Modular Nacelle Service Unit With Deployable Crane Base

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The challenge of installing and maintaining larger wind turbine components is exacerbated by the need for cranes with increased lifting capacity, which must fit within the dimensions of a shipping freight container while supporting larger weights, necessitating a solution that accommodates the increased size and weight of the crane.

Innovation Solution

A crane system with a rotatably movable base that transitions between a stored position within the service unit and a deployed position outside, allowing direct load transfer to the nacelle's base frame, facilitated by vertical and horizontal movements, and a yaw system for alignment, ensuring the crane's load path bypasses the service unit's sidewalls.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the crane lifting capacity is increased to handle larger wind turbine components, then the crane size and weight increase, but the service unit dimensions must remain comparable to a shipping freight container

Engineering Contradiction:

Improvecrane lifting capacityVSAvoidservice unit volume

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

The crane base is designed to be rotatably movable between a stored position within the service unit and a deployed position extending outward. This dynamic configuration allows the crane to achieve greater lifting capacity when deployed while maintaining a compact footprint during transport and storage within the container-sized service unit.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The crane base is positioned within the interior of the service unit when in the stored position, effectively nesting the crane structure within the limited space of the container. This allows the crane to be transported efficiently within standard shipping dimensions while still providing access to greater lifting capacity when needed.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Power

If the crane size and weight are increased to handle larger components, then the lifting capacity improves, but the service unit cannot be efficiently transported and handled as a standard shipping container

Engineering Contradiction:

Improvecrane lifting capacityVSAvoidtransportation efficiency

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The rotatable crane base enables the system to transition between a compact transport configuration and an operational deployment configuration. This dynamic design allows the service unit to maintain standard shipping container dimensions for efficient global transportation while providing access to high-capacity lifting when deployed at the installation site.

Inventive Principle:

Principle #15Dynamics

3Volume of moving object

If the crane is positioned within the service unit interior, then the service unit dimensions can be minimized, but the load path transfers large loads to the service unit sidewalls which may not be structurally adequate

Engineering Contradiction:

Improveservice unit volumeVSAvoidload bearing capacity of service unit sidewalls

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The crane base is extracted from a fully enclosed position within the service unit and repositioned to extend through the sidewall when deployed. This extraction allows the crane's load path to be directly connected to the main nacelle structure outside the service unit, bypassing the sidewalls and transferring large loads to the structurally adequate main nacelle base frame rather than the weaker service unit enclosure.

Inventive Principle:

Principle #2Taking out (Extraction)

4Power

If the crane base is made rotatably movable to transition between stored and deployed positions, then the lifting capacity can be increased while maintaining compact storage, but the device complexity increases

Engineering Contradiction:

Improvecrane lifting capacityVSAvoidcrane base movement mechanism

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The crane base incorporates a rotatable joint that enables smooth transition between stored and deployed positions. This dynamic mechanism provides a straightforward mechanical solution for repositioning the crane base, allowing the system to achieve high lifting capacity when needed while maintaining compact storage, with the rotational movement serving as an elegant and relatively simple mechanical transition.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20260028966A1Service unit with crane for modular nacelle of a wind turbine and method of using same

Publication Date: 2026.01.29 VESTAS WIND SYSTEMS AS

AI summary

A service unit (24) for a wind turbine (10) nacelle (14) that includes a main nacelle unit (22) having a main housing outer wall (72) and a base frame (98) with a mounting pad (100). The base frame (98) is configured to be attached to a tower (12) of the wind turbine (10). The service unit (24) includes a frame (38) that extends between a first end (40) and a second end (42) to define a longitudinal axis (A2) of the service unit (24), and sidewalls (44, 44a, 44b) that define an interior (50). A crane (26) is located within the interior (50) of the service unit (24) and includes a crane base (62) with a mounting interface (68) configured to be connected to the mounting pad (100) to couple the crane (26) to the base frame (98) of the main nacelle unit (22). The crane base (62) is rotatably movable between a stored position where the mounting interface (68) is positioned within the interior (50) of the service unit (24), and a deployed position where the mounting interface (68) extends through one of the sidewalls (44a, 44b) of the service unit (24). A method of erecting or servicing a wind turbine using the service unit (24) is also disclosed.