Patent ID: 12228106

DETAILED DESCRIPTION

With reference toFIGS.1and2, a wind turbine10includes a tower12, a nacelle14disposed at the apex of the tower12, and a rotor16operatively coupled to a generator18via a gearbox20housed inside the nacelle14. In addition to the generator18and gearbox20, the nacelle14may house various components needed to convert wind energy into electrical energy and to operate and optimize the performance of the wind turbine10. The tower12supports the load presented by the nacelle14, rotor16, and other wind turbine components housed inside the nacelle14and operates to elevate the nacelle14and rotor16to 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 rotor16may include a central hub22and a plurality of blades24attached to the central hub22at locations distributed about the circumference of the central hub22. In the representative embodiment, the rotor16includes three blades24, however the number may vary. The blades24, which project radially outward from the central hub22, are configured to interact with passing air currents to produce rotational forces that cause the central hub22to spin about its longitudinal axis. The design, construction, and operation of the blades24are 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 blades24may 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 rotor16may be coupled to the gearbox20directly or, as shown, indirectly via a main shaft extending between the hub22and the gearbox20. The main shaft rotates with the rotor16and is supported within the nacelle14by a main bearing support28which supports the weight of the rotor16and transfers the loads on the rotor16to the tower12. The gearbox20transfers the rotation of the rotor16through a coupling to the generator18. Wind exceeding a minimum level may activate the rotor16, causing the rotor16to rotate in a direction substantially perpendicular to the wind, applying torque to the input shaft of the generator18. The electrical power produced by the generator18may 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 turbine10for power generation.

FIGS.3A and3Billustrate a transport system, generally shown at30, in accordance with one embodiment of the invention for transporting a nacelle14along a network of roads. In an exemplary embodiment, the transport system30may take the form of a tractor trailer having a tractor32and a trailer configured to carry the nacelle14in in a manner described in more detail below. The trailer has a two-part design including a front carrier36and a rear carrier38. The front carrier36includes a fixed frame40, a movable frame42, and a front attachment interface44associated with the movable frame42. The fixed frame40is mountable to the tractor32at a front end thereof by conventional means, and further includes a plurality of wheels46rotatably mounted thereto for supporting at least a portion of the weight of the nacelle14on the road48.

The movable frame42includes a front end movably coupled to the fixed frame40. For example, the movable frame42may be pivotally coupled to the fixed frame40, such as along a pivot axis (e.g., into the page). In this way, the movable frame42may rotate about the pivot axis between a lowered position, wherein a rear end of movable frame42is adjacent the road48, and a raised position, wherein the rear end of movable frame42has been raised generally vertically with respect to the road48.

To facilitate the movement of movable frame42relative to the fixed frame40, the front carrier36may include a first or primary lift actuator56having a front end pivotally coupled to the fixed frame40, and a rear end that terminates in an attachment element62. The primary lift actuator56is capable of moving between a collapsed position and an extended position when actuated. The primary lift actuator56may take the form of an electric actuator, a hydraulic actuator, a pneumatic actuator, or other types of actuators suitable for the present purposes as known to those of ordinary skill in the art. The front carrier36may further include a secondary lift actuator (not shown) to facilitate movement of the movable frame42relative to the fixed frame40. The secondary lift actuator may be coupled to the movable frame42and is similarly configured to move between a collapsed position and an extended position when actuated. The rear end of the movable frame42may include one or more attachment elements66. The attachment elements62,66collectively form the front attachment interface44. Such carriers36and movable frames42are generally known by those of ordinary skill in the art and a further description will not be provided herein.

The rear carrier38has a similar construction and includes a fixed frame70, a movable frame72, and a rear attachment interface74associated with the movable frame72. The fixed frame70includes a plurality of wheels46rotatably mounted thereto for supporting at least a portion of the weight of the nacelle14on the road48. The movable frame72includes a rear end movably coupled to the fixed frame70. For example, the movable frame72may be pivotally coupled to the fixed frame70, such as along a pivot axis (e.g., into the page). In this way, the movable frame72may rotate about the pivot axis between a lowered position, wherein a front end of movable frame72is adjacent the road48, and a raised position, wherein the front end of movable frame72has been raised generally vertically with respect to the road48.

To facilitate the movement of movable frame72relative to the fixed frame70, the rear carrier38may include a first or primary lift actuator82, similar to actuator56, having a rear end pivotally coupled to the fixed frame70and a front end that terminates in an attachment element88. The primary lift actuator82is capable of moving between a collapsed position and an extended position when actuated. The rear carrier38may further include a secondary lift actuator (not shown) to facilitate movement of the movable frame72relative to the fixed frame70. The secondary lift actuator is coupled to the movable frame72and is similarly configured to move between a collapsed position and an extended position when actuated. The front end of the movable frame72may include one or more attachment elements92. The attachment elements88,92collectively form the rear attachment interface74. Such carriers38and movable frames72are generally known by those of ordinary skill in the art and a further description will not be provided herein.

As illustrated inFIGS.3A and3B, the attachment interfaces44,74of the front and rear carriers36,38are configured to be connected to the front and rear ends96,98of the nacelle14, respectively. To facilitate this connection, the transport system30includes a front transport frame100and a rear transport frame102. The front transport frame100is configured to connect to the front end96of the nacelle14and to connect to the attachment interface44associated with the front carrier36of the transport system30. Similarly, the rear transport frame102is configured to connect to the rear end98of the nacelle14and to connect to the attachment interface74associated with the rear carrier38of the transport system30. In an advantageous aspect of the invention, the transport frames100and102are configured to have a multi-dedicated, modular design. More particularly, the transport frames100,102are configured to be nearly identical to each other such that the same transport frame may be interchangeably used on either the front end96of the nacelle14or the rear end98of the nacelle14. Accordingly, a field technician does not have to worry about whether a particular transport frame is attached to the proper end of the nacelle14. Additionally, and perhaps more germane to the present disclosure, the transfer frames100,102are configured to be connectable to nacelles having different sizes. These two above-identified features allow manufacturers and transporters of wind turbine components, such as wind turbine nacelles, to maintain and store an inventory of only one type of transport frame. Furthermore, the transport frames100,102are configured to have a compact design when not in use for transporting a nacelle. This allows efficient storage of the transport frames not only during time periods when the frames are not in use at the manufacturing facility, but also during the return transport of the frames from the installation site back to the manufacturing facility. The transport frames will now be described in further detail.

As noted above, the front and rear transport frames100,102are nearly identical to each other. Accordingly, only the front transport frame100will be described in detail. It should be understood, however, that the rear transport frame102has a similar construction and description. Any differences between the front and rear transport frames100,102will be noted. As illustrated inFIGS.4and5, the transport frame100has a multi-sectional design including a bottom frame section104, an intermediate frame section106, and a top frame section108coupled to each other to form the transport frame100. While in an exemplary embodiment the transport frame100may include three frame sections, it should be realized that the transport frame100may be comprised of more or less frame sections and remain within the scope of the present disclosure.

The bottom frame section104includes a base support110, which in an exemplary embodiment may take the form of a generally rectangular base plate, configured to support the transport frame100on the ground or other support surface. Two generally vertical and spaced apart main beams112,114extend from an upper surface116of the base support110with each terminating at an upper connecting end118. In an exemplary embodiment, the main beams112,114may be formed from generally rectangular tubular steel beam stock. However, other types, materials, and configurations of the main beams112,114may also be possible. The base support110further includes a lower cross beam120that extends between and beyond the main beams112,114and which is generally parallel to the base support110. In an exemplary embodiment, the lower cross beam120may be formed from a generally square or rectangular tubular steel beam stock. However, other types, materials, and configurations of the lower cross beam120may be possible. In one embodiment, the lower cross beam120is a monolithic beam section that extends through openings formed in the main beams112,114and is welded or otherwise secured to the main beams112,114. Alternatively, the lower cross beam120may be formed by three discrete sections which are arranged relative to the main beams112,114and secured thereto to form the lower cross beam120. In any event, the lower cross beam120includes an inboard cross beam section122between the two main beams112,114and a pair of outboard cross beam sections124,126on the outside of the main beams112,114.

The outboard cross beam sections124,126of the cross beam120includes lower nacelle mounts128,130configured to connect to lower nacelle tangs132(seeFIGS.6A and6B) on the nacelle14. The lower nacelle mounts128,130are substantially identical and only lower nacelle mount128will be described in detail. It should be understood, however, that nacelle mount130has a similar construction and description. In an exemplary embodiment, the lower nacelle mount128includes a plurality of mounting plates134spaced apart along the outboard cross beam section124and which define a series of mounting slots136between adjacent mounting plates134. As explained in more detail below, the mounting slots136are configured to receive a nacelle tang132therein and operate as attachment points for coupling to the nacelle14. The size of the nacelle14will dictate into which mounting slot136the nacelle tang132will be received. While three mounting plates134(and two mounting slots136) are shown, it should be recognized that additional mounting plates134and mounting slots136may be provided on each of the nacelle mounts128,130. In one embodiment, the mounting plates134have a trapezoidal shape with a square or rectangular opening138configured to receive the outboard cross beam section124therein. The mounting plates134may be formed from steel and can be welded or otherwise secured to the outboard cross beam section124. The wider end of the trapezoidal plates134may be arranged to confront the nacelle14and include a lower array of aligned openings140through the mounting plates134and an upper array of aligned openings142through the mounting plates134. As explained in more detail below, the upper and lower arrays of openings140,142are configured to receive respective pins144,146for locking and supporting the nacelle tang132to the nacelle mount128.

In addition to the above, the bottom frame section104includes a lower carrier interface148configured to connect to one of the carriers36,38of the transport system30described in detail above. In an exemplary embodiment, the lower carrier interface148includes a lower carrier interface plate150that extends between the main beams112,114and is positioned above the lower cross beam120. By way of example, the lower carrier interface plate150may abut the lower cross beam120. The lower carrier interface plate150may be formed from steel and be welded or otherwise secured to the main beams112,114and/or lower cross beam120. The position of the lower carrier interface plate150may be immediately adjacent the side of the main beams112,114that confronts the carrier36,38during transport. In one embodiment, an upper edge152of the carrier interface plate150may include a generally arcuate surface154for mating to the one or more attachment elements of the attachment interface44,74of the respective carriers36,38of the transport system30.

Furthermore, to provide additional strength and integrity to the bottom frame section104and to the transport frame100in general, the bottom frame section104may include one or more stiffening elements156. By way of example, a pair of stiffening plates156may be positioned between the inboard cross beam section122and the base support110to provide additional support to the lower cross beam120. Additionally, a number of gusset plates156(e.g., triangular gusset plates) may be coupled to the base support110and the main beams112,114; the base support110and the stiffening plates156beneath the inboard cross beam section122; and/or the lower carrier interface plate150and the inboard cross beam section122.

The intermediate frame section106includes two generally vertical and spaced apart main beams162,164with each terminating at a lower connecting end166and an upper connecting end168. In an exemplary embodiment, the main beams162,164may be formed from generally rectangular tubular steel beam stock similar to main beams112,114described above. However, other types, materials, and configurations of the main beams162,164may also be possible. The lower connecting ends166of the main beams162,164are configured to be coupled to the upper connecting ends118of the main beams112,114of the bottom frame section104. For reasons explained in more detail below, the main beams162,164of the intermediate frame section106may be coupled to the main beams112,114of the bottom frame section104by a hinged connection170. More particularly, the lower connecting end166of the main beams162,164are connected to the upper connecting ends118of the main beams112,114by a pivot172(defined by respective ears on the main beams112,114,162,164) that allows relative rotational movement between the intermediate frame section106and the bottom frame section104about hinge or pivot axis174. In one embodiment, the hinged connection170may be positioned on the side of the transport frame100that confronts the carriers36,38(i.e., in a direction away from the nacelle14when the transport frame100is coupled thereto) as illustrated in the figures.

The hinged connection170may further include one or more selectively engageable locks176. When the lock176is engaged, relative rotations between the intermediate frame section106and the bottom frame section104about pivot axis174are prohibited and the main beams112,114are firmly secured to main beams162,164, respectively. On the other hand, when the lock176is disengaged, relative rotations between the intermediate frame section106and the bottom frame section104about pivot axis174are permitted. As discussed in more detail below, this allows the transport frame100to be collapsed during periods of non-use. In one embodiment, the lock176may be positioned on the side of the transport frame100opposite to the pivot172(e.g., on the side that confronts the nacelle14) and on the outer side and/or the inner side of the main beams112,162and114,164. The locks176may be selectively engaged and disengaged manually, such as by a field technician or the like.

The top frame section108includes two generally vertical and spaced apart main beams180,182with each terminating at a lower connecting end184. In an exemplary embodiment, the main beams180,182may be formed from generally rectangular tubular steel beam stock similar to main beams112,114described above. However, other types, materials, and configurations of the main beams180,182may also be possible.

The lower connecting ends184of the main beams180,182are configured to be coupled to the upper connecting ends168of the main beams162,164of the intermediate frame section106. For reasons explained in more detail below, the main beams180,182of the top frame section108may be coupled to the main beams162,164of the intermediate frame section106by a hinged connection186. More particularly, the lower connecting end184of the main beams180,182are connected to the upper connecting ends168of the main beams162,164by a pivot188(defined by a pivot linkage coupled to the main beams162,164,180,182) that allows relative rotational movement between the top frame section108and the intermediate frame section106about hinge or pivot axes190. In one embodiment, the hinged connection186may be positioned on the side of the transport frame100that confronts the nacelle14(i.e., on the side opposite to the hinged connection170) as illustrated in the figures.

The hinged connection186may further include one or more selectively engageable locks192. When the lock192is engaged, relative rotations between the top frame section108and the intermediate frame section106about pivot axes190are prohibited and the main beams180,182are firmly secured to main beams162,164, respectively. On the other hand, when the lock192is disengaged, relative rotations between the top frame section108and the intermediate frame section106about pivot axes190are permitted. As discussed in more detail below, this allows the transport frame100to be collapsed during periods of non-use. In one embodiment, the lock192may be positioned on the side of the transport frame100opposite to the pivot188(e.g., on the side that confronts the carriers36,38) and on the outer side and/or inner side of the main beams162,180and164,182. The locks192may be selectively engaged and disengaged manually, such as by a field technician or the like.

The top frame section108further includes an upper cross beam194that extends between and beyond the main beams180,182and which is generally parallel to the base support110and lower cross beam120. In an exemplary embodiment, the upper cross beam194may be formed from a generally square or rectangular tubular steel beam stock. However, other types, materials, and configurations of the upper cross beam194may be possible. In one embodiment, the upper cross beam194is a monolithic beam section that extends through openings formed in the main beams180,182and are welded or otherwise secured to the main beams180,182. Alternatively, the upper cross beam194may be formed by three discrete sections which are arranged relative to the main beams180,182and secured thereto to form the upper cross beam194. In any event, the upper cross beam194includes an inboard cross beam section196between the two main beams180,182and a pair of outboard cross beam sections198,200on the outside of the main beams180,182.

The outboard cross beam sections198,200of the upper cross beam194includes attachment flanges202for selective mounting of upper nacelle mounts204,206configured to connect to upper nacelle tangs208(seeFIGS.8A-8C) on the nacelle14. By way of example, the upper nacelle mounts204,206may be coupled to attachment flanges202by fasteners such as bolts. Other types of connections, however, may also be possible. The upper nacelle mounts204,206are substantially identical and only mount204will be described in detail. It should be understood, however, that nacelle mount206has a similar construction and description. In an exemplary embodiment, the upper nacelle mount204includes a central beam210and a plurality of mounting plates212spaced apart along the central beam210and which define a series of mounting slots214between adjacent mounting plates212. As explained in more detail below, the mounting slots214are configured to receive a tie rod216for connecting to the upper nacelle tangs208and operate as attachment points for coupling to the nacelle14. The size of the nacelle14will dictate into which mounting slot214the tie rod216will be received. While three mounting plates212(and two mounting slots214) are shown, it should be recognized that additional mounting plates212and mounting slots214may be provided on each of the nacelle mounts204,206. In one embodiment, the mounting plates212have a pentagonal shape with a square or rectangular opening218configured to receive the central beam210therein and a tab220extending from one side. The mounting plates212may be formed from steel and can be welded or otherwise secured to the central beam210. In one embodiment, the tabs220of the mounting plates212may be arranged to extend upwardly from the central beam210and include an array of aligned openings222through the mounting plates212. As explained in more detail below, the array of openings222is configured to receive a pin224for locking and supporting the tie rod216to the upper nacelle mount204.

In addition to the above, the top frame section108includes an upper carrier interface configured to connect to one of the carriers36,38of the transport system30described in detail above. In an exemplary embodiment, the upper carrier interface is similar to the lower carrier interface148and includes an upper carrier interface plate that extends between the main beams180,182and is positioned below the upper cross beam194. By way of example, the upper carrier interface plate may abut the upper cross beam194. The upper carrier interface plate may be formed from steel and be welded or otherwise secured to the main beams180,182and/or upper cross beam194. The position of the upper carrier interface plate may be immediately adjacent the side of the main beams180,182that confronts the carrier36,38during transport. In one embodiment, a lower edge of the upper carrier interface plate may include a generally arcuate surface for mating to the one or more attachment elements of the attachment interface44,74of the respective carriers36,38of the transport system30.

Furthermore, to provide additional strength and integrity to the top frame section108and to the transport frame100in general, the top frame section108may include one or more stiffening elements156. By way of example, a pair of stiffening bars156may be positioned between the inboard cross beam section196and the main beams180,182to provide additional support to the upper cross beam194. Other stiffening elements (e.g., gusset plates, etc.) may also be used to strengthen the top frame section108.

With the transport frames100,102described as above, use of the transport frames for transporting a nacelle14will now be described in detail. As an initial step, the transport frames100,102may be assembled such that the bottom frame section104, intermediate frame section106and top frame section108are coupled together to form the assembled transport frames100,102. Next, the front transport frame100may be coupled to the front end96of the nacelle14and the rear transport frame102may be coupled to the rear end98of the nacelle14. Again, the front and rear transport frames100,102are substantially identical and are interchangeable between being coupled to the front or rear ends of the nacelle14. The coupling of the transport frames100,102to the nacelle14may be performed simultaneous or in a serial manner. In any event and in reference toFIGS.6A and6B, the lower nacelle tangs132are attached to and extend away from the front end96and rear end98of the nacelle14. In an exemplary embodiment, the lower nacelle tangs132include a lower slot236open to a lower edge of the tang132and an upper opening238. The support pin146may be positioned in the lower array of openings140in the lower nacelle mounts128,130and locked into place. The nacelle14may be lifted by a crane or other lifting apparatus (not shown) and then lowered such that the support pins146are received in the lower slot236of the lower nacelle tangs132. Thus, the lower nacelle tangs132rest on and are supported by the lower support pins146in the lower nacelle mounts128,130. Once the lower nacelle tangs132engage the support pins146, the lock pin144may be positioned in the upper array of openings142so as to extend through the upper opening238in the lower nacelle tangs132. This secures the lower nacelle tangs132of the nacelle14to the lower nacelle mounts128,130of the transport frames100,102.

In an advantageous aspect of the present invention, the transport frames100,102are configured to be used on nacelles of different sizes. More particularly, the lower nacelle tangs132will generally be spaced apart by a width that varies depending on the size of the nacelle14. For example, a first nacelle of a first size will generally have the lower nacelle tangs132separated by a first width, and a second nacelle larger than the first nacelle will generally have the lower nacelle tangs132separated by a second width larger than the first width. The lower nacelle mounts128,130are configured to accommodate the different widths of the nacelles. By way of example, in one embodiment the width of the lower nacelle tangs132may be arranged such that the tangs132are received within the inner mounting slots136in the lower nacelle mounts128,130(seeFIG.7A). In another embodiment, such as for a larger nacelle, the width of the lower nacelle tangs132may be arranged such that the tangs132are received within the outer mounting slots136in the lower nacelle mounts128,130(seeFIG.7B). The ability of the lower nacelle mounts128,130of the transport frames100,102to accommodate lower nacelle tangs132of different widths allows the transport frames100,102to be used on nacelles of different sizes. This is an improvement over many transport frames, which are specific for the particular nacelle being transported.

With the transport frames100,102securely coupled to the lower tangs132of the nacelle14, the transport frames100,102may be coupled to the upper tangs208, which are attached to and extend away from the front end and rear end of the nacelle14. In an exemplary embodiment, the upper nacelle tangs208include an opening240. A front tie rod216may be coupled to the upper nacelle mounts204,206and to the upper nacelle tangs208. In this regard and as illustrated inFIG.8A, the front tie rod216may include opposed ends having openings. One end of the front tie rods216may be positioned relative to the upper nacelle mounts204,206such that the opening at that end of the tie rods216aligns with the array of openings222in the upper nacelle mounts204,206. The lock pins224may be positioned in the array of openings222so as to extend through the opening in the front tie rods216to thereby secure the front tie rods216to the front transport frame100. The other end of the tie rod216may extend to the upper nacelle tangs208such that the openings in the front tie rods216align with the opening240in the upper tangs208of the nacelle14. A lock pin244may then be inserted through the openings240to secure the front tie rods216to the nacelle14.

A similar approach may be used to secure the rear transport frame102to the upper tangs208of the nacelle14. However, the rear tie rods216a(seeFIG.1) used to connect the upper nacelle mounts204,206to the upper tangs208of the nacelle14may be slightly different from the front tie rods216used with the front transport frame100. More particularly, the rear tie rods216amay be generally shorter than the front tie rods216, but otherwise are similar to each other. Thus, each transport frame100,102may be provided with both types of tie rods216,216aand the appropriate tie rod may be used to couple the transport frame100,102to the nacelle14depending on whether the transport frame100,102is being used at the front or rear of the nacelle14. In an alternative embodiment, the tie rods may be adjustable (e.g., such as with a telescoping rod arrangement) such that the length of the tie rod may be varied to fit the either the front or rear transport frame100,102.

As noted above, the transport frames100,102are configured to be used on nacelles of different sizes. More particularly, similar to the lower nacelle tangs132, the upper nacelle tangs208will generally be spaced apart by a width that varies depending on the size of the nacelle. For example, a first nacelle of a first size will generally have the upper nacelle tangs208separated by a first width, and a second nacelle larger than the first nacelle will generally have the upper nacelle tangs208separated by a second width larger than the first width. The upper nacelle mounts204,206are configured to accommodate the different widths of the nacelles. By way of example, in one embodiment the width of the upper nacelle tangs208may be arranged such that the tangs208are received within the inner mounting slots214in the upper nacelle mounts204,206(seeFIG.8B). In another embodiment, such as for a larger nacelle, the width of the upper nacelle tangs208may be arranged such that the tangs208are received within the outer mounting slots214in the upper nacelle mounts204,206(seeFIG.8C). The ability of the upper nacelle mounts204,206of the transport frames100,102to accommodate upper nacelle tangs208of different widths allows the transport frames100,102to be used on nacelles of different sizes.

As described above, the transport frames100,102are configured to accommodate nacelles of different sizes by providing some variability in a width direction of the nacelles. In other words, by engaging the lower and upper nacelle tangs132,208with different mounting slots136,214in the lower and upper nacelle mounts128,130,204,206, the transport frames100,102may accommodate nacelles of different sizes. In another exemplary embodiment, the transport frames100,102may be configured to accommodate nacelles of different sizes by providing some variability in a height direction of the nacelles. More particularly, the upper nacelle tangs208will generally be spaced from the lower nacelle tangs132by a height that varies depending on the size of the nacelle. For example, a first nacelle of a first size will generally have the lower nacelle tangs132and the upper nacelle tangs208separated by a first height, and a second nacelle larger than the first nacelle will generally have the lower nacelle tangs132and the upper nacelle tangs208separated by a second height greater than the first height. In one aspect, the spacing between the lower nacelle mounts128,130and the upper nacelle mounts204,206may be configured to accommodate the different heights of the nacelles.

By way of example, in one embodiment the arrangement of the lower nacelle mounts128,130relative to, for example, the base support110may be fixed, and the lower nacelle mounts128,130are configured to receive the lower nacelle tangs132of the nacelle14in the manner described above. The ability to accommodate different heights between the lower and upper nacelle tangs132,208may be achieved by manipulating the arrangement of the upper nacelle mounts204,206on the outboard beam sections198,200of the upper cross beam194. More particularly, as explained above the upper nacelle mounts204,206may be coupled to the attachment flanges202such that the tabs220extend upwardly and the array of openings222that receive the tie rod216is positioned above the upper cross beam194(seeFIG.9A). When the upper nacelle mounts204,206are in this orientation, the upper nacelle mounts204,206may be coupled to upper nacelle tangs208that are spaced from the lower nacelle tangs132by a first height. In another embodiment, such as for a smaller nacelle, the upper nacelle mounts204,206may be coupled to the attachment flanges202such that the tabs220extend downwardly and the array of openings222that receive the tie rod216is positioned below the upper cross beam194(seeFIG.9B). When the upper nacelle mounts204,206are in this orientation, the upper nacelle mounts204,206may be coupled to upper nacelle tangs208that are spaced from the lower nacelle tangs132by a second height less than the first height. The ability to attach the upper nacelle mounts204,206to the transport frames100,102in two different orientations allows the transport frames100,102to be used on nacelles of different sizes (and different separation heights between the lower and upper nacelle tangs132,208). Thus, the transport frames100,102are able to accommodate both width and height variations in the nacelle tangs132,208due to nacelles being of different sizes.

In the above, the various frame sections104,106,108of the transport frame100,102were assembled prior to the nacelle14being coupled to the transport frames100,102. Embodiments of the invention, however, are not so limited. For example, in one embodiment, the nacelle14(e.g., the lower tangs132) may be coupled to the lower nacelle mounts128,130of the bottom frame section104without the intermediate frame section or top frame section106,108being assembled. Such an arrangement, for example, may minimize damaging the nacelle14or the transport frames100,102during coupling. After the nacelle14is secured to the bottom frame section104, such as in the manner described above, the intermediate frame section106and top frame section108may be coupled to the bottom frame section104to form the assembled transport frames100,102. The tie rods216,216amay then be used to couple the upper nacelle mounts206,208to the upper tangs208of the nacelle14. Thus, there may be several alternative ways to assembly and/or couple the transport frames100,102to the ends of the nacelle14which remain within the scope of the present invention.

In any event, after the transport frames100,102are coupled to the ends96,98of the nacelle14, a number of options may be available. For example, if the nacelle14is not ready to be transported to an installation site, the nacelle14may be placed in storage with the transport frames100,102remaining attached to the nacelle14. In one embodiment, the transport frames100,102may support the nacelle14directly on the ground or storage surface. In an alternative embodiment, a plurality of support posts or pylons may support the nacelle14and transport frames100,102off the ground or support surface. When the nacelle14is ready to be transported to a wind turbine installation site, the nacelle14and transport frames100,102may be placed in a loading area by a crane, cart or other lifting/transport vehicle. The transport system30may then be coupled to nacelle14for transport over the network of roads48. More particularly, the front carrier36may be positioned adjacent to the front transport frame100. The movable frame42may then be adjusted to allow the attachment interface44(e.g., the attachment elements62,66) to mount to the lower carrier interface148, such as at interface plate150, and to the upper carrier interface, such as at the interface plate of the front transport frame100. In a similar manner, the rear carrier38may be positioned adjacent to the rear transport frame102. The movable frame42may then be adjusted to allow the attachment interface74(e.g., the attachment elements88,92) to mount to the lower carrier interface148, such as at interface plate150, and to the upper carrier interface, such as at the interface plate of the rear transport frame102. The movable frames72may then be adjusted to lift the nacelle14from the ground or pylons and position the nacelle14for transport along the network of roads48.

As with current “world adaptor” arrangements, during the transport of the nacelle14, it may be desired or necessary to adjust the position of the nacelle14in order to avoid various obstacles along the transport route. In that event, the movable frames42on the front and rear carriers36,38may be manipulated in order to vary the position of the nacelle14and allow it to pass by the obstacles. When the nacelle14arrives at the installation site, the nacelle14may be unloaded with the transport frames100,102remaining connected to the nacelle14. By way of example, if the transport system30is used to transport the nacelle14to the installation site or on the final leg of the route to the installation site, the movable frames42,72on the front and rear carriers36,38may be manipulated to lower the nacelle14onto the ground, pylons or other support surface. At this point, a crane or other lifting device may lift the nacelle14from the transport frames100,102.

In one aspect of the invention, the transport frames100,102may be arranged so as to minimize any potential damage to the nacelle14during the unloading process, and more particularly during the lifting of the nacelle14from the transport frames100,102. In this regard, the intermediate frame section106and the top frame section108may be moved away from the nacelle14such that the nacelle14cannot make contact with these portions of the transport frames100,102during the lifting of the nacelle14. More particularly, the tie rods216,216amay be disengaged from the upper nacelle tangs208(and perhaps also the upper nacelle mounts204,206) and the intermediate and top frame sections106,108pivoted away from the ends of the nacelle14due to the configuration of hinge connection170that defines pivot172. For example, the lock176may be disengaged and the intermediate and top frame sections106,108rotated about pivot axis174away from the nacelle14. Moreover, the lock pins144that secure the lower nacelle tangs132to the lower nacelle mounts128,130may be removed such that the nacelle14rests on the support pins146. In this way, the nacelle14is free to be lifted from the transport frames100,102, and as the nacelle is lifted it does not make any contact with the intermediate and top frame sections106,108of the transport frames. Thus, the likelihood of damage to the nacelle14is reduced.

In another advantageous aspect of the invention, once the nacelle14is removed from the transport frames100,102at the installation site, the transport frames100,102may be configured for transport back to the manufacturing or storage facility for use with another nacelle. As discussed above, many conventional transport frames are large bulky items that occupy a significant amount of space during transport. To address this particular shortcoming and as illustrated inFIGS.10A and10B, the transport frames100,102are configured to have an expanded, in-use state and a collapsed, storage/transport state. In the expanded state, the transport frames100,102are in their in-use position, such as being attached to the ends of the nacelle14, as illustrated in the figures and described above. In the collapsed state, however, the frame sections104,106,108are juxtapositioned relative to each other to have a compact configuration that occupies significantly less space when in storage or when in transport back to a manufacturing facility.

More particularly, in the collapsed position, the locks176may be disengaged (if not already done so during the unloading process) and the intermediate frame section106may be rotated about the pivot axis174of the hinged connection170such that the main beams162,164of the intermediate frame section106are generally to the side of the main beams112,114of the bottom frame section104(as opposed to above the main beams112,114in an in-line manner). Additionally, the hinged connection186between the intermediate and top frame sections106,108may be manipulated to provide a fold between those two sections. More particularly, the lock192may be disengaged and the top frame section108may be rotated about the pivot axes190of the hinged connection186such that the main beams180,182of the top frame section108are generally to the side of the main beams162,164of the intermediate frame section106(as opposed to above the main beams162,164in an in-line manner). The folded configuration is shown inFIG.10B. Folding of the frame sections104,106,108provides a compact arrangement of the transport frames100,102that allows the transport frames100,102to be more easily stored at a site when the transport frames100,102are not in use. Moreover, the compact arrangement of the transport frames100,102further allows the transport frames100,102to be transported from an installation site back to a manufacturing facility or storage facility in a more efficient, low-cost manner.

The transport frames100,102as described herein may provide additional benefits and advantages to manufacturers, transporters, etc. For example, in one embodiment and as illustrated inFIG.11, the bottom frame section104described above may be used as a production tool250during the assembly of the nacelle14. More particularly, the nacelle14generally includes a rigid framework and an outer cover to define an interior. The interior includes many components for the operation of the wind turbine10that may be installed during the manufacture of the nacelle14. In other words, the nacelle14has many pre-assembled components prior to the nacelle being transported to a wind turbine installation site. Such an approach simplifies field assembly of the nacelle14into the wind turbine10. Thus, it may be advantageous to assemble as much of the nacelle14in the factory setting as possible. To this end, the framework of the nacelle14may be assembled and supported within the factory environment on front and rear production tools250during the build out of the nacelle14. The production tools250help in supporting and moving the nacelle14along a production line in the factory setting.

Such a production tool250would in the normal course be removed from the nacelle14after the nacelle is assembled within the factory. That nacelle might then be moved to a location where the transport frames100,102are coupled to the forward and rear ends96,98of the nacelle14in the manner fully described above. In an alternative embodiment, however, the production tools250may take the form of the bottom frame sections104of the transport frames100,102. Thus, when the nacelle14is assembled within the factory (to the extent dictated by the design), the production tools250may remain connected to the nacelle14. That assembly may then be moved to a storage location with the production tools250(i.e., the bottom frame sections104) attached thereto. When the nacelle14is being prepared for transport to an installation site, the intermediate and top frame sections106,108may then be coupled to the bottom frame section104to complete the assembly of the transport frames100,102. Alternatively, prior to the nacelle14being placed in storage, the intermediate and top frame sections106,108may be coupled to the bottom frame section104to complete the assembly of the transport frames100,102. In any event, it may be advantageous to have a portion of the transport frames100,102be used as production tools250during the assembly process of the nacelle14in the manufacturing facility. The modular nature of the transport frames100,102provides such a feature.

While the present invention has been illustrated by a description of various preferred embodiments and while these embodiments have been described in some detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Thus, the various features of the invention may be used alone or in any combination depending on the needs and preferences of the user.