Wind Turbine Nacelle Composite Housing with Captive Pin Mounting
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Solution Overview
Problem
The wind turbine industry faces challenges in reducing production costs, carbon footprint, and the weight of load-carrying frames, which are typically made of heavy and expensive steel, requiring extensive quality control and complex installation processes.
Innovation Solution
A nacelle design using a fibre-reinforced polymer composite material with elongate pins for attachment to a structural frame, eliminating the need for external bolts or nuts, thereby reducing material usage, weight, and installation complexity, and allowing for easier maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a load-carrying frame is made of cast steel or bolted steel, then the structural strength and load-bearing capacity are improved, but the weight and manufacturing cost increase significantly
Solution Approach 1:
The patent applies composite materials by combining a steel structural frame with fiber-reinforced polymer panels. The steel frame provides the necessary load-bearing capacity and structural strength, while the polymer panels reduce the overall weight compared to traditional all-steel construction. This composite approach allows the structure to maintain strength requirements while achieving weight reduction.
2Strength
If a load-carrying frame is made of cast steel or bolted steel, then the structural strength and load-bearing capacity are improved, but the manufacturing cost and quality control expenses increase
Solution Approach 1:
The patent applies composite materials by combining a steel structural frame with fiber-reinforced polymer panels. The steel frame provides the necessary load-bearing capacity and structural strength, while the polymer panels reduce the overall weight compared to traditional all-steel construction. This composite approach allows the structure to maintain strength requirements while achieving weight reduction.
3Strength
If a load-carrying frame is designed as heavy steel construction, then the load-bearing capacity is improved, but the transportation and installation complexity increase
Solution Approach 1:
The patent applies segmentation by dividing the nacelle structure into modular components: a steel structural frame, fiber-reinforced polymer panel sections, and standardized mounting brackets. These segmented modules can be manufactured separately, transported more easily, and assembled on-site, reducing installation complexity compared to transporting and installing a single heavy steel assembly.
4Strength
If traditional bolted connections are used to secure the load-carrying frame to the nacelle cover, then the structural integrity is improved, but the number of external fasteners and installation time increase
Solution Approach 1:
The patent applies merging by integrating the mounting brackets directly into the steel structural frame design, combining the frame structure and mounting features into a single integrated component. This eliminates the need for separate external fasteners and reduces the number of assembly steps, thereby improving installation speed while maintaining structural integrity through the integrated bracket design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly reduces the weight and production costs of wind turbine nacelles, enhances sustainability, and simplifies the installation and maintenance processes by utilizing the shear strength of elongate pins for load transfer, ensuring a robust and cost-effective solution.
Implementation Method 1
utilizing the shear strength of elongate pins for load transfer
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A front end (107) of a nacelle cover (100 formed by a housing (105) is mounted on a structural frame (15) which is affixed to a tower (122) of the wind turbine. The front end (107) is fitted to the structural frame (15) by a plurality of fitting assemblies (204). At least one of the plurality of fitting assemblies (204) comprises a first mount (20) on the housing (105) which defines a first hollow bore (21) extending therethrough, a second mount (27) on the structural frame (15) which defines a second hollow bore (28) extending therethrough, the first and second hollow bores (21, 28) being aligned along a common axis (29), and an elongate pin (34;72) fitted within the first and second hollow bores (21, 28). The elongate pin (34, 72) comprises an elongate body portion (35;73) having at one end (36; 74) thereof an integral, unthreaded head element (37; 75) which has a width greater than a width of the elongate body portion (35;73), the head element (37;75) being fitted to the first mount (20), and at the opposite end (47; 89) thereof a securing element (48; 90) affixed to the elongate body portion (35;73) whereby the elongate pin (34;72) is captive in the first and second hollow bores (21, 28) by the head element (37;75) and the securing element (48; 90) and affixes the housing (105) to the structural frame (15).