WO2013108079A1 - Composants de convertisseur d'énergie éolienne constitués de béton aux performances ultra-élevées - Google Patents

Composants de convertisseur d'énergie éolienne constitués de béton aux performances ultra-élevées Download PDF

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Publication number
WO2013108079A1
WO2013108079A1 PCT/IB2012/050251 IB2012050251W WO2013108079A1 WO 2013108079 A1 WO2013108079 A1 WO 2013108079A1 IB 2012050251 W IB2012050251 W IB 2012050251W WO 2013108079 A1 WO2013108079 A1 WO 2013108079A1
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WO
WIPO (PCT)
Prior art keywords
reinforcing members
article
wall
sidewall
parallel
Prior art date
Application number
PCT/IB2012/050251
Other languages
English (en)
Inventor
Markus Rudolf KRAUSE
Original Assignee
Apamsc Austria Gmbh
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
Application filed by Apamsc Austria Gmbh filed Critical Apamsc Austria Gmbh
Priority to PCT/IB2012/050251 priority Critical patent/WO2013108079A1/fr
Publication of WO2013108079A1 publication Critical patent/WO2013108079A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
    • B28B23/043—Wire anchoring or tensioning means for the reinforcements
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
    • B28B23/12—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed to form prestressed circumferential reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/22—Moulds for making units for prefabricated buildings, i.e. units each comprising an important section of at least two limiting planes of a room or space, e.g. cells; Moulds for making prefabricated stair units
    • 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
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • 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
    • 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
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/70—Treatments or modification of materials
    • F05B2280/702—Reinforcements
    • 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

Definitions

  • Wind energy is one of the fastest growing sources of electricity around the world, and wind turbines employing rotating electrical machines are used to convert wind energy to usable power.
  • Some conventional wind turbines include a turbine rotor having turbine blades and an output shaft which drive an electrical machine that can supply 3-5 Megawatts of power to the utility power network.
  • increased power demand is leading to increased power requirements for each wind turbine.
  • a mere scaling up of the size of the conventional power train and corresponding support structures becomes impractical, due at least in part to the size, weight and cost of some components that accommodate these requirements.
  • a power train in an exemplary conventional wind turbine 10' includes a turbine rotor 20 having blades (not shown) connected to a hub 16'.
  • the wind turbine 10' also includes an electrical generator 30 which is driven by the rotor 20 via a gearbox 26 and a drive shaft (not shown).
  • the generator 30, gearbox 26 and drive shaft are housed in a nacelle 14, shown in outline to permit visualization of the components therein.
  • the rotor 20, gearbox 26 and generator 30 are supported on the wind turbine tower 12 using a conventional, cast iron mainframe 50'.
  • the mainframe 50' is configured to support the rotor 20, the gearbox 26 and the generator 30 in their relative positions on the top of the tower 12.
  • the conventional mainframe 50' when adapted for use in a 2 Megawatt wind turbine, is formed of cast iron and weighs about 28 tons. When the cast iron mainframe 50' is scaled up for use in a 5 Megawatt wind turbine, it will weigh about 70 tons, and the cost of materials is about three times more than for the 2 Megawatt machine. For these and other reasons, providing a wind turbine that can deliver 10 Megawatts or more without merely scaling up of the size of the conventional power train and corresponding support structures would be beneficial.
  • a method of manufacturing a pre-stressed concrete article for use in a multi-directional dynamic loading application includes providing a form comprising a first outer wall, and a first inner wall parallel to and spaced apart from the first outer wall such that an intermediate space is defined between the first inner wall and the first outer wall.
  • the method includes providing a first elongated reinforcing member disposed in the intermediate space extending in a first direction that is parallel to a first plane, a second elongated reinforcing member disposed in the intermediate space extending in a second direction that is angled relative to the first direction and parallel to the first plane, and a third elongated reinforcing member disposed in the intermediate space extending in a third direction that is angled relative to the first direction and the second direction, and parallel to a second plane that is angled relative to the first plane.
  • the method includes applying a tensile force to each of the reinforcing members, and introducing fresh concrete into the intermediate space so as to at least partially embed each of the reinforcing members while under the applied tensile force.
  • the method includes curing the fresh concrete within the intermediate space with the at least partially embedded reinforcing members under the applied tensile force; releasing the tensile force applied to each of the reinforcing members so as to introduce a pre-stress into the cured concrete, and removing the cured-concrete article from the form.
  • the method may include one or more of the following features and/or method steps:
  • the article is removed from the form after the releasing step.
  • the first plane is parallel to the first outer wall.
  • the form further comprises a second outer wall that adjoins, and is non-parallel to, the first outer wall, and a second inner wall parallel to and spaced apart from the second outer wall, the second inner wall adjoining the first inner wall, the vacancy between the second inner wall and second outer wall defining a second intermediate space, the second intermediate space communicating with the intermediate space between the first inner wall and the first outer wall, and the third reinforcing member extends within the second intermediate space.
  • the third direction is transverse to both the first direction and the second direction.
  • the providing step further includes providing a fourth reinforcing member disposed within the second intermediate space extending in a fourth direction that is angled relative to the first, second and third directions.
  • the fourth direction extends in parallel to the second plane.
  • the reinforcing members are linear and pass through corresponding openings provided in the form.
  • the method may include one or more of the following additional features and/or method steps:
  • the concrete is an ultra high performance concrete having a compressive strength of at least 100 N/mm 2 .
  • the concrete is an ultra high performance concrete having a Young's Modulus of at least 45,000 N/mm .
  • the amount of the applied tensile force is greater in at least one region of the form than in other regions of the form.
  • the method further comprises providing a non-uniform density of reinforcing members such that higher numbers of reinforcing members are provided in regions of expected higher stress.
  • the forms are configured to provide the article with a monolithic hollow shape.
  • the forms are configured to provide the article with a monolithic hollow shape having openings formed in at least one side.
  • the article comprises multiple walls, with at least one wall being spaced from another wall with a vacancy formed between the one wall and the another wall, and the article is formed as a monolithic structure in a single casting.
  • the first reinforcing member comprises a first set of reinforcing members, and each reinforcing member of the first set extends in parallel to, and is spaced apart from, the other reinforcing members of the first set
  • the second reinforcing member comprises a second set of reinforcing members
  • each reinforcing member of the second set extends in parallel to, and is spaced apart from, the other reinforcing members of the second set
  • the third reinforcing member comprises a third set of reinforcing members, and each reinforcing member of the third set extends in parallel to, and is spaced apart from, the other reinforcing members of the third set.
  • Each reinforcing member comprises a single -wire filament.
  • Each reinforcing member comprises a multi- strand wire.
  • Each reinforcing member comprises a cylindrical rod.
  • the reinforcing members are formed of metal. The method comprises the following additional step: machining the article.
  • a cast concrete article configured to be used under multi-directional dynamic loading conditions, the article comprising a first sidewall defining a first plane; a second sidewall defining a second plane that is angled relative to the first plane, the second sidewall adjoining the first sidewall along an edge of the first sidewall, and reinforcing members extending linearly within the article, the reinforcing members being bonded to the concrete of the article and applying a compressive stress to the article via the bond.
  • a first portion of the reinforcing members extend in parallel to the first plane, a second portion of the reinforcing members extend in parallel to the second plane, and at least one of the first portion of the reinforcing members and the second portion of the reinforcing members is arranged in a grid pattern, whereby the compressive pre stress is incorporated along multiple nonparallel planes via the reinforcing members disposed within the article.
  • the cast concrete article may include one or more of the following features: Each of the first portion of the reinforcing members and the second portion of the reinforcing members is arranged in a grid pattern.
  • the grid is Cartesian.
  • Each reinforcing member of the first portion of reinforcing members extends in parallel to, and is spaced apart from, the other reinforcing members of the first portion, and each reinforcing member of the second portion of reinforcing members extends in parallel to, and is spaced apart from, the other reinforcing members of the second portion.
  • the article is formed monolithically.
  • the bond which provides the compressive stress is achieved during casting of the article.
  • the internal compressive stress is configured to accommodate external loads applied to the machine part in any direction.
  • the reinforcing members are configured to provide an internal compressive stress to the corresponding sidewall of at least 40 MPa.
  • the cast concrete article may include one or more of the following additional features:
  • the reinforcing members comprise single-wire filaments having a diameter of 6 mm or less.
  • the reinforcing members comprise multi-strand wires, each wire having a diameter of up to 13 mm.
  • the reinforcing members comprise rods having a diameter of up to 30 mm.
  • the reinforcing members are formed of metal.
  • the article includes a hollow interior space that is at least partially defined by interior surfaces of the first sidewall and the second sidewall, and the reinforcing members do not reside within the interior space.
  • the first sidewall further comprises an opening extending between an interior surface of the first sidewall and an exterior surface of the first sidewall, the opening spaced apart from, and surrounded by, a periphery of the first sidewall, and the reinforcing members are arranged within the first sidewall so that they do not reside within the opening after the article has been finished.
  • the article further comprises an insert configured to permit connection of the article to another structure, wherein the insert is at least partially embedded in one of the sidewalls.
  • a wind turbine that can deliver at least 10 Megawatts can be provided having reduced weight and cost.
  • these techniques have application to, and provide corresponding benefits for, smaller wind turbines as well.
  • Structures formed of concrete have conventionally been made in simple shapes and are used in well-defined compressive loading conditions. This is due at least in part to the material properties of cement.
  • cement has very high compressive strength, but relatively low tensile or bending strength.
  • For concrete structures to be used in simple, known, non-compressive loading conditions it is possible to compensate for low tensile or bending strengths in concrete by providing the concrete structure with reinforcing members and/or a pre-stress.
  • concrete is not considered as a material for use in applications where loading is complex (e.g, is applied in more than one direction) and of unknown or varying strength.
  • Ultra High Performance Concrete is a type of concrete characterized by its very high compressive strength (at least 150 N/mm2 as compared to 10-60 N/mm2 for standard concrete).
  • UHPC Ultra High Performance Concrete
  • an article formed of UHPC can advantageously be used to form an article having a complex structure and that is suitable for use in dynamic, multidirectional loading conditions.
  • UHPC articles has many advantages relative to manufacture of cast iron articles, particularly when the article is very large in size (e.g., a wind energy converter mainframe, hub or tower). For example,
  • An article formed of UHPC has characteristics that provide further advantages over an article formed of cast iron. For example,
  • UHPC Because of its dense structure, UHPC is highly resistant to corrosion, even to chloride. For this reason, it doesn't have to be protected from the environment with expensive coatings.
  • UHPC particularly with fiber mixtures, is more ductile than conventional cements, and can be used in dynamic and/or fatigue loading conditions. This quality can be enhanced by adding fiber mixtures to the UHPC.
  • UHPC is less dense than cast iron. Although a UHPC structure may sometimes have to be manufactured with bigger wall thicknesses than a corresponding cast iron structure to achieve the same strength characteristics as the corresponding cast iron structure, the UHPC structure is not heavier than the cast iron structure because of its lower density.
  • FIG. 1 is a perspective view of a power train of a conventional wind turbine.
  • Fig. 2 is a UHPC main frame that replaces the conventional mainframe within the wind turbine of Fig. 1.
  • Fig. 3 is an isolated front perspective view of the mainframe of Fig. 2.
  • Fig. 4 is an isolated rear perspective view of the mainframe of Fig. 2.
  • Fig. 5 is a schematic side cross sectional view of the mainframe of Fig. 3.
  • Fig. 6 is a schematic bottom cross sectional view of the mainframe of Fig. 3.
  • Fig. 7 illustrates the calculated stresses in MPa within the sidewalls of the mainframe of Fig. 2 under load.
  • Fig. 8 is a side view of a conventional wind turbine hub.
  • Fig. 9 is a schematic side cross sectional view of a UHPC wind turbine hub.
  • Fig. 10 is a flow diagram illustrating a method of manufacturing a UHPC article.
  • Fig. 11 is a rear perspective view of a UHPC mainframe within a form that is shown schematically using broken lines, illustrating an arrangement of reinforcing members.
  • Fig. 12 is a front perspective view of the UHPC mainframe of Fig. 11 with the form omitted and portions of the reinforcing members within the front sidewall opening and bottom sidewall opening removed.
  • a UHPC mainframe 50 is a monolithic, hollow structure that is configured to be used in the place of the conventional cast iron mainframe 50' in a wind energy converter 10.
  • the mainframe 50 includes a front sidewall 52, and a rear sidewall 54 opposed to the front sidewall 52.
  • the front sidewall 52 is formed having a front sidewall opening 64.
  • the front sidewall opening 64 is generally circular in shape and extends through the thickness of the sidewall 52 between an interior surface 62 of the mainframe 50 and an exterior surface 65 of the mainframe 50.
  • the front sidewall opening 64 is generally centered within the periphery of the front sidewall 52.
  • the mainframe 50 includes mutually-spaced lateral sidewalls 56, 58 that extend between the front sidewall 52 and the rear sidewall 54.
  • the lateral sidewalls 56, 58 extend normally from respective side edges of the front sidewall 52 and the rear sidewall 54.
  • the front sidewall 52 and rear sidewall 54 have the same width, the front sidewall 52 is greater in height than the rear sidewall 54.
  • the front sidewall 52 has a height that is about three times the height of the rear sidewall 54. Accordingly, the height of the lateral sidewalls 56, 58 varies linearly from the front to the rear sides of the mainframe 50.
  • the mainframe 50 includes a top sidewall 60 that closes a portion of the upper side of the mainframe 50.
  • the top sidewall 60 adjoins the front sidewall 52 and extends between the lateral sidewalls 56, 58 in the region adjacent to the front sidewall 54.
  • the upper side of the mainframe 50 is open between the top sidewall 60 and the rear sidewall 54. This configuration permits access to the interior space of the mainframe 50, whereby power train components can be assembled within the mainframe 50.
  • the mainframe 50 includes a bottom sidewall 62 that closes the lower side of the mainframe 50.
  • the bottom sidewall 62 is formed having a bottom sidewall opening 66.
  • the bottom sidewall opening 66 is generally circular in shape and extends through the thickness of the sidewall 62 between the interior surface of the mainframe 50 and the exterior surface of the mainframe 50.
  • the bottom sidewall opening 66 is generally centered within the periphery of the bottom sidewall 62.
  • each flange 68 is provided on each lateral sidewall 56, 58 of the mainframe 50.
  • each flange 68 is located along the lower edge of each sidewall 56, 58 at a location generally midway between the front sidewall 52 and the rear sidewall 54 on an outward facing surface of the corresponding sidewall 56, 58.
  • Each flange 68 includes several flange through-openings 70 arranged along an arc that is parallel to the outer periphery of the tower 12.
  • the six mainframe sidewalls (front sidewall 52, rear sidewall 54, lateral sidewalls 56, 58, top sidewall 60 and bottom sidewall 62) are formed as a monolithic structure in a single casting from UHPC (discussed further below).
  • the mainframe 50 includes a hollow interior space that is at least partially defined by interior surfaces 63 of the respective plate-like sidewalls 52, 54, 56, 58, 60, 62. In use, some components of the power train of the wind energy converter 10 are received within the interior space and supported by the mainframe sidewalls.
  • each sidewall 52, 54, 56, 58, 60, 62 is of uniform thickness and has the same thickness as the other sidewalls, the sidewalls 52, 54, 56, 58, 60, 62 are not limited to this configuration.
  • each of the six sidewalls 52, 54, 56, 58, 60, 62 includes reinforcing members 90 that extend linearly within the mainframe 50.
  • the reinforcing members 90 are formed of single -wire metal filaments having a diameter of 10 mm. In other embodiments, the filaments have a diameter of 8 mm. In still other embodiments, the filaments have a diameter of 6 mm or less.
  • the reinforcing members 90 are long relative to their diameter, in that they have a length that generally corresponds to the dimension of the sidewall in the direction corresponding to the orientation of the reinforcing member 90 within the sidewall.
  • the reinforcing members 90 are cast within the sidewalls 52, 54, 46, 58 60, 62 while under a tensile load as discussed further below, and thus are bonded to the concrete while in a stretched configuration. When released from the applied tensile load after casting, the reinforcing members 90 exert a compressive stress to the concrete which forms the mainframe 50 via the bond between the reinforcing members 90 and the UHPC. Thus, the sidewalls of mainframe 50 are provided with an internal compressive stress (a "pre-stress") by the reinforcing members 90 in directions corresponding to the orientation of the reinforcing members 90.
  • a pre-stress internal compressive stress
  • each sidewall 52, 54, 56, 58, 60, 62 is provided with a pre-stress that is configured to accommodate external loads applied to the mainframe 50 in any direction.
  • the reinforcing members are configured to provide an internal compressive stress to the corresponding sidewall in a range of about lOMPa in some locations to about 40 MPa or more in other locations.
  • a schematic side sectional view of the mainframe 50 illustrates an exemplary arrangement of the reinforcing members 90 disposed within the front sidewall 52, the bottom sidewall 62, the rear sidewall 54 and the top sidewall 60.
  • the reinforcing members 90 are illustrated here as extending beyond the outer surface 65 of the mainframe 50. Although this configuration occurs during casting of the mainframe 50, it will be understood that after the mainframe 50 has been cast and then released from the casting forms, the reinforcing members 90 reside entirely within the periphery of the outer surface of the finished article.
  • a first set 90a of the reinforcing members 90 extend generally in parallel to a plane PI defined by the first sidewall 52.
  • the first set 90a is an array in which each reinforcing member 90 of the first set 90a extends linearly in a first direction Dl, and is parallel to and spaced apart from the other reinforcing members 90 of the first set 90a.
  • a second set 90b of the reinforcing members 90 is an array in which each reinforcing member 90 of the second set 90b extends linearly in a second direction D2 that is angled relative to the first direction D 1 and is parallel to the first plane PI .
  • the second direction D2 is transverse to the first direction Dl , but is not limited to this configuration.
  • Each reinforcing member 90 of the second set 90b is spaced apart from the reinforcing members of the first set 90a, and is parallel to and spaced apart from the other reinforcing members 90 of the second set 90b.
  • a third set 90c of elongated reinforcing members 90 is disposed within the sidewalls.
  • the third set 90c is an array in which each reinforcing member 90 of the third set 90c extends linearly in a third direction D3 that is angled relative to the first direction Dl and the second direction D2.
  • the third direction D3 extends parallel to a second plane P2 that is angled relative to the first plane PI .
  • the second plane P2 is parallel to the lateral sidewalls 56, 58.
  • the third direction D3 also extends in parallel to a third plane P3, which in turn is parallel to the top and bottom sidewalls 60, 62.
  • the third direction D3 is transverse to both the first and second directions Dl, D2, but is not limited to this configuration.
  • the second plane P2 is transverse to both the first and third planes PI , P3 but is not limited to this configuration.
  • Each reinforcing member 90 of the third set 90c is spaced apart from the reinforcing members of the first set 90a and second set 90b, and is parallel to and spaced apart from the other reinforcing members 90 of the third set 90c.
  • additional sets of elongated reinforcing members 90 can be disposed in the sidewalls.
  • a fourth sets 90d and a fifth set 90e can be included.
  • the fourth set 90d extends in a fourth direction D4
  • the fifth set 90e extends in a fifth direction D5.
  • the fourth and fifth directions D4, D5 are each angled relative to the first direction D 1 , the second direction D2 and the third direction D3, and extend in parallel to the third plane P3.
  • the reinforcing members 90 within the fourth and fifth sets 90d, 90e form an array in which each reinforcing member 90 of the set extends linearly, and is parallel to and spaced apart from the other reinforcing members 90 of the set.
  • first set 90a and second set 90b reside within the first sidewall 52 and, in combination, effectively form a Cartesian grid pattern.
  • the combined effect of all sets provides a compressive pre-stress that is incorporated along multiple non parallel planes that enable the mainframe 50 to be used under multidirectional dynamic loads.
  • reinforcing members 90 do not pass through or reside within the interior space 67 defined by the interior surfaces 63 of the sidewalls 52, 54, 56, 58, 60, 62, and also do not pass through or reside within the sidewall openings 64, 66, of the finished article.
  • the amount of pre-stressed strands 90 used is about one to five percent in volume of the whole structure.
  • the pre-stressed strands 90 are not uniformly distributed throughout the wall structure, but instead are provided in higher concentrations in areas of higher tension stress.
  • the sidewalls 52, 54, 56, 58, 60, 62 of the mainframe 50 may also be provided with an insert (not shown) configured to permit connection of the mainframe 50 to another structure.
  • an insert may be a plate, flange, anchor bolt, bracket or similar structure.
  • the insert is cast with the mainframe 50 so that the insert is at least partially embedded in one of the sidewalls 52, 54, 56, 58, 60, 62. In other embodiments, the insert is attached to the mainframe 50 subsequent to casting.
  • the mainframe 50 is used, for example, to support the rotor 20, the gearbox 26, and the generator 30 on the top of the wind turbine tower 12.
  • the rotor 20 is mounted to an outward facing surface 51 of the front sidewall 52 of the mainframe 50 via a coupling 28 that houses bearings (not shown) that support the driveshaft.
  • the gearbox 26 is disposed within the mainframe 50.
  • the gearbox 26 at least partially rests on, and is fixed to, the mainframe bottom sidewall 62 and/or the left and the right lateral sidewalls 56, 58.
  • a portion of the gearbox 26 extends through the front sidewall opening 64 and is secured to the mainframe front sidewall 52 via the coupling 28.
  • the generator 30 is supported on a platform (not shown) that is cantilevered from an outward facing surface 53 of the rear sidewall 54.
  • Yaw drive engines 32 are used to rotate the mainframe 50 relative to the tower 12 about a vertical axis and are supported on the flanges 68.
  • a yaw drive engine 32 is disposed in each flange opening 70, and includes gearing configured to engage a gear wheel 34 mounted to the top of the tower 12.
  • the principal stress distribution within the mainframe 50 was calculated for expected maximum loads.
  • the highest stress is localized in the vicinity of the front wall opening 64, which corresponds to location at which the mainframe 50 is connected to the rotor 20.
  • there are large regions of relative low stress for example at locations distant from the front wall opening 64. In low stress regions, less pre-stress is required, whereby a lower density of reinforcing members 90 can be used.
  • wall thicknesses can be reduced whereby the weight of the mainframe 50 can be reduced.
  • complex loads of high and varying strength can be accommodated.
  • FIG. 8 illustrates a schematic cross-sectional view of the UHPC hub 16, and shows reinforcing members 90 disposed within each prism sidewall 110, 112, 114.
  • a first set 90w of the reinforcing members 90 extends within the first prism sidewall 110 in parallel with a fourth plane P4 defined by the first prism sidewall 110.
  • a second set 90z of the reinforcing members 90 extends within the second prism sidewall 112 in parallel with a fifth plane P5 defined by the second prism sidewall 112.
  • a third set 90y of the reinforcing members 90 extends within the third prism sidewall 114 in parallel with a sixth plane P6 defined by the third prism sidewall 114.
  • each of the first set 90w, the second set 90z, and the third set 90y also extend in parallel to a seventh plane P7 that is transverse to each of the fourth plane P4, the fifth plane P5 and the sixth plane P6, but are not limited to this.
  • a fourth set 90x of the reinforcing members 90 extends in parallel to a plane transverse to the seventh plane P7.
  • the fourth set 90x extends within the apex regions 116 formed by the intersections between the first prism sidewall 110 and third prism sidewall 114, the first prism sidewall 110 and the second prism sidewall 112, and the second prism sidewall and the third prism sidewall 114. Together, the first set 90w and the fourth set 90x together form a grid arrangement within the first prism sidewall 110. Likewise, the second set 90z and the fourth set 90x together form a grid arrangement within the second prism sidewall 112, and the third set 90y and the fourth set 90x together form a grid arrangement within the third prism sidewall 114. In some embodiments, the grid may be Cartesian.
  • a method of manufacturing a pre-stressed UHPC article for use in the multi-directional, dynamic loading conditions will now be described.
  • a method of manufacturing a pre-stressed UHPC mainframe 50 that is formed as a monolithic structure in a single casting, and is suitable for use in the multidirectional, dynamic loading conditions found within a wind energy converter 10, will be described.
  • the method includes providing a form 200 that is configured to provide a monolithic manufactured article.
  • the manufactured article is hollow.
  • the form 200 shown partially and schematically using broken lines in Fig. 11 , is provided in a shape that generally corresponds to the mainframe's 50 hollow, multi-walled shape.
  • the form includes an outer wall 202, and an inner wall 204 that is parallel to and spaced apart from the outer wall 202 such that an intermediate space 210 is defined between the inner wall and the outer wall.
  • the form 200 includes a first outer wall 202a, and a first inner wall 204a that is parallel to and spaced apart from the first outer wall 202a such that a first intermediate space 210a is defined between the first inner wall 204a and the first outer wall 202a.
  • the form 200 further includes a second outer wall 202b that adjoins, and is non-parallel to, the first outer wall 202a, and a second inner wall 204b that is parallel to and spaced apart from the second outer wall 202b.
  • the second inner wall 204b adjoins the first inner wall 204a.
  • the vacancy between the second inner wall 204a and second outer wall 202b defines a second intermediate space 210b.
  • the second intermediate space 210b communicates with the first intermediate space 210a.
  • the form 200 further includes similar structures for the remaining sidewalls 54, 58, 60 and 62.
  • a curved surface 216 corresponding to the front wall opening 64 is provided that extends between the inner wall 204a and the outer wall 202a of the form 200.
  • a curved surface 218 corresponding to the bottom wall opening 66 is provided that extends between the inner wall 202 and the outer wall 204 of the form 200.
  • the form 200 includes edge surfaces 220 that extend between the inner wall 204 and the outer wall 202 at the peripheries of the sidewalls so as to provide a closed form.
  • reinforcing members 90 are arranged within the form 200 in a configuration that is determined by the expected loading conditions of the mainframe 50 as discussed further below.
  • a first set 90a of elongated reinforcing members 90 is disposed in the first intermediate space 210a.
  • the first set 90a extends linearly in the first direction D 1 which is parallel to the first plane PI .
  • the first plane PI is parallel to the outer wall 202a, and thus is also parallel to the outer surface of the first sidewall 52, but is not limited to this configuration.
  • Each reinforcing member 90 of the first set 90a is parallel to and spaced apart from the other reinforcing members 90 of the first set 90a.
  • a second set 90b of elongated reinforcing members 90 is disposed in the first intermediate space 210a.
  • the second set 90b extends linearly in the second direction D2 that is angled relative to the first direction D 1 and in parallel to the first plane PI .
  • the second direction D2 is transverse to the first direction Dl , but is not limited to this configuration.
  • Each reinforcing member 90 of the second set 90b is spaced apart from the reinforcing members of the first set 90a, and is parallel to and spaced apart from the other reinforcing members 90 of the second set 90b.
  • the method includes providing a third set 90c of elongated reinforcing members 90 disposed both in the first intermediate space 210a and in the second intermediate space 210b.
  • the third set 90c extends linearly in the third direction D3 that is angled relative to the first direction Dl and the second direction D2.
  • the third direction D3 extends parallel to a second plane P2 that is angled relative to the first plane PI .
  • the second plane P2 is parallel to the form walls corresponding to the lateral sidewalls 56, 58.
  • the third direction D3 also extends in parallel to a third plane P3, which in turn is parallel to the form walls corresponding to the top and bottom sidewalls 60, 62.
  • the third direction D3 is transverse to both the first and second directions Dl, D2, but is not limited to this configuration.
  • the second plane P2 is transverse to both the first and third planes P 1 , P3 but is not limited to this configuration.
  • Each reinforcing member 90 of the third set 90c is spaced apart from the reinforcing members of the first set 90a and second set 90b, and is parallel to and spaced apart from the other reinforcing members 90 of the third set 90c.
  • the reinforcing members 90 extend through the respective intermediate space 210 and pass through corresponding openings 214 provided in opposed outer walls 202 of the form 200.
  • the reinforcing members 90 extend through the front sidewall opening 64 and the bottom sidewall opening 66, although only a subset of reinforcing members 90 are shown extending through the front and bottom sidewall openings 64, 66 to enhance clarity of the illustration.
  • the reinforcing members 90 are provided in the remaining portions of the form 200 in a similar manner, and the description is therefore omitted.
  • a tensile force is applied to each of the reinforcing members 90.
  • this is achieved by hydraulic or mechanical devices connected to the reinforcing members 90.
  • the reinforcing members may be connected to and tensioned by threaded spindles.
  • a uniform tensile force may be applied to all reinforcing members 90.
  • higher tensile forces may be applied to a subset of reinforcing members 90 that are located in regions of the sidewall that are expected to experience higher loads. As a result, the amount of the applied tensile force is greater in at least one region of the form than in other regions of the form.
  • fresh concrete is introduced into the intermediate space 210 so as to at least partially embed each of the reinforcing members 90 while under the applied tensile force.
  • fresh concrete refers to mixed batch, non-cured concrete in its wet form.
  • fresh UHPC is introduced into the intermediate space 210.
  • the UHPC has a compressive strength of at least 100 N/mm .
  • the UHPC has a compressive strength of at least 120 N/mm .
  • the UHPC has a compressive strength of at least 180 N/mm 2 .
  • the UHPC has a Young's Modulus of at least 45,000 N/mm 2 . In other embodiments, the UHPC has a Young's Modulus of at least 55,000 N/mm 2 . In still other embodiments the UHPC has a Young's Modulus of at least 60,000 N/mm 2 . In the illustrated embodiment, the intermediate space is completely filled with the UHPC.
  • step 258 the fresh concrete within the intermediate space is then permitted to cure while the at least partially embedded reinforcing members 90 remain under the applied tensile force.
  • the compressive pre-stress provided in the finished main frame 50 is achieved via a bond between the reinforcing members 90 and the concrete.
  • the bond is established during the casting and curing steps 256, 258.
  • the bond accrues by adhesion of the cement with the reinforcing members 90.
  • the adhesion is enhanced by providing the reinforcing members with ribs (not shown).
  • step 260 after the fresh concrete has cured to an extent that the concrete is a solid mass having a predetermined stiffness (i.e., sufficient to withstand the desired compressive pre-stress), and the reinforcing members 90 have bonded to the concrete, the tensile force previously applied to each of the reinforcing members 90 is released. As a result, a compressive pre-stress is introduced into the cured concrete by the reinforcing members 90 via the bond between the reinforcing members 90 and the concrete.
  • the extent of the compressive pre-stress within the concrete is determined by the density of the reinforcing members 90 and the extent of the applied tensile force.
  • the direction of the compressive pre-stress is determined by the direction of the reinforcing members within the concrete.
  • step 262 the cured-concrete mainframe is removed from the form 200.
  • the method is described such that the step of removing the mainframe 50 from the form 200 occurs after the step of releasing the tensile force applied to the reinforcing members 90, the method is not limited to this ordering.
  • the released mainframe 50 can receive additional finishing steps.
  • the mainframe 50 can be machined to provide surface finishing, accurate placement of bolt holes, etc.
  • the reinforcing members 90 are disclosed as being single-wire filaments, other types of reinforcing members 90 may be used.
  • multi-strand wires may be used as reinforcing members, each wire having a diameter of up to 13 mm.
  • rods having a diameter of up to 30 mm may be used as reinforcing members.
  • the reinforcing members are disclosed as being formed of metal, other materials may be used to form the reinforcing members, such as carbon fiber, fiberglass, and other synthetic materials.
  • the mainframe 50 is an example of a hollow polyhedron, which is defined here as a geometric solid whose faces are each fiat polygons.
  • articles having this shape are well suited to be formed of UHPC and pre-stressed as described above since the reinforcing members extend linearly through the walls of the article.
  • cast concrete articles configured to be used under multi-directional dynamic loading conditions are not limited to a being a polyhedron, and can have curvilinear surfaces.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Wind Motors (AREA)

Abstract

Un cadre principal (50) de convertisseur d'énergie éolienne constitué de béton coulé aux performances ultra-élevées est configuré pour être utilisé dans des conditions de charge dynamique multidirectionnelle. Le cadre principal (50) est une structure creuse à parois multiples et comprend des éléments de renforcement (90) s'étendant linéairement dans les parois. Les éléments de renforcement (90) sont liés au béton de l'objet et appliquent une contrainte de compression à l'objet par le biais de la liaison. Les éléments de renforcement (90) sont agencés dans les parois de sorte que la contrainte de compression soit contenue le long de multiples plans non parallèles (P1, P2, P3) dans l'objet. D'autres composants structuraux (90) du convertisseur d'énergie éolienne, tels que le moyeu (16'), peuvent être formés de façon similaire.
PCT/IB2012/050251 2012-01-18 2012-01-18 Composants de convertisseur d'énergie éolienne constitués de béton aux performances ultra-élevées WO2013108079A1 (fr)

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PCT/IB2012/050251 WO2013108079A1 (fr) 2012-01-18 2012-01-18 Composants de convertisseur d'énergie éolienne constitués de béton aux performances ultra-élevées

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PCT/IB2012/050251 WO2013108079A1 (fr) 2012-01-18 2012-01-18 Composants de convertisseur d'énergie éolienne constitués de béton aux performances ultra-élevées

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WO2013108079A1 true WO2013108079A1 (fr) 2013-07-25

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2694811A2 (fr) * 2011-12-06 2014-02-12 Siemens Aktiengesellschaft Bâti d'éolienne
CN107387337A (zh) * 2017-09-01 2017-11-24 三重能有限公司 风力发电机、底架及用于制备该底架的施工设备

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2255022A (en) * 1939-01-25 1941-09-02 Joseph O Ollier Reinforced concrete
GB602153A (en) * 1945-02-08 1948-05-20 Stelio Macerata Improvements in and relating to reinforced concrete constructions
US2561581A (en) * 1946-08-12 1951-07-24 Macerata Stelio Manufacture of reinforced hollow structures
US20070125017A1 (en) * 2001-09-05 2007-06-07 Blount Brian M Thin prestressed concrete panel and apparatus for making the same
US20090232659A1 (en) * 2008-03-11 2009-09-17 Joris Schiffer Concrete to fabricate the nacelle of a wind turbine

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2255022A (en) * 1939-01-25 1941-09-02 Joseph O Ollier Reinforced concrete
GB602153A (en) * 1945-02-08 1948-05-20 Stelio Macerata Improvements in and relating to reinforced concrete constructions
US2561581A (en) * 1946-08-12 1951-07-24 Macerata Stelio Manufacture of reinforced hollow structures
US20070125017A1 (en) * 2001-09-05 2007-06-07 Blount Brian M Thin prestressed concrete panel and apparatus for making the same
US20090232659A1 (en) * 2008-03-11 2009-09-17 Joris Schiffer Concrete to fabricate the nacelle of a wind turbine

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2694811A2 (fr) * 2011-12-06 2014-02-12 Siemens Aktiengesellschaft Bâti d'éolienne
US20150233357A1 (en) * 2011-12-06 2015-08-20 Siemens Aktiengesellschaft Bedplate of a wind turbine
EP2694811B1 (fr) * 2011-12-06 2016-08-24 Siemens Aktiengesellschaft Plaque de support d'éolienne
CN107387337A (zh) * 2017-09-01 2017-11-24 三重能有限公司 风力发电机、底架及用于制备该底架的施工设备

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