PLATFORM ASSEMBLY FOR A WIND TURBINE TOWER

Abstract

A modular platform assembly for a wind turbine tower includes a plurality of individual, multi-sided plate members, with each plate member connected to at least one other plate member along a common side. At least certain of the plate members have an outboard side that defines a circumferential section of the platform assembly. The connected common sides of the plate members define a structural support grid that connects to a wall within a wind turbine tower at a plurality of circumferential positions for supporting the platform assembly relative to the tower.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to wind turbines and, more particularly, to a platform assembly within the tower of a wind turbine.

BACKGROUND OF THE INVENTION

Platforms in wind turbine towers provide operators safe access to areas of a wind turbine that may require servicing, maintenance and inspection. For example, the platforms are typically located adjacent to the tower flange bolts for safe and easy inspection of the flange bolts. Typically, a number of service platforms are located at different heights in the turbine tower and are fixed by welding or with bolts to the tower wall.

A conventional type of platform includes a metal plate, typically a checker plate, which is supported by a number of steel beams fixed to the tower walls. Steel beams are heavy, have to be lifted with a crane when mounting the platform in the tower, and are thus generally difficult to install. Further, a significant number of bosses, clip plates, and the like, are necessary to mount the plate to the beams, which is both time and cost intensive.

The conventional platforms are also tailored to a specific tower diameter, and must be redesigned whenever the tower shell diameter or wall thickness changes. This is due primarily to maintaining a required maximum space of about one-inch between the circumference of the plate and the tower wall.

A further conventional design (referred to as a “bent plate”) includes a self-supporting platform formed from a metal sheet. The round platform may have multiple positions where the sheet has been cold formed such that a double layered I-section is formed which protrudes along the width of the platform. This vertical sheet section of the platform may provide some degree of stability, however the cold forming process is technically demanding and cost intensive.

In light of the above, it is desirable to have a platform for a wind turbine tower which is relatively easy to produce and assemble within the tower, and is versatile so as to be used at different diameter sections of the same or different wind turbine towers.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In accordance with aspects of the invention, a modular platform assembly is provided for a wind turbine tower. In a particular embodiment, the platform assembly includes a plurality of individual, multi-sided plate members, with each of the plate members connected to at least one other plate member along a common side. At least certain ones of the plate members have an outboard side that collectively define a circumferential section of the platform assembly. In one embodiment, all of the plate members have an outboard side and contribute to the circumference of the plate assembly. The connected common sides of the plate members define a structural support grid that connects to an interior wall within a wind turbine tower at a plurality of circumferential positions for supporting the platform assembly relative to the tower.

In a particular embodiment of the platform assembly, the plate members are each formed from a single unitary metal plate, with the metal plates having down-turned flanges along the common sides that are connected together to define the structural support grid. The flanges may, for example, be bolted together along the common sides.

In one embodiment, one of the plate members is common to all of the other plate members and thus shares a common side with each remaining plate member. This common plate member may also have an outboard side that defines a circumferential section of the platform assembly. Alternatively, the common plate member may be an interior plate member that is completely surrounded by the other remaining plate members.

The outboard sides of the plate members that define the circumference of the platform assembly may include integral toe rails defined by up-turned flanges along straight lengths of the outboard sides.

It should be appreciated that any one or combination of the plate members may have any manner of access opening or port defined therein, for example to accommodate a lift or ladder, cable runs, and so forth. The plate members may include up-turned flanges that define a toe rail around the access openings.

The platform assembly may further include a plurality of brackets configured for mounting onto the tower wall at the plurality of circumferential support positions, with the brackets defining a seat for the structural support grid. The brackets may be provided in varying radial lengths (or a sufficiently long radial length) so that the same size platform assembly is mountable to varying diameter sections of the wind turbine tower wall.

The present invention also encompasses any manner of wind turbine having a plurality of the present platform assemblies configured at different heights within the tower. In a particular embodiment, at least two of the platform assemblies within the tower have the same circumferential dimension and are mounted at respective locations within the tower having different diameters. The platform assemblies are supported by brackets having a sufficient radial length so as to accommodate for different radial distances between the platform assemblies and the interior wall of said tower.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 illustrates a perspective view of one embodiment of a wind turbine with a plurality of interior platform assemblies;

FIG. 2 illustrates a perspective top view of an embodiment of a platform assembly;

FIG. 3 illustrates a perspective bottom view of the platform assembly of FIG. 2;

FIG. 4 illustrates a perspective view of components of a platform assembly;

FIG. 5 illustrates a top view of a platform assembly within a wind turbine tower; and

FIG. 6 illustrates a side cut-away view of a bracket configuration between a platform assembly and wind turbine tower.

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. 1 illustrates a perspective view of one embodiment of a conventional wind turbine 10 that may utilize one or more platform assembly 20 in accordance with aspects of the invention. As shown, the wind turbine 10 generally includes a tower 12 erected on a suitable foundation or support surface, a nacelle 14 mounted on the tower 12, and a rotor 18 coupled to the nacelle 16. The rotor 18 includes a rotatable hub and one or more rotor blades 16 coupled to and extending outwardly from the hub. The rotor blades 16 capture the kinetic energy of the wind, which is converted into usable mechanical energy, and subsequently, electrical energy via a drivetrain and generator positioned within the nacelle 14.

The tower 12 is a tubular structure that may be constructed from individual stacked segments that are bolted together at flange locations, as in well known in the art. These segments may be formed from any number or combination of suitable materials, including metal and concrete. Typically, a respective platform assembly 20 is disposed at different heights within the tower 12, for example at the flange bolt locations. These platform assemblies serve various functions, including a rest stop for personnel that climb the tower 12 to access the nacelle 14, inspection and maintenance platforms, equipment support platforms, and so forth. The number of platform assemblies 20 and their respective heights within the tower 12 depends on the individual configuration of the wind turbine 10. The number of platform assemblies is typically from 2 to 6, more typically from 3 to 5. In a non-limiting example, platforms are provided, for example, at 4.4 m height (4.2 m platform diameter), at 21 m (4.2 m diameter), at 46 m (3.3 m diameter), at 68 m (2.7 m diameter) and at 75 m (2.5 m diameter).

An embodiment of a platform assembly 20 is depicted in FIGS. 2 through 4. The assembly is a modular construction in that it includes a plurality of individual, multi-sided plate members 22, with each of the plate members 22 connected to at least one other plate member 22 along a common (shared) side 30. As readily seen in FIG. 2, certain of the plate members 22 have a common side 30 with two other plate members, and certain other plate members 22 have a common side 30 with three other plate members. Certain of the plate members 22 have an outboard side 28 that defines a circumferential section 32 of the overall circumference of the platform assembly 20. For example, in the embodiment of FIGS. 2 and 3, each of the plate members 22 has an outboard side 28 that contributes to the overall circumference of the platform assembly 20.

As particularly seen in FIG. 3, the connected common sides 30 of the plate members 22 define a structural support grid 44 on the underside of the platform assembly 20 that adequately functions as the sole load supporting structure. In the illustrated embodiment, the structural support grid 44 defines a web-like girder with terminal ends 46 that radiate to a plurality of support positions at the circumference of the platform assembly 20. As seen in FIG. 5, the platform assembly 20 is supported on an interior wall 58 of the tower 12 at these support positions where the terminal ends 46 of the support grid 44 are mounted to brackets 54 that are welded, screwed, or otherwise attached to the tower wall 58 (FIG. 5).

The individual plate members 22 may be variously configured. For example, the plate members 22 may be formed from a single unitary metal plate, with the plates collectively defining a generally uninterrupted upper surface 24 of the platform assembly 20. The metal plates may have down-turned flanges 34 (FIG. 4) along the common sides 30 that are connected together on the underside 26 of the assembly 20 and define the structural support grid 44. The vertical dimensions of the flanges 34 (and thus strength of the support grid 44) will be a function of the expected loads on the platform assembly 20. The down-turned flanges 34 may include footers 36 (FIGS. 2 and 3).

The down-turned flanges 34 are desirably bent into their orientation relative to the upper surface 24 so as to avoid welding steps. Alternatively, the flanges 34 may be separately attached, for example by welding, bolts, or other suitable means.

The size, shape, and configuration of the plate members may vary widely within the scope and spirit of the invention. For example, referring to FIGS. 2 and 3, one of the plate members 22 may be a common plate member 42 that shares a common side 30 with each of the remaining plate members 22. This common plate member 42 may also have an outboard side 28 that defines a portion of the overall circumference of the platform assembly 20.

In an alternate embodiment depicted in FIG. 5, the common plate member 42 is an interior plate member and is completely surrounded by the other remaining plate members 22.

Referring to the figures in general, a toe rail 40 is defined around the circumference of the platform assembly 20. In one embodiment, this toe rail 40 may consist of one or more separate components that are attached to the plate members 22. In the illustrated embodiments, as particularly illustrated in FIG. 4, the continuous toe rail 40 is defined by up-turned flanges 38 formed at the outboard sides 28 of the plate members 22. Angle pieces 50 may be provided at the junction of adjacent up-turned flanges 38, as depicted in FIG. 2.

The plate members 22 may be connected together by various means. In the illustrated embodiments, the down-turned flanges 34 along the common sides 30 are bolted together with bolts 48, which may also be considered as components of the continuous support grid 44. In an alternate embodiment, the flanges 34 may be welded together.

Any manner and configuration of access openings 52 may be provided in the plate members 22 for various purposes. For example, an interior access opening 52 may be provided to accommodate a lift, while another is provide in the outboard side 28 of one or more of the plate members 22 for a ladder that extends along the interior was of the tower. Additional access openings 52 may be provided along the outboard sides 28 for cable and bus runs.

Referring to FIGS. 5 and 6, the platform assembly 20 may further include a plurality of brackets 54 that mount onto the interior tower wall 58 by any suitable means at the plurality of circumferential support positions defined by the terminal ends 46 of the support grid 44. The brackets may have any suitable configuration, such as the L-flange shape depicted in FIG. 6, and define a seat for the structural support grid 44, in particular the terminal ends 46, which may be bolted through the footers 36 or otherwise attached to the bracket 54.

As can be appreciated from FIGS. 5 and 6, the same size (diameter) platform assembly 20 may be used at various diameter positions within the tower 12. The brackets 54 have a radial length 56 (FIG. 6) that accommodates for varying distances between the toe rail 40 at the circumferential sections 32 of the plate members 22 and the tower wall 58. A single size of brackets 54 may be manufactured for a given size platform assembly 20, with the brackets 54 having a sufficient radial length 56 to accommodate the various positions of the assemblies 20 within the tower 12. Alternatively, different sized brackets 54 may be manufactured for the various diameter locations within the tower 12.

It should be readily appreciated that the present invention also encompasses any manner of wind turbine 10 (FIG. 1) that utilizes one or more of the platform assemblies 20 in accordance with aspects set forth herein.

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.

Claims

1. A modular platform assembly for a wind turbine tower, comprising:

a plurality of individual, multi-sided plate members, each said plate member connected to at least one other said plate member along a common side;

at least certain of said plate members having an outboard side that defines a circumferential section of said platform assembly; and

said connected common sides of said plate members defining a structural support grid that connects to a wall within a wind turbine tower at a plurality of circumferential positions for supporting said platform assembly relative to the tower.

2. The platform assembly as in claim 1, wherein each of said plate members is formed from a single unitary metal plate, said metal plates comprising down-turned flanges along said common sides, said down-turned flanges connected together to define said structural support grid.

3. The platform assembly as in claim 2, wherein said down-turned flanges are bolted together.

4. The platform assembly as in claim 1, wherein each of said plate members comprises a respective said outboard side such that every said plate member defines a circumferential section of said platform assembly.

5. The platform assembly as in claim 1, wherein one of said plate members is common to all other said plate members and shares a common side with each remaining said plate member.

6. The platform assembly as in claim 1, wherein said common plate member comprises a respective said outboard side and defines a circumferential section of said platform assembly.

7. The platform assembly as in claim 1, wherein said common plate member is an interior plate member completely surrounded by the other remaining said plate members.

8. The platform assembly as in claim 2, wherein said outboard sides comprise up-turned flanges that define a continuous toe rail around a circumference of said platform assembly.

9. The platform assembly as in claim 2, wherein one of said plate members comprises an access opening defined therein, said plate member comprising up-turned flanges that define a toe rail around said access opening.

10. The platform assembly as in claim 1, further comprising a plurality of brackets configured for mounting onto the wind turbine tower wall at said plurality of circumferential support positions, said brackets defining a seat for said structural support grid.

11. The platform assembly as in claim 10, wherein said brackets comprise a sufficient radial length so that the same size platform assembly is mountable to varying diameter sections of the same or different wind turbine tower walls.

12. The platform assembly as in claim 1, wherein said structural support grid has terminal ends only at said circumferential support positions.

13. A wind turbine, comprising:

a tower;

a nacelle supported atop said tower;

a rotor hub and rotor blades configured with said nacelle;

a plurality of platform assemblies disposed at different heights within said tower, each of said platform assemblies further comprising: a plurality of individual, multi-sided plate members, each said plate member connected to at least one other said plate member along a common side; at least certain of said plate members having an outboard side that defines a circumferential section of said platform assembly; and said connected common sides of said plate members defining a structural support grid that connects to an interior wall of said tower at a plurality of circumferential positions for supporting said platform assembly relative to said tower.

14. The wind turbine as in claim 13, wherein each of said plate members is formed from a single unitary metal plate, said metal plates comprising down-turned flanges along said common sides, said down-turned flanges connected together to define said structural support grid, and wherein one of said plate members is common to all other said plate members and shares a common side with each of said remaining plate members.

15. The wind turbine as in claim 14, wherein said outboard sides comprise up-turned flanges that define a continuous toe rail around a circumference of said platform assembly.

16. The wind turbine as in claim 14, further comprising a plurality of brackets mounted on said interior wall of said tower at said circumferential support positions of each said platform assembly, said brackets defining a seat for said structural support grid.

17. The wind turbine as in claim 16, wherein at least two of said platform assemblies within said tower have the same circumferential dimension and are mounted at respective locations within said tower having different diameters, said respective brackets for said platform assemblies having a sufficient radial length so as to accommodate for different radial distances between said platform assemblies and said interior wall of said tower.