US20070104934A1 - Lightweight nacelle for turbines and methods for making same - Google Patents

Lightweight nacelle for turbines and methods for making same Download PDF

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Publication number
US20070104934A1
US20070104934A1 US11/271,098 US27109805A US2007104934A1 US 20070104934 A1 US20070104934 A1 US 20070104934A1 US 27109805 A US27109805 A US 27109805A US 2007104934 A1 US2007104934 A1 US 2007104934A1
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United States
Prior art keywords
fibers
accordance
winding
nacelle
stiffness
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/271,098
Inventor
Ronald Cairo
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General Electric Co
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General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Priority to US11/271,098 priority Critical patent/US20070104934A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CAIRO, RONALD RALPH
Publication of US20070104934A1 publication Critical patent/US20070104934A1/en
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/07—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments otherwise than in a plane, e.g. in a tubular way
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2230/00—Manufacture
    • F05B2230/20—Manufacture essentially without removing material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2240/00—Components
    • F05B2240/10—Stators
    • F05B2240/14—Casings, housings, nacelles, gondels or the like, protecting or supporting assemblies there within
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Definitions

  • This invention relates generally to methods for manufacturing of nacelles for turbines and for nacelles made by such methods. Configurations of the present invention are applicable to many different types of turbines, and are particularly advantageous for wind turbines.
  • At least one known nacelle configuration introduces substantial weight at the top of each wind turbine tower.
  • the high weight at the top of the wind tower tends to increase cost and decrease reliability and life of wind turbines.
  • this nacelle configuration includes a large cutout to accommodate a power shaft. This cutout introduces flexibility to the structure and requires local reinforcing and/or stiffening members.
  • FIG. 2 is a pictorial drawing of a nacelle representative of some configurations of the present invention.
  • some configurations of the present invention comprise a lightweight nacelle 10 .
  • Nacelle 10 itself comprise a plurality of carbon fibers 12 embedded in an epoxy matrix 14 and wound around a mandrel 16 , which is subsequently removed to leave behind a hollow region 60 (best seen in FIGS. 2 and 3 ).
  • Mandrel 16 may comprise an inflatable elastomeric to facilitate removal.
  • Wound carbon fibers 12 in some configurations are pre-impregnated, pitch-based carbon fibers, which may be selected to satisfy predetermined strength requirements, stiffness requirements, or both.
  • nacelle 10 has a thickened dome region 18 and rounded corners 20 .
  • Winding a plurality of fibers 12 in some configurations comprises orienting and winding fibers to provide torsional stiffness and strength.
  • orienting and winding fibers to provide torsional stiffness and strength can comprise winding the fibers in a ⁇ 45 degree orientation.
  • Winding a plurality of fibers 12 ins some configurations comprises orienting and winding fibers to provide lateral strength and stiffness.
  • orienting and winding fibers to provide lateral strength and stiffness can include winding fibers in a 90 degree orientation.

Abstract

A lightweight nacelle includes a plurality of wound carbon fibers embedded in an epoxy matrix around a hollow region. The nacelle is made by a process that includes winding the plurality of carbon fibers around a mandrel.

Description

    BACKGROUND OF THE INVENTION
  • This invention relates generally to methods for manufacturing of nacelles for turbines and for nacelles made by such methods. Configurations of the present invention are applicable to many different types of turbines, and are particularly advantageous for wind turbines.
  • At least one known nacelle configuration introduces substantial weight at the top of each wind turbine tower. The high weight at the top of the wind tower tends to increase cost and decrease reliability and life of wind turbines. In addition, this nacelle configuration includes a large cutout to accommodate a power shaft. This cutout introduces flexibility to the structure and requires local reinforcing and/or stiffening members.
    • BRIEF DESCRIPTION OF THE INVENTION
  • One aspect of the present invention therefore provides a lightweight nacelle that includes a plurality of wound carbon fibers embedded in an epoxy matrix around a hollow region, and having rounded corners.
  • Another aspect of the present invention provides a method for making a nacelle that includes winding a plurality of carbon fibers embedded in an epoxy matrix around a mandrel.
  • It will thus become apparent that configurations of the present invention provide a low-cost, structurally efficient nacelle.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a pictorial schematic drawing representing the winding of carbon fibers embedded in an epoxy matrix as in some configurations of the present invention.
  • FIG. 2 is a pictorial drawing of a nacelle representative of some configurations of the present invention.
  • FIG. 3 is a partial planar cross-section of the nacelle of FIG. 2 taken in plane 3 of FIG. 2.
  • FIG. 4 is a configuration of wind turbine using the nacelle of FIGS. 2 and 3.
    • DETAILED DESCRIPTION OF THE INVENTION
  • Some configurations of the present invention utilize an automated process in which a composite pre-impregnated tape/tow winding is used to fabricate a pitch-based carbon fiber epoxy nacelle for turbine engines. Pitch-based carbon fibers are inexpensive and readily available in a wide variety of strengths and stiffness, thereby allowing the structural response of the nacelle to be tuned to any of various preselected design criteria.
  • In some configurations of the present invention and referring to FIG. 1, carbon fibers embedded in a low-cost epoxy matrix in either tape or tow format are wound around a mandrel. Suitable carbon fibers include, but are not necessarily limited to, pre-impregnated pitch-based carbon fibers. Fiber architecture can be tuned for predetermined strength and stiffness requirements. For example, the fibers can be wound +/−10-degree orientation for axial strength and stiffness (0-degrees is not possible with the winding process due to the winding poles), ±/−45-degree orientation for torsional stiffness and strength, and 90-degree orientation for lateral strength and stiffness. A thicker, dome (i.e., pole) region is a byproduct of some configurations of the present invention and provides natural reinforcement for the shaft cutout. Also, in some configurations of the present invention, rounded corners result from limitations in composite material winding. These rounded corners are also advantageous because they result in aerodynamic surfaces that are less likely to produce flow separation or vortex trails, which are vibration drivers, in high wind gusts. The winding can be performed using an automated process to produce a lighter weight, higher quality, nacelle structure due to well-controlled manufacturing conditions.
  • Thus, and referring to FIG. 1, some configurations of the present invention comprise a lightweight nacelle 10. Nacelle 10 itself comprise a plurality of carbon fibers 12 embedded in an epoxy matrix 14 and wound around a mandrel 16, which is subsequently removed to leave behind a hollow region 60 (best seen in FIGS. 2 and 3). Mandrel 16 may comprise an inflatable elastomeric to facilitate removal. Wound carbon fibers 12 in some configurations are pre-impregnated, pitch-based carbon fibers, which may be selected to satisfy predetermined strength requirements, stiffness requirements, or both.
  • Carbon fibers 12 in some configurations include fibers oriented to provide axial strength and stiffness. For example, in some configurations, fibers 12 include fibers 50 that are wound in a θ=±10 degree orientation. In some configurations, carbon fibers 12 include fibers oriented to provide torsional stiffness and strength, which may, for example, include fibers 52 wound in a θ=±45 degree orientation. And in some configurations, fibers 12 include fibers 54 oriented to provide lateral strength and stiffness. For example, nacelle 10 may include fibers 12 wound at a 90 degree orientation.
  • In many configurations and referring to FIGS. 2 and 3, nacelle 10 has a thickened dome region 18 and rounded corners 20.
  • Referring to FIG. 4, nacelle 10 configurations of the present invention are particularly suitable for use in wind turbines 22 which have a rotor 24 having a least one blade 26, and a generator (not shown, but inside nacelle 10). In many configurations, three blades 26 are provided for aerodynamic efficiency.
  • In some configurations, a method for making a nacelle 10 is provided that comprises winding a plurality of carbon fibers 12 embedded in an epoxy matrix 14 around a mandrel 16. The plurality of carbon fibers 12 can comprise pre-impregnated, pitch-based carbon fibers. In some configurations, the method further includes preselecting the fibers in accordance with predetermined strength requirements, stiffness requirements, or both.
  • The winding a plurality of carbon fibers 12 in some configurations further comprises orienting and winding fibers to provide axial strength and stiffness. For example, orienting and winding the fibers to provide axial strength and stiffness can comprise winding the fibers in a ±10 degree orientation.
  • Winding a plurality of fibers 12 in some configurations comprises orienting and winding fibers to provide torsional stiffness and strength. For example, orienting and winding fibers to provide torsional stiffness and strength can comprise winding the fibers in a ±45 degree orientation.
  • Winding a plurality of fibers 12 ins some configurations comprises orienting and winding fibers to provide lateral strength and stiffness. For example, orienting and winding fibers to provide lateral strength and stiffness can include winding fibers in a 90 degree orientation.
  • While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

Claims (20)

1. A lightweight nacelle comprising a plurality of wound carbon fibers embedded in an epoxy matrix around a hollow region, and having rounded corners.
2. A nacelle in accordance with claim 1 wherein said wound carbon fibers are pre-impregnated, pitch-based carbon fibers.
3. A nacelle in accordance with claim 2 wherein said fibers are selected for predetermined strength requirements, stiffness requirements, or both.
4. A nacelle in accordance with claim 2 wherein said fibers include fibers oriented to provide axial strength and stiffness.
5. A nacelle in accordance with claim 4 wherein said fibers include fibers wound in a +/−10 degree orientation.
6. A nacelle in accordance with claim 2 wherein said fibers include fibers oriented to provide torsional stiffness and strength.
7. A nacelle in accordance with claim 6 wherein said fibers include fibers wound in +/−45 degree orientation.
8. A nacelle in accordance with claim 2 wherein said fibers include fibers oriented to provide lateral strength and stiffness.
9. A nacelle in accordance with claim 6 wherein said fibers include fibers wound at a 90 degree orientation.
10. A nacelle in accordance with claim 1 having a thickened dome region and rounded corners.
11. A wind turbine having a nacelle in accordance with claim 1, a rotor having a least one blade, and a generator.
12. A method for making a nacelle comprising winding a plurality of carbon fibers embedded in an epoxy matrix around a mandrel.
13. A method in accordance with claim 12 wherein said winding a plurality of carbon fibers comprises winding a plurality of pre-impregnated, pitch-based carbon fibers.
14. A method in accordance with claim 13 further comprising preselecting said fibers in accordance with predetermined strength requirements, stiffness requirements, or both.
15. A method in accordance with claim 13 wherein said winding a plurality of carbon fibers comprises orienting and winding fibers to provide axial strength and stiffness.
16. A method in accordance with claim 15 wherein said orienting and winding said fibers to provide axial strength and stiffness comprises winding said fibers in a +/−10 degree orientation.
17. A method in accordance with claim 13 wherein said winding a plurality of fibers comprises orienting and winding fibers to provide torsional stiffness and strength.
18. A method in accordance with claim 17 wherein said orienting and winding fibers to provide torsional stiffness and strength comprises winding said fibers in a +/−45 degree orientation.
19. A method in accordance with claim 13 wherein said winding a plurality of fibers comprises orienting and winding fibers to provide lateral strength and stiffness.
20. A method in accordance with claim 19 wherein said orienting and winding fibers to provide lateral strength and stiffness include winding said fibers in a 90 degree orientation.
US11/271,098 2005-11-10 2005-11-10 Lightweight nacelle for turbines and methods for making same Abandoned US20070104934A1 (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090004460A1 (en) * 2007-06-28 2009-01-01 U.S.A. As Represented By The Administrator Of The National Aeronautics And Space Administration Nanoparticle-Containing Thermoplastic Composites and Methods of Preparing Same

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US4311434A (en) * 1980-04-07 1982-01-19 Agency Of Industrial Science & Technology Wind turbine
US4545728A (en) * 1983-08-30 1985-10-08 Cheney Jr Marvin C Wind turbine generator with improved operating subassemblies
US4600619A (en) * 1984-12-31 1986-07-15 The Boeing Company Continuously wound filament structure for use in noise attenuation element
US4673451A (en) * 1984-09-03 1987-06-16 Toyota Jidosha Kabushiki Kaisha Method for manufacture of fiber reinforced resin structure such as a steering wheel core member
US4976587A (en) * 1988-07-20 1990-12-11 Dwr Wind Technologies Inc. Composite wind turbine rotor blade and method for making same
US5721031A (en) * 1993-07-21 1998-02-24 Unitika Ltd. Fiber-reinforced porous plastic tube
US5875648A (en) * 1995-07-07 1999-03-02 Manufactures De Vetements Paul Boye S.A. Process for the manufacture of a unit containing a solid active material which can be used for producing cold, unit obtained and refrigerating device comprising this unit
US5916682A (en) * 1996-10-14 1999-06-29 Nippon Oil Co., Ltd. Carbon fiber reinforced composite material
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US6327957B1 (en) * 1998-01-09 2001-12-11 Wind Eagle Joint Venture Wind-driven electric generator apparatus of the downwind type with flexible changeable-pitch blades
US6408575B1 (en) * 1999-03-30 2002-06-25 Fuji Jukogyo Kabushiki Kaisha Horizontal axis type wind turbine and method of construction thereof
US20020117228A1 (en) * 2001-02-07 2002-08-29 Tatsuo Nakajima Fiber reinforced plastic pipe and power transmission shaft employing the same
US6538340B2 (en) * 2001-08-06 2003-03-25 Headwinds Corporation Wind turbine system
US20040016595A1 (en) * 2002-04-17 2004-01-29 Robert Andre Multi-component acoustically resistive layer for acoutical attenuation panel and panel thus obtained
US6692681B1 (en) * 1997-01-29 2004-02-17 Raytheon Aircraft Company Method and apparatus for manufacturing composite structures
US6800956B2 (en) * 2002-01-30 2004-10-05 Lexington Bartlett Wind power system
US6966754B2 (en) * 2001-03-28 2005-11-22 Aloys Wobben System and method for monitoring a wind turbine
US7183665B2 (en) * 2004-04-19 2007-02-27 Northern Power Systems, Inc. Direct drive wind turbine
US7244100B2 (en) * 2004-01-29 2007-07-17 Fuji Jukogyo Kabushiki Kaisha Horizontal axis wind turbine and method for controlling horizontal axis wind turbine
US7246991B2 (en) * 2002-09-23 2007-07-24 John Vanden Bosche Wind turbine blade deflection control system

Patent Citations (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4311434A (en) * 1980-04-07 1982-01-19 Agency Of Industrial Science & Technology Wind turbine
US4545728A (en) * 1983-08-30 1985-10-08 Cheney Jr Marvin C Wind turbine generator with improved operating subassemblies
US4673451A (en) * 1984-09-03 1987-06-16 Toyota Jidosha Kabushiki Kaisha Method for manufacture of fiber reinforced resin structure such as a steering wheel core member
US4600619A (en) * 1984-12-31 1986-07-15 The Boeing Company Continuously wound filament structure for use in noise attenuation element
US4976587A (en) * 1988-07-20 1990-12-11 Dwr Wind Technologies Inc. Composite wind turbine rotor blade and method for making same
US5721031A (en) * 1993-07-21 1998-02-24 Unitika Ltd. Fiber-reinforced porous plastic tube
US5875648A (en) * 1995-07-07 1999-03-02 Manufactures De Vetements Paul Boye S.A. Process for the manufacture of a unit containing a solid active material which can be used for producing cold, unit obtained and refrigerating device comprising this unit
US5916682A (en) * 1996-10-14 1999-06-29 Nippon Oil Co., Ltd. Carbon fiber reinforced composite material
US6692681B1 (en) * 1997-01-29 2004-02-17 Raytheon Aircraft Company Method and apparatus for manufacturing composite structures
US6268038B1 (en) * 1997-08-13 2001-07-31 Aerospatiale Societe Nationale Industrielle Acoustically resistive layer, process for production of this layer and absorbent acoustic panel provided with at least one such layer, as well as its process for production
US6327957B1 (en) * 1998-01-09 2001-12-11 Wind Eagle Joint Venture Wind-driven electric generator apparatus of the downwind type with flexible changeable-pitch blades
US6408575B1 (en) * 1999-03-30 2002-06-25 Fuji Jukogyo Kabushiki Kaisha Horizontal axis type wind turbine and method of construction thereof
US20020117228A1 (en) * 2001-02-07 2002-08-29 Tatsuo Nakajima Fiber reinforced plastic pipe and power transmission shaft employing the same
US6966754B2 (en) * 2001-03-28 2005-11-22 Aloys Wobben System and method for monitoring a wind turbine
US6538340B2 (en) * 2001-08-06 2003-03-25 Headwinds Corporation Wind turbine system
US6800956B2 (en) * 2002-01-30 2004-10-05 Lexington Bartlett Wind power system
US20040016595A1 (en) * 2002-04-17 2004-01-29 Robert Andre Multi-component acoustically resistive layer for acoutical attenuation panel and panel thus obtained
US7246991B2 (en) * 2002-09-23 2007-07-24 John Vanden Bosche Wind turbine blade deflection control system
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US7183665B2 (en) * 2004-04-19 2007-02-27 Northern Power Systems, Inc. Direct drive wind turbine

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090004460A1 (en) * 2007-06-28 2009-01-01 U.S.A. As Represented By The Administrator Of The National Aeronautics And Space Administration Nanoparticle-Containing Thermoplastic Composites and Methods of Preparing Same
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US9447260B2 (en) 2007-06-28 2016-09-20 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Methods for preparing nanoparticle-containing thermoplastic composite laminates

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Owner name: GENERAL ELECTRIC COMPANY, NEW YORK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:CAIRO, RONALD RALPH;REEL/FRAME:017236/0434

Effective date: 20051110

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION