Patent Description:
Wind turbines are used to produce electrical energy using a renewable resource and without combusting a fossil fuel. Generally, a wind turbine converts kinetic energy from the wind into electrical power. A horizontal-axis wind turbine includes a tower, a nacelle located at the apex of the tower, and a rotor having a plurality of blades and supported in the nacelle by means of a shaft. The shaft couples the rotor either directly or indirectly with a generator, which is housed inside the nacelle. Consequently, as wind forces the blades to rotate, electrical energy is produced by the generator.

Components of the generator located within the nacelle generate significant heat during operation, which in turn, causes the temperature of the air in the nacelle and the generator components to increase. When the generator components are heated, the overall efficiency of power generation may be decreased. Therefore, the generator components and the nacelle may be cooled to ensure that the heat does not adversely affect power generation and/or damage the components.

Conventional wind turbines may include one or more cooling devices configured to remove the heat generated during operation of the wind turbine. The cooling devices may include standard heat sinks. Another exemplary cooling device is a cooler top positioned along one side (e.g., the roof or sides) of the nacelle and including one or more panels partially enclosed by a cover. The air flowing past the wind turbine cools a second fluid flowing through the panels, the second fluid being directed to other heat exchangers within the nacelle to remove heat from generator components and the nacelle. To this end, the cooling devices operate to thereby reduce the temperature of the nacelle and the generator components.

In present cooler top designs, the panels have a cooling area that is arranged to directly face the incoming wind. In other words, the plane of the cooling area is arranged perpendicular to the incoming wind. While this arrangement of the panels is sufficient for its intended purpose, there are some drawbacks to such a design. For example, as the power production per wind turbine increases, so does the required cooling capacity. Increasing cooling capacity with the present cooler top designs may be accomplished by scaling in two directions, i.e., the height of the panel(s) (e.g., in the vertical direction) and the width of the panel(s) (e.g., in the horizontal direction). There is, however, a practical limit as to how high and how wide a panel or series of panels may be made on top of a nacelle. In this regard, the width of the panel(s) is generally limited by the width of the nacelle to which the cooler top is attached. Moreover, the height of the panel(s) may be bound by strength limitations in the structure that supports the panel(s) on the nacelle.

Thus, there remains a need for cooler top designs that provide improved cooling capacity. More particularly, there is need for a cooler top design that is scalable in more than two dimensions to provide a still higher cooling capacity. An example of a prior art wind turbine cooling system can be found in <CIT>.

To these and other ends, a wind turbine a tower a nacelle rotatably coupled to the tower. The nacelle has a longitudinal axis configured to be aligned with the direction of the flow of the incoming wind during operation of the wind turbine. When the nacelle is so aligned, it defines a longitudinal direction, a traverse direction, and a vertical direction. The wind turbine includes one or more heat-generating components housed in the wind turbine and a modular cooler affixed to the nacelle and operatively coupled to the one or more heat-generating components for cooling the heat-generating components. The modular cooler comprising one or more cooling modules, where each cooling module including one or more cooling units. Each cooling unit further includes a heat exchanger defining a cooling area that defines a normal axis and a deflector plate to direct the incoming wind through the heat exchanger by diverting the flow of the incoming wind by an angle that is less than <NUM>° relative to the longitudinal direction. Each of the one or more cooling units of the modular cooler is oriented such that the normal axis of the heat exchanger is non-parallel to the longitudinal axis of the nacelle.

In one embodiment, the deflector plate defines a plane forming an angle with the longitudinal direction that is less than <NUM>°.

In one embodiment, the one or more cooling modules may include a plurality of cooling units arranged adjacent each other along at least one of the longitudinal direction, traverse direction, and vertical direction. In these embodiments, the cooling units form building blocks that allow the modular cooler to be scaled in multiple directions, i.e., in the longitudinal direction, traverse direction, and vertical direction. In another embodiment, the modular cooler may include a plurality of cooling modules arranged adjacent each other along at least one of the longitudinal direction, traverse direction, and vertical direction. In these embodiments, the cooling modules form building blocks that allow the modular cooler to be scaled in multiple directions, i.e., in the longitudinal direction, traverse direction, and vertical direction.

In an embodiment, the heat exchanger may include one or more heat transfer panels. In one aspect of this embodiment, the heat exchanger includes a plurality of heat transfer panels arranged adjacent each other in the longitudinal direction of the nacelle and the deflector plate is positioned relative to the heat exchanger such that the incoming wind is directed to each of the plurality of heat transfer panels.

In one embodiment, the heat exchanger is oriented such that the normal axis is substantially parallel to the vertical direction. In another embodiment, the heat exchanger is oriented such that the normal axis is substantially parallel to the transverse direction.

In one embodiment, each cooling unit includes first and second side walls positioned at opposing ends of the deflector plate. The first and second side walls cooperate with the deflector plate to direct the incoming wind through the heat exchanger.

The invention also contemplates a method assembling a modular cooler on a nacelle of a wind turbine, where the nacelle has a longitudinal axis configured to be aligned with the direction of the flow of the incoming wind during operation of the wind turbine. When the nacelle is so aligned, it defines a longitudinal direction, a traverse direction, and a vertical direction. The method includes providing one or more cooling modules, where each cooling module includes one or more cooling units. Each cooling unit includes a heat exchanger having a cooling area that defines a normal axis and a deflector plate, which may define a plane. The method further includes attaching the one or more cooling modules to the nacelle in an orientation such that the normal axis of the heat exchanger of the one or more cooling units is non-parallel to the longitudinal axis of the nacelle. The method further includes positioning the deflector plate relative to the heat exchanger of the one or more cooling units such that the flow of the incoming wind is diverted by an angle that is less than <NUM>° relative to the longitudinal direction to thereby direct the flow of the incoming wind through the heat exchanger.

In one aspect, the one or more cooling modules includes a plurality of cooling units and the step of attaching the one or more cooling units includes arranging the plurality of cooling units adjacent each other in a direction along at least one of the longitudinal direction, traverse direction, and vertical direction. For example, the cooling units may be arranged adjacent to each other in only the longitudinal direction, in both the longitudinal and traverse directions, or in the longitudinal, traverse, and vertical directions, or in any combination of the three directions.

In another aspect, the modular cooler includes a plurality of cooling modules and the step of attaching the one or more cooling modules includes arranging the plurality of cooling modules adjacent each other along at least one of the longitudinal direction, traverse direction, and vertical direction. For example, the cooling modules may be arranged adjacent to each other in only the longitudinal direction, in both the longitudinal and traverse directions, or in the longitudinal, traverse, and vertical directions, or in any combination of the three directions.

In one embodiment, the heat exchanger includes a plurality of heat transfer panels and the step of attaching the one or more cooling modules includes arranging the plurality of heat transfer panels adjacent each other in the longitudinal direction of the nacelle and the step of positioning the deflector plate includes positioning the deflector plate relative to the heat exchanger such that the incoming wind is directed to each of the plurality of heat transfer panels.

In one embodiment, the step of attaching the one or more cooling modules includes orienting the heat exchanger such that the normal axis is substantially parallel to the vertical direction. In another embodiment, the step of attaching the one or more cooling modules includes orienting the heat exchanger such that the normal axis is substantially parallel to the transverse direction.

In one embodiment, the method further includes positioning first and second side walls at opposing ends of the deflector plate, wherein the first and second side walls cooperate with the deflector plate to direct incoming wind through the heat exchanger.

Another embodiment is directed to a modular cooler for a nacelle of a wind turbine, where the nacelle has a longitudinal axis configured to be aligned with the direction of the flow of the incoming wind during operation of the wind turbine. When the nacelle is so aligned, it defines a longitudinal direction, a traverse direction, and a vertical direction. The modular cooler includes one or more cooling modules, where each cooling module includes one or more cooling units. Each cooling unit includes a heat exchanger having a cooling area defining normal axis and a deflector plate to direct the incoming wind through the heat exchanger during operation of the wind turbine by diverting the flow of the incoming wind by an angle that is less than <NUM>° relative to the longitudinal direction. Each of the one or more cooling units of the modular cooler is configured to be oriented such that the normal axis of the heat exchanger is non-parallel to the longitudinal axis of the nacelle when the modular cooler is affixed to the nacelle.

In one embodiment the one or more cooling modules includes a plurality of cooling units configured to be arranged adjacent each other along at least one of the longitudinal direction, traverse direction, and vertical direction. In another embodiment, the modular cooler includes a plurality of cooling modules configured to be arranged adjacent each other along at least one of the longitudinal direction, traverse direction, and vertical direction.

In one aspect, the heat exchanger includes a plurality of heat transfer panels configured to be arranged adjacent each other in the longitudinal direction of the nacelle. In another aspect, the heat exchanger is configured to be oriented such that the normal axis is substantially parallel to the vertical direction or the transverse direction.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.

With reference to <FIG>, a wind turbine <NUM> includes a tower <NUM>, a nacelle <NUM> disposed at the apex of the tower <NUM>, and a rotor <NUM> operatively coupled to a generator (not shown) housed inside the nacelle, and a gearbox (not shown) also housed inside the nacelle <NUM>. In addition to the generator and gearbox, the nacelle <NUM> may house various components needed to convert wind energy into electrical energy and to operate and optimize the performance of the wind turbine <NUM>. The tower <NUM> supports the load presented by the nacelle <NUM>, rotor <NUM>, and other wind turbine components housed inside the nacelle <NUM> and operates to elevate the nacelle <NUM> and rotor <NUM> to a height above ground level or sea level, as may be the case, at which air currents having lower turbulence and higher velocity are typically found. The nacelle <NUM> has a longitudinal axis LA that is configured to be aligned with the direction of the flow of the incoming wind during the operation of the wind turbine.

When longitudinal axis (LA) is so aligned, the nacelle defines a longitudinal direction (X), a transverse direction (Y), and a vertical direction (Z) as illustrated in <FIG>.

The rotor <NUM> may include a central hub <NUM> and a plurality of blades <NUM> attached to the central hub <NUM> at locations distributed about the circumference of the central hub <NUM>. In the representative embodiment, the rotor <NUM> includes three blades <NUM>, however the number may vary. The blades <NUM>, which project radially outward from the central hub <NUM>, are configured to interact with passing air currents to produce rotational forces that cause the central hub <NUM> to spin about its longitudinal axis. The design, construction, and operation of the blades <NUM> are familiar to a person having ordinary skill in the art of wind turbine design and may include additional functional aspects to optimize performance. For example, pitch angle control of the blades <NUM> may be implemented by a pitch control mechanism (not shown) responsive to wind velocity to optimize power production in low wind conditions, and to feather the blades if wind velocity exceeds design limitations.

The rotor <NUM> may be coupled to the gearbox directly or, as shown, indirectly via by a drive shaft (not shown). Either way, the gearbox transfers the rotation of the rotor <NUM> through a coupling (not shown) to the generator. Wind exceeding a minimum level may activate the rotor <NUM>, causing the rotor <NUM> to rotate in a direction substantially perpendicular to the wind, applying torque to the input shaft of the generator. The electrical power produced by the generator may be supplied to a power grid (not shown) or an energy storage system (not shown) for later release to the grid as understood by a person having ordinary skill in the art. In this way, the kinetic energy of the wind may be harnessed by the wind turbine <NUM> for power generation.

The generator, gearbox, and possibly other components housed in the nacelle <NUM> generate a significant amount of heat during operation of the wind turbine <NUM>. The generator, gearbox, and other components in the nacelle <NUM> may be characterized as heat-generating components <NUM> (<FIG>). To optimize or improve operation of the wind turbine <NUM>, the heat produced by these heat-generating components <NUM> must be properly managed and exhausted to the external environment. To this end, the wind turbine <NUM> may include a cooling system for transferring the heat from the heat-generating components <NUM> to the external environment. In a typical arrangement, the cooling system includes a thermal circuit having a pump that circulates a working fluid, such as water or other suitable refrigerant, through conduit lines between the heat-generating components <NUM> in the nacelle <NUM>, tower <NUM>, or other portion of the wind turbine <NUM>, and a heat-exchanging cooler <NUM>. The cooler <NUM> is positioned external to the nacelle <NUM> and is typically mounted to a surface of the nacelle <NUM>, such as the roof <NUM> of the nacelle <NUM> or one or more sidewalls of the nacelle <NUM> (not shown). In various alternative embodiments, the cooler <NUM> may be located at other positions of the wind turbine <NUM>, such as on the tower <NUM>. In any event, the cooler <NUM> is exposed to an external air flow that may be used to achieve a cooling effect.

In use, the cooling system is arranged to provide the working fluid to the heat-generating components <NUM> where the working fluid picks up or absorbs heat from the heat-generating components <NUM>. One or more heat exchangers may be provided to efficiently transfer heat from the heat generating components <NUM> in the wind turbine <NUM> to the working fluid of the cooling system. The pump of the cooling system then directs the heated working fluid to the cooler <NUM>. As noted above, the cooler <NUM> is typically positioned external to the nacelle <NUM> behind the rotor <NUM> and is subject to an air flow through the cooler <NUM>. The passage of the air through the cooler <NUM> causes the heat in the working fluid to transfer to the external air, thus cooling the working fluid. The now cooled working fluid is then directed back to the heat-generating components <NUM> in the nacelle <NUM> under the direction of the pump and the cycle is repeated. The cooling system essentially transfers heat from the heat-generating components <NUM> and immediate environment (e.g., inside the nacelle <NUM>) to the external environment in order to maintain the operating temperature of the wind turbine components at a suitable level that provides efficient operation of the wind turbine <NUM>.

With reference to <FIG>, the cooler <NUM> has two cooling modules <NUM> located next to each other on the roof <NUM> of the nacelle <NUM> with the cooling modules <NUM> extending across the width of the nacelle <NUM>. In other words, the two cooling modules <NUM> are arranged adjacent to each other in a direction substantially perpendicular to the longitudinal axis LA of the nacelle <NUM>, i.e., arranged horizontally adjacent to each other. The two cooling modules <NUM> are largely the same in their construction and both are coupled to the cooling system of the wind turbine <NUM>. Advantageously, if less cooling capacity is needed for a particular wind turbine, a single cooling module <NUM> may be located on the roof <NUM> of the nacelle <NUM> as illustrated in <FIG>. Similarly, if additional cooling capacity is needed for a particular wind turbine, the height of each cooling module <NUM> may be increased to include additional heat exchangers as illustrated in <FIG>. As shown in <FIG>, additional cooling units <NUM> are arranged adjacent to each other in a direction perpendicular to the longitudinal axis LA of the nacelle <NUM>. More specifically, <FIG> shows that the cooling units <NUM> are vertically stacked. As shown in <FIG> and for purposes of this description, the cooling module <NUM> has a width W, a length L, and a height H. The width W of the cooling module <NUM> extends generally in the same direction as the width of the nacelle <NUM>, i.e., side to side, and the length of the cooling module <NUM> extends generally in the same direction as the length of the nacelle <NUM>, i.e., front to back. The height H of the cooling module <NUM> extends generally in the same direction as the height of the nacelle <NUM>, i.e., bottom to top.

With reference to <FIG>, each cooling module <NUM> is comprised of at least one individual cooling unit <NUM> and preferably a plurality of individual cooling units <NUM>. The cooling module <NUM> in <FIG> is comprised of four individual cooling units <NUM> that are stacked vertically one on top of the other. As will be discussed below, the number of individual cooling units <NUM> used in each cooling module <NUM> may be dictated by the cooling capacity needed for a particular wind turbine. Heated working fluid enters the individual cooling units <NUM> via an inlet liquid manifold <NUM> and the cooled working fluid exits the individual cooling units <NUM> via and outlet liquid manifold <NUM>.

<FIG> is a disassembled view of the individual cooling unit <NUM> showing the main components of the individual cooling unit <NUM>. Specifically, the individual cooling unit <NUM> includes a heat exchanger <NUM> with a cooling area <NUM>, a deflector plate <NUM>, side walls <NUM>, support frames <NUM>, and fluid conduits <NUM>. The cooling area <NUM> defines a normal axis NA that is substantially perpendicular to the cooling area <NUM>. As used herein, the term "substantially perpendicular" means <NUM>±<NUM> degrees and more preferably <NUM>±<NUM> degree. The fluid conduits <NUM> may be operatively coupled to opposing ends of the heat exchanger at ports <NUM>. Each support frames <NUM> includes a fluid conduit support <NUM> for supporting one of the fluid conduits <NUM>. Each heat exchanger <NUM> is oriented substantially horizontally in the individual cooling unit <NUM> in the cooling module <NUM> such that the normal axis NA is substantially perpendicular to the longitudinal axis LA of the nacelle <NUM> (e.g., see <FIG>).

This horizontal orientation of the heat exchangers <NUM> is different from the vertical orientation of heat exchangers in traditional coolers mounted on the roof of a wind turbine where the cooling area of those heat exchangers directly faces the incoming wind. Because of the horizontal orientation of the heat exchangers <NUM>, the cooling area <NUM> does not directly face the incoming wind. For the cooling modules <NUM> in <FIG>, the cooling area <NUM> is substantially perpendicular to the incoming wind. Instead, the deflector plate <NUM> may be positioned relative to the heat exchange <NUM> to direct the incoming wind upwardly into the cooling area of the heat exchanger <NUM> by diverting the flow of the incoming wind by an angle θ that is less than <NUM>° relative to the longitudinal direction (X). That is, the deflector plate <NUM> may be tilted upwardly to deflect the incoming air into the bottom of the heat exchanger <NUM>. Alternatively, the deflector plate <NUM> may be tilted downwardly to deflect the incoming air into the top of the heat exchanger <NUM>. In any event, the deflector plate <NUM> defines a plane that may be non-parallel to the longitudinal axis LA of the nacelle <NUM>. The cooling unit <NUM> is oriented such that the normal axis NA of the heat exchanger is non-parallel to the longitudinal axis LA of the nacelle <NUM>.

The support frames <NUM> are configured to be stacked so that individual cooling units <NUM> may be arranged one on top of the other. To that end, each support frame <NUM> includes an insertion end <NUM> at the bottom of the support frame <NUM> that is dimensioned to be slid into a receiver end <NUM> at the top of the support frame <NUM>. Thus, when an additional individual cooling unit <NUM> is to be stacked on top of an existing individual cooling unit <NUM>, the insertion ends <NUM> on the additional individual cooling unit <NUM> are slid into the receiver ends <NUM> on the existing individual cooling unit <NUM>. Accordingly, in one aspect of the invention, the cooler <NUM> has a modular design with one or more cooling modules <NUM> and each module <NUM> including one or more cooling units <NUM>. The cooling modules <NUM> are designed to have additional cooling units <NUM> incorporated into the cooling modules <NUM> in a relatively straightforward manner in order to increase the cooling capacity of the cooler <NUM>.

<FIG>, <FIG>, and <FIG> schematically illustrate different flow paths for the working fluid to enter and exit the cooling module <NUM> with four individual cooling units <NUM>. In <FIG>, the working fluid flows upward through the inlet liquid manifold <NUM>, into and through each of the four heat exchangers <NUM> in the respective individual cooling units <NUM>, and flows downward through outlet liquid manifold <NUM>. The flow path illustrated in <FIG> correspondence to the flow path of the cooling module <NUM> in <FIG> where the inlet liquid manifold <NUM> and the outlet liquid manifold <NUM> are located at opposing sides of the cooling module <NUM>. This arrangement may be referred to as a single pass system because the working fluid flows through each heat exchanger <NUM> only one time.

<FIG> illustrates an alternate flow path through the cooling module <NUM> with four individual cooling units <NUM>. For the purpose of explaining <FIG>, the bottom most heat exchanger <NUM> in the bottom most individual cooling unit <NUM> will be referred to as heat exchanger one 40a and each subsequently higher heat exchanger will be referred to as heat exchanger two 40b, three 40c, and four 40d. In this embodiment, both the inlet liquid manifold <NUM> and the outlet liquid manifold <NUM> are located on the same side of the cooling module <NUM>, which may provide a more compact cooling module <NUM> compared to the cooling module <NUM> in <FIG>. The working fluid flows upward through the inlet liquid manifold <NUM>, into heat exchanger two 40b and heat exchanger four 40d. The working fluid flows out of heat exchanger two 40b, through a connecting conduit <NUM>, into heat exchanger one 40a, and flows downward through outlet liquid manifold <NUM>. Similarly, the working fluid flows out of heat exchanger four 40d, through a connecting conduit <NUM>, into heat exchanger three 40c, and flows downward through outlet liquid manifold <NUM>. This arrangement may be referred to as a dual pass system because the working fluid flows through two heat exchanger pairs, e.g., 40c, 40d, before the working fluid flows out through the outlet liquid manifold <NUM>.

<FIG> illustrates yet another alternate flow path through the cooling module <NUM> with four cooling units <NUM>. The naming convention of the heat exchangers 40a-40d in <FIG> will follow that used for the heat exchangers 40a-40d in <FIG>. In this embodiment, both the inlet liquid manifold <NUM> and the outlet liquid manifold <NUM> are located on the same side of the cooling module <NUM>, like in <FIG>. The working fluid flows upward through the inlet liquid manifold <NUM>, into heat exchangers one and two 40a, 40b, into a connecting manifold <NUM>, into and through heat exchangers three and four 40c, 40d, and then flows downward through outlet liquid manifold <NUM>. Like <FIG>, this arrangement may be referred to as a dual pass system as the working fluid flows through at least two heat exchangers 40a-40d before the working fluid flows out through the outlet liquid manifold <NUM>. While <FIG> illustrate various exemplary flow paths of the working fluid through the cooling module <NUM>, it should be recognized that there may be other flow path arrangements through the cooling module <NUM> that sufficiently cool the working fluid. Thus, aspects of the invention should not be limited to any particular flow path arrangement through the cooling module <NUM>.

Other working fluid flow paths through the heat exchangers 40a-40d may be implemented to optimize the efficiency of the cooler <NUM>. One consideration to improve efficiency is to connect the heat exchanger that experiences the highest air flow therethrough (likely the highest heat exchanger (40d) in the cooling module <NUM>) with the heat exchanger that experiences the lowest air flow therethrough (likely the lowest heat exchanger (40a) in the cooling module). For example, this suggests connecting heat exchangers 40d and 40a and connecting heat exchangers 40c and 40b. This would be another dual pass configuration. Other flow paths, such as parallel flow, counter flow, and cross flow, may also be used to optimize heat transfer.

<FIG> schematically illustrates the air flowing through the heat exchangers <NUM> of the cooling module <NUM>. Only the heat exchangers <NUM> and the deflector plates <NUM> are illustrated to provide a clear view of air flow path. As shown, the deflector plates <NUM> help deflect/direct the incoming wind upwards and into the bottom side of the heat exchangers <NUM> and out the top side of the heat exchangers <NUM>. The deflector plate <NUM> above the heat exchanger <NUM> helps to deflect/direct the wind rearward and out of the cooling module <NUM>. The upper most heat exchanger <NUM> does not have a deflector plate <NUM> above it so the air through that heat exchanger <NUM> departs with a more vertical velocity component compared to the air flow from the other heat exchangers <NUM>.

As noted above, the cooling modules <NUM> are made up of individual cooling units <NUM>.

To alter the cooling capacity of a cooling module <NUM>, the number of individual cooling units <NUM> can be decreased or increased. For example, each of the cooling modules <NUM> in <FIG> have four individual cooling units <NUM>. To increase the cooling capacity of those cooling modules <NUM>, two additional individual cooling units <NUM>, for example, may be added as shown in <FIG>. As such the height of the cooling modules <NUM> has increased. Thus, the cooling modules <NUM> are scalable in the height direction to increase the cooling capacity of the cooler <NUM>.

Another approach to scaling in the height direction is to keep the overall height of the cooling module <NUM> the same but add or remove individual cooling units <NUM> from the cooling module <NUM>. For example, <FIG> illustrates the cooling module <NUM> with the height H shown in <FIG> with four individual cooling units <NUM> equally spaced apart along the height H. <FIG>, however, illustrates the cooling module <NUM> with the same height H with only three individual cooling units <NUM>, also equally spaced apart along the height H. The individual cooling units <NUM> are spaced farther apart in <FIG> compared to the spacing of the individual cooling units <NUM> in <FIG>. To accommodate the greater spacing of the individual cooling units <NUM> in <FIG>, the deflector plate <NUM> is longer and inclined greater to the horizon than the deflector plate <NUM> in <FIG> illustrates the cooling module <NUM> with the height H and with six individual cooling units <NUM> equally spaced apart along the height H. The individual cooling units <NUM> are spaced closer together than the individual cooling units <NUM> in <FIG>. To accommodate that closer spacing, the deflector plate <NUM> is shorter and inclined less to the horizon than the deflector plate <NUM> in <FIG>.

In addition, the overall cooling capacity of the wind turbine's cooling system may increase or decrease by adding or removing cooling modules across the width of the nacelle <NUM>. In <FIG>, for example, two cooling modules <NUM> are aligned across the width of the nacelle <NUM>. In <FIG>, however, only one cooling module <NUM> is present, so the cooling capacity for the wind turbine is reduced compared to the arrangement in <FIG>. Thus, the cooling modules <NUM> are scalable in the width direction to increase the cooling capacity of the cooler <NUM>.

A second embodiment of a cooling module <NUM> is illustrated in <FIG>. The cooling module <NUM> is similar to the cooling module <NUM> describe above, but with some differences. For example, in the description above the individual cooling unit <NUM>, which makes up the cooling module <NUM>, has a single heat exchanger <NUM> and when the individual cooling units <NUM> are stacked on top of each other, they form a single, vertical column of heat exchangers <NUM>, see, e.g., <FIG> and <FIG>. In contrast, the cooling module <NUM> has one or more individual cooling units <NUM> with each cooling unit <NUM> having one heat exchanger <NUM>, but that heat exchanger <NUM> has two heat transfer panels 75a, 75b arranged adjacent to each other in a direction substantially parallel to the longitudinal axis LA of the nacelle <NUM> (e.g., substantially parallel to the incoming wind). As used herein, the term "substantially parallel" means <NUM>±<NUM> degrees and more preferably <NUM>±<NUM> degree. When the individual cooling units <NUM> are stacked on top of each other, they form two, vertical columns of heat transfer panels 75a, 75b. Thus, cooling module <NUM> (<FIG> and <FIG>) may be considered a single-column configuration whereas the cooling module <NUM> (<FIG>) may be considered a dual-column configuration. While the individual cooling unit <NUM> includes two heat transfer panels 75a, 75b, it has a single deflector plate <NUM> extending from the front to the rear of the individual cooling unit <NUM> and is positioned relative to the heat exchanger <NUM> such that the incoming wind is directed to each of the heat transfer panels 75a, 75b. Finally, each heat transfer panel 75a, 75b is connected to a respective inlet liquid manifolds 78a, 78b located at one end of the cooling module <NUM> and respective outlet liquid manifolds (not shown) on the other end of the cooling module <NUM> similar to working fluid flow path used on the cooling module <NUM> in <FIG> and <FIG>. The inlet liquid manifolds 78a, 78b and the outlet liquid manifolds may also be configured to match the working fluid path illustrated in <FIG> and <FIG>, for example.

As discussed above with respect to <FIG>, the number of individual cooling units <NUM> in a cooling module <NUM> of a given height H may vary. The cooling module <NUM> in <FIG> has four, equally spaced apart individual cooling units <NUM>. <FIG> illustrates the cooling module <NUM> with the same height H with only three individual cooling units <NUM>, also equally spaced apart along the height H. The individual cooling units <NUM> in <FIG> are space farther apart compared to the individual cooling units in <FIG> illustrates the cooling module <NUM> with the height H and with six individual cooling units <NUM> equally spaced apart along the height H. The individual cooling units <NUM> are spaced closer together than the individual cooling units <NUM> in <FIG>. Alternatively, the height of the cooling module <NUM> may be increased with an increasing number of cooling units <NUM>. These figures demonstrate that the cooling modules <NUM> are scalable in the length direction to increase the cooling capacity of the cooler <NUM>.

<FIG> is a top view illustrating another embodiment of a cooling module <NUM> with individual cooling units <NUM>, each with a heat exchanger <NUM> and a deflector plate <NUM>. The cooling module <NUM> is similar in construction to the cooling module <NUM> illustrated in <FIG> and <FIG>, for example. The cooling module <NUM> is essentially the cooling module <NUM> laid over on its side. As such, each heat exchanger <NUM> is oriented substantially vertically such that the normal axis NA of the heat exchanger <NUM> is substantially perpendicular to the longitudinal axis LA of the nacelle <NUM>. Consequently, like heat exchangers <NUM>, the cooling areas of heat exchangers <NUM> do not directly face the incoming wind. More specifically, the heat exchangers <NUM> in <FIG> are oriented such that the normal axes NA of the heat exchangers <NUM> are substantially perpendicular to the incoming wind. To account for this, a deflector plate <NUM> directs the incoming wind into the heat exchangers <NUM>, thereby moving the incoming wind laterally through the heat exchangers <NUM> instead of upwardly like the deflector plates <NUM> in cooling module <NUM>. The deflector plates <NUM> of the cooling module <NUM> may be configured to direct the incoming wind laterally through either side of the heat exchangers <NUM>.

Like the cooling module <NUM>, cooling module <NUM> may be modified to adjust its cooling capacity as required by the particular wind turbine. In one example, one cooling module <NUM> may be placed/stacked vertically atop the existing cooling module <NUM>. In another example, the cooling module <NUM> may be made wider by adding additional individual cooling units <NUM> as shown in <FIG>. As illustrated in <FIG>, the cooling module <NUM> is a dual column configuration similar to the cooling module <NUM> in <FIG>. In <FIG>, the cooling module <NUM> includes eight cooling units <NUM> with each cooling unit having a heat exchanger <NUM> where each heat exchanger <NUM> has two heat transfer panels 106a, 106b in two columns. While the individual cooling units <NUM> include two transfer panels 106a, 106b, it has a single deflector plate <NUM> extending from the front to the rear of the individual cooling unit <NUM>. Thus, with the heat exchanger <NUM> in a substantially vertical orientation, the cooler <NUM> remains scalable in multiple dimensions, i.e., the width, height, and length directions of the cooler <NUM>.

The majority of the description above and the associated figures describe and illustrate the concept of adjusting the cooling capacity of the wind turbine by adding or subtracting one or more cooling modules <NUM>, <NUM>, <NUM>, <NUM> or adding or subtracting cooling units <NUM> to a particular cooling module <NUM>. Aspects of the invention are not so limited. In this regard, aspects of the present invention also contemplate constructing the cooler <NUM> out of cooling units <NUM> without forming multiple individual cooling modules. That is, the cooling capacity may be calculated for a particular wind turbine and individual cooling units may be installed on the nacelle <NUM> to provide the required cooling capacity. For example, cooling units may be installed one on top of another so as to extend vertically away from the roof of the nacelle. The cooling units may be installed side-by-side extending across the width of the nacelle. Finally, the cooling units may be installed in a direction aligned with the longitudinal axis of the nacelle. The cooling units may also be installed in two or three directions in the same installation. For example, at one wind turbine, a first plurality of cooling units may be stacked (vertical scaling) to create a first column of cooling units. Then a second column of cooling units may be positioned directly adjacent to the first column of cooling units such that the cooler extends across the width of the nacelle (horizontal scaling). In other words, the cooler <NUM> is scalable in three directions through arrangement (and suitable interconnections) of cooling units <NUM>. Thus, the cooling units <NUM> are essentially building blocks for forming the overall cooler <NUM>.

<FIG> illustrate the concept of scaling by varying the number cooling units in different directions. <FIG> is a plan view of the nacelle <NUM> with two cooling units <NUM> extending across the width of the nacelle <NUM>. If additional cooling capacity is required, an additional cooling unit <NUM> may be added along the width of the nacelle <NUM>. <FIG> is an elevational view of the nacelle <NUM> with three cooling units <NUM> stacked one on top of the other. If additional cooling capacity is required, an additional cooling unit <NUM> may be added atop the other three cooling units <NUM> in a vertical direction. Similarly, <FIG> is an elevation view of the nacelle <NUM> with two stacks of cooling units <NUM> extending in a direction aligned with the longitudinal axis LA of the nacelle <NUM>. In <FIG>, the bottom, left most heat exchanger <NUM> and deflector plate <NUM> are absent because that heat exchanger <NUM> would receive little if any airflow in that position. Instead, that space may be used to place equipment, such as pumps, piping, and manifolds. Again, if additional cooling capacity is required, an additional stack of cooling units <NUM> may be added in front of the other two stacks of cooling units <NUM> so that the cooler <NUM> expands in a direction aligned with the longitudinal axis LA of the nacelle <NUM>. As mentioned above, the additional cooling units <NUM> may be added in multiple directions. For example, the cooler <NUM> may be constructed from cooling units <NUM> arranged according to a combination of <FIG> and <FIG>, a combination of <FIG> and <FIG>, or any other combination, including a combination of <FIG>, <FIG>.

<FIG> illustrates the cooling module <NUM> with the heat exchangers <NUM> oriented differently from the orientation of the heat exchangers <NUM> discussed above. In <FIG>, the heat exchangers <NUM> are positioned between and oriented perpendicular to the adjacent deflector plates <NUM>. Such an arrangement will maximize the velocity of the air flow through the heat exchangers <NUM>.

<FIG> schematically illustrates another embodiment of the cooler with the air flowing through the heat exchangers <NUM> of the cooling module <NUM>. Only the heat exchangers <NUM> and the deflector plates <NUM> are illustrated to provide a clear view of air flow path. As shown, the deflector plates <NUM> help deflect/direct the incoming wind downwards and into the top side of the heat exchangers <NUM> and out the bottom side of the heat exchangers <NUM>. The deflector plate <NUM> below the heat exchanger <NUM> helps to deflect/direct the wind rearward and out of the cooling module <NUM>. The uppermost cooling unit <NUM> have a deflector plate <NUM> above it to capture air above the uppermost heat exchanger <NUM> and direct it downwards into the top of the heat exchanger <NUM> in the uppermost cooling unit. The space below the lowermost heat exchanger <NUM> is occupied by a deflector plate <NUM>. The space in front of the lowermost deflector plate <NUM> in the lowermost cooling unit <NUM> may be utilized for equipment, piping, manifolds, valves, or other relevant equipment (not shown).

Due to the shape of the nacelle at the rear, there may be an area of lower pressure immediately behind the nacelle. This will have a positive effect on the air flow through the cooling module <NUM>, as this will keep up the velocity of the air through the heat exchanger <NUM> and thereby the volume of air flowing through. Thereby the cooling capacity may increase. This will especially affect the lower cooling units <NUM> closer to the nacelle <NUM>.

Claim 1:
A wind turbine (<NUM>), comprising:
a tower (<NUM>);
a nacelle (<NUM>) rotatably coupled to the tower (<NUM>) and having a longitudinal axis (LA) configured to be aligned with the direction of the flow of the incoming wind during operation of the wind turbine (<NUM>), wherein when so aligned, the nacelle defines a longitudinal direction (X), a traverse direction (Y), and a vertical direction (Z);
one or more heat-generating components (<NUM>) housed in the wind turbine (<NUM>); and
a modular cooler (<NUM>) affixed to the nacelle (<NUM>) and operatively coupled to the one or more heat-generating components (<NUM>) for cooling the heat-generating components (<NUM>), the modular cooler (<NUM>) comprising one or more cooling modules (<NUM>), each cooling module (<NUM>) including one or more cooling units (<NUM>), each cooling unit (<NUM>) further comprising:
a heat exchanger (<NUM>) defining a cooling area (<NUM>), the cooling area (<NUM>) defining a normal axis (NA); and
a deflector plate (<NUM>) to direct the incoming wind through the heat exchanger (<NUM>) by diverting the flow of the incoming wind by an angle that is less than <NUM>° relative to the longitudinal direction (X),
wherein each of the one or more cooling units (<NUM>) of the modular cooler (<NUM>) is oriented such that the normal axis (NA) of the heat exchanger (<NUM>) is non-parallel to the longitudinal axis (LA) of the nacelle (<NUM>).