Wind Turbine Nacelle Panel Segmentation for Container Transport
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Solution Overview
Problem
The logistical challenge of transporting and assembling large wind turbine nacelle components that exceed standard shipping container dimensions, leading to increased manufacturing and transport costs, is addressed by constructing multi-part panels using a single large mould with dividers to fit within container constraints.
Innovation Solution
A method involving a mould divided into regions by dividers to form multi-part panels, allowing each portion to fit within standard shipping containers, with connection interfaces defined by T-shaped profiles, and using spacers and sealants for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If nacelle panels are manufactured as single large parts, then structural stability is improved, but transportability using standard shipping containers deteriorates
Solution Approach 1:
The panel is divided into multiple sections by inserting dividers into the mould during manufacturing. These dividers create separation lines that allow the panel to be split into smaller, transportable portions while maintaining the overall structural integrity when assembled. The dividers are positioned to create segments that fit within standard shipping container dimensions.
Solution Approach 2:
The dividers are inserted into the mould before the composite material is cured. This preliminary placement ensures that the separation lines are pre-defined in the correct positions, allowing the panel to be cleanly divided into transportable sections after curing without compromising the structural design.
2Length of moving object
If dedicated moulds are used for each panel section, then transportability is improved, but manufacturing cost deteriorates
Solution Approach 1:
A single large mould is used to manufacture entire nacelle panels, and by inserting dividers at different positions, the same mould can produce panels of various lengths and configurations. This eliminates the need to design and manufacture separate dedicated moulds for each panel section, significantly reducing tooling costs while maintaining the ability to produce transportable sizes.
Solution Approach 2:
Instead of creating multiple small moulds, the invention segments the manufacturing process by using one large mould with removable dividers. The dividers allow the same mould to effectively create multiple panel configurations, achieving the benefit of customized panel sizes without the cost of multiple moulds.
3Length of moving object
If multiple panel portions are assembled on site, then transportability is improved, but assembly complexity deteriorates
Solution Approach 1:
The connection interfaces are pre-formed during the manufacturing process by having dividers create protruding connection elements on the panel portions. These connection features are built-in during moulding, so that when panels are assembled on-site, the connection process is simplified to matching and joining pre-prepared interfaces rather than creating connections from scratch.
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
Reduces manufacturing and transport costs by utilizing existing large moulds, enabling efficient assembly of nacelles with structurally strong and watertight connections.
Implementation Method 1
arranging composite material in the mould; curing the composite material
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Method of manufacturing a panel (1) of a wind turbine nacelle (2), which method comprises the steps of providing a mould (3) for the panel (1); arranging at least one divider (4) in the mould (3) to spatially divide the mould (3) into at least a first mould region (3A) and a second mould region (3B); arranging composite material (5) in the mould (3); curing the composite material (5); and separating the cured panel (1') into at least a first panel portion (1A) and a second panel portion (1B) along a line (X) defined by a divider (4). Method of constructing a wind turbine nacelle (80), and a wind turbine (8) comprising such a nacelle (80).