Spaceframe nacelle for a wind turbine generator and method of manufacturing the spaceframe nacelle

Abstract

A nacelle for a wind turbine generator includes a spaceframe having at least one exterior panel and at least one interior panel joined to the exterior panel. Each of the exterior and interior panels have a plurality of generally U-shaped channel portions with flanges extending outward from the channel portion. The flanges of the exterior panel are joined to the flanges of the interior panel to define a plurality of ribs, a plurality of joints, and a plurality of openings.

1 . A nacelle for a wind turbine generator, the nacelle comprising a spaceframe including at least one exterior panel and at least one interior panel joined to the exterior panel, each of the exterior and interior panels having a plurality of generally U-shaped channel portions with flanges extending outward from the channel portion, the flanges of the exterior panel being joined to the flanges of the interior panel to define a plurality of ribs, a plurality of joints, and a plurality of openings. 
     
     
         2 . The nacelle of  claim 1 , wherein the exterior and interior panels are joined together by welds. 
     
     
         3 . The nacelle of  claim 1 , wherein the exterior and interior panels are joined together using rivets. 
     
     
         4 . The nacelle of  claim 1 , wherein the exterior and interior panels are joined together using crimping inserts. 
     
     
         5 . The nacelle of  claim 1 , wherein each of the exterior panel and the interior panel is a stamped sheet metal member. 
     
     
         6 . The nacelle of  claim 1 , wherein each of the ribs has a generally square cross-sectional shape. 
     
     
         7 . The nacelle of  claim 1 , further comprising a shell covering the spaceframe. 
     
     
         8 . A nacelle for a wind turbine generator, the nacelle comprising a spaceframe including a plurality of ribs, a plurality of joints, and a plurality of openings, the spaceframe comprising at least a first region and a second region, the first region having a first load-bearing strength and the second region having a second load-bearing strength, the first load-bearing strength of the first region being greater than the second load-bearing strength of the second region. 
     
     
         9 . The nacelle of  claim 8 , wherein the openings of the spaceframe located in the second region are larger than the openings located in the first region. 
     
     
         10 . The nacelle of  claim 8 , wherein the ribs and joints of the spaceframe located in the second region are formed from a material that is different than a material used to form the ribs and joints located in the first region. 
     
     
         11 . The nacelle of  claim 8 , wherein an average mass of the spaceframe is approximately 50% to 76% less than an average mass of a conventional, bedplate nacelle adapted for use with the same sized wind turbine generator as the spaceframe. 
     
     
         12 . The nacelle of  claim 8 , wherein the spaceframe comprises a front region, a back region, and a middle region extending between the front and back regions, and wherein the first region corresponds to the front region and the second region corresponds to the middle region. 
     
     
         13 . The nacelle of  claim 12 , wherein the spaceframe is optimized so that each of the regions of the spaceframe has a predetermined strength, stiffness, and fatigue life. 
     
     
         14 . A wind turbine generator comprising:
 a tower;   a nacelle rotatably coupled to a top of the tower for rotational movement with respect to the tower, the nacelle comprising a spaceframe including at least one exterior panel and at least one interior panel joined to the exterior panel, the exterior panel and the interior panel collectively defining a plurality of ribs, a plurality of joints, and a plurality of openings; and   a blade and hub assembly operatively coupled to the nacelle.   
     
     
         15 . A method of constructing a spaceframe for a nacelle, said method comprising:
 stamping a first sheet of metal to form a plurality of openings therein;   forming a plurality of generally U-shaped channels with flanges extending outward from the channels in the first sheet of metal;   stamping a second sheet of metal to form a plurality of openings therein;   forming a plurality of generally U-shaped channels with flanges extending outward from the channels in the second sheet of metal;   aligning the U-shaped channels and associated flanges of the first sheet of metal with the U-shaped channels and associated flanges of the second sheet of metal so that the aligned U-shaped channels cooperatively define a generally box-shaped cross-section and the flanges are in engagement; and   securely joining the flanges of the first sheet of metal and the flanges of the second sheet of metal.   
     
     
         16 . The method of  claim 15 , wherein securely joining the flanges of the first sheet of metal and the flanges of the second sheet of metal comprises welding the flanges of the first sheet of metal and the flanges of the second sheet of metal together. 
     
     
         17 . The method of  claim 16 , wherein welding the flanges of the first sheet of metal and the flanges of the second sheet of metal comprises welding the flanges together using a resistance seam welding process. 
     
     
         18 . The method of  claim 16 , wherein welding the flanges of the first sheet of metal and the flanges of the second sheet of metal comprises welding the flanges together using a high-energy beam welding process. 
     
     
         19 . The method of  claim 15 , wherein securely joining the flanges of the first sheet of metal and the flanges of the second sheet of metal comprises crimping the flanges of the first sheet of metal and the flanges of the second sheet of metal together using a crimpable insert, said insert being designed to provide sufficient clamping load in all primary load paths and direction. 
     
     
         20 . The method of  claim 15 , wherein securely joining the flanges of the first sheet of metal and the flanges of the second sheet of metal comprises inserting mechanical fasteners through the flanges of the first sheet of metal and the flanges of the second sheet of metal.