Modular Wind Turbine Nacelle Segmentation for Transport

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Solution Overview

Problem

Existing wind turbine nacelles face challenges in modularity, ease of design and manufacturing, and transportation costs, while requiring increased size to accommodate larger components, which complicates handling and maintenance.

Innovation Solution

A modular nacelle design comprising a main unit and separate auxiliary units, each divided into sub-units, allowing individual assembly and encapsulation during transport, utilizing shipping freight container dimensions for efficient handling and logistics, with interfaces for easy attachment and detachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If the nacelle size is increased to accommodate larger wind turbine components, then the capacity to house required components is improved, but the transportation and handling costs increase and complexity increases

Engineering Contradiction:

Improvenacelle volumeVSAvoidtransportation and handling

Core Design Contradiction:

Volume of stationary objectVSEase of manufacture

Solution Approach 1:

The nacelle is divided into a main unit and multiple auxiliary units that can be manufactured, transported, and assembled separately. The main unit houses the rotor-supporting assembly, while auxiliary units contain other components. This segmentation allows each module to be optimized for transport while maintaining the overall large volume needed for housing components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Auxiliary units are designed to be attachable to the main unit, creating a nested configuration where smaller functional units are integrated onto the central main unit. This allows the nacelle to achieve large effective volume through modular attachment rather than requiring a single large transported structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If the nacelle is designed as a single integrated unit, then structural integrity is improved, but modularity and ease of maintenance are reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidmodularity

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The nacelle is segmented into a main unit and auxiliary units with defined interfaces. Each unit maintains structural integrity independently, while the interfaces between units allow for modular assembly and disassembly, enabling both strength and adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The auxiliary units are designed with standardized interfaces that allow them to be attached to the main unit for operation, then detached for maintenance or replacement. This universal interface design enables the same auxiliary unit to be reused across different configurations, enhancing both structural reliability and maintenance flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If components are transported separately to the assembly site, then transportation flexibility is improved, but the assembly complexity and time increase

Engineering Contradiction:

Improvetransportation flexibilityVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Auxiliary units are pre-assembled and prepared at manufacturing locations before transport to the wind turbine site. This preliminary assembly of modular units reduces the complexity and time required for final assembly, as units arrive ready-to-install rather than requiring complex on-site assembly procedures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By segmenting the nacelle into transportable auxiliary units that can be shipped separately and then quickly attached to the main unit, the system achieves both transportation flexibility and efficient assembly. The standardized interfaces enable rapid connection without complex assembly procedures.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If the auxiliary unit is separated into sub units, then supplier independence and packaging flexibility are improved, but the number of interfaces and assembly steps increase

Engineering Contradiction:

Improvesupplier independenceVSAvoidnumber of interfaces

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The auxiliary unit is divided into multiple sub-units that can be supplied by different manufacturers. Each sub-unit has standardized interfaces for attachment to the main auxiliary unit, allowing supplier independence while controlling interface complexity through standardization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Standardized universal interfaces are designed for the auxiliary unit sub-units, allowing different suppliers to provide compatible components that can be assembled using the same connection mechanisms. This reduces the variety of interface types needed while maintaining supplier independence and assembly flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4062061B1A nacelle for a wind turbine

Publication Date: 2026.04.01 VESTAS WIND SYSTEMS AS

Figure 1a
Figure 1b
Figure 2~3

AI summary

A wind turbine nacelle configured for mounting on a wind turbine tower and for supporting a rotor-supporting assembly, the nacelle comprising a main unit, and at least one auxiliary unit. To increase flexibility and improve assembly and maintenance procedures of the wind turbine, the auxiliary unit comprises at least two sub units each accommodating at least one wind turbine component, e.g. a converter or a transformer. The sub units are attached individually to the main unit or they are joined and attached as one component to the main unit.