Spacer for wind turbine cables

The present disclosure is directed to a cable securement assembly for protecting cables and/or cable bundles within a wind turbine. The cable securement assembly includes a cable spacer having an inner surface and an outer surface separated by a thickness and one or more fastening components. The inner surface defines an open center configured to receive the plurality of cables therein. The inner surface defines a plurality of cable locations defined by one or more through holes configured through the thickness. The one or more fastening components are configured to secure one or more of the plurality of cables at each cable location via the through holes.

FIELD OF THE INVENTION

The present subject matter relates generally to wind turbines and, more particularly, to a spacer for wind turbine drip-loop cables.

BACKGROUND OF THE INVENTION

In many wind turbines, the nacelle contains many electrical components that enable a controlled and efficient conversion of wind energy into electrical energy such as, for example, one or more generators, a wind turbine controller, and/or cooling systems. In addition, cables that feed electrical power into electrical supply grids are often routed from the nacelle to the electrical supply grids via the tower. Thus, a plurality of cables may be present in and around the nacelle, as well as down through the tower (e.g. through openings in one or more tower platforms) so as to couple all of the electrical components to a power source.

To maximize the energy production of a wind turbine, the nacelle is typically able to rotate or pivot versus the fixed position of the tower. This allows the rotor blades to be in an optimum position with respect to the wind direction. Hence, the wind turbine is able to exploit a maximum amount of wind energy at all times. Equally, to avoid unfavorable wind gusts or extremely high wind speeds the position of the nacelle may be adjusted accordingly. Based on this movement of the nacelle the cables routed from the nacelle to the tower may be pulled together in a kind of knurl, which is not under control. This twisting and curling behavior of the cables during operation of a wind turbine may lead to several issues such as overheating in the knurls or undesired movement of cables. The undesired movement of the cables may cause excessive wear to the cables and/or may damage surrounding structures. In the worst case, such uncontrolled movements of the cables may result in entanglement of the cables inside of the tower that may eventually lead to system failure.

To address the aforementioned issues, fiberglass reinforced material may be installed around the cable bundles and/or rubber mats may be installed within tower platform openings to control undesired movements of the cables. In certain wind turbines, however, the fiberglass reinforced material fails to stay installed around the cables. Still additional methods for protecting drip loop cables include utilizing large PVC tubing installed within tower platform openings. However, in many cases, such tubing results in high cable air temperatures.

In view of the foregoing, an improved system and method for spacing apart and protecting drip loop cables within the wind turbine would be welcomed in the art. Hence, the subject matter of the present disclosure is directed to a cable securement assembly having an cable spacer.

BRIEF DESCRIPTION OF THE INVENTION

In accordance with one embodiment of the present disclosure, a cable securement assembly configured to space apart and protect a plurality of cables within a wind turbine is disclosed. The cable securement assembly includes a cable spacer having an inner surface and an outer surface separated by a thickness and one or more fastening components. Further, the inner surface defines an open center configured to receive the plurality of cables therein. The inner surface defines a plurality of cable locations defined by one or more through holes configured through the thickness. The one or more fastening components are configured to secure one or more of the plurality of cables at each cable location via the through holes.

In one embodiment, the fastening components may include at least one of zip ties, ropes, strings, plastic inserts, fasteners, or similar. In another embodiment, the cable spacer may be configured or sized to fit within at least one of an opening of a platform within a tower of the wind turbine or a drip loop bracket.

In further embodiments, the cable spacer may be formed from one continuous piece of material. In addition, the continuous piece of material may include a slot configured to assist with installation of the one or more cables therein. In alternative embodiments, the cable spacer may be formed from multiple segments joined together. Further, the multiple segments may be joined together via one or more fastening components as described herein. In yet another embodiment, each of the multiple segments may include corresponding locking ends such that the multiple segments may be joined together via the corresponding locking ends.

In another aspect, the present disclosure is directed to a wind turbine. The wind turbine includes a tower secured to a support surface and having at least one platform configured therein, a nacelle configured atop the tower, a plurality of cables configured within the tower and the nacelle, and a cable securement assembly configured to space apart and protect the cables within the tower. The cable securement assembly includes a cable spacer having an inner surface and an outer surface separated by a thickness and one or more fastening components. Further, the inner surface defines an open center configured to receive the plurality of cables therein. The inner surface defines a plurality of cable locations defined by one or more through holes configured through the thickness. The one or more fastening components are configured to secure one or more of the plurality of cables at each cable location via the through holes. It should be understood that the cable securement assembly may also include any of the additional features as described herein.

In yet another aspect, the present disclosure is direction to a method for securing and protecting a plurality of cables within a wind turbine. For example, in one embodiment, the method includes securing one or more of the plurality of cables within a first segment of a cable spacer at one or more cable locations via one or more fastening components. Another step includes securing one or more of the plurality of cables within a second segment of the cable spacer at one or more cable locations via one or more fastening components. The method also includes securing the first and second segments together, wherein the cable spacer is configured to space apart and protect the plurality of cables therein.

In another embodiment, the plurality of cable locations may be defined by one or more through holes configured through a thickness of the cable spacer. Thus, the method may also include inserting one or more fastening components into the one or more through holes so as to secure one or more of the plurality of cables at each cable location. In still a further embodiment, the method may include securing the first and second segments together via one or more fastening components or corresponding locking ends of the first and second segments.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “cable” is intended to be representative of any type of cable such as, for example, single- double- or triple-core power cables, radial field or collectively shielded power cables or any other conductive or non-conductive cables or cords that are routed from the nacelle to the tower of a wind turbine, for example, control cables.

Generally, the present disclosure is directed to a wind turbine system that controls movements of internal cables configured therein and protects said cables from mechanical abrasion. More specifically, the wind turbine system may include a cable securement assembly having at least one cable spacer that provides spacing of the cables to manage thermal performance and mechanical protection thereof. Further, the cable spacer has inner and outer surfaces separated by a thickness. The inner surface defines an open center configured to receive the plurality of cables therein. For example, in one embodiment, the cable spacer permits insertion of the cables therein by having a segmented configuration. More specifically, the cable spacer may include first and second halves that are detachable such that the cables can be inserted therein and the halves can be reattached. Alternatively, the cable spacer may be a single, continuous piece of material having a slot configured through a side wall thereof such that the cables can be inserted into the spacer via the slot. Thus, the cable spacer is configured to permit insertion of the cables therein through the side wall of the cable spacer. Further, the cable spacer can be installed and/or removed from existing wind turbine systems.

In addition, the cable spacer may include a plurality of cable locations defined by one or more through holes configured through the thickness of the spacer. Thus, fastening components may be configured to secure cables and/or cable bundles at each cable location via the through holes. Accordingly, the various embodiments of the cable spacer described herein prevents several issues associated with wind turbine cables, including, but not limited to overheating, movement (or entanglement) of the cables, and/or unnecessary wear on the cables and surrounding structures.

In addition, the spacers may further increase the reliability and service life of wind turbines by minimizing the risk of system failure due to entanglement of the cables. Such system failures may require interrupting the operation of a wind turbine for de-entanglement or repairs associated with uncontrolled cables. Further, the spacers are configured to increase safety with respect to service personnel that may need to access the nacelle or tower during operation of a wind turbine.

The tower12may also include a plurality of tower sections24assembled atop one another. Further, the tower12may be constructed of any number of tower sections24. For example, in the illustrated embodiment, the tower12includes four tower sections24. In addition, the tower sections24may include one or more platforms30that are integrated with a tower section24and/or mounted with a tower section24.

The platforms30provide operators safe access to areas of the wind turbine10that may require servicing, maintenance, and inspection. For example, the platforms30may be located adjacent to tower flange bolts for safe and easy inspection, or may be located adjacent to preassembled power modules for inspection and maintenance purposes. Thus, the location of the platforms30within a tower section24may vary so as to accommodate the needs of a specific wind turbine10.

Referring now toFIG. 2, an enlarged perspective view of the nacelle16of the wind turbine10including the cable securement assembly100according to the present disclosure is illustrated. As shown, the hub20is rotatably coupled to an electric generator42positioned within nacelle16by rotor shaft44(sometimes referred to as either a main shaft or a low speed shaft), a gearbox46, a high speed shaft48, and a coupling50. Further, the rotor shaft44is disposed coaxial to longitudinal axis26. Rotation of the rotor shaft44rotatably drives the gearbox46that subsequently drives the high speed shaft48. Thus, the high speed shaft48rotatably drives the generator42with the coupling50and rotation of the high speed shaft48facilitates production of electrical power by the generator42. In addition, as shown in the illustrated embodiment, the gearbox46and the generator42may be supported by support52and support54. In the exemplary embodiment, the gearbox46utilizes a dual-path geometry to drive the high speed shaft48. Alternatively, the rotor shaft44may be coupled directly to the generator42with the coupling50.

Each rotor blade22may also include a pitch adjustment mechanism32configured to rotate each rotor blade22about its pitch axis34. For example, as shown, the pitch adjustment mechanism32may include a pitch drive motor38(e.g., any suitable electric motor), a pitch drive gearbox40, and a pitch drive pinion43. In such embodiments, the pitch drive motor38may be coupled to the pitch drive gearbox40such that the pitch drive motor38imparts mechanical force to the pitch drive gearbox40. Similarly, the pitch drive gearbox40may be coupled to the pitch drive pinion43for rotation therewith. The pitch drive pinion43may, in turn, be in rotational engagement with a pitch bearing45coupled between the hub20and a corresponding rotor blade22such that rotation of the pitch drive pinion43causes rotation of the pitch bearing45. Thus, in such embodiments, rotation of the pitch drive motor38drives the pitch drive gearbox40and the pitch drive pinion43, thereby rotating the pitch bearing45and the rotor blade22about the pitch axis34.

The nacelle16may also include a yaw drive mechanism56that may be used to rotate the nacelle16and the hub20about the yaw axis38to control the perspective of the rotor blades22with respect to the wind direction28(FIG. 1). In addition, the nacelle16may also include at least one meteorological mast58that includes a wind vane and anemometer (neither shown inFIG. 2). The mast58provides information to control system36that may include wind direction and/or wind speed. The control system36is configured to control the wind turbine10and/or any wind turbine components thereof.

Still referring toFIG. 2, the nacelle16may also include a main forward support bearing60and a main aft support bearing62. The forward support bearing60and the aft support bearing62facilitate radial support and alignment of the rotor shaft44. Further, the forward support bearing60is coupled to the rotor shaft44near the hub20, whereas the aft support bearing62is positioned on the rotor shaft44near the gearbox46and/or the generator42. Alternatively, the nacelle16may include any number of support bearings that enable the wind turbine10to function as disclosed herein. In addition, the rotor shaft44, the generator42, the gearbox46, the high speed shaft48, the coupling50, and any associated fastening, support, and/or securing device including, but not limited to, support52and/or support54, and forward support bearing60and aft support bearing62, are sometimes referred to as a drive train64.

Referring now toFIGS. 3 and 4, a top view of a cable securement assembly100and example locations for the assembly100within the tower12are illustrated according to one embodiment of the present disclosure. As shown inFIG. 3, the tower12includes a plurality of cables66configured therein. More specifically, as shown, the plurality of cables66are routed from the nacelle16(FIG. 2) down through the tower12near the support surface14in a drip loop configuration. Thus, any platform(s)30within the tower12contain at least one platform opening33configured to allow the cables66to pass therethrough. In addition, the tower12may include one or more drip loop brackets68configured to maintain the drip loop74from swinging too far from side to side. The drip loop brackets68may also be used as supports for various tower components, such as, e.g. a twist switch (not shown). Further, the cables66may be routed through a drip loop saddle65or saddle deck that is typically located towards a lower portion of the tower12and is configured to hold the lower ends of the cables66.

The cable securement assembly100includes one or more cable spacer(s)70located at any location along the vertical run of the drip loop cables66, e.g. as shown inFIG. 3. For example, in one embodiment, the cable spacer70may be located within the platform opening33and/or within one or more of the drip loop brackets68. Such locations have minimal clearances; therefore, the cable spacer70is designed so as to fit within such clearances. In further embodiments, the cable spacer(s)70may be located at any other location along the drip loop cables66, in addition to those specific locations described herein.

Referring particularly toFIGS. 4 and 5, various components of the cable securement assembly100are illustrated. As shown, the assembly100includes at least one cable spacer70and one or more fastening components80that provide secure spacing of the cables66so as to manage thermal performance and mechanical protection thereof. Further, the cable spacer70has an inner surface78and an outer surface77separated by a thickness72. The inner surface78defines an open center71configured to receive the plurality of cables66therein and a plurality of cable locations69defined by one or more through holes76configured through the thickness72. Thus, the fastening components80are configured to secure the cables66and/or cable bundles67at each cable location69via the through holes76.

It should be understood that any number of cable locations spaced apart by any suitable distance79may be defined within the cable spacer70. Thus, the distance79between the cable locations may be adjustable to ensure proper ventilation of the cables66and/or to meet certain standard requirements (e.g. IEC, NEC, and CEC). For example, as shown inFIG. 4, ten cable locations69are spaced circumferentially by distance79about the spacer70. In additional embodiments, the spacer70may include more than ten or less than ten cable locations69and the distance may be adjusted accordingly.

In particular embodiments, each of the cable locations69may be defined by one or more through holes76. For example, as shown inFIG. 5, four through holes76define one of the cable locations69. In still additional embodiments, any number of through holes76, including more than four or less than four, may define a cable location69. Thus, at least one cable66or cable bundle67may be positioned at each spacer location69and secured thereto by the fastening components80via through holes76.

In addition, any number of cables66may be secured at each cable location69. For example, as shown inFIG. 4, two cable locations69have a single cable66configured thereon; one cable location69contains a cable bundle67with two cables66configured thereon, and seven cable locations69contain cable bundles67having three cables66each. Alternatively, each cable bundle67may include more than three or less than three cables66.

As mentioned, the through holes76of the spacer70are spaced circumferentially about the spacer70and extend from an outer surface77to an inner surface78thereof. Thus, the through holes76are configured to receive the one or more fastening devices80so as to secure the cables66and/or cable bundles67to the inner surface78of the spacer70. For example, in one embodiment, the fastening components80may include zip ties, ropes, strings, plastic inserts, fasteners, or similar. It should be understood that the number of through holes76, as well as the position and size of the through holes76may vary.

Referring now toFIGS. 6-8, various views of further embodiments of the cable spacer70, particularly illustrating spacers formed from multiple segments, are illustrated. As shown inFIG. 6, for example, the cable spacer70may be formed from at least a first segment84and a second segment86. In still additional embodiments, the cable spacer70may be formed from more than two segments. The multi-segmented configuration provides for simple installation of the cables66within the spacer70and subsequent joining thereof. In addition, each of the segments84,86may include be joined together using any suitable joining means. For example, in one embodiment, the segments84,86may be joined together via one of the fastening components80described herein. In still additional embodiments, each of the segments84,86may include corresponding locking ends87,88such that the multiple segments84,86may be joined together via the corresponding locking ends87,88. The locking ends87,87may have any suitable configuration so as to maintain contact between the two segments84,86. For example, as shown inFIG. 6, the corresponding locking ends87,88may include alternating rectangular protrusions configured to mesh together. In addition, the corresponding locking ends87,88may also include one or more through holes89to further assist with joining the segments84,86together.

In still further embodiments, as shown inFIG. 7, additional corresponding locking ends87,88suitable for joining the multiple segments84,86are illustrated. As shown, the corresponding locking ends87,88may have any suitable shape and/or configuration (e.g. rectangle, square, triangle, dovetail, zig-zag, circular, or similar) so as to maintain contact between the segments82,84. In addition, any combination of shapes and/or configuration may be used for the corresponding locking ends87,88. For example, as shown inFIG. 8, a combination of rectangular protrusions having varying heights form the corresponding locking ends87,88.

In alternative embodiments, the cable spacer may be formed from one continuous piece of material. For example,FIG. 9illustrates a cable spacer170having such a single-segment configuration. As shown, the spacer170has an inner surface178and an outer surface177separated by a thickness172. The inner surface178defines an open center171configured to receive the plurality of cables66therein. In addition, the cable spacer170may include any of the additional features as described herein, e.g. a plurality of cable locations defined by one or more through holes, one or more fastening components configured through the through holes so as to secure the cables, etc. In addition, the cable spacer170may include a slot175configured axially through the spacer70. Thus, in various embodiments, the slot175is configured to assist with installation of the cables within the cable spacer70. The single-segment configuration provides a simple, easy to manufacture embodiment having all of the advantages as described herein pertaining to the multi-segmented configuration.

Referring now toFIG. 10, a flow diagram of a method200for securing and protecting a plurality of cables within a wind turbine is illustrated. For example, as shown, the method200includes securing one or more of the cables within a first segment of a cable spacer at one or more cable locations via one or more fastening components (step202). Another step204of the method200includes securing one or more of the cables within a second segment of the cable spacer at one or more cable locations via one or more fastening components. Thus, a next step206of the method includes securing the first and second segments together, wherein the cable spacer is configured to space apart and protect the plurality of cables therein.

As mentioned, the plurality of cable locations may be defined by one or more through holes configured through a thickness of the cable spacer. Thus, the method200may also include inserting one or more fastening components into the one or more through holes so as to secure one or more of the plurality of cables at each cable location. The method200may include securing the first and second segments together via one or more fastening components or corresponding locking ends of the first and second segments.

The above-described systems and methods facilitate for controlling the twisting of cables and/or to protect said cables from mechanical wear, which are routed from the nacelle into the tower of a wind turbine so as to prevent system malfunctions, overheating, and/or undesired movement of the cables within the tower. Additionally, system safety may be increased and excessive wear of the cables or cable bundles as well as wear on surrounding structures, such as, for example, ladders or lights may be reduced.

The systems and methods of the present disclosure are not limited to the specific embodiments described herein, but rather, components of the systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the cable securement assembly may be employed in other wind turbines, for example vertical wind turbines, other power generating machines or devices where at least one cable is routed from one section to another, whereby the one section moves in opposing directions to the other, and are not limited to practice with only the wind turbine systems as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other rotor blade applications.