Nacelle cover panel

Abstract

SOLUTION: The present disclosure is related to a nacelle cover panel and a nacelle cover assembly. The nacelle cover panel is configured to be attached to a nacelle of a wind turbine. Further, the nacelle cover panel comprises a composite panel including at least an outer roof surface and an inner surface, and a structural frame coupled to the composite panel. Methods of providing the nacelle assembly are also disclosed.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a wind turbine nacelle. More particularly, the present disclosure relates to a nacelle cover panel that is an interface plate configured to couple a composite panel to a structural frame, and a nacelle cover assembly including the same. The present disclosure further relates to a method of providing a nacelle assembly for a wind turbine.

Background Art

[0002] Wind turbines are generally used to supply power to an electrical grid. This type of wind turbine generally includes a tower and a rotor disposed on the tower. The rotor typically includes a hub and a plurality of blades and is configured to rotate under the influence of wind on the blades. This rotation usually generates torque that is transmitted directly "direct drive" or "gearless" or using a gearbox through a rotor shaft to a generator. In this way, the generator generates electricity that can be supplied to the electrical grid.

[0003] Wind turbines have evolved rapidly over the past few decades, and the components of wind turbines have been improved to withstand higher loads and adverse weather. The wind turbine nacelle houses the drive train and other tower top components and protects them from external factors such as precipitation, dust, ultraviolet rays, and lightning strikes. Further, the wind turbine nacelle generally provides an inlet and an outlet for the air flow within the generator. It withstands the wind force received by the blades and the heat generated by the drive train (drive train) and provides a work platform for qualified workers.

[0004] To maintain the nacelle and rotor in alignment with the wind direction, the nacelle is typically mounted on a yaw bearing and can rotate. To maximize the relatively large volume and internal free volume defined by the nacelle, the nacelle cover may be located far from the structural components of the nacelle at least in some positions and therefore must withstand the heavy loads during wind turbine operation on its own. These loads include, for example, the loads of the cooling system and handrails, loads associated with potential evacuation or rescue procedures at several established support points, the weight of one or more flexi-cranes or pedestrian areas, etc.

[0005] A nacelle cover may include a single piece or multiple pieces assembled to provide cover for the nacelle. The nacelle and nacelle cover may be assembled at an assembly plant or assembled on-site. Furthermore, in some cases, the nacelle cover may be assembled above the tower, which means that the nacelle cover(s) can be transported by crane from at least the base of the wind turbine to the nacelle of the wind turbine. Therefore, during these transport operations, the nacelle cover must be able to withstand its own weight when lifted from a dedicated lifting point.

[0006] Nacelle covers are generally constructed from composite materials, often manufactured from resin-injected fiberglass composites to meet requirements regarding size, internal and external geometric shape, and weight. While composite materials such as fiberglass epoxy or other combinations can reduce the overall weight of the nacelle cover, they may not possess the structural integrity to withstand the aforementioned loads acting upon them. For this reason, the nacelle cover can be mechanically bonded to the wind turbine's nacelle frame at several points, thereby providing structural rigidity.

[0007] Joining the nacelle cover to the nacelle frame is generally a very time-consuming process involving a cumbersome alignment of parts. Furthermore, the nacelle cover typically needs to transfer load from external nacelle components to the nacelle frame, which can potentially cause holes to form in the cover. In marine environments, wind turbine components inside the nacelle corrode quickly, increasing the frequency of maintenance and the need for parts replacement. Therefore, during nacelle assembly, it may be necessary to seal all holes to ensure there are no leaks inside the nacelle. This results in a complex and cumbersome task, and the problem worsens as the number of sealing points increases. Thus, during nacelle assembly, workers may be required to seal all holes to ensure there are no leaks inside the nacelle afterward. This results in a complex and cumbersome task, and the problem is exacerbated as the number of sealing points increases.

[0008] This disclosure provides a method and system for overcoming some of the aforementioned shortcomings, at least partially. [Overview of the project] [Problems that the invention aims to solve]

[0009] In one aspect of the present disclosure, a nacelle cover panel for a wind turbine is provided. The nacelle cover panel of the present disclosure is configured to be mounted on the nacelle of a wind turbine and includes a composite panel and a structural frame. The composite panel includes at least an outer roof surface and an inner surface, and the structural frame is coupled to the composite panel on the inner surface.

[0010] According to this embodiment, the nacelle cover assembly, comprising a structural frame that does not undergo deformation during curing, can provide more precise positioning of connection points to the nacelle frame to which it may be attached. This simplifies and reduces the time required for assembling the nacelle cover with the rest of the wind turbine nacelle structure. Since the structural frame is coupled to a composite panel and supplied as a ready-made unit, the nacelle assembly time can be reduced, and a secure and reliable connection can be achieved.

[0011] In a further aspect of the present disclosure, an interface plate is provided configured to connect a composite panel to a structural frame. The interface plate connects the composite panel to the structural frame at a composite panel opening. Furthermore, the interface plate includes a plurality of holes for receiving fasteners and a flange configured to contact a substantially flat surface of the composite panel and to at least partially seal the opening.

[0012] In this embodiment, the interface plate provides a robust structural connection from the outside of the nacelle to the nacelle structural frame. Therefore, any external nacelle component located on top of the nacelle can be connected to the interface plate. This connection reduces the main load acting on the composite panel. Furthermore, the interface plate facilitates a fast and reliable connection between the composite panel and the structural frame, and also reduces the risk of leakage within the nacelle.

[0013] In a further embodiment, a method for providing a nacelle assembly is provided. The method includes providing a nacelle base component and a nacelle cover panel including a composite panel having at least an outer roof surface and an inner surface, and a structural frame coupled to the composite panel. Furthermore, the method also includes securing the nacelle base component to the nacelle cover panel via the structural frame coupled to the composite panel.

[0014] In this additional embodiment, the nacelle assembly is assembled, but without relying on composite parts, it relies on a structural frame that allows for significantly smaller geometric tolerances. Assembly with the rest of the nacelle is simplified, resulting in shorter assembly line times.

[0015] Therefore, securing the nacelle cover panels to the nacelle base components can result in a more reliable process. As a result, the use of a crane or any other lifting means may be more efficient than conventional methods, and thus the assembly process may be faster and less expensive. Furthermore, the fact that the nacelle assembly includes a nacelle cover assembly from which individual nacelle cover panels can be removed for maintenance, replacement, or upgrade results in a more versatile nacelle assembly. Thus, a further advantage of this embodiment is that temporary or permanent replacement of nacelle cover panels is easy for strategic or operational reasons.

[0016] Throughout this disclosure, the terms “roof surface” and “outer roof surface” are used interchangeably and refer to the outer surface relative to the nacelle.

[0017] Further objects, advantages, and features of the embodiments of this disclosure will become apparent to those skilled in the art upon examination of the specification, or may be acquired through practice. [Brief explanation of the drawing]

[0018] [Figure 1] A schematic perspective view of an example of a wind turbine is shown. [Figure 2] An example of a wind turbine hub and nacelle is shown. [Figure 3] This figure schematically shows a perspective view of an example of a nacelle cover assembly that includes multiple nacelle cover panels. [Figure 4A] A schematic perspective top view of an example of a nacelle cover assembly including a single nacelle cover panel is shown. [Figure 4B]Figure 4A shows a schematic perspective view of the nacelle cover assembly from below. [Figure 5] A schematic perspective view of the bottom, including a longitudinal section, shows another example of a nacelle cover assembly on an existing frame of the nacelle base. [Figure 6] This diagram schematically shows a detailed cross-sectional view of the interface location where the nacelle cover panel and the external nacelle components are connected. [Figure 7] A schematic perspective view of an example of a nacelle assembly is shown. [Figure 8] A flowchart illustrating an example of a method for providing a nacelle assembly is shown. [Modes for carrying out the invention]

[0019] Hereinafter, embodiments of the present disclosure are given in detail, with one or more examples shown in the drawings. Each example is provided for illustrative purposes only, and not as a limitation. Indeed, it will be apparent to those skilled in the art that various modifications and changes can be made in this disclosure without departing from the scope or spirit of the teaching. For example, features illustrated or described as part of one embodiment can be used in conjunction with another embodiment to obtain yet another embodiment. Thus, this disclosure is intended to encompass modifications and variations that fall within the scope of the appended claims and their equivalents.

[0020] FIG. 1 is a perspective view of an example of a wind turbine 10. In this example, the wind turbine 10 is a horizontal axis windmill. Alternatively, the wind turbine 10 may be a vertical axis wind turbine. In an embodiment, the wind turbine 10 includes a tower 15 extending from a support system 14 on the ground 12, a nacelle 16 attached to the tower 15, and a rotor 18 coupled to the nacelle 16. The rotor 18 includes a rotatable hub 20 and at least one rotor blade 22 coupled to the hub and extending outward from the hub 20. In this example, the rotor 18 has three rotor blades 22. In another embodiment, the rotor 18 includes more than 3 or less than 3 rotor blades 22. The tower 15 may be made of tubular steel to define a cavity (not shown in FIG. 1) between the support system 14 and the nacelle 16. In an alternative embodiment, the tower 15 is any suitable type of tower having any suitable height. According to another method, the tower may be a hybrid tower including a concrete portion and a tubular steel portion. Also, the tower can be a partial or complete lattice tower (lattice tower).

[0021] The rotor blades 22 are spaced relative to the hub 20 to enable the conversion of kinetic energy from the wind into mechanical energy, and thus electrical energy, by rotating the rotor 18. The rotor blades 22 are fitted to the hub 20 by coupling the blade root portion 24 to the hub 20 in a plurality of load transfer regions 26. The load transfer regions 26 may have hub load transfer regions and blade load transfer regions (both not shown in FIG. 1). The loads / forces induced on the rotor blades 22 are transmitted to the hub 20 via the load transfer regions 26.

[0022] In an embodiment, the rotor blade 22 can have a length ranging from about 15 meters (m) to about 90 meters or more. The rotor blade 22 can have any suitable length that enables the wind turbine 10 to function as described herein. For example, non-limiting examples of blade lengths include lengths less than 20 m, 37 m, 48.7 m, 50.2 m, 52.2 m, or greater than 91 m. When wind hits the rotor blade 22 from the wind direction 28, the rotor 18 rotates about the rotor shaft 30. When the rotor blade 22 rotates and is subject to centrifugal force, the rotor blade 22 is also subject to various forces and moments. Thus, the rotor blade 22 can deflect and / or rotate from a neutral position or an unbiased position to a deflected position.

[0023] Furthermore, the pitch angle of the rotor blade 22, i.e., the angle that determines the orientation of the rotor blade 22 relative to the wind direction, can be changed by the pitch system 32, and the load and power generated by the wind turbine 10 can be controlled by adjusting the angular position of at least one rotor blade 22 relative to the wind vector. The pitch axis 34 of the rotor blade 22 is shown. During operation of the wind turbine 10, the pitch system 32 can change the pitch angle of the rotor blade 22 such that the angle of attack of (a part of) the rotor blade decreases, facilitating a decrease in the rotational speed and / or facilitating a stall of the rotor 18.

[0024] In this example, the blade pitch of each rotor blade 22 is individually controlled by the wind turbine control device 36 or the pitch control system 80. Alternatively, the blade pitch of all the rotor blades 22 may be controlled simultaneously by this control system.

[0025] Furthermore, in this embodiment, as the wind direction 28 changes, the yaw direction of the nacelle 16 may rotate about the yaw axis 38 to position the rotor blade 22 relative to the wind direction 28.

[0026] In the embodiment, the wind turbine control device 36 is shown to be concentrated within the nacelle 16, but the wind turbine control device 36 may be a distributed system located throughout the wind turbine 10, on the support system 14, within the wind farm, and / or in a remote control center. The wind turbine control device 36 includes a processor 40 configured to perform the methods and / or steps described herein. Furthermore, many of the other components described herein include processors.

[0027] As used herein, the term “processor” is not limited to integrated circuits as referred to in the art as computers, but broadly means controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits, and other programmable circuits, and these terms are used interchangeably herein. It should be understood that processors and / or control systems may also include memory, input channels, and / or output channels.

[0028] Figure 2 is an enlarged cross-sectional view of a portion of the wind turbine 10. In this embodiment, the wind turbine 10 includes a nacelle 16 and a rotor 18 rotatably coupled to the nacelle 16. Specifically, the hub 20 of the rotor 18 is rotatably coupled to a generator 42 located within the nacelle 16 by a main shaft 44, a gearbox 46, a high-speed shaft 48, and a coupling 50. In this embodiment, the main shaft 44 is at least partially coaxial with the longitudinal axis (not shown) of the nacelle 16. The rotation of the main shaft 44 drives the gearbox, which in turn drives the high-speed shaft 48 by converting the relatively slow rotational motion of the rotor 18 and the main shaft 44 into the relatively fast rotational motion of the high-speed shaft 48. The latter is connected to the generator 42 to generate electrical energy with the help of the coupling 50. Furthermore, a transformer 90 and / or appropriate electronic equipment, switches and / or inverters can be placed within the nacelle 16 to convert the electrical energy generated by the generator 42, which has a voltage between 400V and 1000V, into electrical energy with a medium voltage (10-35KV). This electrical energy is then conducted from the nacelle 16 to the tower 15 via power cables.

[0029] The gearbox 46, generator 42, and transformer 90 may be supported by a main support structure frame of the nacelle 16, which optionally embodies a main frame 52. The gearbox 46 may include a gearbox housing connected to the main frame 52 by one or more torque arms 103. In embodiments, the nacelle 16 also includes a main front support bearing 60 and a main rear support bearing 62. Furthermore, the generator 42 may be attached to the main frame 52 by decoupling support means 54, in particular to prevent vibrations from the generator 42 from being introduced into the main frame 52 and becoming a source of noise emission.

[0030] Optionally, the main frame 52 is configured to bear the weight of the rotor 18 and the components of the nacelle 16, as well as the total load generated by the wind and rotational loads, and to introduce these loads into the tower 15 of the wind turbine 10. The rotor shaft 44, generator 42, gearbox 46, high-speed shaft 48, coupling 50, and associated fastenings, supports, and / or fixing devices, including but not limited to the support 52, front support bearings 60 and rear support bearings 62, may be referred to as the drivetrain 64.

[0031] In some examples, the wind turbine may be a direct-drive wind turbine without a gearbox 46. The generator 42 operates at the same rotational speed as the rotor 18 of the direct-drive wind turbine. Therefore, they generally have a much larger diameter than the generators used in wind turbines with a gearbox 46 to supply the same amount of power as those used in wind turbines with a gearbox.

[0032] The nacelle 16 may also include a yaw drive mechanism 56 used to rotate the nacelle 16, thereby causing the rotor 18 to also rotate around the yaw axis 38, in order to control the proximity of the rotor blades 22 to the wind direction 28.

[0033] To properly position the nacelle 16 with respect to the wind direction 28, the nacelle 16 may also include at least one weather measurement system 58 which may include a wind vane and an anemometer. The weather measurement system 58 can provide the wind turbine control device 36 with information including the wind direction 28 and / or wind speed. In this example, the pitch system 32 is at least partially located within the hub 20 as a pitch assembly 66. The pitch assembly 66 includes one or more pitch drive systems 68 and at least one sensor 70. Each pitch drive system 68 is coupled to each rotor blade 22 (shown in Figure 1) to adjust the pitch angle of the rotor blade 22 along the pitch axis 34. Figure 2 shows only one of the three pitch drive systems 68.

[0034] In this example, the pitch assembly 66 includes a hub 20 and at least one pitch bearing 72 coupled to each rotor blade 22 (shown in Figure 1) to rotate each rotor blade 22 around the pitch axis 34. The pitch drive system 68 includes a pitch drive motor 74, a pitch drive gearbox 76, and a pitch drive pinion 78. The pitch drive motor 74 is coupled to the pitch drive gearbox 76 so that the pitch drive motor 74 imparts mechanical force to the pitch drive gearbox 76. The pitch drive gearbox 76 is coupled to the pitch drive pinion 78 so that the pitch drive pinion 78 is rotated by the pitch drive gearbox 76. The pitch bearing 72 is coupled to the pitch drive pinion 78 so that the pitch bearing 72 is rotated by the rotation of the pitch drive pinion 78.

[0035] The pitch drive system 68, upon receiving one or more signals from the wind turbine controller 36, is coupled to the wind turbine controller 36 to adjust the pitch angle of the rotor blades 22. In embodiments, the pitch drive motor 74 is any suitable motor driven by an electric and / or hydraulic system, enabling the pitch assembly 66 to function as described herein. Alternatively, the pitch assembly 66 may include any suitable structure, configuration, arrangement, and / or components, such as, but are not limited to, a hydraulic cylinder, a spring, and / or a servo mechanism. In certain embodiments, the pitch drive motor 74 is driven by the rotational inertia of the hub 20 and / or energy extracted from a stored energy source (not shown) that supplies energy to the components of the wind turbine 10.

[0036] The pitch assembly 66 may also include one or more pitch control systems 80 for controlling the pitch drive system 68 in accordance with a control signal from the wind turbine controller 36 in certain preferred circumstances and / or during overspeed of the rotor 18. In this example, the pitch assembly 66 includes at least one pitch control system 80 communicably coupled to each pitch drive system 68 in order to control the pitch drive system 68 independently of the wind turbine controller 36. In this example, the pitch control system 80 is coupled to the pitch drive system 68 and the sensor 70. During normal operation of the wind turbine 10, the wind turbine controller 36 can control the pitch drive system 68 to adjust the pitch angle of the rotor blades 22.

[0037] In one embodiment, for example, a generator 84 including a battery and an electric capacitor is located inside or within the hub 20 and coupled to the sensor 70, pitch control system 80, and pitch drive system 68 to provide a power source to these components. In this embodiment, the wind turbine generator 84 provides a continuous source of power to the pitch assembly 66 while the wind turbine 10 is in operation. In another embodiment, the generator 84 supplies power to the pitch assembly 66 only during an electrical power loss event of the wind turbine 10. An electrical power loss event may include a power grid loss or dip, a malfunction of the wind turbine 10's electrical system, and / or a failure of the wind turbine controller 36. During an electrical power loss event, the generator 84 operates to supply power to the pitch assembly 66 so that the pitch assembly 66 can operate during the electrical power loss event.

[0038] In this embodiment, the pitch drive system 68, sensor 70, pitch control system 80, cable, and generator 84 are each located within a cavity 86 defined by the inner surface 88 of the hub 20. In another embodiment, the components are located relative to the outer roof surface of the hub 20 and may be directly or indirectly coupled to the outer roof surface.

[0039] Figure 3 is a schematic perspective view of a nacelle cover assembly 100 for a wind turbine. Figure 3 shows a nacelle cover assembly 100 configured to be installed inside the nacelle of a wind turbine, comprising three nacelle cover panels 110, 120, 130 including at least an outer roof surface 110' and an inner surface 110'', and a structural frame (shown in Figure 4B, reference numeral 112) coupled to the composite panels 110, 120, 130 on the inner surface.

[0040] As shown in the example in Figure 3, the nacelle cover assembly 100 may be formed by one or more nacelle cover panels 110, 120, 130, each having one or more structural frames, so that together the nacelle cover assembly 100 substantially covers the entire top surface of the nacelle. Note that the structural frames in this example are bonded to the inner surfaces 110'' of the nacelle cover panels 110, 120, 130 and are therefore not visible in the figure.

[0041] The fact that the nacelle cover assembly 100 may be formed by a plurality of nacelle cover panels 110, 120, 130 allows for a modular configuration, which means that specific parts of the nacelle cover assembly 100 can be removed for maintenance and / or replaced for a new cover or an upgraded cover. Alternatively, the nacelle cover assembly 100 may be formed by a single composite panel spanning all or part of the nacelle top surface.

[0042] As previously mentioned, to meet the requirements of size, internal and external geometric shape, and weight, the nacelle cover panels 110, 120, and 130 may contain glass fiber and / or polyester resin. The nacelle cover panels 110, 120, and 130 may additionally or alternatively contain other fibers and resins, such as carbon fiber, basalt fiber, or aramid fiber, and in particular epoxy or vinyl ether resin.

[0043] Furthermore, Figure 3 shows that the nacelle cover panels 110, 120, 130 may further include one or more interface plates 113. Also in this example, the nacelle cover panels 110, 120, 130 include composite panels having one or more openings 104 on the outer roof surfaces 110', 120', 130'. One or more openings 104 are configured to receive one or more interface plates 113 which are configured to be mechanically connected to the structural frame.

[0044] In this example, not all interface plates 113 are illustrated. The number and arrangement of openings 104 and interface plates 113 may differ in different nacelle cover panels 110, 120, 130 of a wind turbine due to structural rigidity requirements and / or external nacelle components on them. The structure and function of interface plates 113 will be discussed later, particularly with reference to Figure 6. Note that all features of composite panels and interface plates 113 can be incorporated into nacelle cover panels 110, 120, 130 or nacelle cover assemblies 100 containing them, and vice versa.

[0045] Figures 4A and 4B are schematic perspective top and bottom views, respectively, of an example of a nacelle cover assembly 100. In this example, the nacelle cover assembly 100 includes a single nacelle cover panel 110, the structural frame 112 which is coupled to the composite panel and protrudes at least partially from the inner surface 110'' of the composite panel. The structural frame 112 includes support zones 114 which connect the structural frame 112 to an existing frame 115 (shown in Figure 5) located within the wind turbine nacelle 16.

[0046] Figure 4B shows the arrangement of the structural frame 112, which in this example forms a roughly orthogonal grid of structural beams. However, other arrangements of the elements forming the structural frame 112 are also possible, for example, having non-linear angles between beam sections, or having reinforcing ribs instead of beams. The structural frame 112 provides strength and rigidity to the nacelle cover. Therefore, the structural frame 112 can be made of a material having greater strength and rigidity than the composite panel material. Here, strength can be considered as ultimate tensile strength, and rigidity can be expressed as having a higher modulus of elasticity.

[0047] The structural frame 112 can be formed from carbon steel. The proportion of carbon in the steel composition can be varied according to the specific requirements of the assembly in order to minimize production costs while maintaining high performance standards. Furthermore, other metal alloys, particularly other steel alloys, can also be used for both specific components of the structural frame and its main beams. Alternatively, the structural frame 112 may be made from fiber profiles, more precisely, drawn fiber profiles, and combinations of metal and fiber profiles.

[0048] Furthermore, the nacelle cover assembly 100 in the examples of Figures 4A and 4B shows that the nacelle cover panel 110 may also include one or more sides 111 that extend substantially perpendicular to the thickness of the cover panel, i.e., in the length and / or width direction of the nacelle. These sides 111 allow the internal volume of the nacelle to be closed laterally. To do so, the sides 111 may be provided with receptacles and / or fasteners for coupling to the wind turbine nacelle casing (particularly its side walls), the nacelle base, or other elements of the nacelle 16, thereby at least partially isolating the interior of the nacelle 16 from external hazards.

[0049] Figure 5 is a schematic perspective bottom view of the nacelle cover assembly 100. As shown in the figure, the nacelle cover assembly 100 may be mounted on the existing frame 115 of the nacelle 16. In these figures, the longitudinal section views show certain elements in more detail. More specifically, the structural frame 112 shows that it includes beams 116 having a rectangular hollow section. Furthermore, the longitudinal section provides a more detailed view of the interface plate 113 and its connection to the cooling system 117 from the upper side, and to the structural frame 112 from the lower side.

[0050] The interface plate 113, which will be described in more detail with reference to Figure 6, represents a connecting element between the structural frame 112 and external nacelle components such as the cooling system 117 located on the outer roof surface 110'. Thus, the cooling system 117 and other elements attached to the top of the nacelle cover assembly 100, namely handrails, lifting points, cranes, or others, may be coupled to the structural frame 112 via the interface plate 113. This ensures that loads acting on the interface plate 113 are transmitted to the structural frame 112, preventing excessive load on the composite panel. For this purpose, one or more interface plates 113 may include one or more through holes and fasteners, and the structural frame may include receiving sections for mechanically attaching the interface plate 113 to the structural frame 112 using fasteners, as described in reference to Figure 6.

[0051] In the embodiment shown in Figure 5, the cooling system 117 includes a connector 119 for securing the cooling system 117 to the interface plate 113. The same principle can be applied to any other external components that can be connected to the nacelle cover assembly 100 or nacelle cover panel 110 via the interface plate 113.

[0052] Furthermore, Figure 5 shows the mounting of the structural frame 112 between the existing frame 115 within the nacelle 16 via a support zone 114. The support zone 114 can be formed, for example, by groups grouped together by mounting commons, or, in the illustrated example, as a substantially flat plate. Any attachments or fittings can be used to facilitate the coupling of the structural frame 112 of the cover assembly to the internal frame 115 of the nacelle.

[0053] Figure 6 schematically shows a detailed cross-sectional view of an interface plate 113 configured to connect a nacelle cover assembly 100 or composite nacelle panel 110 to a structural frame 112. In this example, the interface plate is positioned within the composite panel opening 104 and includes holes 131 for receiving fasteners 118, and the structural frame 112 includes a hollow rectangular beam 116 and a connecting plate 113' for receiving fasteners 118 and mechanically attaching the interface plate 113 to the structural frame 112. The interface plate includes holes 131 that can extend through the interface plate and may be configured to receive fasteners 118. The holes 131 in the interface plate 113 may also coincide with holes (e.g., blind holes) in the connecting plate 113'. The holes 131 in the interface plate 113 may be configured to receive fasteners 118 for connecting any external nacelle components located on the upper part of the interface plate 113 and the outer roof surface 110' (i.e., railings, cooling systems, or others) to the structural frame 112.

[0054] The holes 131 in the interface plate 113 or the holes in the connecting plate 113' may have internal threads that match the respective threads of the fasteners. In this example, the internal threads are located in the holes of the connecting plate 113'. In other examples, the interface plate 113 may include a set of holes dedicated to connection to the structural frame 112 and another set of holes for connection to any external nacelle components.

[0055] Furthermore, Figure 6 shows that the interface plate 113 may include a flange 134 configured to contact a substantially flat surface of the nacelle cover assembly 100 or the nacelle cover panel 110. Thus, the flange 134 is positioned at least partially on the outer roof surface 110' of the composite panel. The flange 134 of the interface plate may overlap the composite roof panel. The flange 134 provides a contact area that can reduce the ingress of debris and / or water from the outside into the nacelle 16.

[0056] Furthermore, in other examples, the interface plate 113 may include a gasket positioned at least partially on the composite panel roof surface 110' to at least partially seal the composite nacelle panel opening 104. To provide an additional sealing barrier, in further examples, the interface plate 113 may include adhesive elements for mechanically or chemically attaching one or more interface plates 113 to the nacelle cover panel 110 or nacelle cover assembly 100.

[0057] Furthermore, the hole 131 is surrounded, either entirely or partially, by a recess 133 configured to receive a sealant and / or gasket, thereby at least partially sealing the connection between the interface plate 113 and the connecting plate 113'. In the example shown in Figure 6, the connecting plate 113' of the structural frame 112 further includes a recess 132 configured to receive a structural adhesive that connects the connecting plate 113' to the inner surface 110'' of the composite panel.

[0058] As described above, the interface plate 113 can provide load transfer (load transmission) from the nacelle's external components to the existing frame 115. Therefore, the interface plate 113 can be formed from a material having sufficient strength and rigidity to effectively transfer the load to the internal existing frame 115. Furthermore, since the interface plate 113 can be exposed to weather and atmospheric conditions, such as the marine environment, the interface plate 113 may be made from a non-corrosive material.

[0059] In further embodiments, the interface plate 113 may be made of stainless steel. More specifically, it can be manufactured from marine-grade stainless steel. Interface plates 113 made from such materials, typically molybdenum-containing materials, can resist the corrosive effects of salt in seawater, reducing maintenance and extending the lifespan of the components.

[0060] In Figure 6, the structural frame is shown to include a hollow rectangular beam 116 and a connecting plate 113'. However, structural frames can also be used that include beams with other geometric shapes, or even elements other than hollow beams.

[0061] The interface plate 113 can directly transmit external loads to the structural frame and the existing nacelle frame 115 (inside the wind turbine nacelle 16) via the support zone 114, and its configuration enhances watertightness. Furthermore, the fact that the interface plate 113 can be installed on the assembly line significantly reduces the number of connection points of the nacelle cover assembly 100 or nacelle cover panel 110 that can be inspected on-site or at the end of the assembly process, thereby reducing the final assembly time.

[0062] Figure 7 is a perspective view of an example of a nacelle assembly 200. In this example, the nacelle assembly 200 includes a schematicly shown nacelle base component 210 and a nacelle cover assembly 100, the nacelle cover assembly 100 including a composite panel and a nacelle cover panel 110 which includes at least an outer roof surface 110' and an inner surface. The nacelle cover panel 110 includes a structural frame 112 coupled to the composite panel and one or more interface plates 113. Furthermore, the outer roof surface 110' of the composite panel includes one or more openings 104 that receive one or more interface plates 113 which are coupled to the structural frame. Note that the structural frame is located on the inner surface of the composite panel and is therefore hidden beneath the outer roof surface 110'.

[0063] In this example, a handrail 122 is mounted on the top of the nacelle cover assembly 100, and a connector 119 is connected to the structural frame via an interface plate 113. The embodiment also shows that the nacelle cover assembly 100 includes a cooling system 117 connected to the structural frame 112 via the interface plate 113 and lift points 121. One or more of the lift points 121 may include the interface plate 113 so that the nacelle cover assembly 100 or nacelle cover panel 110 is lifted from the point where it is mechanically connected to the structural frame. Other types of external components may be mounted within the nacelle assembly 200, either additionally or alternatively.

[0064] In another embodiment of this disclosure, Method 600 is provided. Method 600 is suitable for providing a nacelle assembly 200. Method 600 is schematically shown in Figure 8.

[0065] The method includes providing a nacelle base component 210 in block 601. The nacelle base component 210 can take various forms, such as an existing frame 115 or a more complex structure having a shell or panels to at least partially isolate the interior of the nacelle from external atmospheric hazards. The nacelle base component typically includes a structural frame and a portion of the nacelle housing. Thus, the nacelle base component 210 may include a panel acting as a base, a panel acting as at least a side wall, and the existing internal frame 115 of the nacelle.

[0066] Method 600 also includes providing a nacelle cover panel 110 in block 602, which includes a composite panel comprising at least an outer roof surface 110' and an inner surface 110'', and a structural frame 112 coupled to the composite panel at the inner surface 110''. Since the structural frame 112 is directly connected to the composite panel, the nacelle cover panel 110 can be directly attached to the nacelle 16 without requiring interconnections.

[0067] Method 600 includes, in block 603, joining the nacelle base component 210 to the nacelle cover panel 110 via a structural frame 112 coupled to the composite panel. This joining step is relatively simple and can reduce installation and commissioning time. Since the structural frame 112 is not subject to geometric modifications during the assembly line, the joints between the components remain consistent.

[0068] In embodiments, a method 600 for providing a nacelle assembly 200 may include providing one or more additional nacelle cover panels 120, 130 and fixing the additional nacelle cover panels 120, 130 provided to the nacelle base component 210 to cover substantially the entire top surface of the nacelle.

[0069] Furthermore, in other embodiments, the provided nacelle cover panels 110, 120, 130 may include one or more openings 104 for receiving one or more interface plates 113. The method 600 may further include providing one or more interface plates 113, arranging one or more interface plates 113 within one or more openings 104, and coupling the interface plates 113 to the structural frame 112. As described above, the connection between the interface plates 113 and the structural frame 112 significantly reduces the external load acting on the composite panel when external nacelle components (such as cooling systems, handrails, escape routes, and flexi-cranes) are directly connected to the interface plates 113. It also reduces the number of watertightness check points at site, resulting in shorter installation times and reduced maintenance and commissioning times.

[0070] In this embodiment, method 600 may further include sealing the opening 104 in which the interface plate 103 is located. The sealing may include sealing around the opening 104 and any connection point or hole 131 configured to receive fasteners for joining the interface plate 113 to the structural frame 112.

[0071] In this embodiment, method 600 may further include providing an adhesive to at least the contact surface between the composite panel and the interface plate 113. The composite panel and the interface plate may be attached to each other by adhesive.

[0072] The interface plate 113 provided in method 600 may further include an elongated flange 134 to increase the contact surface between the composite panel and the interface plate 113 and further reduce the risk of water leakage. Other alternatives, such as providing the interface plate 113 with gaskets, are also possible to reduce the risk of water leakage.

[0073] This description uses examples to disclose teachings including preferred embodiments and to enable a person skilled in the art to carry out teachings including manufacturing and using any apparatus or system and performing any incorporated methods. The patentable scope is defined by the claims and may include other examples that may arise for a person skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims. Aspects from the various embodiments described, as well as other known equivalents to each such aspect, may be mixed and harmonized by a person skilled in the art to construct additional embodiments and technologies in accordance with the principles of this application. Where reference numerals related to the drawings are enclosed in parentheses in the claims, they are intended solely to enhance the understanding of the claims and should not be construed as limiting the scope of the claims. [Explanation of symbols]

[0074] 10 Wind Turbines 12 Ground 14 Support System 15 Towers 16 Nacer 18 rotors 20 Hubs 22 rotor blades 24. Blade base 26 Load transfer region 28 Wind direction 30 rotor shaft 32 Pitch System 34 Pitch axis 36 Wind Turbine Control Device 38 Yaw axis 42 Generators 44 Main shaft 46 Gearbox 48 High-speed shaft 50 Couplings 52 Mainframes 54 Decoupling support means 56 Yaw drive mechanism 58 Weather Measurement Systems 60 Main front support bearing 62 Main rear support bearing 64 Drivetrain 66 Pitch Assembly 68 Pitch Drive System 70 sensors 72 Pitch Bearing 74 Pitch drive motor 76 Pitch Drive Gearbox 78 Pitch Drive Pinion 80 Pitch Control System 84 Generators 86 Cavity 88 Inner self 90 Transformer 100 Nacelle Cover Assembly 103 Torque Arm 104 Opening 110, 120, 130 Nacelle Cover Panel 110', 120', 130' Outer roof surface 110'', 120'', 130'' inner surface 111 Side view 112 Structural Frame 113 Interface Plate 114 Support Zone 115 frame 116 Beam 117 Cooling System 118 Fastener 119 Connector 121 Lifting points 122 Handrail 131 holes 132 recess 133 Recess 134 Flange 200 Nacelle Assembly 210 Nacelle Base Components

Claims

1. A nacelle cover panel (110, 120, 130) configured to be attached to a nacelle (16) of a wind turbine (10), comprising: a composite panel including at least an exterior roof surface (110', 120', 130') and an interior surface (110'', 120'', 130''); a structural frame (112) coupled to the composite panels at its interior surfaces (110'', 120'', 130''); Including, the outer roof surface (110', 120', 130') of the composite panel comprises one or more openings (104); a nacelle cover panel (110, 120, 130) positioned at least partially within the one or more openings (104); The nacelle cover panel (110, 120, 130) further comprises one or more interface plates (113) mechanically connected to the structural frame (112).

2. The one or more interface plates (113) include one or more through holes (131) and fasteners (118); 10. The nacelle cover panel (110, 120, 130) of claim 1, wherein the structural frame (112) includes receptacles for receiving fasteners (118) to mechanically attach the one or more interface plates (113) to the structural frame (112).

3. The nacelle cover panel (110, 120, 130) of claim 2, wherein the one or more interface plates (113) include a flange (134) configured to be at least partially supported on the roof surface (110') of the composite panel.

4. The nacelle cover panel (110, 120, 130) of claim 1, wherein the one or more interface plates (113) include a gasket configured to be at least partially supported on the roof surface (110') of the composite panel.

5. The nacelle cover panel (110, 120, 130) of any one of claims 2 to 5, wherein one or more interface plates (113) are bonded to the composite panel.

6. The nacelle cover panel (110, 120, 130) of claim 1, wherein the one or more interface plates (113) are made of stainless steel.

7. The nacelle cover panel (110, 120, 130) of claim 1, wherein the structural frame (112) includes a support zone (114) that connects the structural frame (112) to an existing frame (115) located within the wind turbine nacelle (16).

8. The nacelle cover panel (110, 120, 130) of claim 1, wherein the structural frame comprises a carbon steel beam (116) having an optionally rectangular hollow portion.

9. The nacelle cover panel (110, 120, 130) of claim 1, wherein the composite panel comprises fiberglass and polyester resin.

10. A nacelle cover assembly (100) comprising a plurality of nacelle cover panels (110, 120, 130) according to any one of claims 1 to 9, wherein the nacelle cover assembly (100) covers substantially the entire top surface of the nacelle.

11. A method (600) of providing a nacelle assembly (200), comprising: Providing a nacelle base component (210); providing a nacelle cover panel (110, 120, 130) including a composite panel including at least an exterior roof surface (110', 120', 130') and an interior surface (110'', 120'', 130'', a structural frame (112) coupled to the composite panel and one or more openings (104) for receiving one or more interface plates (113); coupling a nacelle base component (210) to a nacelle cover panel (110, 120, 130) via a structural frame (112) coupled to a composite panel at an inner surface (110'', 120'', 130''); providing one or more interface plates (113); placing one or more interface plates (113) in the one or more openings (104) and connecting the one or more interface plates (113) to a structural frame (112); A method (600) comprising:

12. providing one or more additional nacelle cover panels (110, 120, 130); coupling additional nacelle cover panels (110, 120, 130) provided on the nacelle base component (210) to cover substantially the entire nacelle top surface; 12. The method (600) of claim 11, further comprising:

13. 13. The method (600) of claim 11 or 12, further comprising providing an adhesive for attaching the composite panel to one or more interface plates (113).

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