Modular Nacelle Support Frame for Heavy Auxiliary Unit Assembly
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Solution Overview
Problem
The challenge of attaching auxiliary nacelle units to main nacelle units in large wind turbines is exacerbated by the increasing weight and height of components, which can strain the sides of the main nacelle unit, requiring improved methods to support and attach these units efficiently.
Innovation Solution
A modular nacelle design with a support assembly that includes movable support frames, such as cross struts and link arms, which transition between stored and deployed positions to support wind turbine components directly from the base frame, reducing the load on the nacelle unit walls and allowing for secure attachment and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If auxiliary nacelle units are attached to the sides of the main nacelle unit, then the nacelle can accommodate heavy wind turbine components, but the weight and torque loads increase requiring massive towers and yaw assemblies
Solution Approach 1:
The support assembly extends the load-bearing path vertically from the base plate through the main nacelle unit to the auxiliary nacelle units, rather than relying solely on the side walls. This dimensional change in load path allows heavy components to be accommodated without proportionally increasing tower and yaw assembly loads
Solution Approach 2:
The nacelle is divided into main nacelle units and auxiliary nacelle units, with the support assembly providing a dedicated load-bearing structure. This segmentation allows the main nacelle base plate to directly support auxiliary units through the support assembly, distributing loads more efficiently rather than concentrating them on the side walls
2Ease of manufacture
If the sides of the main nacelle unit are used to support auxiliary nacelle units, then attachment is simplified, but the sides may not be strong enough to carry the weight of several tonnes
Solution Approach 1:
The support assembly acts as an intermediary structure between the main nacelle unit base plate and the auxiliary nacelle units. It provides a strong, dedicated load-bearing path that transfers weights directly to the base plate, eliminating the need for the side walls to support heavy loads while maintaining ease of attachment
3Productivity
If wind turbine components are transported to the assembly site, then the turbine can be assembled, but increasing size and weight make transportation increasingly challenging
Solution Approach 1:
The nacelle is segmented into modular main and auxiliary units that can be manufactured separately and transported independently. This allows the overall turbine to be assembled from smaller, more manageable components rather than transporting one massive integrated nacelle
Solution Approach 2:
The support assembly provides a vertical load path that enables auxiliary nacelle units to be attached after the main nacelle is positioned on the tower. This allows components to be transported to the assembly site in a logical sequence and attached in a controlled manner, simplifying the transportation and assembly process
Data Source
AI summary
A main nacelle unit (22) for forming a nacelle (14) of a wind turbine (10) includes a main housing (28) having an outer wall (30a, 30b) and containing a base frame (52) configured to be attached to a tower (12) of the wind turbine (10). The main nacelle unit (22) also includes at least one support frame (56) configured to support a wind turbine component (54) external to the main housing (28). A portion of the support frame (56) is attached to the base frame (52) and movable between a stored position and a deployed position. In the stored position, the portion of the support frame (56) is configured to be positioned within the confines of the main housing (28), and in the deployed position, the portion of the support frame (56) is configured to extend through the main housing outer wall (30a, 30b) to support the wind turbine component (54) external to the main housing (28). A method of assembling a wind turbine using the support assembly is also disclosed.