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WO2007132408A2 - Modular construction of a nacelle - Google Patents

Modular construction of a nacelle Download PDF

Info

Publication number
WO2007132408A2
WO2007132408A2 PCT/IB2007/051765 IB2007051765W WO2007132408A2 WO 2007132408 A2 WO2007132408 A2 WO 2007132408A2 IB 2007051765 W IB2007051765 W IB 2007051765W WO 2007132408 A2 WO2007132408 A2 WO 2007132408A2
Authority
WO
WIPO (PCT)
Prior art keywords
plate
nacelle
slot
shaped element
shaped
Prior art date
Application number
PCT/IB2007/051765
Other languages
French (fr)
Other versions
WO2007132408A3 (en
Inventor
Ulrik Raimund
Original Assignee
Jupiter Plast A/S
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jupiter Plast A/S filed Critical Jupiter Plast A/S
Publication of WO2007132408A2 publication Critical patent/WO2007132408A2/en
Publication of WO2007132408A3 publication Critical patent/WO2007132408A3/en

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/0004—Joining sheets, plates or panels in abutting relationship
    • F16B5/0084—Joining sheets, plates or panels in abutting relationship characterised by particular locking means
    • F16B5/0088—Joining sheets, plates or panels in abutting relationship characterised by particular locking means with locking means moving substantially perpendicular to the main plane, e.g. pins, screws
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/10—Assembly of wind motors; Arrangements for erecting wind motors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2230/00—Manufacture
    • F05B2230/60—Assembly methods
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2240/00—Components
    • F05B2240/10—Stators
    • F05B2240/14—Casings, housings, nacelles, gondels or the like, protecting or supporting assemblies there within
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2250/00—Geometry
    • F05B2250/20—Geometry three-dimensional
    • F05B2250/29—Geometry three-dimensional machined; miscellaneous
    • F05B2250/292—Geometry three-dimensional machined; miscellaneous tapered
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2260/00—Function
    • F05B2260/30—Retaining components in desired mutual position
    • F05B2260/301—Retaining bolts or nuts
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the invention relates to a nacelle for a wind turbine and of the kind that comprises a number of plate-shaped elements having outer faces and inner faces that together form the inner face and outer face of the nacelle and that at least two of the elements of the nacelle are constructed with projecting tabs for forming a joint between the elements having outer faces that mainly are flush with each other.
  • the nacelle for a wind turbine are located at the top of the wind turbine tower and contains the components that are used to convert the energy from the rotor to electric energy. These components comprises, among others, gears, brakes, generator, control system, cooling system and yawing system.
  • nacelles are made of an assembly kit of, among others, smaller plate-shaped elements that are assembled by means of mountings at the place of use.
  • two plate-shaped elements are assembled by means of angle brackets.
  • One angle side is screwed on to the inner face of a plate-shaped elements by means of screws through the wall of the plate-shaped elements so that the second angle side will project into the nacelle.
  • a corresponding but inverted angle bracket is mounted, and the second angle bracket of the two plate-shaped elements are screwed together.
  • the joint between the plate-shaped elements of the nacelle is difficult to make watertight, which reduces the lifetime of the components contained in the nacelle.
  • a joint between two curved, plate-shaped elements is furthermore both expensive and complicated as the angle brackets must be constructed with due account being taken to the curvature of the plate-shaped elements to obtain a joint as closely fitting as possible.
  • the screws will always project through the nacelle wall to its outer face which partly can affect the flowing of the wind across the outer face of the nacelle but also disfigure the appearance of the nacelle. Screw heads and bolt heads on the outer face of the nacelle can furthermore initiate corrosion and wear on contact with polluted and salty passing turbulent air.
  • a nacelle of the kind mentioned in the opening paragraph in which the nacelle is made up of smaller transportable, plate-shaped elements that can be assembled at the erection site of the wind turbine without visible screws or bolts on the outer face of the nacelle.
  • a nacelle is provided by means of plate-shaped elements that are assembled by means of more watertight joints than known nacelles .
  • a nacelle in which curved plate-shaped elements can be assembled quicker, easier and tighter without custom-made mountings .
  • a nacelle which has a more aerodynamic outer face than known nacelles of plate-shaped elements.
  • a nacelle is provided, which is simpler to maintain and overhaul than known nacelles.
  • the joint comprises that at least one slot is made in the first plate-shaped element, said slot extends from the inner face of the second plate-shaped element, that at least one transverse hole is made in the tab of the second plate-shaped element, said hole extends from the inner face of the second plate-shaped element and to or across the slot when the first and second plate- shaped element are assembled, that a lock mounting with a lock plate is fitted in at least a part of the slot, and that the lock mounting and the tab of the second plate-shaped element are clamped together by means of a clamping means extending through the transverse hole.
  • the outer face of the first plate-shaped element and the outer face of the second plate-shaped element not including the tab form the exterior of the nacelle in the assembled and mounted state of the plate-shaped elements, said exterior will appear free of bolt heads or screw heads.
  • the nacelle comprises that the slot extends mainly crosswise of the tab of the first plate-shaped element.
  • the nacelle furthermore comprises that at least a section of the slot is shaped as a T-slot extending into or through the tab of the first plate-shaped element.
  • the transverse hole in the tab of the second element extend to or over the T-slot when the first plate-shaped element and the second plate- shaped element are in assembled state.
  • the lock plate of the lock mounting is wider than at least a part of the opening of the T-slot and the lock plate is located at least in the T- slot.
  • the slot is shaped as a T-slot, it is especially easy to insert and fix the mounting in the slot .
  • the width of the lock plate ensures that the lock mounting is maintained in the opening of the slot, and the lock plate can be accommodated and tightly maintained in the slot of the first plate-shaped element without auxiliary means.
  • the lock mounting uses fewer clamping means that conventional angle brackets for conventional nacelles, and it is therefore both quicker and easier to assemble the plate-shaped elements to the nacelle according to the present invention.
  • a slot extending obliquely inwards in the first plate-shaped element facilitates the insertion of the lock plate and ensures that the material thickness in the area of the tab of the first plate-shaped element that faces the tab of the second plate-shaped element is so great that the nacelle can counterbalance the loads and stresses that it is subjected to by the elements but also during mounting.
  • the slot can easily be made by milling the slot in the tab of the first plate-shaped element. To ensure that this tab has sufficient strength to accommodate the lock plate, this tab can have a material thickness greater than that of the tab of the second plate-shaped element.
  • the transverse hole is formed as a groove extending from an outer edge of the tab of the second plate-shaped element and at least a distance into this tab, the tabs of the first and second plate-shaped elements can easily be joined when the plate-shaped elements of the nacelle are to be assembled.
  • the lock plate of the lock mounting according to the present invention can have a mainly tapered section so that the lock plate easily can be guided in place in the slot.
  • the lock plate of the lock mounting can furthermore be made with a projection opposite the mainly tapered section, said projection fitting into the groove on the tab of the second plate-shaped element.
  • the projection can advantageously serve as guide pin in the groove when the tabs of the two plate- shaped elements are to be assembled.
  • An especially simple and inexpensive projection can be formed by folding a portion of the lock plate.
  • the lock plate of the lock mounting opposite the mainly tapered section is formed with a notch, the lock plate will project the least possible from the slot in the assembled state of the two plate-shaped elements.
  • the tabs of the two plate-shaped elements can advantageously taper at angles that are complementary at joining. This design of the tabs allows assembling of curved plate-shaped elements without using custom-made mountings.
  • the lock mounting is mounted in the slot and transverse hole, the tabs are adjusted by displacement in relation to each other taking the curvature into consideration, and the two plate-shaped elements are clamped together by means of the clamping means of the lock mounting.
  • the joint will maintain its tightness despite its curvature.
  • the angles can for example be between about 5° and 15°, preferably between about 8° and 12° and especially about 10°.
  • the plate-shaped elements can typically be formed as a sandwich construction having a shell of e.g. metal or plastic enclosing a core of dimensionally stable foam.
  • the requirements to the chosen shell material include that this material must be formable or mouldable, weigh the least possible but still have high strength and great rigidity.
  • the material should also be corrosion-resistant and be able to withstand wide temperature variations .
  • suitable shell materials comprise aluminium, stainless steel and fibreglass reinforced resin.
  • the best suited foam material has a dimensional stability after setting which, when the foam is supported by the sides of the slot, can absorb the load from the lock plate.
  • foam materials comprises polyurethane foam and polyvinyl chloride foam.
  • the T-slot can extend into the foam core of the first plate-shaped element to thereby support the lock plate and absorb possible loads and stresses produced due to the action of the environment on the nacelle wall.
  • An especially watertight design of a nacelle according to the present invention comprises a sealing strip inserted between two tabs which abut on each other in the mounted state of the nacelle.
  • a simple clamping means for use in the lock mounting for the nacelle according to the present invention can comprise a screw or a bolt and related nut.
  • the screw can be attached on the lock plate for example by welding, or the lock plate can be made with a thread cooperating with a loose screw or bolt.
  • a washer can be placed between the tab of the second plate- shaped element and nut. The washer will reduce and distribute the surface pressure on the surface of the tab.
  • fig. 1 shows a conventional wind turbine
  • fig. 2 is a sectional view taken along the line II-II of fig. 1 showing an example of a conventional assembly of plate- shaped elements for a known wind turbine nacelle,
  • fig. 3 is another example of a conventional assembly in which the plate-shaped elements are formed with tabs overlapping in the assembled state of the plate-shaped elements,
  • fig. 4 is an exploded perspective fractional view from the inside of two plate-shaped elements for a nacelle according to the invention and an associated first embodiment of a mounting,
  • fig. 6 is a sectional view taken along the line VI-VI of fig. 5,
  • fig. 7 is the fractional view in fig. 4 of the second plate- shaped element seen from the outside and mounted with a sealing strip
  • fig. 8 is a perspective view of a second embodiment of a lock mounting for joining plate-shaped elements to a nacelle according to the present invention
  • fig. 9 is a perspective view of a third embodiment of a lock mounting for assembling of plate-shaped elements to a nacelle according to the present invention.
  • fig. 10 is an inside view of a total of five plate-shaped elements assembled to a larger nacelle part
  • the wind turbine in fig. 1 is generally designated by the reference numeral 1.
  • the wind turbine 1 comprises a tower 2, a nacelle 3 having a rotor 4 with a total of two blades 5a, 5b.
  • the nacelle 3 is made up of a number of plate-shaped elements 3a, 3b, 3c, of which only three are shown in fig. 1.
  • the plate- shaped elements are assembled by joints 6a, 6b and leave bolt heads 7a, 7b on the exterior 8 of the nacelle 3.
  • Fig. 2 is a fractional sectional view taken along the line II- II of fig. 1 of a first example of a conventional joint 6a of two plate-shaped elements 3a, 3b with angle brackets 9a, 9b.
  • the angle brackets 9a has a first angle side 9a' mounted on the inner face 10a of the plate-shaped element 3a by means of a bolt 11a.
  • the thread 12a of the bolt 11a is inserted through the hole 13a in the plate-shaped element 3a and the hole 14a in the first angle side 9a' of the angle bracket 9a flushing with the hole 13a so that the bolt head 7a is on the outer face 8a of the plate-shaped element.
  • a nut 15a By means of a nut 15a, the angle bracket 9a and the first plate-shaped element 3a are clamped together so that the second angle side 9a' ' is mainly flush with the outer edge 16a on the first plate-shaped element 3a.
  • the second angle side 9a'' will therefore project into the interior of the nacelle 3.
  • the angle bracket 9b is mounted in a similar way on the second plate-shaped element 3b by means of a bolt lib so that the first angle side 9b' of the second angle bracket 9b is screwed onto the inner face 10b of the second plate-shaped element and the second angle side 9b' ' is mainly flush with the outer edge 16b of the second plate-shaped element.
  • the angle brackets 9a, 9b are inverted in relation to each other. Their second angle side 9a' ',9b'' abut on each other so that they can be assembled in a conventional way by a third bolt 17 through the second angle sides 9a" ,9b".
  • Fig. 3 shows a second example of a conventional joint 18 of a first plate-shaped element 19 with a second plate-shaped element 20 formed with respective tabs 21,22.
  • the tabs 21,22 overlaps each other when the plate-shaped elements 19,20 are assembled by means of the inverted angle bracket 9a, 9b.
  • the first angle bracket 9a is mounted on the inner face 23a of the first plate-shaped element 19 by means of a bolt 11a through the wall of the first plate-shaped element 19 and the first angle side 9a' of the first angle bracket 9a.
  • a bolt 11a By means of a nut 15a, the bolt 11a is tightened so that the angle bracket 9a is securely fastened to the inner face 23a of the first plate-shaped element 19.
  • the bolt 11a is fastened through the wall of the first plate- shaped element 19 at a point where the material thickness corresponds to the wall thickness.
  • an inverted angle bracket 9b is mounted with a bolt lib through the tab 22, that is in an area of the second plate-shaped element 20, in which the material thickness is far thinner than the material thickness of the wall of the second plate-shaped element.
  • the bolt head 7b is shown to be countersunk in the tab 22 so that the tabs 19,20 overlap with flushing outer faces 24a, 24b. This can also be obtained by allowing the bolt head 7b to be received in a recess, not shown, in the tab 21 of the first plate-shaped element.
  • the second angle sides 9a' ',9b'' of the two angle brackets 9a, 9b are bolted together as described with reference to fig. 2.
  • This type of joint leaves fewer bolt heads on the outer face of the nacelle than the method referred to in fig. 2 for assembling plate-shaped elements but if the bolt lib for example is to be inspected and possibly replaced, it is necessary to completely disassemble the assembly 18 in order for the repair technician to be able to obtain access .
  • the assembly 18 is not suited for assembling curved plate-shaped elements either.
  • Fig. 4 is an exploded fractional view of two plate-shaped elements, respectively a first plate-shaped element 25 and a second plate-shaped element 26, and an exploded view of a lock mounting 47.
  • the first plate-shaped element 25 has an inner face 25a, an outer face 25b, and a tab 27 ending in an outer edge 28.
  • a slot 29 is made in form of a T-shaped slot.
  • the T-shaped slot consists of a narrow slot 29a extending into a wider section 29b in such a way that the narrow slot 29a faces in a direction towards the outer edge 28 of the tab 27.
  • the tab 27 tapers at an angle ⁇ as the material thickness of the plate-shaped element 25 decreases from the start of the tab 27 approximately in the middle of the narrow slot 29a of the T-shaped slot 29 in a direction towards the outer edge 28 of the tab 27.
  • the second plate-shaped element 26 has an inner face 26a, an outer face 26b, and a tab 30 ending in an outer edge 31.
  • a transverse groove 32 extends a distance into the tab 30 which tapers at an angle ⁇ complementary to the angle ⁇ of the tab of the first plate-shaped element 25.
  • the plate-shaped elements 25,26 are made of a shell material, for example fibreglass reinforced polyester, filled with a dimensionally stable foam 33, for example polyurethane foam. As shown in the figure, the shell can be divided into a number of foam-filled channels 34, and the sandwich materials described herein are known to a person skilled in the art.
  • the lock mounting 47 comprises a flat lock plate 35, a bolt 39, a washer 37, and a nut 38.
  • the lock plate 35 has a thickness allowing it to be received tightly in the slot 29.
  • the lock plate 35 also has a tapered section 36 so that the lock mounting 47 easier can be guided in under the narrow slot 29a of the T-shaped slot 29 via the wide section 29b.
  • a threaded bolt 39 project from the tapered section 36.
  • the bolt 39 has a diameter allowing it to pass through both the narrow slot 29a of the T-shaped slot 29 and the transverse groove 32 of the second plate-shaped element 26 when the plate-shaped elements 25,26 are assembled by using the lock mounting 47 as described in the following with reference to figs. 5 and 6.
  • the first plate-shaped element 25 is assembled to the second plate-shaped element 26 by using the lock mounting 47 into a joint 40.
  • the lock plate 35 is wider than the narrow slot 29a of the T- shaped slot 29.
  • the tapered section 36 of the lock plate 35 is completed inserted in and under the narrow slot 29a of the T- shaped slot 29, and due to its larger width, the lock plate 35 can easily be maintained in and under the narrow slot 29a with the bolt 39 in the overlaying groove 32 in the tab 30 of the second plate-shaped element 26.
  • the washer 37 which is wider than the groove 32, is guided in over and is covering this groove 32.
  • the two plate-shaped elements are subsequently assembled by tightening the nut 38 so that the washer is made to closely abut on the outer face 26a of the tab 30, and the tabs 27,30, which are abutting closely on each other, are, during this, clamped between the washer 37 and the lock plate 35.
  • the washer 37 and the lock plate 35 now contribute to the distribution of the clamping force over a larger area.
  • the two plate-shaped elements 25,26 are now assembled by means of a single bolt which is easy to access from the interior of the nacelle.
  • Fig. 7 shows the fraction in fig. 4 of a second plate-shaped element seen from the outside and mounted with a sealing strip 41 which, when the two tabs closely adjoin each other to form the joint 40 as shown in fig. 6, seals this joint 40 against penetrating moisture.
  • the sealing strip 41 is optional.
  • Fig. 8 shows a second embodiment of a lock mounting 42 with a lock plate 35 having a threaded bolt 39 mounted perpendicular to the tapered section 36 of the lock plate 35, and a second section 43 facing in opposite direction of this section 36 and having a projection 44. In this case, the lock plate 35 is shorter than the lock plate 35 for the mounting 47 shown in figs.
  • the projection 44 retards the lock plate 35 from being pressed to far in towards the bottom of the slot 29 and is furthermore useful when the lock plate is to be pulled out of the slot 29 when the nacelle is to be inspected or serviced.
  • Fig. 9 shows a third embodiment of a lock mounting 42 with a lock plate 35 and a threaded bolt 39 mounted perpendicular to the tapered section 36 of the lock plate 35 and a dovetailed slot 46 arranged opposite the tapered section 36.
  • the lock plate 35 is shorter and is composed of less material than the lock plate 35 for the mounting 47 shown in figs. 4, 5, and 6 and can therefore be received almost in its entire size in the slot 29.
  • Fig. 10 is an inside view of a total of five plate-shaped elements assembled by joints 40.
  • the plate-shaped elements have tabs of both types, that is they have both projecting tabs 30 as shown in the fractional view of the second plate- shaped element in figs. 4, 5, and 6, and projecting tabs 27 as shown in the fractional view of a first plate-shaped element 25 in figs. 4, 5, and 6.
  • the plate-shaped elements can be made with any combination of these tabs which permits assembling with a mounting 47,42,45.
  • Fig. 11 is in outside view of the five plate-shaped elements assembled with flushing joints 40 without visible external means .
  • a nacelle can be made with a smoother surface than hitherto known, which gives a more aerodynamic nacelle.
  • the parts for the nacelle can furthermore be assembled very easily and quickly and are easier to service than known nacelles.
  • the principles for the assembling of plate-shaped elements can also be used for other purposes than nacelles for wind turbines such as temporary walls and other types of cabins.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Wind Motors (AREA)

Abstract

A nacelle (3) for a wind turbine (1) of the kind that comprises a number of plate-shaped elements (25,26) having outer faces (25b, 26b) and inner faces (25a, 25b) together forming the inner face (25) and outer face (26) of the nacelle, and that at least two of the plate-shaped elements (25,26) of the nacelle (3) are made with projecting tabs (27,30) for forming a joint (40) between the plate-shaped elements (25,26) having outer faces (25b, 26b) mainly flushing with each other. The joint (40) comprises that at least one slot (29) is made in the first plate-shaped element, said slot extending from the inner face (25a) of the first plate-shaped element (25), that at least one transverse hole (32) is made in a tab (30) of a second plate-shaped element (26), said hole extends from the inner face (25a) of the second plate-shaped element (26) and to or over the slot (32) when the first (25) and second (26) plate-shaped element are assembled, that a lock mounting (42,45,47) with a lock plate (35) is fitted in at least a part of the slot (29), and that the lock mounting (42,45,47) and the tab (30) of the second plate-shaped element (26) are clamped together by means of a clamping means (37,38,39) extending through the transverse hole (32). The plate-shaped elements (25,26) serve for making a nacelle (3) having a smoother surface than hitherto known. The parts for the nacelle can furthermore be assembled easily and quickly and are easier to service than known nacelles.

Description

Nacelle
The invention relates to a nacelle for a wind turbine and of the kind that comprises a number of plate-shaped elements having outer faces and inner faces that together form the inner face and outer face of the nacelle and that at least two of the elements of the nacelle are constructed with projecting tabs for forming a joint between the elements having outer faces that mainly are flush with each other.
The nacelle for a wind turbine are located at the top of the wind turbine tower and contains the components that are used to convert the energy from the rotor to electric energy. These components comprises, among others, gears, brakes, generator, control system, cooling system and yawing system.
Increasingly larger wind turbines require larger and larger nacelles with resulting transport difficulties. To address this problem, modern nacelles are made of an assembly kit of, among others, smaller plate-shaped elements that are assembled by means of mountings at the place of use.
In a known technique, two plate-shaped elements are assembled by means of angle brackets. One angle side is screwed on to the inner face of a plate-shaped elements by means of screws through the wall of the plate-shaped elements so that the second angle side will project into the nacelle. On the adjacent plate-shaped element, a corresponding but inverted angle bracket is mounted, and the second angle bracket of the two plate-shaped elements are screwed together.
In this known technique, the joint between the plate-shaped elements of the nacelle is difficult to make watertight, which reduces the lifetime of the components contained in the nacelle. A joint between two curved, plate-shaped elements is furthermore both expensive and complicated as the angle brackets must be constructed with due account being taken to the curvature of the plate-shaped elements to obtain a joint as closely fitting as possible. Moreover, the screws will always project through the nacelle wall to its outer face which partly can affect the flowing of the wind across the outer face of the nacelle but also disfigure the appearance of the nacelle. Screw heads and bolt heads on the outer face of the nacelle can furthermore initiate corrosion and wear on contact with polluted and salty passing turbulent air.
In connection with normal maintenance and safety check, screws and bolts are checked, replaced, or tightened. Upon tightening and replacement, it is however difficult to hold the outside bolt heads.
In a first aspect according to the present invention, a nacelle of the kind mentioned in the opening paragraph is provided, in which the nacelle is made up of smaller transportable, plate-shaped elements that can be assembled at the erection site of the wind turbine without visible screws or bolts on the outer face of the nacelle.
In a second aspect according to the present invention, a nacelle is provided by means of plate-shaped elements that are assembled by means of more watertight joints than known nacelles .
In a third aspect according to the present invention, a nacelle is provided, in which curved plate-shaped elements can be assembled quicker, easier and tighter without custom-made mountings .
In a fourth aspect according to the invention, a nacelle is provided, which has a more aerodynamic outer face than known nacelles of plate-shaped elements. In a fifth aspect according to the invention, a nacelle is provided, which is simpler to maintain and overhaul than known nacelles.
The novel and unique feature according to the invention, whereby this is achieved, is the fact that the joint comprises that at least one slot is made in the first plate-shaped element, said slot extends from the inner face of the second plate-shaped element, that at least one transverse hole is made in the tab of the second plate-shaped element, said hole extends from the inner face of the second plate-shaped element and to or across the slot when the first and second plate- shaped element are assembled, that a lock mounting with a lock plate is fitted in at least a part of the slot, and that the lock mounting and the tab of the second plate-shaped element are clamped together by means of a clamping means extending through the transverse hole.
When the tab of the first plate-shaped element overlaps the tab of the second plate-shaped element, the slot overlays the tab of the second plate-shaped element and thereby the transverse hole so that the lock mounting with clamping means extend into the interior of the nacelle. It has the advantage that re-tightening and replacement of bolts and screws expediently can take place from the interior of the nacelle.
The outer face of the first plate-shaped element and the outer face of the second plate-shaped element not including the tab form the exterior of the nacelle in the assembled and mounted state of the plate-shaped elements, said exterior will appear free of bolt heads or screw heads.
In an especially preferred embodiment of a nacelle according to the invention, the nacelle comprises that the slot extends mainly crosswise of the tab of the first plate-shaped element. The nacelle furthermore comprises that at least a section of the slot is shaped as a T-slot extending into or through the tab of the first plate-shaped element. The transverse hole in the tab of the second element extend to or over the T-slot when the first plate-shaped element and the second plate- shaped element are in assembled state. The lock plate of the lock mounting is wider than at least a part of the opening of the T-slot and the lock plate is located at least in the T- slot.
If the slot is shaped as a T-slot, it is especially easy to insert and fix the mounting in the slot . The width of the lock plate ensures that the lock mounting is maintained in the opening of the slot, and the lock plate can be accommodated and tightly maintained in the slot of the first plate-shaped element without auxiliary means. The lock mounting uses fewer clamping means that conventional angle brackets for conventional nacelles, and it is therefore both quicker and easier to assemble the plate-shaped elements to the nacelle according to the present invention.
A slot extending obliquely inwards in the first plate-shaped element facilitates the insertion of the lock plate and ensures that the material thickness in the area of the tab of the first plate-shaped element that faces the tab of the second plate-shaped element is so great that the nacelle can counterbalance the loads and stresses that it is subjected to by the elements but also during mounting.
The slot can easily be made by milling the slot in the tab of the first plate-shaped element. To ensure that this tab has sufficient strength to accommodate the lock plate, this tab can have a material thickness greater than that of the tab of the second plate-shaped element.
If the transverse hole is formed as a groove extending from an outer edge of the tab of the second plate-shaped element and at least a distance into this tab, the tabs of the first and second plate-shaped elements can easily be joined when the plate-shaped elements of the nacelle are to be assembled.
Advantageously, the lock plate of the lock mounting according to the present invention can have a mainly tapered section so that the lock plate easily can be guided in place in the slot.
The lock plate of the lock mounting can furthermore be made with a projection opposite the mainly tapered section, said projection fitting into the groove on the tab of the second plate-shaped element. The projection can advantageously serve as guide pin in the groove when the tabs of the two plate- shaped elements are to be assembled. An especially simple and inexpensive projection can be formed by folding a portion of the lock plate.
If the lock plate of the lock mounting opposite the mainly tapered section is formed with a notch, the lock plate will project the least possible from the slot in the assembled state of the two plate-shaped elements.
The tabs of the two plate-shaped elements can advantageously taper at angles that are complementary at joining. This design of the tabs allows assembling of curved plate-shaped elements without using custom-made mountings. The lock mounting is mounted in the slot and transverse hole, the tabs are adjusted by displacement in relation to each other taking the curvature into consideration, and the two plate-shaped elements are clamped together by means of the clamping means of the lock mounting. As the two tabs have mainly complementary and overlapping tabs, the joint will maintain its tightness despite its curvature.
The angles can for example be between about 5° and 15°, preferably between about 8° and 12° and especially about 10°. The plate-shaped elements can typically be formed as a sandwich construction having a shell of e.g. metal or plastic enclosing a core of dimensionally stable foam. The requirements to the chosen shell material include that this material must be formable or mouldable, weigh the least possible but still have high strength and great rigidity. The material should also be corrosion-resistant and be able to withstand wide temperature variations . Examples of suitable shell materials comprise aluminium, stainless steel and fibreglass reinforced resin.
The best suited foam material has a dimensional stability after setting which, when the foam is supported by the sides of the slot, can absorb the load from the lock plate. Examples of such foam materials comprises polyurethane foam and polyvinyl chloride foam.
The above materials and sandwich constructions are known to a person skilled in the art and will not be described or illustrated further in the present application.
In the preferred embodiment, the T-slot can extend into the foam core of the first plate-shaped element to thereby support the lock plate and absorb possible loads and stresses produced due to the action of the environment on the nacelle wall.
An especially watertight design of a nacelle according to the present invention comprises a sealing strip inserted between two tabs which abut on each other in the mounted state of the nacelle.
A simple clamping means for use in the lock mounting for the nacelle according to the present invention can comprise a screw or a bolt and related nut. The screw can be attached on the lock plate for example by welding, or the lock plate can be made with a thread cooperating with a loose screw or bolt. To prevent that the nut is pressed down into and damages the inner face of the second plate-shaped element when the tabs of two plate-shaped elements are clamped tightly together, a washer can be placed between the tab of the second plate- shaped element and nut. The washer will reduce and distribute the surface pressure on the surface of the tab.
The invention will be explained in greater details below, describing only exemplary embodiments with reference to the drawing, in which
fig. 1 shows a conventional wind turbine,
fig. 2 is a sectional view taken along the line II-II of fig. 1 showing an example of a conventional assembly of plate- shaped elements for a known wind turbine nacelle,
fig. 3 is another example of a conventional assembly in which the plate-shaped elements are formed with tabs overlapping in the assembled state of the plate-shaped elements,
fig. 4 is an exploded perspective fractional view from the inside of two plate-shaped elements for a nacelle according to the invention and an associated first embodiment of a mounting,
fig. 5 shows the same in assembled state,
fig. 6 is a sectional view taken along the line VI-VI of fig. 5,
fig. 7 is the fractional view in fig. 4 of the second plate- shaped element seen from the outside and mounted with a sealing strip, fig. 8 is a perspective view of a second embodiment of a lock mounting for joining plate-shaped elements to a nacelle according to the present invention,
fig. 9 is a perspective view of a third embodiment of a lock mounting for assembling of plate-shaped elements to a nacelle according to the present invention,
fig. 10 is an inside view of a total of five plate-shaped elements assembled to a larger nacelle part, and
fig. 11 in an exterior view of fig. 10.
The wind turbine in fig. 1 is generally designated by the reference numeral 1. The wind turbine 1 comprises a tower 2, a nacelle 3 having a rotor 4 with a total of two blades 5a, 5b. The nacelle 3 is made up of a number of plate-shaped elements 3a, 3b, 3c, of which only three are shown in fig. 1. The plate- shaped elements are assembled by joints 6a, 6b and leave bolt heads 7a, 7b on the exterior 8 of the nacelle 3.
Fig. 2 is a fractional sectional view taken along the line II- II of fig. 1 of a first example of a conventional joint 6a of two plate-shaped elements 3a, 3b with angle brackets 9a, 9b.
The angle brackets 9a has a first angle side 9a' mounted on the inner face 10a of the plate-shaped element 3a by means of a bolt 11a. The thread 12a of the bolt 11a is inserted through the hole 13a in the plate-shaped element 3a and the hole 14a in the first angle side 9a' of the angle bracket 9a flushing with the hole 13a so that the bolt head 7a is on the outer face 8a of the plate-shaped element. By means of a nut 15a, the angle bracket 9a and the first plate-shaped element 3a are clamped together so that the second angle side 9a' ' is mainly flush with the outer edge 16a on the first plate-shaped element 3a. The second angle side 9a'' will therefore project into the interior of the nacelle 3.
The angle bracket 9b is mounted in a similar way on the second plate-shaped element 3b by means of a bolt lib so that the first angle side 9b' of the second angle bracket 9b is screwed onto the inner face 10b of the second plate-shaped element and the second angle side 9b' ' is mainly flush with the outer edge 16b of the second plate-shaped element.
In mounted state, the angle brackets 9a, 9b are inverted in relation to each other. Their second angle side 9a' ',9b'' abut on each other so that they can be assembled in a conventional way by a third bolt 17 through the second angle sides 9a" ,9b".
Fig. 3 shows a second example of a conventional joint 18 of a first plate-shaped element 19 with a second plate-shaped element 20 formed with respective tabs 21,22. The tabs 21,22 overlaps each other when the plate-shaped elements 19,20 are assembled by means of the inverted angle bracket 9a, 9b.
The first angle bracket 9a is mounted on the inner face 23a of the first plate-shaped element 19 by means of a bolt 11a through the wall of the first plate-shaped element 19 and the first angle side 9a' of the first angle bracket 9a. By means of a nut 15a, the bolt 11a is tightened so that the angle bracket 9a is securely fastened to the inner face 23a of the first plate-shaped element 19.
The bolt 11a is fastened through the wall of the first plate- shaped element 19 at a point where the material thickness corresponds to the wall thickness.
On the second plate-shaped element 20, an inverted angle bracket 9b is mounted with a bolt lib through the tab 22, that is in an area of the second plate-shaped element 20, in which the material thickness is far thinner than the material thickness of the wall of the second plate-shaped element. The bolt head 7b is shown to be countersunk in the tab 22 so that the tabs 19,20 overlap with flushing outer faces 24a, 24b. This can also be obtained by allowing the bolt head 7b to be received in a recess, not shown, in the tab 21 of the first plate-shaped element.
If the two plate-shaped elements 19,20 are to be assembled to each other to the assembly 18, the second angle sides 9a' ',9b'' of the two angle brackets 9a, 9b are bolted together as described with reference to fig. 2.
This type of joint leaves fewer bolt heads on the outer face of the nacelle than the method referred to in fig. 2 for assembling plate-shaped elements but if the bolt lib for example is to be inspected and possibly replaced, it is necessary to completely disassemble the assembly 18 in order for the repair technician to be able to obtain access . The assembly 18 is not suited for assembling curved plate-shaped elements either.
Fig. 4 is an exploded fractional view of two plate-shaped elements, respectively a first plate-shaped element 25 and a second plate-shaped element 26, and an exploded view of a lock mounting 47.
The first plate-shaped element 25 has an inner face 25a, an outer face 25b, and a tab 27 ending in an outer edge 28. In the inner face 25a, a slot 29 is made in form of a T-shaped slot. The T-shaped slot consists of a narrow slot 29a extending into a wider section 29b in such a way that the narrow slot 29a faces in a direction towards the outer edge 28 of the tab 27. The tab 27 tapers at an angle α as the material thickness of the plate-shaped element 25 decreases from the start of the tab 27 approximately in the middle of the narrow slot 29a of the T-shaped slot 29 in a direction towards the outer edge 28 of the tab 27.
The second plate-shaped element 26 has an inner face 26a, an outer face 26b, and a tab 30 ending in an outer edge 31. A transverse groove 32 extends a distance into the tab 30 which tapers at an angle β complementary to the angle α of the tab of the first plate-shaped element 25.
The plate-shaped elements 25,26 are made of a shell material, for example fibreglass reinforced polyester, filled with a dimensionally stable foam 33, for example polyurethane foam. As shown in the figure, the shell can be divided into a number of foam-filled channels 34, and the sandwich materials described herein are known to a person skilled in the art.
The lock mounting 47 comprises a flat lock plate 35, a bolt 39, a washer 37, and a nut 38.
The lock plate 35 has a thickness allowing it to be received tightly in the slot 29. The lock plate 35 also has a tapered section 36 so that the lock mounting 47 easier can be guided in under the narrow slot 29a of the T-shaped slot 29 via the wide section 29b. A threaded bolt 39 project from the tapered section 36. The bolt 39 has a diameter allowing it to pass through both the narrow slot 29a of the T-shaped slot 29 and the transverse groove 32 of the second plate-shaped element 26 when the plate-shaped elements 25,26 are assembled by using the lock mounting 47 as described in the following with reference to figs. 5 and 6.
In fig. 5, the first plate-shaped element 25 is assembled to the second plate-shaped element 26 by using the lock mounting 47 into a joint 40. The tabs 27,30 tapering at complementary angles overlap each other so that the outer faces 25b, 26b of the plate-shaped elements are flush with each other and do not present outer bolt heads.
The location of the lock mounting 47 in the T-slot 29 and the joint 40 according to the invention of the two tabs 27,30 is more clearly shown in the sectional view in fig. 6.
The lock plate 35 is wider than the narrow slot 29a of the T- shaped slot 29. The tapered section 36 of the lock plate 35 is completed inserted in and under the narrow slot 29a of the T- shaped slot 29, and due to its larger width, the lock plate 35 can easily be maintained in and under the narrow slot 29a with the bolt 39 in the overlaying groove 32 in the tab 30 of the second plate-shaped element 26. The washer 37 which is wider than the groove 32, is guided in over and is covering this groove 32. The two plate-shaped elements are subsequently assembled by tightening the nut 38 so that the washer is made to closely abut on the outer face 26a of the tab 30, and the tabs 27,30, which are abutting closely on each other, are, during this, clamped between the washer 37 and the lock plate 35. The washer 37 and the lock plate 35 now contribute to the distribution of the clamping force over a larger area. The two plate-shaped elements 25,26 are now assembled by means of a single bolt which is easy to access from the interior of the nacelle.
Fig. 7 shows the fraction in fig. 4 of a second plate-shaped element seen from the outside and mounted with a sealing strip 41 which, when the two tabs closely adjoin each other to form the joint 40 as shown in fig. 6, seals this joint 40 against penetrating moisture. Within the scope of the present invention, the sealing strip 41 is optional. Fig. 8 shows a second embodiment of a lock mounting 42 with a lock plate 35 having a threaded bolt 39 mounted perpendicular to the tapered section 36 of the lock plate 35, and a second section 43 facing in opposite direction of this section 36 and having a projection 44. In this case, the lock plate 35 is shorter than the lock plate 35 for the mounting 47 shown in figs. 4, 5 and 6, and a smaller part of the lock plate 35 therefore projects from the slot 29. The projection 44 retards the lock plate 35 from being pressed to far in towards the bottom of the slot 29 and is furthermore useful when the lock plate is to be pulled out of the slot 29 when the nacelle is to be inspected or serviced.
Fig. 9 shows a third embodiment of a lock mounting 42 with a lock plate 35 and a threaded bolt 39 mounted perpendicular to the tapered section 36 of the lock plate 35 and a dovetailed slot 46 arranged opposite the tapered section 36. The lock plate 35 is shorter and is composed of less material than the lock plate 35 for the mounting 47 shown in figs. 4, 5, and 6 and can therefore be received almost in its entire size in the slot 29.
Fig. 10 is an inside view of a total of five plate-shaped elements assembled by joints 40. The plate-shaped elements have tabs of both types, that is they have both projecting tabs 30 as shown in the fractional view of the second plate- shaped element in figs. 4, 5, and 6, and projecting tabs 27 as shown in the fractional view of a first plate-shaped element 25 in figs. 4, 5, and 6. Within the scope of the invention, the plate-shaped elements can be made with any combination of these tabs which permits assembling with a mounting 47,42,45.
Fig. 11 is in outside view of the five plate-shaped elements assembled with flushing joints 40 without visible external means . By means of plate-shaped elements according to the present invention, a nacelle can be made with a smoother surface than hitherto known, which gives a more aerodynamic nacelle. The parts for the nacelle can furthermore be assembled very easily and quickly and are easier to service than known nacelles. These advantages are significant in connection with wind turbine nacelles as such nacelles are located at the top of very high towers and the maintenance servicing therefore involves great risks to the repair technician.
Within the scope of the invention, the principles for the assembling of plate-shaped elements can also be used for other purposes than nacelles for wind turbines such as temporary walls and other types of cabins.

Claims

1. A nacelle (3) for a wind turbine (1) and of the kind that comprises a number of plate-shaped elements (25,26) having outer faces (25b, 26b) and inner faces (25a, 26a) together forming the inner face (25) and outer face (26) of the nacelle (3), and that at least two of the plate-shaped elements (25,26) of the nacelle are formed with projecting tabs (27,30) for forming a joint (40) between the plate-shaped elements (25,26) with outer faces (25b, 26b) that are mainly flush with each other, characterized in that the joint (40) comprises at least one slot (29) is made in a first plate- ' shaped element (25) , said slot extending from the inner face (25a) of the first plate-shaped element (25), that at least one transverse hole (32) is made in the tab (30) of the second plate-shaped element (26) , said hole extends from the inner face (26a) of the second plate-shaped element (26) and to or across the slot (29) when the first (25) and second plate-shaped element (26) are assembled, that a lock mounting (42,45,47) with a lock plate (35) is fitted in at least a part of the slot (29), and that the lock mounting (42,45,47) and the tab (30) of the second plate-shaped element (26) are clamped together by means of a clamping means (37,38,38) extending through the transverse hole (32) .
2. A nacelle (3) according to claim 1, characterized in that the slot (29) extends mainly crosswise of the tab (27) of the first plate-shaped element (25), that at least a section of the slot (29) is formed with a T-slot (29a, 29b) extending into or through the tab (30) of the first plate-shaped element (26) , that the transverse hole (32) in the tab (30) of the second plate-shaped element (26) extends into or over the T-slot (29a, 29b) when the plate-shaped first element (25) and the second plate-shaped element (26) are in assembled state, that the lock plate (35) of the lock mounting (42,45,47) is wider than at least a part of the opening of the T-slot (29a, 29b), and that the lock plate (35) is fitted in at least the T-slot (29a, 29b).
3. A nacelle (3) according to claim 1 or 2, characterized in that the slot (29) extends obliquely inwards in the first plate-shaped element (25) .
4. A nacelle (3) according to claim 1, 2, or 3, characterized in that the transverse hole (32) is a groove (32) extending from an outer edge (31) of the tab
(30) of the second plate-shaped element (26) and at least a distance into this tab (30) .
5. A nacelle (3) according to any of the preceding claims, characterized in that one end of the lock plate (35) of the lock mounting (42,45,47) has a mainly tapered section (36).
6. A nacelle (3) according to claim 5, characterized in that the lock plate (35) of the lock mounting (42) opposite the tapered section (36) of the lock mounting (42) is formed with a projection (44) fitting into the groove (32).
7. A nacelle (3) according to claim 5, characterized in that the lock plate (35) of the lock mounting (45) opposite the mainly tapered sections (36) is formed with a slot (46).
8. A nacelle (3) according to any of the preceding claims 1
- 7, characterized in that the tabs (27,30) of the two plate-shaped elements (25,26) taper at complementary angles (α,β) in the joint (40).
9. A nacelle (3) according to any of the preceding claims 1
- 7, characterized in that the plate-shaped elements (25,26) are formed as a sandwich construction having a shell (25a, 25b; 26a, 26b) enclosing a core (33) of a dimensionally stable foam (33) .
10. A nacelle (3) according to any of the preceding claims 1
9, characterized in that a sealing strip (41) is inserted between the two tabs (27,30) which abut on each other in the mounted state of the nacelle (3) .
PCT/IB2007/051765 2006-05-11 2007-05-10 Modular construction of a nacelle WO2007132408A2 (en)

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EP2218911A1 (en) * 2009-02-12 2010-08-18 Deen Polyester Constructies B.V. Housing with a special connection assembly as well as a method for manufacturing such a housing.
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