Wind Turbine Nacelle Segmentation for Transportable Assembly

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Solution Overview

Problem

The challenge of increasing wind turbine nacelle size to accommodate larger components while maintaining transportability and reducing transportation and handling costs, and ensuring modular design and ease of maintenance.

Innovation Solution

A modular nacelle design comprising a main unit and at least one auxiliary unit, where the auxiliary unit houses operative components like transformers and converters, which are suspended directly on the main unit, allowing for separate transport and assembly, and the main unit forms a direct load path to the tower, utilizing standardized shipping containers for ease of handling.

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 transportability and handling costs are worsened

Engineering Contradiction:

Improvenacelle volumeVSAvoidtransportability

Core Design Contradiction:

Volume of stationary objectVSEase of operation

Solution Approach 1:

The nacelle is divided into a main unit and one or more auxiliary units that can be separately manufactured and transported. The auxiliary units are then assembled to the main unit at the installation site, enabling transport of smaller components while achieving the required total nacelle volume for large wind turbine components.

Inventive Principle:

Principle #1Segmentation

2Strength

If the nacelle is designed as a single integrated unit, then structural integrity is improved, but modular design and maintenance accessibility are worsened

Engineering Contradiction:

Improvestructural integrityVSAvoidmodular design

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The nacelle is segmented into a main unit housing the rotor-supporting assembly and auxiliary units housing power conversion components. These segmented units are connected through fixation structures that maintain structural integrity while enabling modular configuration and ease of maintenance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Connection structures and fixation mechanisms act as intermediaries between the main unit and auxiliary units, providing robust structural coupling that maintains integrity while allowing for modular assembly and disassembly during installation and maintenance phases.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Force

If the auxiliary unit is designed to carry the full load of the operative component, then load bearing capacity is improved, but transportation costs and complexity are worsened

Engineering Contradiction:

Improveload bearing capacityVSAvoidtransportation complexity

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The load-bearing function is segmented from the auxiliary unit and assigned to the main unit through direct suspension of the operative component on the main unit. The auxiliary unit serves only as a protective housing, significantly reducing its weight and transportation complexity while the main unit provides the necessary load-bearing capacity.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP4062059B1A nacelle for a wind turbine

Publication Date: 2025.10.29 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. The auxiliary unit accommodates a at least one component, e.g. a converter or transformer. To provide efficient transportation, lower costs and easier assembly, the operative component is suspended directly on the main unit.