, posing a risk of decreased connection strength or even structural loosening under long-term loads, making it difficult to effectively balance lightweighting with high structural strength.

[0005] Therefore, it is necessary to invent a lightweight, high-strength structure for the casing of large wind turbines to solve the above problems. Summary of the Invention

[0006] The purpose of this invention is to provide a lightweight, high-strength structure for a large wind turbine housing. By setting up air ducts inside the housing and using the airflow entering the air ducts during operation to generate driving force, dynamic clamping force is generated between the split shells. This solves the problem in the prior art where simply using static hollowing to reduce weight leads to a decrease in the strength of the outer shell structure and easy loosening of the connection parts during long-term operation.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a lightweight, high-strength structure for a large wind turbine housing, comprising a bottom cover and a top cover, wherein the bottom cover and the top cover are fixedly connected by bolts, and a shaft groove is provided on one side of both the bottom cover and the top cover, and the two sets of shaft grooves form a complete annular space, an inspection port is provided at the bottom of the inner wall of the bottom cover, lightweight components are provided inside both the bottom cover and the top cover, and a reinforcing component is provided between the bottom cover and the top cover.

[0008] As a preferred embodiment of the present invention, the lightweight component includes air ducts, which are sequentially opened inside the bottom cover and the top cover. Each set of air ducts is sequentially equipped with a guide ring, and the guide rings are made of lightweight carbon fiber material.

[0009] As a preferred embodiment of the present invention, each of the air ducts is provided with an air inlet on one side, and the air inlets are all located on the side close to the rotating shaft groove.

[0010] As a preferred embodiment of the present invention, each group of air ducts has an air outlet on the side away from the air inlet, and each group of air outlets is located at the edge where the top cover and the bottom cover are connected and fitted.

[0011] As a preferred embodiment of the present invention, each group of air inlets is equipped with a filter screen, and each group of filter screens is inclined, and the filter screens are made of lightweight carbon fiber material.

[0012] As a preferred embodiment of the present invention, the reinforcing component includes connecting grooves, which are symmetrically and sequentially opened at the fitting connection points of the bottom cover and the top cover, and each set of air outlets communicates with the corresponding connecting groove.

[0013] As a preferred embodiment of the present invention, a rotating plate is rotatably installed in each of the connecting grooves located on the bottom cover, and a rotating plate is also installed in each of the connecting grooves of the top cover.

[0014] As a preferred embodiment of the present invention, each of the rotating plates in each group is equipped with a baffle on one side, and the baffle inside the bottom cover is in contact with the air outlet inside the top cover, and the baffle inside the top cover is also in contact with the air outlet inside the bottom cover in the same way.

[0015] As a preferred embodiment of the present invention, each of the baffles is provided with an inclined groove on the side near the air outlet.

[0016] As a preferred embodiment of the present invention, a connecting arm is rotatably installed between the rotating plate inside the bottom cover and the corresponding connecting groove inside the top cover, and a set of connecting arms is also rotatably installed between the rotating plate inside the top cover and the corresponding connecting groove inside the bottom cover.

[0017] Compared with the prior art, the technical effects and advantages provided by the present invention in the above technical solution are as follows: When the wind turbine is in operation, external airflow enters the casing through the air inlet on the windward side and flows through a pre-designed air duct. Guided by the conical structure of the guide ring, the airflow is accelerated and maintains a stable flow. The accelerated airflow continues along the air duct and eventually exits from the air outlet, entering a connecting groove located at the edge of the casing. In the connecting groove, the airflow acts on the surface of the baffle, thereby driving the connected rotating plate to rotate. This process not only reduces the static wind pressure on the windward side of the casing by diverting the airflow and alleviates the stress on the overall structure, but more importantly, the rotation of the rotating plate drives the connecting arm to move, forming a continuous and dynamic radial clamping force between the bottom and top casings, thereby enhancing the rigidity and integrity of the connection in real time during operation. By systematically arranging air ducts within the casing and optimizing the material and structural design of internal components, this solution achieves efficient weight reduction of the casing through a dual approach. The air ducts themselves, designed as negative space, directly reduce the amount of material required for the overall casing wall thickness. Structural perforations significantly reduce weight while maintaining the basic form. Furthermore, the guide rings and filter assemblies within the air ducts are made of lightweight carbon fiber, further reducing the weight of internal auxiliary structures. This integrated design approach not only reduces ineffective mass through the rational distribution of physical space but also achieves precise weight reduction in key areas through materials science optimization, effectively meeting the lightweight design requirements of large wind turbine generator sets for casing components. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the inspection port structure of the present invention; Figure 3 This is a schematic diagram of the connecting groove structure of the present invention; Figure 4 This is a schematic diagram of the air duct structure of the present invention; Figure 5 This is a schematic diagram of the air outlet layout structure of the present invention; Figure 6 This is a schematic diagram of the guide ring layout structure of the present invention; Figure 7 This is a schematic diagram of the air inlet structure of the present invention; Figure 8 This is a schematic diagram of the baffle structure of the present invention; Figure 9 This is a schematic diagram of the filter screen structure of the present invention; Figure 10 This is a schematic diagram of the guide ring structure of the present invention; Figure 11 For the present invention Figure 5 Enlarged structural diagram at point A in the middle.

[0020] Explanation of reference numerals in the attached figures: 001, Bottom cover; 101, Top cover; 103, Rotating shaft groove; 102, Inspection port; 002, Lightweight component; 201, Air inlet; 202, Guide ring; 203, Air duct; 204, Air outlet; 205, Filter screen; 003, Reinforcing component; 301, Connecting groove; 302, Rotating plate; 303, Baffle; 304, Inclined groove; 305, Connecting arm. Detailed Implementation

[0021] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0022] This invention provides, for example Figure 1-10 To achieve the above objectives, the present invention provides the following technical solution: a lightweight, high-strength structure for a large wind turbine housing, comprising a bottom cover 001 and a top cover 101, the bottom cover 001 and the top cover 101 being bolted together, both the bottom cover 001 and the top cover 101 having a shaft groove 103 on one side, and the two sets of shaft grooves 103 forming a complete annular space, an inspection port 102 being provided on the lower part of the inner wall of the bottom cover 001, lightweight components 002 being provided inside both the bottom cover 001 and the top cover 101, and a reinforcing component 003 being provided between the bottom cover 001 and the top cover 101.

[0023] Furthermore, in the above structure, the lightweight component 002 includes an air duct 203, which is sequentially opened inside the bottom cover 001 and the top cover 101. Each air duct 203 is sequentially equipped with a guide ring 202, and the guide ring 202 is made of lightweight carbon fiber material.

[0024] By creating air duct 203, the bottom cover 001 and top cover 101 can be made lighter while forming an airflow channel within their internal space. The conical structure inside the guide ring 202 can guide and accelerate the incoming airflow, improving aerodynamic efficiency. The specific carbon fiber material of the guide ring 202 is ZA60XC-12K.

[0025] Furthermore, in the above structure, each group of air ducts 203 has an air inlet 201 on one side, and the air inlet 201 is located on the side close to the rotating shaft groove 103.

[0026] By placing the air inlet 201 in the windward area near the shaft groove 103, it can effectively capture airflow and smoothly guide it into the air duct 203, thereby realizing the auxiliary utilization of wind energy.

[0027] Furthermore, in the above structure, each group of air ducts 203 has an air outlet 204 on the side away from the air inlet 201, and each group of air outlets 204 is located at the edge where the top cover 101 and the bottom cover 001 are connected and fitted.

[0028] By placing the air outlet 204 at the edge of the casing connection, the airflow in the air duct 203 can be directed out, which helps to disperse the wind pressure on the casing surface, avoid local stress concentration, and thus improve the structure's wind load resistance.

[0029] Furthermore, in the above structure, each group of air inlets 201 is equipped with a filter screen 205, and each group of filter screens 205 is set at an angle, and the filter screens 205 are made of lightweight carbon fiber material.

[0030] The angled filter 205 effectively blocks debris from entering the air duct 203, preventing blockage of the air inlet 201. Its angle also reduces the rate of impurity adhesion, ensuring long-term unobstructed airflow. The specific carbon fiber material of the filter 205 is model ZA60XC-12K.

[0031] Furthermore, in the above structure, the reinforcing component 003 includes a connecting groove 301, which is symmetrically opened in sequence at the fitting connection of the bottom cover 001 and the top cover 101, and each set of air outlets 204 is connected to the corresponding connecting groove 301.

[0032] The design of the connecting groove 301 and the air outlet 204 allows the airflow discharged from the air duct 203 to be guided into the connecting groove 301, providing a power source for the subsequent process.

[0033] Furthermore, in the above structure, each set of connecting grooves 301 on the bottom cover 001 is rotatably installed with a rotating plate 302, and each set of connecting grooves 301 on the top cover 101 is also installed with a rotating plate 302.

[0034] The rotating plate 302 can be driven by airflow to generate rotational motion, converting wind energy into mechanical action and providing a power basis for the dynamic clamping of the connection parts. Furthermore, in the above structure, each rotating plate 302 has a baffle 303 installed on one side, and the baffle 303 in the bottom cover 001 is in contact with the air outlet 204 in the top cover 101. The baffle 303 in the top cover 101 is also in contact with the air outlet 204 in the bottom cover 001 in the same way.

[0035] By arranging the baffle 303 directly opposite the air outlet 204, it can efficiently withstand the impact of airflow and convert wind pressure into rotational torque, thereby reliably driving the rotating plate 302 to rotate.

[0036] Furthermore, in the above structure, each set of baffles 303 has an inclined groove 304 around the side near the air outlet 204.

[0037] The inclined slot 304 allows the airflow to escape in a specific direction, which reduces eddies and wind resistance while pushing the baffle 303, thereby improving aerodynamic efficiency and ensuring smooth rotation.

[0038] Furthermore, in the above structure, a connecting arm 305 is rotatably installed between the rotating plate 302 inside the bottom cover 001 and the corresponding connecting groove 301 inside the top cover 101, and a set of connecting arms 305 is also rotatably installed between the rotating plate 302 inside the top cover 101 and the corresponding connecting groove 301 inside the bottom cover 001.

[0039] The connecting arm 305 generates a tensioning effect when the rotating plate 302 rotates, causing the bottom cover 001 and the top cover 101 to come closer to each other, forming a dynamic fastening effect, thereby significantly enhancing the connection rigidity and overall structural strength between the two.

[0040] like Figure 1-10 As shown, during the daily operation of a wind turbine, the turbine blades are always rotating in the wind. At this time, the air inlet 201, located near the blade side of the casing, is also on the windward side. Under the action of wind pressure, the external airflow is naturally guided into the air inlet 201 and enters the internal air duct 203. This process can directly divert and guide part of the oncoming wind pressure, thereby effectively reducing the static wind load borne by the entire casing and achieving preliminary optimization of the structural stress.

[0041] As the airflow enters the duct 203, it is accelerated by the conical spatial structure designed inside the guide ring 202. The guide ring 202 not only guides and straightens the airflow, but its acceleration effect also improves the efficiency of the airflow within the limited flow channel, ensuring that the airflow can reach the outlet 204 at the end of the duct 203 with higher kinetic energy.

[0042] After being accelerated, the airflow exits from the outlet 204 and then enters the connecting groove 301 located at the mating edge of the bottom cover 001 and the top cover 101. Constrained and guided by the connecting groove 301, the airflow is concentrated and acts on the baffle 303 mounted on the rotating plate 302. The baffle 303 is continuously pushed by the air pressure, causing the rotating plate 302, which is fixed to it, to rotate around its axis.

[0043] The rotation of the rotating plate 302 drives the connecting arms 305, which are respectively hinged to the bottom cover 001 and the top cover 101, to move. During the movement, the two sets of connecting arms 305 generate a mutual tension force, which is transmitted to the connection interface between the bottom cover 001 and the top cover 101, so that a continuous and dynamic clamping force is generated between them.

[0044] In summary, this design converts natural wind energy during operation into mechanical force that strengthens structural connections. Through the air inlet 201, the airflow ultimately drives the connecting arm 305 to generate tension, achieving real-time, proactive enhancement of the connection strength between the top cover 101 and the bottom cover 001 during wind turbine operation. This not only reconciles the inherent contradiction between lightweight design and structural strength but also endows the outer shell structure with an intelligent, self-reinforcing characteristic.

[0045] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A lightweight, high-strength structure for a large wind turbine housing, comprising a bottom cover (001) and a top cover (101), characterized in that: The bottom cover (001) and the top cover (101) are fixedly connected by bolts. A rotating shaft groove (103) is provided on one side of both the bottom cover (001) and the top cover (101), and the two sets of rotating shaft grooves (103) form a complete annular space. An inspection port (102) is provided at the bottom of the inner wall of the bottom cover (001). Lightweight components (002) are provided inside both the bottom cover (001) and the top cover (101). A reinforcing component (003) is provided between the bottom cover (001) and the top cover (101). The lightweight component (002) includes an air duct (203), which is sequentially opened inside the bottom cover (001) and the top cover (101). Each air duct (203) is sequentially equipped with a guide ring (202), and the guide ring (202) is made of lightweight carbon fiber material. Each group of air ducts (203) has an air inlet (201) on one side, and the air inlets (201) are all located on the side close to the rotating shaft groove (103); Each group of air ducts (203) has an air outlet (204) on the side away from the air inlet (201), and each group of air outlets (204) is located at the edge where the top cover (101) and the bottom cover (001) are connected and fitted. The reinforcing component (003) includes a connecting groove (301), which is symmetrically opened in sequence at the fitting connection of the bottom cover (001) and the top cover (101), and each set of air outlets (204) is connected to the corresponding connecting groove (301). Each set of connecting grooves (301) on the bottom cover (001) is rotatably installed with a rotating plate (302), and each set of connecting grooves (301) on the top cover (101) is also installed with a rotating plate (302). Each rotating plate (302) in each group is equipped with a baffle (303) on one side, and the baffle (303) in the bottom cover (001) is in contact with the air outlet (204) in the top cover (101), and the baffle (303) in the top cover (101) is also in contact with the air outlet (204) in the bottom cover (001) in the same way; Each of the baffles (303) in each group has an inclined groove (304) around the side near the air outlet (204). A connecting arm (305) is rotatably installed between the rotating plate (302) inside the bottom cover (001) and the corresponding connecting groove (301) inside the top cover (101), and a set of connecting arms (305) is also rotatably installed between the rotating plate (302) inside the top cover (101) and the corresponding connecting groove (301) inside the bottom cover (001).

2. The lightweight, high-strength structure of a large wind turbine casing according to claim 1, characterized in that: Each air inlet (201) is equipped with a filter screen (205), and each filter screen (205) is set at an angle. The filter screen (205) is made of lightweight carbon fiber material.

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