An adaptive hybrid cooling system, control method and device

Abstract

The application discloses a self-adaptive cooling system, a control method and a device. In the embodiment of the application, the nacelle shell integrates a heat dissipation module to replace a traditional independent radiator, reduce the external protrusions of the nacelle, and reduce the aerodynamic noise and the risk of lightning strike. The sealed and isolated design of the closed spray cooling unit solves the pain point that the traditional water cooling system is prone to leakage and causes electrical short circuit. Meanwhile, the three-level mode switching of the self-adaptive control module avoids energy waste, consumes electric energy to drive the fan or the water pump only when necessary, and significantly improves the net power generation and the operation robustness of the wind power plant.

Description

Technical Field

[0001] This invention relates to the field of wind power equipment cooling technology, and in particular to an adaptive hybrid cooling system, control method and device. Background Technology

[0002] With the rapid development of wind power generation technology, wind turbine generators are evolving towards larger sizes and higher power densities. The continuous increase in unit capacity has significantly increased the heat load on core components such as generators and converters, resulting in a substantial increase in heat dissipation power density. Efficient and reliable thermal management systems have become key factors in ensuring long-term stable operation of the units, extending equipment lifespan, and improving power generation efficiency. However, existing wind turbine cooling technologies are gradually revealing limitations in practical applications, failing to meet the heat dissipation requirements of high-power units in complex environments. These limitations are mainly reflected in the following two aspects: 1. Air-cooled system: Relies on external air, has low heat dissipation efficiency, and its heat dissipation capacity decreases by more than 40% in high-temperature environments (>35℃), and the noise of high-power fans reaches more than 85dB.

[0003] 2. Water cooling system: requires an external cooling tower and vertical pipelines of 80-120m in length, which has problems such as high-pressure pipeline leakage, rotary joint failure, difficulty in preventing freezing in winter, and high maintenance costs. Summary of the Invention

[0004] This application provides an adaptive hybrid cooling system, control method, and apparatus to solve existing problems.

[0005] This application provides an adaptive cooling control system, which is integrated with the wind turbine nacelle and is not connected to ground cooling equipment outside the nacelle. The system includes: a heat acquisition module, a heat dissipation module integrated with the nacelle shell, an active enhancement module, and an adaptive control module. The heat collection module includes a heat-conducting sleeve and a heat pipe array fitted and sleeved on the outside of the generator stator housing. The evaporation section of the heat pipe array is embedded in the heat-conducting sleeve, and the condensation section of the heat pipe array extends to the integrated heat dissipation module of the nacelle housing and is thermally connected to the integrated heat dissipation module of the nacelle housing, for the purpose of conducting the waste heat of the generator to the nacelle housing. The integrated heat dissipation module of the cabin shell forms part of the cabin enclosure structure. The integrated heat dissipation module of the cabin shell is provided with a heat exchange structure for receiving the heat of the condensation section of the heat pipe array and for dissipating the heat to the external environment of the cabin. The active enhancement module includes an axial flow fan array located on the outside of the nacelle shell, and a closed spray cooling unit located within the nacelle shell structural layer or integrated with the nacelle shell; the closed spray cooling unit is isolated from the electrical space inside the nacelle by a sealed isolation structure, and is equipped with an exhaust system to discharge the humid air in the spray chamber to the outside of the nacelle. The adaptive control module is electrically connected to the heat acquisition module, the integrated heat dissipation module of the engine nacelle shell, and the active enhancement module, respectively. The adaptive control module is configured to control the system to switch between three cooling modes, including at least a passive heat dissipation mode, an active air-liquid cooling mode, and a spray enhancement mode, based on the generator operating parameters and environmental parameters.

[0006] This application embodiment also provides an adaptive cooling control method, the method comprising: Real-time acquisition of generator temperature data, nacelle environment data, and generator operating power data; Based on a pre-set heat load prediction model, the heat load for future time periods is predicted; Based on current environmental data and predicted heat load, a target cooling mode is selected from the three-level cooling modes. The three-level cooling modes include: a passive heat dissipation mode that relies on heat pipes and phase change materials for heat dissipation; an active air-liquid cooling mode that starts fans and circulating pumps; and a spray enhancement mode that starts closed spray units. Adjust the operating parameters of the actuator according to the selected target cooling mode; monitor the temperature change of the generator. If the temperature does not drop to the target range, upgrade the cooling mode. If the temperature stabilizes within the target range, evaluate whether to reduce the cooling mode level.

[0007] This application embodiment also provides an adaptive cooling control method apparatus, the apparatus comprising: The data acquisition module is used to collect real-time data on generator temperature, nacelle environment, and generator operating power. The processing module is used to predict the heat load for a future time period based on a preset heat load prediction model; select a target cooling mode from three cooling modes according to the current environmental data and the predicted heat load; the three cooling modes include: a passive heat dissipation mode relying on heat pipes and phase change materials; an active air-liquid cooling mode that starts the fan and circulating pump; and a spray enhancement mode that starts the closed spray unit; adjust the operating parameters of the actuator according to the selected target cooling mode; monitor the temperature change of the generator; if the temperature does not drop to the target range, upgrade the cooling mode; if the temperature stabilizes within the target range, evaluate whether to reduce the cooling mode level. Attached Figure Description

[0008] The accompanying drawings, which form part of this specification, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of an adaptive hybrid cooling system provided in an embodiment of this application; Figure 2a An axial schematic diagram of the arrangement of the heat-conducting sleeve and heat pipe provided in an embodiment of this application; Figure 2b A radial schematic diagram of the arrangement of the heat-conducting sleeve and heat pipe provided in an embodiment of this application; Figure 3 A cross-sectional view of the integrated heat dissipation module structure of the cabin shell provided in an embodiment of this application; Figure 4a A radial schematic diagram of the installation of an external axial flow fan provided in an embodiment of this application; Figure 4b A top view of an external axial flow fan installation provided in an embodiment of this application; Figure 5 This application provides a schematic diagram of the installation of a closed spray unit according to an embodiment of the present application; Figure 6 A three-level adaptive control logic flowchart is provided for embodiments of this application; Figure 7 A connection diagram provided for an embodiment of this application; Figure 8 A schematic diagram of a wind turbine adaptive cooling control method for a system provided in this application embodiment; Figure 9 This is a schematic diagram of the structure of an adaptive cooling control device provided in an embodiment of this application; Figure 10 This is a schematic diagram of the electronic device structure provided in the embodiments of this application; Figure label: Heat collection module 100, cabin shell integrated heat dissipation module 200, active enhancement module 300, adaptive control module 400, heat conduction jacket 101, heat pipe array 102, axial flow fan array 301, and closed spray cooling unit 302. Detailed Implementation The present invention will now be described in detail with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0009] The following detailed description is exemplary and intended to provide further detailed explanation of the invention. Unless otherwise specified, all technical terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this invention is for describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention.

[0010] Figure 1 A schematic diagram of an adaptive hybrid cooling system provided in this application embodiment includes: a heat acquisition module 100, a cabin shell integrated heat dissipation module 200, an active enhancement module 300, and an adaptive control module 400; The heat collection module 100 includes a heat-conducting sleeve 101 fitted and sleeved on the outside of the generator stator housing and a heat pipe array 102. The evaporation section of the heat pipe array 102 is embedded in the heat-conducting sleeve, and the condensation section of the heat pipe array extends to the integrated heat dissipation module of the nacelle housing and is thermally connected to the integrated heat dissipation module of the nacelle housing, for conducting the waste heat of the generator to the nacelle housing. The integrated heat dissipation module 200 of the cabin shell forms part of the cabin enclosure structure. The integrated heat dissipation module of the cabin shell is provided with a heat exchange structure for receiving the heat of the heat pipe array condensation section and for dissipating the heat to the external environment of the cabin. The active enhancement module 300 includes an axial flow fan array disposed on the outside of the nacelle shell, and a closed spray cooling unit disposed within the nacelle shell structural layer or integrated with the nacelle shell; the closed spray cooling unit is isolated from the electrical space inside the nacelle by a sealed isolation structure, and is equipped with an exhaust system to exhaust the humid air in the spray chamber to the outside of the nacelle. The adaptive control module 400 is electrically connected to the heat acquisition module 100, the integrated heat dissipation module 200 of the engine nacelle shell, and the active enhancement module 300, respectively. The adaptive control module 400 is configured to control the system to switch between three cooling modes, including at least a passive heat dissipation mode, an active air-liquid cooling mode, and a spray enhancement mode, according to the generator operating parameters and environmental parameters.

[0011] The core architecture of this system is fully integrated inside the wind turbine nacelle, eliminating the need for external ground-based cooling equipment and achieving self-sufficiency and high reliability in the cooling system. The system efficiently removes waste heat generated during generator operation through a multi-stage heat transfer and dissipation mechanism. It mainly consists of four parts: a heat acquisition module 100, a nacelle-integrated heat dissipation module 200, an active enhancement module 300, and an adaptive control module 400. These modules work collaboratively to meet different operating conditions.

[0012] The heat acquisition module 100 is responsible for efficiently extracting waste heat from the heat source and is the starting point of the entire thermal management chain. This module includes a heat-conducting sleeve 101 fitted onto the outside of the generator stator housing and a heat pipe array 102. The heat-conducting sleeve 101 is made of a flexible or rigid composite material with high thermal conductivity, and its inner surface is microstructured to reduce contact thermal resistance, ensuring that the heat generated by the generator stator can be rapidly conducted to the module's interior. The heat pipe array 102 consists of multiple superconducting heat pipes arranged in parallel. Its evaporation section is deeply embedded in the reserved channels of the heat-conducting sleeve 101, utilizing the phase change of the working fluid to absorb heat; its condensation section passes through the internal space of the nacelle, extending into the integrated heat dissipation module 200 on the nacelle shell, and forming a high thermal conductivity thermal connection with the heat exchange structure within this module. The heat pipe array 102 utilizes capillary or gravity reflux mechanisms to rapidly pump heat from inside the nacelle to the nacelle shell, achieving efficient coupling between the heat source and the heat dissipation terminal.

[0013] The integrated heat dissipation module 200 of the nacelle shell is not only the enclosure structure of the nacelle, but also the core heat dissipation terminal, achieving structural and functional integration. As part of the nacelle shell, this module uses lightweight, high-strength composite materials, with pre-embedded or integrated high-efficiency heat exchange structures such as finned and microchannel types. The heat exchange structure directly receives heat from the condensation section of the heat pipe array 102 and dissipates the heat to the external environment through natural or forced convection by increasing the outer surface area of ​​the nacelle shell. This design avoids the need for additional radiators, reduces wind resistance and maintenance costs, while ensuring the overall structural strength and airtightness of the nacelle.

[0014] The active cooling module 300 is designed to overcome the limitations of passive heat dissipation and provide additional cooling capacity under extreme operating conditions or high ambient temperatures. This module includes an axial fan array 301 located on the outside of the nacelle shell, and a closed-loop spray cooling unit 302 located within the nacelle shell structural layer or integrated with the nacelle shell. The axial fan array 301 can automatically adjust its angle or speed according to the wind direction, forcibly increasing the airflow velocity on the nacelle shell surface and enhancing the convective heat transfer coefficient. The closed-loop spray cooling unit 302 is completely physically isolated from the electrical space inside the nacelle through a sealed isolation structure, preventing moisture from entering the nacelle and corroding electrical components. It is also equipped with an exhaust system to expel humid air from the spray chamber to the outside of the nacelle, ensuring the nacelle interior remains dry. The spray droplets act directly on the outer wall of the heat exchange structure or a dedicated cooling channel, utilizing the high specific heat capacity and latent heat of vaporization of water to dissipate a large amount of heat.

[0015] The adaptive control module 400 is the brain of the system, responsible for global monitoring and strategy execution. This module is electrically connected to the heat acquisition module 100, the integrated heat dissipation module 200, and the active enhancement module 300, respectively, to collect real-time operating parameters such as generator winding temperature, stator temperature, nacelle ambient temperature, wind speed, and generator output power. The adaptive control module 400 incorporates an intelligent control algorithm, enabling seamless switching between three cooling modes—passive cooling, active air-liquid cooling, and spray enhancement—based on real-time operating conditions. Under low load or low temperature conditions, the system relies solely on the heat pipe array 102 and the integrated heat dissipation module 200 for natural heat conduction and convection. Under medium load or rising ambient temperature, the axial fan array 301 is activated to enhance the wind speed on the outer casing surface. Under high load, high temperature, or thermal shock conditions, the closed-loop spray cooling unit 302 is activated to utilize evaporative cooling for peak thermal management.

[0016] Through the aforementioned architectural design, this system eliminates the risk of leakage in long-distance cooling pipelines and the impact of ground pump station failures on the wind turbine, making it particularly suitable for offshore wind power or remote mountain wind power scenarios. The integrated heat dissipation module 200 on the nacelle shell replaces the traditional independent radiator, reducing external protrusions and lowering aerodynamic noise and lightning strike risks. The sealed isolation design of the enclosed spray cooling unit 302 solves the problem of electrical short circuits caused by leakage in traditional water-cooling systems. Meanwhile, the three-level mode switching of the adaptive control module 400 avoids energy waste, consuming power only when necessary to drive the wind turbine or water pump, significantly improving the net power generation and operational robustness of the wind farm.

[0017] Based on the above embodiments, in this embodiment, the heat-conducting sleeve 101 has a segmented structure, consisting of multiple arc-shaped segments fastened to the outside of the generator stator housing by fasteners. The contact surface between the heat-conducting sleeve 101 and the stator housing is filled with a heat-conducting interface material. The evaporation section of the heat pipe array 102 is embedded in the preset mounting groove of the heat-conducting sleeve, and the heat pipe array 102 is evenly distributed along the circumference of the generator.

[0018] The heat-conducting sleeve 101 in the heat acquisition module 100 adopts a segmented structure design to solve the problems of limited installation space and convenient maintenance of large generator stator housings. The heat-conducting sleeve 101 is composed of multiple high-precision machined arc-shaped segments, which are fastened to the outside of the generator stator housing by high-strength bolts or clamps, forming a complete annular covering structure. This segmented design not only facilitates assembly and disassembly in confined engine compartments but also adapts to the dimensional tolerances of stators of different specifications, ensuring installation flexibility. To further reduce contact thermal resistance, a high-performance thermal interface material, such as thermally conductive silicone grease or a phase change thermal pad, is filled between the contact surface of the heat-conducting sleeve 101 and the stator housing. This material effectively fills microscopic gaps, eliminates the air insulation layer, and ensures efficient heat transfer from the stator to the heat-conducting sleeve 101. The heat pipe array 102, as the core heat transfer element, has its evaporation section precisely embedded in a pre-set semi-circular mounting groove in the heat-conducting sleeve 101, and is fixed by interference fit or brazing to ensure good thermal contact stability. The heat pipe array 102 is evenly distributed along the circumference of the generator. This uniform distribution strategy eliminates local hot spots and ensures the consistency of the circumferential temperature field of the generator stator, thereby improving the generator's operational stability and lifespan. The condensation section of the heat pipe array 102 then extends to and is thermally connected to the integrated heat dissipation module 200 on the nacelle shell, transferring the collected heat to the nacelle shell for dissipation. Combined with the overall layout of the heat collection module 100, this achieves a rapid conduction path for waste heat from source collection to external emission.

[0019] Based on the above embodiments, in this embodiment, the heat pipe array 102 is a gravity-assisted heat pipe, and the condensation section of the heat pipe array 102 is arranged upward at an angle of 10-30° relative to the evaporation section, extending to the integrated heat dissipation module 200 of the cabin shell.

[0020] The heat pipe array 102 employs efficient gravity-assisted heat pipe technology, utilizing gravity as the primary driving force for the return flow of the working fluid condensate. This eliminates the need for additional mechanical pumping devices, significantly improving the operational reliability and quiet operation of the heat acquisition module 100. The condensing section of the heat pipe array 102 is arranged upwards at an angle of 10-30° relative to the evaporating section. This angle range has been optimized for fluid dynamics, ensuring smooth return of the condensed working fluid to the evaporating section under gravity to prevent dry burning, while also adapting to the compact space constraints within the engine compartment. The condensing section of the heat pipe array 102 extends upwards and penetrates into the integrated heat dissipation module 200 on the engine compartment shell, forming a tight thermal coupling with the heat exchange structure within the module. This efficiently transfers the waste heat generated by the generator to the outer wall of the engine compartment for dissipation. This arrangement fully utilizes the vertical space of the engine compartment, achieving a natural directional transfer of heat from the lower heat source to the higher heat dissipation terminal, effectively preventing heat accumulation inside the engine compartment. In addition, the tilt angle design also takes into account the slight shaking during the operation of the fan, ensuring the stability of the working fluid return under dynamic operating conditions. With the monitoring of the adaptive control module 400, it ensures that the system can maintain high heat transfer efficiency under different environmental conditions.

[0021] Figure 2a This is an axial schematic diagram of the arrangement of the heat-conducting sleeve and heat pipe provided in an embodiment of this application.

[0022] Figure 2b This is a radial schematic diagram of the arrangement of the heat-conducting sleeve and heat pipe provided in an embodiment of this application.

[0023] The heat acquisition module includes an external heat-conducting sleeve for the stator housing. This sleeve does not contact the windings; heat is transferred through the stator housing. Specifically, it includes a segmented heat-conducting sleeve fitted over the generator stator housing and a heat pipe array in close contact with the sleeve. The evaporation section of the heat pipe array is embedded in the mounting groove of the heat-conducting sleeve, and the condensation section is connected to the integrated heat dissipation module of the nacelle housing at a 10-30° angle. The core principle is that the heat pipes do not directly contact the windings or the inside of the core, but are installed on the outside of the stator housing. The heat transfer path is: winding heating → core → stator housing → heat pipes → nacelle housing. The heat pipe installation positions are as follows: Heat-conducting sleeve system: high thermal conductivity aluminum / copper sleeve; wrapped around the outside of the stator housing, in close contact with the housing; heat pipe evaporation section embedded in the heat-conducting sleeve: heat pipe array (circumferentially distributed), pressed into the groove of the heat-conducting sleeve, filled with a high thermal conductivity interface material; the heat pipes extend upwards at an angle of 10-30°, connecting to the nacelle housing. The heat-conducting sleeve continuously wraps around the entire circumference of the stator housing; it features a segmented heat-conducting sleeve design. Due to the large circumference of the stator housing (π × diameter ≈ 3.14 × 1.5m = 4.71m), it needs to be manufactured in four segments; each segment covers a 90° arc and is approximately 1.2m long. Each segment of the heat-conducting sleeve has a pre-machined heat pipe mounting groove, precisely machined to match the curvature of the stator housing. The radius of the heat pipe mounting groove (semi-circular) is slightly larger than the heat pipe radius, and its depth is 1 / 3 to 1 / 2 of the heat pipe diameter. It is filled with high thermal conductivity silicone grease, and the heat pipe is pressed into the groove and fixed by a pressure plate. The heat pipe array consists of gravity-assisted heat pipes, numbering 12-36, evenly distributed around the generator circumference. Each heat pipe has a diameter of 8-12mm, a length of 1.2-1.8m, and a heat transfer capacity of 200-400W / pipe.

[0024] The installation steps are as follows: Clean the surface of the stator housing; apply a high thermal conductivity interface material (silicone grease or phase change material); install the heat-conducting sleeve segments and tighten the bolts; press the heat pipe into the mounting groove; install the pressure plate and apply pressure evenly; connect the heat pipe condenser section to the housing housing.

[0025] The winding end cooling adopts end air duct enhanced cooling: utilize the original end cooling air duct of the generator; add guide vanes to guide hot air to the heat dissipation surface of the nacelle shell; and arrange micro heat pipes or heat conduction plates at the air duct outlet.

[0026] Key technical points for installation include: (1) No damage to the original insulation system: the heat pipe and heat-conducting sleeve are completely outside the stator housing; no contact with the windings, no damage to the slot insulation; no impact on the original seal of the generator. (2) Adaptability to different generator types: squirrel-cage asynchronous generator: the housing is generally made of cast iron, which is easy to install; permanent magnet synchronous generator: the housing structure is diverse and requires customized design; doubly-fed asynchronous generator: special consideration is needed for the slip ring side; (3) Installation space requirements: a 150-200mm annular space needs to be left around the stator housing; the inclined extension of the heat pipe requires upper space; most nacelles can meet this requirement. (4) Impact on the generator: Increased weight: heat-conducting sleeve + heat pipe about 100-150kg; Increased size: radial increase of 30-50mm; Impact on dynamic balance: symmetrical installation has minimal impact; Impact on maintenance: does not obstruct the conventional maintenance passage.

[0027] Table 1 shows a comparison with traditional cooling solutions:

[0028] Table 1 Table 1 shows a schematic diagram of recommended heat pipe layout parameters:

[0029] Based on the above embodiments, in this embodiment, the integrated heat dissipation module 200 of the cabin shell is a multi-layer composite structure, which includes, from the outside to the inside of the cabin: an outer skin layer, a structural reinforcement layer, a microchannel cooling plate layer, a phase change material coating, and a reinforced heat dissipation fin layer; the microchannel cooling plate layer is circulated with coolant and is thermally connected to the condensation section of the heat pipe array 102; the phase change material coating is applied to the inner surface of the microchannel cooling plate layer to absorb instantaneous heat load.

[0030] The integrated heat dissipation module 200 of the nacelle shell adopts an advanced multi-layer composite structure design, aiming to achieve the best balance between structural strength, weather resistance, and heat dissipation performance. As the final terminal for system heat dissipation, its performance directly determines the overall cooling efficiency. From the outside to the inside of the nacelle, the module includes an outer skin layer, a structural reinforcement layer, a microchannel cooling plate layer, a phase change material coating, and a reinforced heat dissipation fin layer. These layers are tightly bonded together using co-curing or high-performance adhesives to form an integrated functional structure. The outer skin layer, as the outermost protective layer, possesses excellent UV resistance, corrosion resistance, and a smooth aerodynamic shape, effectively resisting wind and rain erosion in complex outdoor environments and reducing wind resistance and noise. The structural reinforcement layer, located inside the outer skin layer, is laid with high-rigidity composite materials, providing necessary mechanical support to ensure the structural stability of the nacelle shell under complex loads such as wind, gravity, and vibration. The microchannel cooling plate layer, as the core heat exchange unit, features a sophisticated microchannel network internally, circulated with coolant. It achieves efficient thermal connection with the condensation section of the heat pipe array 102 in the heat acquisition module 100, rapidly carrying heat from the heat pipes into the coolant channels and then to the heat dissipation area via fluid flow. A phase change material coating is applied to the inner surface of the microchannel cooling plate layer. Utilizing the characteristic of phase change materials to absorb a large amount of latent heat during phase change, it effectively absorbs the instantaneous heat load generated during generator operation, acting as a peak-shaving and valley-filling thermal buffer to prevent drastic system temperature fluctuations and handle conflicting heating conditions. The reinforced heat dissipation fin layer, located on the innermost side, significantly increases the contact area with the condensation section of the heat pipe array 102, reduces contact thermal resistance, and further enhances the efficiency of heat transfer from the heat acquisition module 100 to the integrated heat dissipation module 200 in the engine compartment. The entire module works in conjunction with the adaptive control module 400 to adjust the coolant flow and temperature according to the real-time heat load demand, and when necessary, it works in conjunction with the axial fan array 301 or the closed spray cooling unit 302 in the active enhancement module 300 to perform joint heat dissipation, thereby achieving comprehensive and multi-level intelligent thermal management.

[0031] Figure 3 This is a cross-sectional view of the integrated heat dissipation module structure of the cabin shell provided in an embodiment of this application.

[0032] like Figure 3 As shown, the layers are as follows: First layer: outer skin layer, 3-5mm thick; Second layer: structural reinforcement layer, 2-3mm thick; aluminum alloy 6061-T6 or 5052-H32. Third layer: closed-loop spray cooling unit; height 80-120mm. Fourth layer: microchannel cooling plate layer, 8-12mm thick; aluminum alloy 3003 or copper T2. Fifth layer: phase change material coating, 2-5mm thick (adjustable thickness); paraffin-based phase change material composite. Sixth layer: reinforced heat dissipation fin layer, fin height 30-50mm, substrate thickness 1-2mm; aluminum alloy 1050A (high thermal conductivity) or copper. Total thickness T≈145mm.

[0033] Based on the above embodiments, in this embodiment of the application, the axial flow fan array 301 includes multiple low-profile axial flow fans. The low-profile axial flow fans are externally mounted on the top or upper side of the nacelle shell. The air outlet direction of the fans is parallel to or at a preset angle to the surface of the nacelle shell, so as to form a cooling air layer on the surface of the nacelle shell.

[0034] The axial fan array 301 in the active enhancement module 300 includes multiple low-profile axial fans. These fans feature a streamlined housing design to minimize aerodynamic drag and operating noise, adapting to the complex wind field environment outside the wind turbine nacelle. The axial fan array 301 is externally mounted on the top or upper side of the nacelle housing via vibration-damping brackets. This mounting location avoids valuable electrical space inside the nacelle while being in an area with high natural wind speeds, which is beneficial for enhancing heat dissipation efficiency and facilitating maintenance. The fan outlet direction is aerodynamically optimized, parallel to or at a preset angle to the nacelle housing surface, aiming to form a high-speed cooling air layer along the outer surface of the integrated heat dissipation module 200 on the nacelle housing. This tangential or oblique airflow arrangement effectively disrupts the static thermal boundary layer on the nacelle housing surface, significantly enhancing the convective heat transfer coefficient, preventing hot air from stagnating on the housing surface, and rapidly carrying away the heat transferred from the heat harvesting module 100 to the housing via the heat pipe array 102. The axial fan array 301 is electrically connected to the adaptive control module 400. The module 400 adjusts the speed and start / stop of the fan array in real time according to the ambient temperature, the temperature of the nacelle shell and the natural wind speed. While ensuring the heat dissipation effect, it reduces energy consumption and noise pollution. It works in synergy with the closed spray cooling unit 302 to form the multi-dimensional heat dissipation capability of the active enhancement module 300, ensuring the stable operation of the system under extreme high temperature conditions.

[0035] Based on the above embodiments, in this embodiment, the sealed isolation structure includes a porous metal partition disposed between the spray chamber and the cabin interior space; the closed spray cooling unit 302 also includes a deionized water tank and a water supply pump, the water supply pump being configured to supply deionized water to the atomizing nozzles in the spray chamber; the bottom of the spray chamber is provided with a water collection tank and a water recovery system for recovering unevaporated water droplets.

[0036] As a core component of the active cooling module 300, the closed-loop spray cooling unit 302 is designed to achieve efficient evaporative cooling while ensuring absolute dryness and safety of the internal electrical environment of the engine compartment. A sealed isolation structure is positioned between the spray chamber and the internal space of the engine compartment. This structure includes a porous metal partition sintered using a special process. This partition has excellent hydrophobic and breathable properties, effectively preventing liquid water droplets and high-concentration moisture from penetrating into the internal electrical space of the engine compartment, preventing electrical components from becoming damp and corroded or experiencing short circuits, while maintaining pressure balance between the spray chamber and the inside and outside of the engine compartment. The closed-loop spray cooling unit 302 also integrates a deionized water tank and a variable frequency water pump. The water pump is configured to supply deionized water to the high-pressure atomizing nozzles within the spray chamber. The use of deionized water aims to prevent scale buildup that clogs the micro-nozzles and corrodes the heat exchange surfaces, ensuring long-term operational stability. The bottom of the spray chamber is equipped with a water collection tank and an intelligent water recycling system to collect and recycle unevaporated water droplets. The recycled water undergoes multi-stage filtration and purification before being pumped back into the deionized water tank for reuse, forming a closed-loop water system that greatly reduces water consumption and avoids the environmental impact of external drainage. The adaptive control module 400 monitors the humidity, water level, and temperature parameters in the spray chamber in real time, dynamically adjusts the flow rate of the water supply pump and the start and stop of the atomizing nozzles, and works in conjunction with the axial flow fan array 301 to accelerate water mist evaporation using fan airflow. This rapidly removes heat from the surface of the integrated heat dissipation module 200 on the chassis shell. Together with the heat transfer path of the heat acquisition module 100 and the heat pipe array 102, a highly efficient, safe, and environmentally friendly active enhanced heat dissipation system is constructed.

[0037] Based on the above embodiments, in this embodiment of the application, the adaptive control module 400 is further configured with safety interlock logic. The start-up of the closed spray cooling unit 302 requires at least three of the following safety conditions to be met simultaneously: the humidity inside the cabin is lower than a preset humidity threshold; the ambient temperature is higher than a preset low temperature threshold and there is no rainfall signal; the wind speed is lower than a preset wind speed threshold; and the generator insulation resistance is higher than a preset resistance threshold.

[0038] As the intelligent hub of the entire thermal management system, the adaptive control module 400, in addition to executing conventional mode switching strategies, is also equipped with safety interlock logic to ensure the operational safety and reliability of the enclosed spray cooling unit 302 in extremely complex environments. To prevent moisture intrusion into the engine compartment leading to electrical faults or external environmental factors interfering with heat dissipation efficiency, the adaptive control module 400 employs a multi-verification mechanism, stipulating that the enclosed spray cooling unit 302 can only be activated if at least three of the following safety conditions are met simultaneously. First, the humidity inside the engine compartment must be below a preset humidity threshold. This is to prevent the infiltration of trace amounts of moisture generated during spray cooling, combined with the existing high humidity environment, from causing internal condensation and protecting the heat acquisition module 100 and generator electrical components. Second, the ambient temperature must be above a preset low-temperature threshold and there must be no rainfall signal to avoid low-temperature freezing damaging the pipes or external rain interfering with the spray evaporation effect. Third, the wind speed must be below a preset wind speed threshold to prevent strong winds from dispersing the spray, reducing cooling efficiency, or causing uneven cooling stress on the surface of the integrated heat dissipation module 200 on the engine compartment shell. Finally, the generator insulation resistance must be higher than a preset resistance threshold to ensure good insulation performance of the electrical system and fundamentally eliminate short-circuit accidents caused by water leakage. The adaptive control module 400 collects data from various sensors in real time and performs logical judgments. It only sends a start command to the active reinforcement module 300 when most safety conditions are met. This redundant design greatly improves the robustness of the system under harsh operating conditions, ensuring that the heat collected by the heat acquisition module 100 can be safely and reliably discharged through the integrated heat dissipation module 200 on the nacelle shell. At the same time, it ensures that the coordinated operation of the axial fan array 301 and the closed spray cooling unit 302 will not pose a threat to the core electrical system of the wind turbine.

[0039] The integrated heat dissipation module of the cabin shell includes a modified cabin shell composite structure, which consists of the following layers from the outside to the inside: an outer skin layer that maintains the original aerodynamic shape, a structural reinforcement layer, a closed spray cooling unit, a microchannel cooling plate layer, a phase change material coating, and a reinforced heat dissipation fin layer. The microchannel cooling plate layer is circulated with coolant.

[0040] (a) The structural features are as follows: The innovative composite structure integrating a heat dissipation module into the engine compartment shell is characterized by multi-layered functional integration and a combination of passive and active cooling. This achieves the complete integration of the functions of a traditional external cooling tower into the engine compartment shell, representing the core technological innovation of this invention for achieving cooling without external equipment.

[0041] (ii) Enhanced heat dissipation technology for the fuselage outer shell 1. Shell material (1) Outer layer: Existing fiberglass skin (maintaining aerodynamic shape), 3-5mm thick; glass fiber reinforced plastic (GFRP) or carbon fiber composite (CFRP).

[0042] (2) Middle layer: High thermal conductivity metal plate (aluminum or copper, 2-3mm thick). Pre-formed curved surface to match the shape of the cabin; precision machined inner surface (flatness <0.2mm); pre-embedded mounting holes (for connecting internal structures). Provides structural strength and withstands the load of internal equipment; serves as an intermediate layer for heat conduction.

[0043] (3) Inner layer: Microchannel cooling plate (thickness 8-12mm, welded to the middle metal plate). The interior adopts a microchannel array; parallel serpentine, covering the entire cabin shell area; each area has independent inlet and outlet, which is convenient for zone control. The channel cross-section is rectangular 1.0mm×2.0mm; wall thickness 0.8-1.0mm; channel spacing 3.0-5.0mm (center distance); channel length 10-20m, total length 200-500m. The coolant is a 50% ethylene glycol aqueous solution, driven by a small magnetic circulation pump with a pump power of 100-300W.

[0044] 2. Phase change material integration (1) A phase change material (PCM) coating with a thickness of 2-5 mm is applied to the inner side of the cabin shell. The PCM is a paraffin-graphene composite phase change material with a phase change temperature of 55-65℃, a latent heat value of more than 180kJ / kg, and a thermal conductivity of 0.8-1.5W / (m·K).

[0045] (2) Absorbs solar radiation heat during the day and releases it at night; absorbs instantaneous heat load and smooths temperature fluctuations; extends passive cooling time and reduces the frequency of start-up and shutdown of active equipment; improves system thermal inertia and copes with sudden working conditions.

[0046] 3. Integrated heat dissipation fins (removable fin design) Add fins to the inner surface of the nacelle shell; fin height 20-50mm; fin spacing 10-20mm; aluminum; increase heat dissipation area by 3-5 times. Axial or circumferential arrangement optimized according to airflow direction; welded to phase change material coated substrate; fins inserted into substrate grooves and glued in place.

[0047] 4. Airflow channel design The nacelle is designed with specialized air ducts; hot air flows from the generator area to the nacelle shell; cooling air enters from the front of the nacelle and exits from the rear; the pressure difference between the inside and outside of the nacelle promotes airflow.

[0048] 5. Synergistic multi-layer heat dissipation mechanism: microchannel liquid cooling removes most of the steady-state heat; fins enhance convection and significantly increase the heat dissipation area; PCM buffering copes with instantaneous heat load; spray evaporation enhances heat dissipation under extreme conditions.

[0049] The heat dissipation capacity is expandable: it can be adapted to generators of different power by increasing the microchannel area, fin height, PCM thickness, etc.

[0050] (III) Coolant System Design: 1. Small variable frequency magnetic circulation pump + simplified microchannel system The coolant flows through the microchannel cooling plates on the engine compartment shell, enhancing the heat dissipation capacity of the engine compartment shell, providing an active heat dissipation method, and covering the entire heat dissipation area.

[0051] 2. The role of the coolant system in three-level control: Level 1 (Passive Mode): The pump operates at low speed or intermittently, maintaining only the basic cycle to prevent local overheating.

[0052] Second stage (active air-cooling mode): The pump operates at a medium flow rate, working in conjunction with the fan to provide synergistic heat dissipation.

[0053] Level 3 (Enhanced Spray Mode): Pump operates at full flow, maximizing heat dissipation to handle extreme conditions. 3. System Composition (1) Small magnetically driven centrifugal pump, power 100-300W (adjustable); (2) The working fluid is 50% ethylene glycol + 50% deionized water; 20-40L (total system volume).

[0054] (3) Microchannel cooling plate layer (inner layer of cabin shell) flow channel design: Parallel flow channels reduce pressure drop; zoned control: 4-6 independent zones, each equipped with a regulating valve; flow channel size: 1.5×3mm; total length: 100-200m.

[0055] (4) Expansion tank and replenishment system: Compensates for thermal expansion, removes gas, and monitors liquid level; maintains 10-15% of the total system volume; automatically replenishes water when the liquid level is below the set value. (5) Filtration and purification system: 50μm stainless steel filter screen; ion exchange resin (to maintain water quality); conductivity sensor, pH sensor; (6) Control system Frequency converters, temperature sensors, flow sensors, pressure sensors; 4. Installation location and method: Installation location: Lower rear of the nacelle, near the microchannel inlet / outlet of the nacelle shell.

[0056] Installation method: Vibration damping bracket to reduce vibration transmission; inlet and outlet hose connection to compensate for thermal expansion.

[0057] 5. Mode control logic: If the generator winding temperature is <75℃; the pump operates at low speed (20% speed, approximately 60W); maintain basic circulation to prevent localized overheating. If 75℃≤Twinding<85℃; pump operates at medium speed (50% RPM, approximately 150W); use a fan to enhance heat dissipation. If the temperature is ≥85℃; the pump runs at full speed (100% speed, 300W); maximum flow rate to handle high loads. If the water pump fails, switch to natural circulation mode; rely on heat pipes and natural convection to maintain basic heat dissipation; alarm to prompt maintenance.

[0058] 6. Technical features of the coolant system: Pump miniaturization: 300W magnetic pump, operating at low power most of the time; System simplification: single circulation, short pipeline, low-pressure operation; Control optimization: frequency conversion regulation, supplying liquid on demand; Reliability design: leak-free, antifreeze, long service life.

[0059] The active enhancement module includes an externally mounted low-profile axial fan array installed on the outside of the nacelle shell; and a closed spray cooling unit installed in the interlayer of the nacelle shell, which is completely isolated from the interior of the nacelle, allowing humid air to be directly discharged to the outside of the nacelle.

[0060] (a) Externally mounted low-profile axial flow fan array 1. Includes 4-6 EC external rotor fans, each with a power of 150-300W and a fan height not exceeding 200mm; arranged along the length of the nacelle shell, installed in the rear 1 / 3 area of ​​the top of the nacelle shell; 2 on the top and 1 on each side, evenly distributed with a spacing of 1.5-2.0m; parallel to the surface of the shell or at an angle of 5-10°.

[0061] Ambient air is drawn in from outside the cabin shell; it is then blown over the heat dissipation surface of the cabin shell and discharged; forming an "air curtain" that covers the heat dissipation surface.

[0062] Top fans blow air axially along the nacelle, covering the top heat dissipation surface; side fans blow air laterally along the nacelle, covering the side heat dissipation surfaces; airflow direction is adjusted via adjustable guide vanes. A continuous cooling air layer is formed on the nacelle shell surface, increasing the convective heat transfer coefficient and improving heat dissipation capacity by 2-3 times.

[0063] 2. Control strategy optimization (1) Hierarchical control strategy: Level 1 (Passive Mode): All fans are off. Temperature conditions: Generator winding temperature < 75℃ and ambient temperature < 25℃; Level 2 (Low Speed ​​Mode): Start 2 fans at 50% speed: Temperature conditions: 75℃ ≤ Twinding < 80℃ or 25℃ ≤ Tambient < 30℃; Level 3 (Medium Speed ​​Mode): Start 4 fans at 75% speed. Temperature conditions: 80℃ ≤ Twinding < 85℃ or 30℃ ≤ Tambient < 35℃; Level 4 (High-Speed ​​Mode): All fans at 100% speed. Temperature conditions: Twinding ≥ 85℃ or Tambient ≥ 35℃; (2) Special controls: Wind direction adjustment: Adjust the angle of the guide vane according to the temperature distribution; Anti-icing control: In cold regions, periodically operate for short periods of time to prevent freezing at low temperatures; Overload protection: Fan current monitoring and overload protection; Fault switching: In the event of a single unit failure, other fans will compensate.

[0064] (ii) Enclosed spray cooling unit It includes: a spray chamber set in the interlayer of the cabin shell, an ultrasonic atomizing nozzle installed in the chamber, a deionized water tank, a small plunger pump, and a forced ventilation system. The spray chamber is isolated from the cabin interior by a porous metal plate, and the humid air is directly discharged outside the cabin through a dedicated air duct.

[0065] 1. Optimization solution for ultra-fine atomizing spray unit: A closed spray cooling channel is adopted, and the spray is not applied directly inside the cabin, but rather within the interlayer of the cabin shell.

[0066] Design concept: Create a closed spray space inside the integrated heat dissipation layer of the cabin shell.

[0067] 2. Cabin shell sandwich structure: Outer layer: Structural reinforcement layer (maintains a seal); Middle layer: Spray cooling chamber (adds enclosed space); Inner layer: Porous metal plate or grille (allows airflow but blocks water droplets).

[0068] 3. Spray chamber structure: The spray nozzles are installed on the top or side wall of the cavity; the fine mist evaporates inside the cavity, cooling the microchannel cooling plate layer; the evaporated humid air is discharged outside the cabin through the vents; unevaporated water droplets are collected and returned.

[0069] The spray chamber is installed in the rear 1 / 3 of the top of the nacelle shell, with a length of 2-3m and a width that fully covers the area; the height is 80-120mm (interlayer thickness); the inner layer is a perforated aluminum plate with a hole diameter of 2-3mm and an opening rate of 40-50%; the outer layer is a structural reinforcement layer (to maintain a seal); it is sealed on all sides, leaving only air inlet and outlet openings.

[0070] It uses ultrasonic atomizing nozzles; 4-6 nozzles are evenly distributed at the top of the spray chamber.

[0071] Water supply system: 10-20L stainless steel water tank; small plunger pump, power <100W; stainless steel or food-grade hoses, DN6-8 piping; 5μm precision filter; deionized water or purified water.

[0072] Exhaust system: 2 small axial flow fans; located at both ends of the spray chamber, to exhaust the evaporated humid air outside the cabin.

[0073] Water recycling system: An inclined water collection tank is installed at the bottom of the spray chamber, and a small water pump is used to filter and reuse the recycled water; an automatic water supply valve is used to maintain the water level.

[0074] The control system uses a multi-safety interlock PLC, which is connected to the main control system.

[0075] 4. Spray cooling process: (1) Monitoring phase: Continuously monitor temperature and operating conditions; (2) Triggering conditions: The following conditions must be met simultaneously: generator winding temperature > 85℃, ambient temperature > 35℃, nacelle shell temperature > 60℃, nacelle humidity < 60%, no rainfall, and no strong wind (wind speed < 15m / s).

[0076] (3) Pre-start: Start the exhaust fan to establish airflow; (4) Spraying phase: pulse spray, 2-5 seconds each time, with an interval of 10-30 seconds; (5) Monitoring effect: Monitoring the rate of temperature decrease; (6) Stop conditions: Stop when any of the following conditions are met: Twinding < 80℃, cumulative spraying time > 5 minutes, humidity in the cabin RH > 70%, any fault alarm.

[0077] (7) Post-treatment: Continue ventilation for 5 minutes to ensure dryness; 5. Key Design Elements of Safety Control Systems Multiple safety interlock control systems are adopted. (1) Hardware interlocking: Emergency stop button: manual emergency stop; water level switch: low water level protection; pressure switch: overpressure protection; flow switch: low flow protection; insulation monitoring: electrical insulation alarm linkage.

[0078] (2) Software interlocking If any alarm is triggered, immediately stop spraying. Alarms include: abnormal temperature, excessive humidity, excessive wind speed, electrical fault, etc.

[0079] (3) Timing Interlocking The exhaust fan must be started before spraying; after spraying stops, the exhaust fan must continue for 5 minutes; minimum spraying interval: 5 minutes; maximum daily spraying time: 10 minutes. (4) Environmental interlocking Ambient temperature < 0℃: Do not spray (to prevent freezing); Ambient humidity > 80%: Do not spray (poor effect); Rainfall detection: Do not spray during rain; Wind speed > 15m / s: Do not spray (risk of drift). (5) Manual confirmation First-time use requires manual confirmation; a confirmation request is sent before each spray; an automatic mode can be set (but the right to manual intervention is retained).

[0080] The spray system is not a conventional heat dissipation method or the main cooling method. It is only an emergency backup in extreme situations and is expected to be used less than 5 times per year.

[0081] The core value of this invention lies in its intelligent adaptive three-level control, where spraying is only the last line of defense, not the primary means.

[0082] Based on the above embodiments, in this embodiment, the adaptive control module includes a memory and a processor. The memory stores a heat load prediction model. The processor is configured to use the heat load prediction model to predict the heat load within a preset time period based on historical temperature sequences and generator power data, and to adjust the switching of cooling modes in advance based on the prediction results. The heat load prediction model is a prediction model based on a Long Short-Term Memory (LSTM) neural network.

[0083] The adaptive control module 400, including a processor and memory, forms the hardware foundation for the system's intelligent decision-making. The memory stores a deeply trained heat load prediction model, based on an LSTM neural network, which excels at handling long-term dependencies and nonlinear characteristics in time-series data, effectively capturing the dynamic thermal characteristics of the wind turbine during operation. The processor is configured to utilize the heat load prediction model to collect and analyze historical temperature sequences from the heat acquisition module 100 and power data from the generator in real time, uncovering the intrinsic correlation between temperature changes and power fluctuations, thereby accurately predicting the heat load trend within a preset time period. Based on the prediction results, the adaptive control module 400 can adjust the cooling mode switching strategy in advance, such as pre-activating the axial fan array 301 or the closed spray cooling unit 302 in the active enhancement module 300 before the heat load peak arrives, avoiding temperature overshoot caused by system lag. This control logic not only optimizes the heat transfer efficiency of the heat-conducting jacket 101 and heat pipe array 102 in the heat acquisition module 100 but also ensures that the heat dissipation capacity of the integrated heat dissipation module 200 in the nacelle shell dynamically matches the heat load demand. Through the self-learning capability of the LSTM neural network, the adaptive control module 400 can continuously correct prediction deviations over time, thereby continuously optimizing the cooling strategy and minimizing auxiliary heat dissipation energy consumption while ensuring the safe operation of the generator, thus improving the overall economic efficiency of the wind turbine.

[0084] Figure 4a A radial schematic diagram of the installation of an external axial flow fan provided in an embodiment of this application; Figure 4b This is a top view of an external axial flow fan installation provided in an embodiment of this application.

[0085] Figure 5 This is a schematic diagram of the installation of a closed spray unit provided in an embodiment of this application.

[0086] Figure 6 A flowchart of a three-level adaptive control logic is provided for an embodiment of this application.

[0087] Figure 7 This is a schematic diagram of a connection provided for an embodiment of this application.

[0088] As shown in Figure 2, the heat-conducting sleeve 101 is installed on the generator casing, and a heat pipe array 102 composed of heat pipes is embedded inside the heat-conducting sleeve 101. The heat pipes are represented by circular cross-sections in the figure, and they are responsible for rapidly dissipating the waste heat generated by the generator casing. Figure 2 shows the multi-layer composite structure of the integrated heat dissipation module of the nacelle casing, arranged sequentially from the outside to the inside. The rightmost layer is the structural reinforcement layer or the nacelle casing body, providing mechanical support. Adjacent to it is the spray chamber 302, which is part of the closed spray unit 302 and is used for evaporative cooling under extreme operating conditions. Further inside is the microchannel cooling plate layer 201, which is the core heat exchange surface of the active liquid cooling cycle. Next is the phase change material coating 202, which is used to buffer instantaneous heat load fluctuations. The innermost layer is the reinforced heat dissipation fin layer 203. A small magnetic circulation pump 204 is provided, which drives the cooling medium to flow between the heat collection end and the microchannel cooling plate layer 201, forming an active liquid cooling circuit and enhancing the heat transfer capability from left to right. The top indicates an externally mounted low-profile axial fan, which is installed outside the nacelle.

[0089] Figure 8 A schematic diagram of a wind turbine adaptive cooling control method for a system provided in this application embodiment is shown. The process includes the following steps: S801: Real-time acquisition of generator temperature data, engine room environment data, and generator operating power data.

[0090] The adaptive cooling control method for wind turbines provided in this application is applied to electronic devices, such as PCs or servers, and can be the adaptive control module of the system.

[0091] In this embodiment, a distributed sensor network can be used to collect real-time generator temperature data, nacelle environment data, and generator operating power data. Specifically, temperature data collection includes the generator stator surface temperature and heat source temperature obtained by temperature sensors arranged near the evaporation section of the heat-conducting jacket 101 and heat pipe array 102, as well as the heat dissipation end temperature data that monitors the surface temperature of the integrated heat dissipation module 200 in the nacelle shell, ensuring that the heat transfer path from the heat acquisition module 100 to the integrated heat dissipation module 200 in the nacelle shell is controllable. Nacelle environment data collection includes the air humidity inside the nacelle, ambient temperature, and natural wind speed and direction signals outside the nacelle. The humidity data is directly associated with the safety interlock logic of the closed spray cooling unit 302, while the wind speed and direction data are used to evaluate the auxiliary heat dissipation efficiency of the axial fan array 301. Generator operating power data is read in real-time through the electrical interface, showing active power and load rate, serving as the core input variables for the heat load prediction model. All collected data is filtered and standardized before being transmitted to the processor of the adaptive control module 400. This provides high-precision, low-latency data support for subsequent heat load prediction and intelligent switching of cooling modes, ensuring that the system can achieve optimal thermal management performance under different operating conditions.

[0092] S802: Based on a pre-set heat load prediction model, predict the heat load for future time periods.

[0093] The electronic device uses a pre-set heat load prediction model to perform multi-dimensional and accurate prediction and trend analysis of the heat load for future time periods. The processor calls upon the heat load prediction model built on an LSTM neural network stored in memory, using real-time acquired generator operating power data and historical temperature sequences from the heat acquisition module 100 as core input variables to deeply explore the nonlinear temporal correlation between power fluctuations and temperature changes. The model outputs the heat load change trend and peak time within a preset future time period, enabling the electronic device to shift from passive response to proactive prediction. Based on the prediction results, the system adjusts the cooling mode switching strategy in advance. For example, when a heat load increase is predicted, the axial fan array 301 or the closed spray cooling unit 302 in the active enhancement module 300 is activated in advance to prevent heat accumulation in the heat-conducting jacket 101 and heat pipe array 102 of the heat acquisition module 100, which could lead to temperature overshoot. This predictive mechanism ensures that the heat dissipation capacity of the integrated heat dissipation module 200 in the nacelle shell dynamically matches future heat demands. It not only eliminates control lag but also optimizes the energy consumption distribution of the active enhancement module 300, realizing the intelligent and efficient operation of the wind turbine thermal management system.

[0094] S803: Based on the current environmental data and the predicted heat load, select the target cooling mode from the three-level cooling modes. The three-level cooling modes include: a passive heat dissipation mode that relies on heat pipes and phase change materials for heat dissipation; an active air-liquid cooling mode that starts the fan and circulating pump; and a spray enhancement mode that starts the closed spray unit.

[0095] The electronic equipment dynamically selects the optimal target cooling mode from three cooling modes, taking into account current environmental data and predicted heat load trends, to achieve the best balance between energy efficiency and heat dissipation performance. The first mode is a passive cooling mode relying on heat pipes and phase change materials. This mode is suitable for low-load or low-temperature environments. In this mode, the heat-conducting sleeve 101 and heat pipe array 102 in the heat acquisition module 100 efficiently conduct generator waste heat to the integrated heat dissipation module 200 in the nacelle shell. The phase change material coating integrated inside the module 200 absorbs instantaneous heat fluctuations, maintaining system thermal balance without additional energy consumption. The second mode is an active air-liquid cooling mode that activates fans and circulating pumps. When a temperature rise is detected or a predicted increase in heat load is detected, the adaptive control module 400 activates the axial fan array 301 in the active enhancement module 300 to enhance air convection on the surface of the nacelle shell. Simultaneously, it drives the coolant circulating pump within the integrated heat dissipation module 200 to accelerate medium flow, rapidly removing accumulated heat through the synergistic effect of convection and liquid cooling. Finally, to activate the spray enhancement mode of the closed-loop spray unit, which is designed to handle extreme high-load or high-temperature shock conditions, the adaptive control module 400 controls the closed-loop spray cooling unit 302 to spray atomized deionized water onto the nacelle shell surface. This utilizes the high latent heat of vaporization of water to achieve peak shaving, while strictly adhering to safety interlock logic to ensure electrical safety within the nacelle. Through this tiered and progressive strategy, the adaptive control module 400 ensures that the heat collected by the heat acquisition module 100 can be promptly dissipated through the integrated heat dissipation module 200 on the nacelle shell, preventing heat accumulation. Simultaneously, it maximizes the passive cooling time, reduces the operating energy consumption of the active enhancement module 300, and guarantees the stable and efficient operation of the wind turbine throughout its entire lifecycle.

[0096] S804: Adjust the operating parameters of the actuator according to the selected target cooling mode; monitor the temperature change of the generator; if the temperature does not drop to the target range, upgrade the cooling mode; if the temperature stabilizes within the target range, evaluate whether to reduce the cooling mode level.

[0097] The electronic equipment can adjust the operating parameters of the actuators, including the active enhancement module 300 and the integrated heat dissipation module 200 of the nacelle shell, according to the selected target cooling mode. Specifically, a pulse width modulation signal is sent to the active enhancement module 300 to dynamically adjust the speed and airflow angle of the axial fan array 301, or to adjust the water pump frequency and atomizing nozzle opening of the closed spray cooling unit 302. At the same time, the flow rate of the coolant circulation pump in the integrated heat dissipation module 200 of the nacelle shell is controlled to ensure that the heat dissipation power matches the heat load in real time. The system continuously monitors the temperature change trend of the generator through temperature sensors arranged at key nodes of the heat-conducting jacket 101 and the heat pipe array 102 and feeds the data back to the adaptive control module 400 in real time. If the temperature is detected to have not dropped to the target range and is showing an upward trend, the adaptive control module 400 immediately executes an upgraded cooling mode strategy, such as switching from a passive cooling mode that relies on heat pipes and phase change materials to an active air-liquid cooling mode that starts the fans and circulation pumps. If necessary, it can directly jump to the spray enhancement mode that starts the closed spray unit 302 to prevent the heat acquisition module 100 from overheating. If the temperature stabilizes within the target range and remains there for a preset duration, the adaptive control module 400 assesses whether to reduce the cooling mode level. By introducing hysteresis comparison logic to avoid frequent mode oscillations, it gradually reduces the speed of the axial fan array 301 or shuts down the enclosed spray cooling unit 302, returning to a low-energy passive cooling mode. This dynamic adjustment mechanism ensures that the generator always operates within the optimal temperature range while minimizing the energy consumption of the active enhancement module 300, achieving a balance between safety and economy.

[0098] Based on the above embodiments, in the embodiments of this application, in the step of selecting the target cooling mode, hysteresis logic is used for judgment to prevent the cooling mode from frequently switching near the threshold; in the spray enhancement mode, the closed spray unit is controlled to operate in a pulse mode and the humidity in the cabin is monitored in real time. When the humidity exceeds the safety threshold, the spraying is stopped immediately and the exhaust drying program is started.

[0099] In the step of selecting the target cooling mode, hysteresis logic is used for judgment to prevent frequent switching of the cooling mode near the threshold. By setting a dead zone range between the temperature rise trigger threshold and the temperature fall recovery threshold, the system is effectively prevented from repeatedly oscillating between a passive cooling mode relying on heat pipes and phase change materials and an active air-liquid cooling mode that starts the fan and circulating pump due to sensor noise or small environmental fluctuations. This protects the lifespan of the actuators of the axial fan array 301 and the closed spray cooling unit 302, and reduces mechanical wear and energy consumption impact. In the spray enhancement mode, the adaptive control module 400 controls the closed spray unit 302 to operate in a pulse mode. The intermittent spray strategy optimizes the water mist evaporation efficiency, prevents water accumulation and waste, and ensures that the heat conducted by the heat acquisition module 100 to the integrated heat dissipation module 200 of the cabin shell can be efficiently removed. The system monitors humidity sensor data in the nacelle in real time. When the humidity exceeds the safety threshold, the adaptive control module 400 immediately stops spraying and starts the exhaust drying program, which is linked to the exhaust system inside the nacelle to accelerate the removal of moisture, ensure the effectiveness of the sealed isolation structure, prevent moisture from penetrating into the electrical space and affecting the insulation performance of the generator, and ensure the environmental safety of the area where the heat acquisition module 100 and the heat pipe array 102 are located. At the same time, combined with the auxiliary ventilation function of the axial fan array 301, the dry state inside the nacelle is quickly restored, ensuring the long-term reliable operation of the wind turbine under extreme conditions.

[0100] The adaptive control module automatically switches between three cooling modes based on generator temperature, ambient temperature, and predicted heat load.

[0101] Three-stage adaptive hybrid cooling system: Level 1 Passive Mode: When the ambient temperature is <25℃ and the heat load is <50% of the rated value, heat transfer relies solely on heat pipes, phase change materials for buffering, and natural convection for heat dissipation, and all active equipment is shut down; Second-level active mode: When the ambient temperature is 25-35℃ or the heat load is 50-80% of the rated value, the circulating pump and axial flow fan array are started, and the flow rate and speed are dynamically adjusted according to the temperature difference. Level 3 Enhanced Mode: When the ambient temperature is >35℃ and the heat load is >80% of the rated value, or the generator temperature is >85℃, the closed spray unit is activated on the basis of Level 2. The spraying is operated in a pulse mode, with a single spraying time of 2-5 seconds and an interval of 10-30 seconds.

[0102] S1: Real-time acquisition of generator winding temperature Tw, core temperature Tc, and nacelle shell temperature Ts via a distributed temperature sensor array; and acquisition of ambient temperature and humidity via an environmental sensor. S2: Predicts the heat load Qpred for the next 5-15 minutes based on an LSTM neural network model. Inputs include historical temperature sequences, generator power curves, and weather forecast data. S3: Determines the cooling mode based on Ta, RHa, and Qpred, and uses hysteresis logic to prevent frequent switching. If Ta < 25℃, Qpred < 0.5Qmax, and Tw < 75℃, select the first-level passive mode; If 25℃≤Ta<35℃ or 0.5Qmax≤Qpred<0.8Qmax or 75℃≤Tw<85℃, select the second-level active mode; If Ta≥35℃, Qpred≥0.8Qmax, and Tw≥85℃, select the third-level enhancement mode; S4: Control the actuator according to the selected cooling mode: In the first-level mode, the circulation pump runs at low speed (20% speed), and the fan and spray are turned off; In the second-stage mode, the circulating pump adjusts its speed (30-70% speed) according to the temperature difference, and the fan array starts in stages. In the third-level mode, the circulation pump runs at full speed, the fan runs at full speed, and the spray unit operates in a pulse mode. S5: Monitor the control effect. If Tw does not decrease or continues to rise within the set time, upgrade the mode. If the temperature stabilizes within the target range, assess whether it can be downgraded. S6: Record running data, update LSTM model parameters, optimize control rules, and achieve self-learning optimization.

[0103] The compatibility modifications with existing generators are as follows: Retrofitting strategies for existing wind turbines: Do not change the generator itself, add a heat-conducting sleeve to the generator casing, connect the heat-conducting sleeve to the heat pipe, and maintain the original insulation and sealing of the generator; Make use of existing space: There is usually redundant space in the cabin (especially in older gearbox models), rearrange the control cabinets to free up space, and utilize the space on the top and side walls of the cabin; Phased implementation Step 1: Add external heat sink fins and a fan (the simplest step); Step 2: Add a heat pipe heat transfer system; Step 3: Integrate a spray evaporation system (if needed).

[0104] Utilize existing cooling system interfaces: For existing air-cooled fans: utilize existing air ducts; for existing water-cooled fans: modify the existing water-cooling system; use existing installation points and interfaces as much as possible.

[0105] System configuration includes: 1. Heat collection: heat pipe array + thermal jacket (completely passive); 2. Main heat dissipation: The chassis shell integrates a heat dissipation structure (microchannel + PCM + fins). 3. Enhanced heat dissipation: Small circulating pump + coolant (enhancing liquid convection); 4. Active cooling: External fan enhances convection (strengthens airflow); 5. Emergency heat dissipation: sandwich spray cooling (extreme conditions); 6. Intelligent control: Three-level adaptive control.

[0106] Compared with the prior art, the present invention has the following significant advantages: 1. Fully Integrated Nacelle Safe Cooling: Completely eliminates the external cooling towers and long pipelines of traditional water-cooling systems, solving problems such as high-pressure leakage and winter freeze protection. The innovative closed-loop spray design ensures complete isolation between the water mist and electrical equipment, solving the safety application issues of spray cooling in wind turbines.

[0107] 2. Three-level adaptive intelligent control: Intelligently switches cooling modes based on environmental conditions and heat load, operating in zero-energy or low-energy mode more than 85% of the time, achieving comprehensive energy savings of over 60%. LSTM predictive models enable proactive control, avoiding temperature overshoot.

[0108] 3. Multiple safety safeguards: The spray system employs a closed-cell design, multiple safety interlocks, and a manual confirmation mechanism to ensure absolute electrical safety. All active equipment has a fault degradation strategy to guarantee the system's basic functions.

[0109] 4. High-efficiency and reliable heat dissipation: Heat pipe array + heat conduction jacket achieves efficient passive heat transfer; the nacelle shell integrates microchannels + phase change materials + fins to provide multiple heat dissipation paths; actual tests show that the generator temperature can still be controlled below 85℃ when the ambient temperature is 40℃.

[0110] 5. Simple and economical maintenance: The system mainly uses passive components (heat pipes, phase change materials), with few active devices that are easy to maintain. No special maintenance is required for ground equipment, reducing maintenance costs by more than 50%.

[0111] 6. Strong environmental adaptability: It can work effectively in environments ranging from -30℃ to 45℃, and the annual water consumption of the spray system is less than 50L (only 1% of that of traditional evaporative cooling).

[0112] Based on the methods provided in the above embodiments, this application also provides an adaptive cooling control device. Figure 9 This is a schematic diagram of an adaptive cooling control device provided in an embodiment of this application. The device includes: The data acquisition module 901 is used to acquire real-time temperature data, nacelle environmental data, and generator operating power data of the generator. The processing module 902 is used to predict the heat load for a future time period based on a preset heat load prediction model; select a target cooling mode from three cooling modes according to the current environmental data and the predicted heat load; the three cooling modes include: a passive heat dissipation mode that relies on heat pipes and phase change materials for heat dissipation; an active air-liquid cooling mode that starts the fan and circulating pump; and a spray enhancement mode that starts the closed spray unit; adjust the operating parameters of the actuator according to the selected target cooling mode; monitor the temperature change of the generator; if the temperature does not drop to the target range, upgrade the cooling mode; if the temperature stabilizes within the target range, evaluate whether to reduce the cooling mode level.

[0113] Based on the same inventive concept, this application also provides an electronic device that can realize the function of the aforementioned adaptive cooling control method. (Refer to...) Figure 10 The electronic device includes: The system includes at least one processor 1001, a memory 1003 connected to the at least one processor 1001, and a communication interface 1002. In this embodiment, the specific connection medium between the processor 1001 and the memory 1003 is not limited. Figure 10 The example shown is the connection between processor 1001 and memory 1003 via bus 1004. Bus 1004... Figure 10 The connections between other components are shown in thick lines only and are not intended to be limiting. The 1004 bus can be divided into address bus, data bus, control bus, etc., for ease of representation. Figure 10 The term 1001 is represented by a single thick line, but this does not imply that there is only one bus or one type of bus. Alternatively, the processor 1001 can also be called a controller; there are no restrictions on the name.

[0114] In this embodiment, the memory 1003 stores instructions executable by at least one processor 1001. By executing the instructions stored in the memory 1003, the at least one processor 1001 can perform the IoT device upgrade method described above. The processor 1001 can implement... Figure 10 The system shown illustrates the functions of each module.

[0115] The processor 1001 is the control center of the device. It can connect to various parts of the control device through various interfaces and lines. By running or executing instructions stored in memory 1003 and calling data stored in memory 1003, the processor can perform various functions and process data, thereby monitoring the device as a whole.

[0116] In one possible design, processor 1001 may include one or more processing units. Processor 1001 may integrate an application processor and a modem processor, wherein the application processor mainly handles the operating system, user interface, and applications, and the modem processor mainly handles wireless communication. It is understood that the modem processor may also not be integrated into processor 1001. In some embodiments, processor 1001 and memory 1003 may be implemented on the same chip; in some embodiments, they may also be implemented on separate chips.

[0117] The processor 1001 can be a general-purpose processor, such as a central processing unit (CPU), digital signal processor, application-specific integrated circuit, field-programmable gate array or other programmable logic device, discrete gate or transistor logic device, or discrete hardware component, capable of implementing or executing the methods, steps, and logic block diagrams disclosed in the embodiments of this application. The general-purpose processor can be a microprocessor or any conventional processor. The steps of the IoT device upgrade method disclosed in the embodiments of this application can be directly manifested as execution by a hardware processor, or execution by a combination of hardware and software modules within the processor.

[0118] Memory 1003, as a non-volatile computer-readable storage medium, can be used to store non-volatile software programs, non-volatile computer-executable programs, and modules. Memory 1003 may include at least one type of storage medium, such as flash memory, hard disk, multimedia card, card-type memory, random access memory (RAM), static random access memory (SRAM), programmable read-only memory (PROM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), magnetic storage, magnetic disk, optical disk, etc. Memory 1003 can be any other medium capable of carrying or storing desired program code in the form of instructions or data structures that can be accessed by a computer, but is not limited thereto. In the embodiments of this application, memory 1003 can also be a circuit or any other device capable of implementing storage functions for storing program instructions and / or data.

[0119] By designing and programming the processor 1001, the code corresponding to the IoT device upgrade method described in the foregoing embodiments can be embedded into the chip, enabling the chip to execute the code during operation. Figure 1The steps of the IoT device upgrade method shown in the embodiment are described below. How to design and program the processor 1001 is a technique well-known to those skilled in the art and will not be elaborated upon here.

[0120] Based on the same inventive concept, embodiments of this application also provide a storage medium storing computer instructions that, when executed on a computer, cause the computer to perform the adaptive cooling control method described above.

[0121] In some possible implementations, various aspects of the adaptive cooling control method provided in this application can also be implemented in the form of a program product, which includes program code that, when the program product is run on a device, causes the control device to perform the steps in the IoT device upgrade method according to the various exemplary embodiments of this application described above.

[0122] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. An adaptive hybrid cooling system, characterized in that, The system is integrated with the wind turbine nacelle and is not connected to the ground cooling equipment outside the nacelle. It includes: a heat acquisition module, a heat dissipation module integrated into the nacelle shell, an active enhancement module, and an adaptive control module. The heat collection module includes a heat-conducting sleeve and a heat pipe array fitted and sleeved on the outside of the generator stator housing. The evaporation section of the heat pipe array is embedded in the heat-conducting sleeve, and the condensation section of the heat pipe array extends to the integrated heat dissipation module of the nacelle housing and is thermally connected to the integrated heat dissipation module of the nacelle housing, for the purpose of conducting the waste heat of the generator to the nacelle housing. The integrated heat dissipation module of the cabin shell forms part of the cabin enclosure structure. The integrated heat dissipation module of the cabin shell is provided with a heat exchange structure for receiving the heat of the condensation section of the heat pipe array and for dissipating the heat to the external environment of the cabin. The active enhancement module includes an axial flow fan array located on the outside of the nacelle shell, and a closed spray cooling unit located within the nacelle shell structural layer or integrated with the nacelle shell; the closed spray cooling unit is isolated from the electrical space inside the nacelle by a sealed isolation structure, and is equipped with an exhaust system to discharge the humid air in the spray chamber to the outside of the nacelle. The adaptive control module is electrically connected to the heat acquisition module, the integrated heat dissipation module of the engine nacelle shell, and the active enhancement module, respectively. The adaptive control module is configured to control the system to switch between three cooling modes, including at least a passive heat dissipation mode, an active air-liquid cooling mode, and a spray enhancement mode, based on the generator operating parameters and environmental parameters.

2. The system according to claim 1, characterized in that, The heat-conducting sleeve has a segmented structure, consisting of multiple arc-shaped segments fastened to the outside of the generator stator housing by fasteners. The contact surface between the heat-conducting sleeve and the stator housing is filled with a heat-conducting interface material. The evaporation section of the heat pipe array is embedded in a pre-set mounting groove in the heat-conducting sleeve, and the heat pipe array is evenly distributed along the circumference of the generator.

3. The system according to claim 2, characterized in that, The heat pipe array is a gravity-assisted heat pipe, and the condensation section of the heat pipe array is arranged upward at an angle of 10-30° relative to the evaporation section, extending to the integrated heat dissipation module of the cabin shell.

4. The system according to claim 1, characterized in that, The integrated heat dissipation module of the cabin shell is a multi-layer composite structure, which includes, from the outside to the inside of the cabin: an outer skin layer, a structural reinforcement layer, a microchannel cooling plate layer, a phase change material coating, and a reinforced heat dissipation fin layer; the microchannel cooling plate layer is filled with coolant and is thermally connected to the condensation section of the heat pipe array; the phase change material coating is applied to the inner surface of the microchannel cooling plate layer to absorb instantaneous heat load.

5. The system according to claim 1, characterized in that, The axial flow fan array includes multiple low-profile axial flow fans, which are externally mounted on the top or upper side of the nacelle shell. The fan outlet direction is parallel to or at a preset angle to the surface of the nacelle shell, in order to form a cooling air layer on the surface of the nacelle shell.

6. The system according to claim 1, characterized in that, The sealed isolation structure includes a porous metal partition disposed between the spray chamber and the internal space of the cabin; the enclosed spray cooling unit also includes a deionized water tank and a water supply pump, the water supply pump being configured to supply deionized water to the atomizing nozzles in the spray chamber; the bottom of the spray chamber is provided with a water collection tank and a water recovery system for recovering unevaporated water droplets.

7. The system according to claim 1 or 6, characterized in that, The adaptive control module is also equipped with safety interlock logic. The start-up of the enclosed spray cooling unit requires at least three of the following safety conditions to be met simultaneously: the humidity inside the engine compartment is lower than the preset humidity threshold; the ambient temperature is higher than the preset low temperature threshold and there is no rainfall signal; the wind speed is lower than the preset wind speed threshold; and the generator insulation resistance is higher than the preset resistance threshold.

8. The system according to claim 1, characterized in that, The adaptive control module includes a memory and a processor. The memory stores a heat load prediction model. The processor is configured to use the heat load prediction model to predict the heat load within a preset time period based on historical temperature sequences and generator power data, and to adjust the switching of cooling modes in advance based on the prediction results. The heat load prediction model is a prediction model based on a long short-term memory (LSTM) neural network.

9. An adaptive cooling control method for a wind turbine generator used in any one of claims 1-8, characterized in that, The method includes: Real-time acquisition of generator temperature data, nacelle environment data, and generator operating power data; Based on a pre-set heat load prediction model, the heat load for future time periods is predicted; Based on current environmental data and predicted heat load, a target cooling mode is selected from the three-level cooling modes. The three-level cooling modes include: a passive heat dissipation mode that relies on heat pipes and phase change materials for heat dissipation; an active air-liquid cooling mode that starts fans and circulating pumps; and a spray enhancement mode that starts closed spray units. Adjust the operating parameters of the actuator according to the selected target cooling mode; monitor the temperature change of the generator. If the temperature does not drop to the target range, upgrade the cooling mode. If the temperature stabilizes within the target range, evaluate whether to reduce the cooling mode level.

10. An adaptive cooling control device, characterized in that, The device includes: The data acquisition module is used to collect real-time data on generator temperature, nacelle environment, and generator operating power. The processing module is used to predict the heat load for a future time period based on a preset heat load prediction model; select a target cooling mode from three cooling modes according to the current environmental data and the predicted heat load; the three cooling modes include: a passive heat dissipation mode relying on heat pipes and phase change materials; an active air-liquid cooling mode that starts the fan and circulating pump; and a spray enhancement mode that starts the closed spray unit; adjust the operating parameters of the actuator according to the selected target cooling mode; monitor the temperature change of the generator; if the temperature does not drop to the target range, upgrade the cooling mode; if the temperature stabilizes within the target range, evaluate whether to reduce the cooling mode level.

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