Patent ID: 12188454

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

Referring now to the drawings,FIG.1illustrates a perspective view of a wind turbine10. As shown, the wind turbine10generally includes a tower12extending from a support surface14, a nacelle16mounted on the tower12, and a rotor18coupled to the nacelle16. Thus, the nacelle16corresponds to the overall housing structure and has a bottom wall, opposing side walls, a front wall, a rear wall, and a top wall. Further, the front wall may have a main shaft opening configured to receive a main shaft34(FIG.2) there through that is connectable to the rotor18.

As shown inFIG.1, the rotor18includes a rotatable hub20and at least one rotor blade22coupled to and extending outwardly from the hub20. For example, inFIG.1, the rotor18includes three rotor blades22. However, in alternative wind turbines, the rotor18may include more or less than three rotor blades22. Each rotor blade22may be spaced about the hub20to facilitate rotating the rotor18to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy. For instance, the hub20may be rotatably coupled to an electric generator24(FIG.2) positioned within the nacelle16to permit electrical energy to be produced.

The wind turbine10may also include a wind turbine controller26centralized within the nacelle16. However, in other wind turbines, the controller26may be located within any other component of the wind turbine10or at a location outside the wind turbine10. Further, the controller26may be communicatively coupled to any number of the components of the wind turbine10in order to control the components. As such, the controller26may include a computer or other suitable processing unit. Thus, in several wind turbines, the controller26may include suitable computer-readable instructions that, when implemented, configure the controller26to perform various different functions, such as receiving, transmitting and/or executing wind turbine control signals.

Referring now toFIG.2, a simplified, internal view of an exemplary nacelle16of the wind turbine10shown inFIG.1, particularly illustrating the drivetrain components thereof, is illustrated. More specifically, as shown, the generator24may be coupled to the rotor18for producing electrical power from the rotational energy generated by the rotor18. The rotor18may be coupled to the main shaft34, which is rotatable via a main bearing (not shown). The main shaft34may, in turn, be rotatably coupled to a gearbox output shaft36of the generator24through a gearbox30. The gearbox30may include a gearbox housing38that is connected to the bedplate46by one or more torque arms48. More specifically, in certain wind turbines, the bedplate46may be a forged component in which the main bearing (not shown) is seated and through which the main shaft34extends. As is generally understood, the main shaft34provides a low speed, high torque input to the gearbox30in response to rotation of the rotor blades22and the hub20. Thus, the gearbox30thus converts the low speed, high torque input to a high speed, low torque output to drive the gearbox output shaft36and, thus, the generator24.

Each rotor blade22may also include a pitch adjustment mechanism32configured to rotate each rotor blade22about its pitch axis28via a pitch bearing40. Similarly, the wind turbine10may include one or more yaw drive mechanisms42communicatively coupled to the controller26, with each yaw drive mechanism(s)42being configured to change the angle of the nacelle16relative to the wind (e.g., by engaging a yaw bearing44of the wind turbine10).

In some embodiments, the wind turbine may be an onshore wind turbine. In several embodiments, the wind turbine may be an offshore wind turbine.

In some embodiments, a component of a wind turbine can include a mechanical, electrical or electromechanical device, in particular associated with energy production or conversion. In embodiments, a component can include at least one of a drivetrain, a drivetrain component and a transformer. In particular, a drivetrain component may include a gearbox, a main shaft, a main bearing and/or a generator.

In some embodiments, a nacelle may include a base coupled to a tower of the wind turbine. The base can include a bedplate and/or at least a part of the bottom wall of the nacelle. In some embodiments, the roof can be configured for mounting to a base of the nacelle, in particular using a releasable connecting device, e. g. by positive locking of the roof and the base or via a fastener such as a bolt.

FIGS.3A-Beach illustrate a schematic view of a part of a nacelle according to the prior art. For clarity, only torque arms48and a gearbox38are shown. The remaining configuration of the nacelle may be for example as described above with regard toFIG.2.

InFIG.3A, the torque arms48are attached directly to the gearbox38. The torque arms48are supported by a frame of the nacelle via elastomers50. In particular, an elastomer50is arranged between each of the torque arms and the frame.

InFIG.3B, elastomers (not shown) are arranged between the torque arms48and the gearbox38as vibration dampers. In this example, the torque arms are supported directly by the frame. The use of vibration dampers between the frame and the torque arm is typically also understood as being a direct support. InFIGS.3A-B, support regions are indicated by hatched areas.

As can be seen, the orientation of the torque arms48inFIGS.3A-Bis at least substantially horizontal. In particular, the torque arms48are positioned symmetrically around a drive train axis of the nacelle. More particularly, a symmetry plane is oriented vertically and parallel to the drive train axis. In the context of the present disclosure, a horizontal orientation is particularly to be understood with respect to a mounted state of the nacelle. In a mounted state, the nacelle may be mounted on a tower, the tower extending from a support surface. A horizontal orientation may be understood as an orientation perpendicular to a tower axis, particularly to a main direction of extension of the tower. The horizontal orientation can be parallel to the support surface.

FIGS.4A-Eeach illustrate a schematic view of a part of a nacelle according to embodiments of the present disclosure. For clarity, only torque arms48and a component of the drivetrain are shown. In the depicted embodiments, the component of the drivetrain is a gearbox38. As to the remaining configuration of the nacelle, for example the description above regardingFIG.2may be referred to.

A nacelle for a wind turbine according to the present disclosure includes a drivetrain with a drivetrain axis. The nacelle further includes at least two torque arms positioned around the drivetrain axis. In the embodiments shown inFIGS.4A-E, the nacelle includes two torque arms48. The torque arms48are attached to a member of the drivetrain, particularly to the gearbox38. Generally, the member of the drivetrain can be for example a gearbox or a generator. The torque arms may be fixedly attached to the member of the drive train.

A gearbox axis may coincide with the drivetrain axis. In particular, the gearbox axis coincides with an axis of an input shaft of the gearbox. The input shaft is particularly a low speed shaft. More particularly, the low speed shaft is connected to a hub of the nacelle. In the exemplary embodiments shown inFIGS.4A-E, the torque arms are oriented perpendicularly to the drivetrain axis.

In the context of the present disclosure, an orientation of a torque arm is particularly to be understood as a direction parallel to a line connecting the drivetrain axis with a point, particularly an idealized point, of structural support of the torque arm. The nacelle further includes a frame attached to a yaw bearing. The torque arms48of the drive train are supported by the frame. InFIGS.4A-D, support regions are indicated by hatched areas.

At least one of the torque arms has an orientation deviating at least substantially from being horizontal. An advantage of the orientation deviating at least substantially from being horizontal is that an amount of space available next to the drivetrain may be increased. In particular, space available for example for walkways, egress routes or material handling may be larger. Additionally or alternatively, the nacelle may be built smaller, particularly narrower, as compared to a conventional nacelle. A nacelle according to the present disclosure may also have a reduced height compared to a conventional nacelle.

Logistic requirements, particularly regarding a transport of the nacelle, may be reduced. Furthermore, efforts regarding an installation in the field may be lowered. An efficiency of material utilization may be increased. Moreover, a size, particularly a transport dimension, of the drivetrain itself can be reduced. This may be particularly beneficial in case the drivetrain is to be transported separately from the nacelle.

As can be seen in the conventional design shown inFIGS.3A-B, space next to the drivetrain is blocked by the torque arms48. Compared to this, for example in the nacelle according to the present disclosure shown inFIG.4A, blocking of space next to the drivetrain by the torque arm48depicted on the left side is reduced or eliminated. The free space next to the drivetrain may be used for example for walkways, egress routes or material handling. Accordingly, the width or the height of the nacelle can potentially be reduced, since space above the drive train or next to the torque arms is not needed for this purpose. In particular, technicians and material can pass the drivetrain or a component of the drivetrain next to it, instead of above it. In this regard, a component of the drivetrain may be for example a gearbox, a gearbox support structure, or a generator.

In other words, the design of the torque arms is driven at least mainly by space requirements or load paths and not symmetry considerations. Generally, loads occurring during an operation of the wind turbine are not necessarily symmetrical. The respective loads on the torque arms are not necessarily equal. In particular, loads from a torque may differ with respect to a direction of rotation of the wind turbine.

In embodiments, for example as shown inFIG.4A, two of the torque arms deviate at least substantially from being parallel to each other. The angle between the two torque arms may be smaller than for example 175°, 160°, or 145°.

In embodiments, at least one of the torque arms has an orientation deviating from being horizontal by an angle of at least 10°. The orientation may deviate from being horizontal by an angle of at least for example 5, 15, or 25°. In the context of the present disclosure, an orientation deviating at least substantially from being horizontal may be understood as deviating from being horizontal by an angle of at least 10°.

In embodiments, for example as shown inFIG.4B, two torque arms48may have an orientation deviating at least substantially from being horizontal. The space savings in the nacelle as described above may be further increased.

In embodiments, the shapes of the torque arms may differ from each other, particularly depending on the load. The shapes of the torque arms may be based on a direction of rotation of the wind turbine in an operating state. In particular, the shapes of the torque arms may be chosen in view of size and load requirements, while at least mostly disregarding symmetry considerations.

In embodiments, the nacelle may include at least three torque arms. For example, the nacelle may include three, four or five torque arms. In particular, the number of the torque arms may be chosen in view of size and load requirements, while at least mostly disregarding symmetry considerations.

In embodiments, for example as shown inFIGS.4C-4D, at least one of the torque arms is non-linear. In particular, at least one of the torque arms includes a first section extending from the member along a first direction and a second section continuing from the first section along a second direction. In other words, at least one of the torque arms may for example have at least one kink or may be curved. An angle between the first and the second direction may be larger than for example 10, 15, or 20°. Space utilization or load path distribution may be further optimized.

In embodiments, for example as shown inFIG.4A, at least one of the torque arms is supported by the frame from underneath. A support from underneath is particularly to be understood with respect to a mounted state of the nacelle. In a mounted state, the nacelle may be mounted on a tower, the tower extending from a support surface. More particularly, a support from underneath may be understood as the torque arm being supported from a side facing the tower or the support surface. InFIG.4A, the torque arm48depicted on the right is supported from underneath.

In embodiments, at least one of the torque arms is supported by the frame from above. A support from above may be understood as the torque arm being supported from a side opposite a side facing the tower or the support surface of the tower.

In embodiments, for example as shown inFIGS.4D-4E, at least one of the torque arms is supported in at least one of a lateral direction and a longitudinal direction with respect to the drivetrain axis. In the embodiment shown inFIG.4D, the torque arm48depicted on the left is supported from a lateral direction with respect to the drivetrain axis. In the embodiment shown inFIG.4E, both depicted torque arms48are supported from a longitudinal direction with respect to the drivetrain axis. A support in the longitudinal direction can be provided for example via bolts inserted into the holes indicated on the torque arms48depicted inFIG.4E.

FIG.5illustrates a schematic view of a part of a nacelle according to embodiments of the present disclosure. Further, a section of a tower12of the wind turbine, including a yaw axis54, is shown. In the depicted embodiment, a central axis52of the nacelle intersects the drivetrain axis and runs parallel to the yaw axis54.

In embodiments, as shown inFIG.5, the nacelle is configured such that in a mounted state, a distance between the drivetrain axis and a yaw axis54is larger than 1 cm. The distance between the drivetrain axis and the yaw axis may be larger than for example 1, 2, 4, or 8 cm. Providing a distance between the drivetrain axis and the yaw axis may improve load distribution or space utilization in the nacelle.

In embodiments, a main axis of a first torque arm48crosses a main axis of a second torque arm48in a point having a distance from the yaw axis54larger than 1, 2, 4, or 8 cm.

FIG.6illustrates a flow diagram of an embodiment of a method of supporting a torque in a nacelle of a wind turbine according to the present disclosure. The method100of supporting a torque in a nacelle of a wind turbine having a drivetrain with a drivetrain axis starts in block110. The method includes, in block120, providing at least two torque arms positioned around the drivetrain axis and attached to a member of the drivetrain. The torque arms may be fixedly attached to a member of the drivetrain.

The method further includes, in block130, providing a frame attached to a yaw bearing, wherein the torque arms of the drive train are supported by the frame. At least one of the torque arms has an orientation deviating at least substantially from being horizontal. The method concludes in block140.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.