System and method for locking a wind turbine rotor during extended maintenance

Abstract

The present invention relates to a system and method for locking a wind turbine rotor during extended maintenance. A rotor lock assembly for locking a wind turbine rotor includes at least one removable rotor lock. The removable rotor lock has a housing including an opening and a mounting portion, a pin positioned within the opening, and a locking mechanism. The opening extends from a first end to a second end. The mounting portion is adapted to be mounted to a bearing housing adjacent to a rotor lock plate of the rotor.

Description

Technical Field

[0001] The present disclosure relates generally to wind turbines, and more particularly to systems and methods for locking a rotor of a wind turbine during extended maintenance operations. Background Art

[0002] Wind power is considered to be one of the cleanest and most environmentally friendly energy sources currently available, and in this regard, wind turbines have received increasing attention. A modern wind turbine typically includes a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The nacelle includes a rotor assembly coupled to the gearbox and the generator. The rotor assembly and the gearbox are mounted on a bedplate support frame positioned within the nacelle. More specifically, in many wind turbines, the gearbox is mounted to the bedplate via one or more torque arms or arms. One or more rotor blades capture the kinetic energy of the wind using the known airfoil principle. The rotor blades transfer kinetic energy in the form of rotational energy so as to rotate a shaft that couples the rotor blades to the gearbox or directly to the generator (if a gearbox is not used). The generator then converts the mechanical energy into electrical energy that can be deployed to the utility grid.

[0003] More specifically, most commercially available wind turbines utilize a multi-stage gear train to connect the turbine blades to the generator. The wind rotates the rotor blades, which in turn spin the low-speed shaft (i.e., the main shaft). The main shaft is coupled to the input shaft of a gearbox, which has a higher-speed output shaft connected to the generator. Thus, the purpose of the gear train is to increase the speed of mechanical motion. Furthermore, the gearbox and generator are typically supported by one or more bearings and mounted to the bedplate assembly via one or more torque arms or supports.

[0004] During the lifecycle of a wind turbine, it may occasionally become necessary to perform maintenance operations on various components of the wind turbine. Typically, such maintenance cannot be performed on a wind turbine if the rotor is able to rotate in response to wind loads. Therefore, maintenance operations often require securing the rotor in a fixed position. Typically, rotation of the rotor can be initially stopped by a combination of braking applied to the rotor shaft and pitching the rotor blades. The rotor can be secured in place using a low-speed rotor lock, which is typically an integral component of the wind turbine.

[0005] Generally, low-speed rotor locks are designed to withstand the expected loads on the rotor in response to winds up to a certain threshold. Therefore, low-speed rotor locks can generally only be employed for periods of time when it is possible to predict with reasonable certainty that the wind will not exceed the threshold. This period is typically limited to a few hours. However, certain maintenance procedures cannot be completed within this timeframe.

[0006] In view of the foregoing, the art is continually seeking new and improved systems and methods for securing a rotor in a fixed position at higher wind speeds that may be encountered during extended maintenance windows. Summary of the Invention

[0007] 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.

[0008] In one aspect, the present disclosure relates to a rotor lock assembly for locking a rotor of a wind turbine. The rotor lock assembly may include at least one removable rotor lock. The removable rotor lock(s) may include a housing including an opening and a mounting portion. The opening may extend from a first end to a second end thereof. The mounting portion may be adapted to be mounted to a bearing housing adjacent to a rotor lock plate of the rotor. The removable rotor lock(s) may include a pin positioned within the opening. The pin may include a proximal end and a distal end. The pin may be movable within the opening such that the distal end moves toward and engages the rotor lock plate of the rotor. The removable rotor lock(s) may also include a locking mechanism for locking the pin in place.

[0009] In an embodiment, the rotor lock assembly may further include a plurality of fasteners for securing the mounting portion of the housing to the bearing housing through the plurality of fastener openings in the mounting portion. Additionally, in an embodiment, a pin may engage the rotor lock plate via a through-hole configured to pass through the rotor lock plate. The through-hole may define an axis parallel to and offset relative to the main axis of the rotor. In another embodiment, the rotor lock assembly may further include an alignment system operably coupled to the pin to align the pin with the through-hole in the rotor lock plate.

[0010] In an embodiment, the removable rotor lock(s) may include a first removable rotor lock and a second removable rotor lock. The first removable rotor lock may be coupled to a first quarter of the bearing housing, and the second removable rotor lock may be coupled to an adjacent second quarter of the bearing housing. In additional embodiments, the housing may include: a bushing element positioned within the opening; and a bushing securing mechanism oriented to engage corresponding features of the bushing element and secure the bushing element within the opening.

[0011] In additional embodiments, the pin is movable within the bushing element via at least one of axial movement or rotational movement. The pin is movable via at least one of a direct-manual engagement system, a hydraulic engagement system, a gear engagement system, or a motorized engagement system operably coupled to the pin. In additional embodiments, a proximal end of the pin engages a locking mechanism.

[0012] In an embodiment, the distal end of the pin may include a tapered cross-sectional profile.In another embodiment, the housing may further include at least one attachment location for providing a lifting point for lifting the rotor lock assembly uptower.

[0013] In another aspect, the present disclosure relates to a method for performing a maintenance and / or repair procedure on a rotor component of a wind turbine. The method may include coupling (one or more) removable rotor locks to a main bearing housing. The method may include preventing the rotor from rotating and advancing an integrated low-speed rotor lock of the wind turbine to engage a first corresponding feature of a rotor lock plate. The method may include advancing a pin of at least one removable rotor lock to an advanced position to engage a second corresponding feature of the rotor lock plate. The method may also include securing the pin in the advanced position by engaging a locking mechanism.

[0014] In one embodiment, a method for performing a maintenance and / or repair procedure on a rotor component of a wind turbine may further include aligning a pin with a corresponding feature of a rotor lock plate via an alignment system operably coupled to the pin. In an embodiment, advancing the pin may include advancing the pin via at least one of a direct-manual engagement system, a hydraulic engagement system, a gear engagement system, or a motorized engagement system operably coupled to the pin.

[0015] In an embodiment, the method may include coupling a first rotor lock and a second rotor lock to a first quarter of the bearing housing and an adjacent second quarter of the main bearing housing, respectively. In an embodiment, the method may also include performing a maintenance procedure on the assembled nacelle above the tower. In an additional embodiment, the method may include hoisting the first and second removable rotor locks above the tower through an access hatch located on the underside of the nacelle.

[0016] In another aspect, the present disclosure relates to a wind turbine repair system. The wind turbine repair system may include a rotor lock plate circumferentially mounted to a rotor shaft of a wind turbine. The rotor lock plate may define a plurality of openings having axes parallel to and offset relative to the rotor shaft. The wind turbine repair system may include a low-speed rotor lock coupled to a platen support frame perpendicular to the rotor lock plate; a bearing housing; and at least one removable rotor lock mounted to the bearing housing. The removable rotor lock may include a housing having an opening and a mounting portion. The opening may extend from a first end to a second end. The mounting portion may be adapted to be mounted to the bearing housing adjacent to the rotor lock plate of the rotor. The removable rotor lock may also include a pin positioned within the opening. The pin may include a proximal end and a distal end. The pin may be movable within the opening such that the distal end moves toward and engages the rotor lock plate of the rotor. The removable rotor lock may also include a locking mechanism for locking the pin in place.

[0017] 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 present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] A full and complete disclosure of the invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification taken in conjunction with the accompanying drawings, in which:

[0019] Figure 1 shows a perspective view of one embodiment of a wind turbine according to aspects of the present disclosure;

[0020] Figure 2 a perspective view of one embodiment showing a simplified interior view of one embodiment of a nacelle of a wind turbine according to aspects of the present disclosure;

[0021] Figure 3 shows a simplified side view of a rotor lock assembly according to aspects of the present disclosure;

[0022] Figure 4 shows a simplified rear view of a rotor lock assembly according to aspects of the present disclosure;

[0023] Figure 5A shows a perspective view of a rotor lock according to aspects of the present disclosure;

[0024] Figure 5B Shown Figure 5A An exploded perspective view of the embodiment depicted in FIG.

[0025] Figure 6 A perspective view of a portion of a bearing housing according to aspects of the present disclosure is shown.

[0026] Figure 7 A flow chart illustrating one embodiment of a method for performing a maintenance and / or repair procedure on a rotor component of a wind turbine according to aspects of the present disclosure is shown. DETAILED DESCRIPTION

[0027] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided as an illustration of the present invention, not as a limitation thereof. Indeed, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the present invention. For example, a feature shown or described as part of one embodiment may be used together with another embodiment to produce additional other embodiments. Therefore, it is intended that the present invention encompasses such modifications and variations as fall within the scope of the appended claims and their equivalents.

[0028] Generally, the present disclosure relates to a rotor lock assembly for locking a wind turbine rotor during extended maintenance operations. The rotor lock assembly includes one or more removable rotor locks. The removable rotor locks may include a housing, a bushing element, a pin, and a locking mechanism. The housing has an opening and a mounting portion extending from a first end to a second end. The mounting portion is adapted or formed to be mounted to a corresponding attachment location on an outer surface of a main bearing housing adjacent to a rotor lock plate of the rotor. The bushing element is positioned within the opening of the housing, and the pin is positioned within the bushing element. The pin has a proximal end and a distal end. The pin is movable within the bushing element such that a force applied to the pin causes the pin to move toward and engage the rotor lock plate of the rotor. The pin can be locked in this engaged position by an attached locking mechanism. The removable rotor locks may be sized to share the workload with an integral low-speed rotor lock coupled to a bedplate support frame. The shared workload of the removable rotor lock(s) and the low-speed rotor lock may be sufficient to withstand forces generated by winds exceeding predicted speeds during an extended maintenance period.

[0029] Generally, maintenance and / or repair procedures can be performed on components of a wind turbine by coupling (one or more) removable rotor locks to the main bearing housing of the wind turbine. Rotation of the rotor in response to wind forces can be stopped, and a built-in or integral low-speed rotor lock of the wind turbine can be advanced to engage a feature, such as a hole or recess, of a rotor lock plate. With the rotor in a locked position, a pin of the removable rotor lock(s) can be advanced to engage a second feature of the rotor lock plate. The pin can be secured in the advanced position by engagement of a locking mechanism. With the rotor thus secured, extended maintenance operations can be performed on the wind turbine while the wind turbine may be subjected to a wide range of wind speeds.

[0030] Referring now to the accompanying drawings, Figure 1A perspective view of one embodiment of a wind turbine 100 according to the present disclosure is shown. As shown, the wind turbine 100 generally includes a tower 102 extending from a support surface 104, a nacelle 106 including a housing 160 mounted on the tower 102, and a rotor 108 coupled to the nacelle 106. The rotor 108 includes a rotatable hub 110 and at least one rotor blade 112 coupled to the hub 110 and extending outwardly from the hub 110. For example, in the illustrated embodiment, the rotor 108 includes three rotor blades 112. However, in alternative embodiments, the rotor 108 may include more or less than three rotor blades 112. The individual rotor blades 112 may be spaced about the hub 110 to facilitate rotating the rotor 108 so that kinetic energy can be converted from the wind into usable mechanical energy and subsequently into electrical energy. For example, the hub 110 may be rotatably coupled to a generator 118 ( Figure 2 ), to allow the generation of electrical energy.

[0031] Wind turbine 100 may also include a wind turbine controller 114 centralized within nacelle 106. However, in other embodiments, controller 114 may be located within any other component of wind turbine 100 or at a location external to the wind turbine. Furthermore, controller 114 may be communicatively coupled to any number of components of wind turbine 100 to control the components. Thus, controller 114 may include a computer or other suitable processing unit. Thus, in several embodiments, controller 114 may include suitable computer-readable instructions that, when implemented, configure controller 114 to perform a variety of different functions, such as receiving, transmitting, and / or executing wind turbine control signals.

[0032] Now refer to Figure 2 , showing Figure 1 , a simplified interior view of one embodiment of a nacelle 106 of a wind turbine 100 is shown in FIG. As shown, a generator 118 may be coupled to the rotor 108 for generating electricity from the rotational energy generated by the rotor 108. For example, as shown in the illustrated embodiment, the rotor 108 may include a rotor shaft 122 coupled to the hub 110 for rotation therewith. The rotor shaft 122 is rotatably supported by main bearings 144. The rotor shaft 122 may, in turn, be rotatably coupled to a generator shaft 124 of the generator 118 via a gearbox 126, which is connected to a bedplate support frame 136 via one or more torque arms 142. As generally understood, the rotor shaft 122 may provide a low-speed, high-torque input to the gearbox 126 in response to rotation of the rotor blades 112 and the hub 110. The gearbox 122 may then be configured to convert the low-speed, high-torque input into a high-speed, low-torque output to drive the generator shaft 124, and thus the generator 118.

[0033] Each rotor blade 112 may also include a pitch adjustment mechanism 120 configured to rotate each rotor blade 112 about its pitch axis 116. Furthermore, each pitch adjustment mechanism 120 may include a pitch drive motor 128 (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox 130, and a pitch drive pinion 132. In such an embodiment, the pitch drive motor 128 may be coupled to the pitch drive gearbox 130 such that the pitch drive motor 128 imparts mechanical force to the pitch drive gearbox 130. Similarly, the pitch drive gearbox 130 may be coupled to the pitch drive pinion 132 for rotation therewith. The pitch drive pinion 132, in turn, may be in rotational engagement with a pitch bearing 134 coupled between the hub 110 and the corresponding rotor blade 112 such that rotation of the pitch drive pinion 132 causes rotation of the pitch bearing 134. Thus, in such an embodiment, rotation of pitch drive motor 128 drives pitch drive gearbox 130 and pitch drive pinion 132, thereby rotating pitch bearing 134 and rotor blades 112 about pitch axis 116. Similarly, wind turbine 100 may include one or more yaw drive mechanisms 138 communicatively coupled to controller 114, wherein each yaw drive mechanism(s) 138 is configured to change the angle of nacelle 106 relative to the wind (e.g., by engaging yaw bearing 140 of wind turbine 100).

[0034] like Figure 3 and Figure 4 , the main bearing 144 may generally correspond to a tapered roller bearing, but may be any suitable bearing, including, for example, a spherical roller bearing, a ball bearing, or any other suitable bearing. Additionally, as shown, the main bearing 144 may be secured in place via a bearing housing 146. The main bearing 144 may also be mounted to the bedplate support member 136 of the nacelle 106 via one or more torque supports 148.

[0035] Still refer to Figure 4 In an embodiment, the wind turbine 100 may be equipped with a rotor lock plate 150. The rotor lock plate 150 may surround the rotor shaft 122 of the wind turbine 100. The rotor lock plate 150 may include a plurality of features 152 that may be engaged to secure the rotor 108 and prevent the rotor 108 from rotating in response to wind loads. In an embodiment, the features 152 may be a plurality of through-holes 154 defined by the rotor lock plate 150. The through-holes 154 may define an axis (H) that is parallel to and offset from the main axis 122 of the rotor 108. A ). It will be appreciated that in embodiments, features 152 may be, for example, depressions, grooves, ridges, teeth, or high friction areas that may be engaged to secure rotor 108 .

[0036] In such Figure 3 , the wind turbine 100 may also be equipped with a low-speed rotor lock 156. As shown, the low-speed rotor lock 156 may be built into and integral with the bedplate support frame 136. The low-speed rotor lock 156 may include a low-speed rotor lock pin 158 that may be advanced to engage a corresponding feature 152 of the rotor lock plate 150. The low-speed rotor lock 156 may be sized to resist forces created by winds up to a first wind threshold.

[0037] exist Figure 3 and Figure 4 , side and rear views of a rotor lock assembly 200 according to an embodiment of the present disclosure are shown. The rotor lock assembly 200 may lock the rotor 108 of the wind turbine 100 to facilitate maintenance operations during a time period when there is a likelihood of encountering winds exceeding a first wind threshold. According to aspects of the present disclosure, the rotor lock assembly 200 may include (one or more) removable rotor locks 202. More specifically, as shown, the removable rotor lock(s) 202 may be coupled to a quarter circumference of the bearing housing 146 adjacent to the rotor lock plate 150. In an embodiment, as shown Figure 5A , the removable rotor lock(s) 202 may include a housing 204, a bushing member 206, a pin 208, and a locking mechanism 210. It should be appreciated that in at least one embodiment, each rotor lock 202 may include a single pin 208, with the housing 204 being sized to accommodate the single pin 208 positioned within the bushing member 206.

[0038] In such Figure 4 In the embodiment depicted in FIG, rotor lock assembly 200 may include at least a first removable rotor lock 212 and a second removable lock 214. First removable rotor lock 212 may be coupled to a first quarter of bearing housing 146. Second removable rotor lock 214 may be coupled to a second quarter of bearing housing 146 adjacent to the first quarter. Thus, in an embodiment, removable rotor lock 202 works together with low-speed rotor lock 156 to resist wind loads including a 15% safety margin.

[0039] It should be appreciated that the various rotor locks may be subject to different portions of the wind load. For example, in an embodiment, low-speed rotor lock 156 may be configured to resist up to 50% of the expected wind load, while the pair of removable rotor locks may each be configured to resist up to 25% of the expected wind load. Alternatively, low-speed rotor lock 156 may be configured to resist up to 70% of the expected wind load, while first removable rotor lock 212 may be configured to resist up to 20% of the expected wind load, and second removable rotor lock 214 may be configured to resist up to 10% of the expected wind load.

[0040] Figure 5A and Figure 5B 1 and 2 show a perspective view and an exploded perspective view of the rotor lock(s) 202 according to aspects of the present disclosure. Furthermore, as shown, the rotor lock(s) 202 may include a housing 204. The housing 204 may include an opening 216. The opening 216 may extend from a first end 220 to a second end 222. The housing 204 may also include a mounting portion 218. The mounting portion 218 may be adapted to be mounted to the bearing housing 146 adjacent to the rotor lock plate 150 of the rotor 108. In applications such as Figure 4 In the embodiment depicted in FIG, housing 204 may have a rounded triangular cross-sectional shape, wherein the housing tapers radially from a maximum width at mounting portion 218. Mounting portion 218 may have a surface profile corresponding to that of portions of main bearing housing 146.

[0041] In an embodiment, the mounting portion 218 may define a plurality of fastener openings 224. A plurality of fasteners 226 may be inserted through the plurality of fastener openings 224 to secure the mounting portion 218, and thus the removable rotor lock(s) 202, to the bearing housing 146. The plurality of fasteners 226 may include screws, bolts, studs and nuts, or removable rivets. It should be appreciated that in alternative embodiments, the removable rotor lock(s) 202 may be coupled to the bearing housing 146 by any suitable means. For example, the rotor lock(s) 202 may be coupled to the bearing housing by adhesion, fusion, welding, or other mechanical means such as a dovetail groove. It should be further appreciated that in embodiments where fasteners 226 are not employed, the plurality of fastener openings 224 may be omitted from the mounting portion 218.

[0042] In such Figure 5A In the embodiment depicted in FIG, the housing 204 can be equipped with at least one attachment location 228. The attachment location(s) 228 can be coupled to the housing 204. For example, the attachment location(s) 228 can be a lifting eye, an eye plate, a lifting eye, an eye nut, or an eye bolt. Alternatively, the attachment location(s) 228 can include a protrusion, a recess, or a combination thereof that is integrally formed with the housing 204.

[0043] The attachment location(s) 228 may provide a lifting point for lifting the repositionable rotor lock(s) 202 above the tower. The housing 204 may be sized to have a lifting footprint that allows the housing 204 to be hoisted above the tower through an access hatch located on the underside of the nacelle 106. Additionally, the housing 204 may be sized to allow the housing 204 to be moved from the access hatch to the bearing housing 146 without having to remove the outer shell 160 or employ a ground crane. It should be appreciated that multiple rotor locks 202 sized as described herein may facilitate utilizing multiple pins 208 to secure the rotor lock plate 150 in situations where a single housing accommodating multiple pins is not removable without removing the outer shell 160.

[0044] Now refer to Figure 6 , according to aspects of the present disclosure, presents a perspective view of a portion of the bearing housing 146. Figure 6 As depicted in FIG, bearing housing 146 may include a removable rotor lock mounting point 162. As depicted, removable rotor lock mounting point 162 may include a flat surface 164 defining a plurality of fastener openings 166. The plurality of fastener openings 166 may be configured to couple removable rotor lock(s) 202 to mounting point 162 via a plurality of fasteners 226, which are inserted through the plurality of fastener openings 224 of mounting portion 218. Flat surface 164 has a long axis oriented perpendicular to rotor shaft 122. Removable rotor lock mounting point 162 may also include a pair of mounting ridges 168 oriented perpendicular to rotor shaft 122, with flat surface 164 disposed between the pair of mounting ridges 168. It should be appreciated that in alternative embodiments, flat surface 164 may be a curved surface formed to receive or be received by mounting portion 218.

[0045] Reference again Figure 3-5B, the (one or more) rotor locks 202 may include a bushing element 206. The bushing element 206 may be positioned within the opening 216. The bushing element 206 may have a first portion 230, which may be inserted into the housing 204. The bushing element 206 may also have a second portion 232, which may extend outward from the open second end 220. The bushing element 206 may include a fixing feature 234. The fixing feature 234 may be configured as a protrusion or a recess, which may be engaged by a bushing fixing mechanism 236 coupled to the housing 204. The bushing fixing mechanism 236 may fix the bushing element 206 within the opening 216 of the housing 204. It should be appreciated that the bushing element 206 may be a unitary body. Alternatively, the bushing element 206 may include multiple segments. For example, the first portion 230 may be a first segment, and the second portion 232 may be a second segment. In additional examples, the bushing element 206 may be divided by a vertical plane to create a first half and a second half.

[0046] Still refer to Figure 3-5B The rotor lock(s) 202 may include a pin 208. The pin 208 may be positioned within the bushing member 206. The pin 208 may include a proximal end 238 and a distal end 240. The pin 208 may be movable within the bushing member 206. Upon application of force, the distal end 240 may advance or move toward and engage the rotor lock plate 150 of the rotor 108. In at least one embodiment, the proximal end 238 may be formed with a feature that can be engaged by a locking mechanism 210 coupled to at least one of the bushing member 206 or the housing 204 to secure the pin 208 in the forward or engaged position. In at least one embodiment, the locking mechanism 210 may include a lockout-tagout feature that prevents unauthorized removal of the pin 208. It should be appreciated that in at least one embodiment, engagement of the rotor lock plate 150 may be facilitated by an alignment system operably coupled to the pin 208 , which may be configured to align the pin 208 with the through-hole 154 of the rotor lock plate 150 .

[0047] In such Figure 3-5B In the embodiment depicted in FIG, the pin 208 can be moved along the axis (H A ) to move within the bushing element 206 by at least one of axial movement or rotational movement. The movement of the pin 208 can be activated by the engagement system 242. The engagement system 242 can be at least one of a direct-manual engagement system, a hydraulic engagement system, a gear engagement system, or a motorized engagement system operably coupled to the pin 208. For example, Figure 5AAs depicted in FIG, a direct-manual engagement system may involve a technician applying force directly on the engagement protrusion 244 to slide the pin 208 in an axial direction. Alternatively, the force applied by the technician may cause the pin 208 and / or the bushing element 206 to rotate and advance or retract in response to a plurality of threads. In yet another embodiment, a tool may be used to turn a crank that may be coupled to a gear system configured to move the pin 208 within the bushing element 206.

[0048] In such Figure 5B In the embodiment depicted in FIG, the distal end 240 of the pin 208 may be relieved to facilitate insertion and / or extraction of the pin 208 relative to the rotor lock plate 150. In at least one embodiment, the distal end 240 of the pin 208 may have a tapered cross-sectional profile. The tapered cross-sectional profile of the distal end 240 may include, for example, a pointed arch, a chamfered corner, or a rounded cross-sectional profile.

[0049] refer to Figure 7 , shows a flow chart of one embodiment of a method 300 for performing a maintenance and / or repair procedure on a component of a wind turbine. Figure 3-5B The method 300 is implemented with reference to the rotor lock assembly 200 . Figure 6 The steps are depicted as being performed in a particular order for purposes of illustration and discussion. One of ordinary skill in the art, using the disclosure provided herein, will appreciate that the various steps of method 300, or any other method disclosed herein, may be adapted, modified, rearranged, performed simultaneously, or modified in various ways without departing from the scope of the present disclosure.

[0050] As shown at (302), method 300 includes coupling at least one removable rotor lock to a main bearing housing. As shown at (304), method 300 includes preventing the rotor from rotating, and at (306), includes advancing an internal low-speed rotor lock of the wind turbine to engage a first corresponding feature of a rotor lock plate. As shown at (308), method 300 includes advancing a pin of at least one removable rotor lock to an advanced position to engage a second corresponding feature of the rotor lock plate. Additionally, as shown at (310), method 300 includes securing the pin in the advanced position by engaging a locking mechanism.

[0051] In an additional embodiment, the method (300) may further include aligning the pin with a corresponding feature of the rotor lock plate via an alignment system operably coupled to the pin. Furthermore, advancing the pin may include advancing the pin via an engagement system operably coupled to the pin. In another embodiment, the method (300) may include coupling the second rotor lock to the main bearing housing.

[0052] In an additional embodiment, the method (300) may include performing a maintenance procedure on the assembled nacelle above the tower. In yet another embodiment, the method (300) may include hoisting the first removable rotor lock and the second removable rotor lock above the tower through an access hatch positioned on an underside of the nacelle.

[0053] In addition, the skilled person will recognize the interchangeability of the various features from different embodiments. Similarly, those of ordinary skill in the art can mix and match the various method steps and features described and other known equivalents for each such method and feature to construct additional systems and techniques according to the principles of the present disclosure. Of course, it will be understood that not all such purposes or advantages described above may be achieved according to any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein can be embodied or performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without having to achieve other purposes or advantages as taught or suggested herein.

[0054] This written description uses examples to disclose the invention (including the best mode) and also to enable anyone skilled in the art to practice the invention (including making and using any devices or systems, and performing any combined 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. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that are insubstantially different from the literal language of the claims, such other examples are intended to be within the scope of the claims.

[0055] For reasons of completeness, various aspects of the disclosure are set forth in the following numbered clauses:

[0056] Clause 1. A rotor lock assembly for locking a rotor of a wind turbine, the rotor lock assembly comprising:

[0057] At least one removable rotor lock comprising:

[0058] a housing including an opening extending from a first end to a second end thereof and a mounting portion adapted to be mounted to a bearing housing adjacent a rotor lock plate of the rotor; and,

[0059] a pin positioned within the opening, the pin comprising a proximal end and a distal end, the pin being movable within the opening such that the distal end moves toward and engages a rotor lock plate of the rotor; and,

[0060] A locking mechanism used to lock the pin in place.

[0061] Clause 2. The rotor lock assembly of Clause 1, further comprising a plurality of fasteners for securing the mounting portion of the housing to the bearing housing through the plurality of fastener openings of the mounting portion.

[0062] Clause 3. The rotor lock assembly of Clause 1, wherein the pin engages the rotor lock plate via a through hole configured to pass through the rotor lock plate, the through hole defining an axis parallel to and offset relative to the main axis of the rotor.

[0063] Clause 4. The rotor lock assembly of Clause 3, further comprising an alignment system operably coupled to the pin to align the pin with the through-hole of the rotor lock plate.

[0064] Clause 5. The rotor lock assembly of Clause 1, wherein the at least one removable rotor lock comprises a first removable rotor lock and a second removable rotor lock.

[0065] Clause 6. The rotor lock assembly of Clause 5, wherein the first removable rotor lock is coupled to a first quarter of the bearing housing and the second removable rotor lock is coupled to an adjacent second quarter of the bearing housing.

[0066] Clause 7. The rotor lock assembly of Clause 1, wherein the housing further comprises: a bushing element positioned within the opening; and a bushing securing mechanism oriented to engage corresponding features of the bushing element and secure the bushing element within the opening.

[0067] Clause 8. The rotor lock assembly of clause 7, wherein the pin is movable within the bushing element via at least one of axial movement or rotational movement, and wherein the pin is moved by at least one of a direct-manual engagement system, a hydraulic engagement system, a gear engagement system, or a motorized engagement system operably coupled to the pin.

[0068] Clause 9. The rotor lock assembly of clause 1, wherein the proximal end of the pin engages the locking mechanism.

[0069] Clause 10. The rotor lock assembly of clause 1, wherein the distal end of the pin comprises a tapered cross-sectional profile.

[0070] Clause 11. The rotor lock assembly of Clause 1, wherein the housing further comprises at least one attachment location for providing a lifting point for lifting the removable rotor lock above the tower.

[0071] Clause 12. A method for performing a maintenance procedure and / or a repair procedure on a component of a wind turbine, the method comprising:

[0072] coupling at least one removable rotor lock to the main bearing housing;

[0073] Prevent the rotor from rotating;

[0074] advancing an internal low-speed rotor lock of the wind turbine to engage a first corresponding feature of a rotor lock plate;

[0075] advancing a pin of at least one removable rotor lock to an advanced position to engage a second corresponding feature of the rotor lock plate; and,

[0076] The pin is secured in the advanced position by engagement of the locking mechanism.

[0077] Clause 13. The method according to Clause 12, further comprising:

[0078] The pin is aligned with a corresponding feature of the rotor lock plate via an alignment system operably coupled to the pin.

[0079] Clause 14. The method of clause 12, wherein advancing the pin comprises advancing the pin via at least one of a direct-manual engagement system, a hydraulic engagement system, a gear engagement system, or a motorized engagement system operably coupled to the pin.

[0080] Clause 15. The method of clause 12, wherein the at least one removable rotor lock comprises a first removable rotor lock coupled to a first quarter circumference of the bearing housing, the method further comprising:

[0081] A second removable rotor lock is coupled to an adjacent quadrant of the main bearing housing.

[0082] Clause 16. The method according to Clause 12, further comprising:

[0083] Maintenance procedures are performed on the assembled nacelle above the tower.

[0084] Clause 17. The method according to Clause 15, further comprising:

[0085] The first and second removable rotor locks are hoisted above the tower through an access hatch located on the underside of the nacelle.

[0086] Clause 18. A wind turbine repair system comprising:

[0087] a rotor lock plate circumferentially mounted to a rotor shaft of the wind turbine, the rotor lock plate defining a plurality of openings, each of the plurality of openings having an axis parallel to and offset relative to the rotor shaft;

[0088] a low-speed rotor lock coupled to a platen support frame perpendicular to the rotor lock plate;

[0089] a bearing housing; and

[0090] A removable rotor lock mounted to the bearing housing, the removable rotor lock comprising:

[0091] a housing including an opening extending from a first end to a second end thereof and a mounting portion adapted to be mounted to a bearing housing adjacent a rotor lock plate of the rotor,

[0092] a pin positioned within the opening, the pin including a proximal end and a distal end, the pin movable within the opening such that the distal end moves toward and engages a rotor lock plate of the rotor; and

[0093] A locking mechanism used to lock the pin in place.

[0094] Clause 19. The wind turbine repair system of clause 18, wherein the bearing housing further comprises a mounting point for a removable rotor lock, the mounting point for the removable rotor lock comprising:

[0095] a planar surface defining a plurality of fastener openings, the planar surface having a long axis oriented perpendicular to the rotor axis,

[0096] A pair of mounting ridges are oriented perpendicular to the rotor axis, wherein the flat surface is disposed between the pair of mounting ridges.

[0097] Clause 20. The wind turbine repair system of clause 18, wherein the removable rotor lock comprises a first removable rotor lock, and the rotor lock mounting point comprises a first rotor lock mounting point positioned within a first quarter of the main bearing housing, the system further comprising:

[0098] A second removable rotor lock is coupled to the second rotor lock mounting point positioned within the second quarter of the main bearing housing.

Claims

1. A rotor lock assembly for locking a rotor of a wind turbine, the rotor lock assembly comprising: At least one removable rotor lock comprising: a housing comprising an opening, a mounting portion, a bushing element positioned within the opening, the bushing securing mechanism oriented to engage corresponding features of the bushing element and secure the bushing element within the opening, the opening extending from a first end to a second end thereof, the mounting portion adapted to be mounted to a bearing housing adjacent a rotor lock plate of the rotor; and, a pin positioned within the opening, the pin including a proximal end and a distal end, the pin movable within the opening such that the distal end moves toward and engages the rotor lock plate of the rotor; and a locking mechanism for locking the pin in place.

2. The rotor lock assembly according to claim 1, wherein: The rotor lock assembly further includes a plurality of fasteners for securing the mounting portion of the housing to the bearing housing through a plurality of fastener openings in the mounting portion.

3. The rotor lock assembly according to claim 1, wherein: The pin engages the rotor lock plate via a through hole configured to pass through the rotor lock plate, the through hole defining an axis parallel to and offset relative to a main axis of the rotor.

4. The rotor lock assembly according to claim 3, wherein: The rotor lock assembly further includes an alignment system operably coupled to the pin to align the pin with the through-hole of the rotor lock plate.

5. The rotor lock assembly according to claim 1, wherein: The at least one removable rotor lock includes a first removable rotor lock and a second removable rotor lock.

6. The rotor lock assembly according to claim 5, wherein: The first removable rotor lock is coupled to a first quarter of the bearing housing, and the second removable rotor lock is coupled to an adjacent second quarter of the bearing housing.

7. The rotor lock assembly according to claim 1, wherein: The pin is capable of moving within the bushing element via at least one of axial movement or rotational movement, and wherein the pin moves via at least one of a direct-manual engagement system, a hydraulic engagement system, a gear engagement system, or a motorized engagement system operably coupled to the pin.

8. The rotor lock assembly according to claim 1, wherein: The proximal end of the pin engages the locking mechanism.

9. The rotor lock assembly according to claim 1, wherein: The distal end of the pin includes a tapered cross-sectional profile.

10. The rotor lock assembly according to claim 1, wherein: The housing further includes at least one attachment location for providing a lifting point for lifting the removable rotor lock above a tower.

11. A method for performing a maintenance procedure and / or a repair procedure on a component of a wind turbine, the method comprising: coupling at least one removable rotor lock to a main bearing housing, the at least one removable rotor lock comprising a housing including an opening, a mounting portion, a bushing element positioned within the opening, and a bushing securing mechanism oriented to engage corresponding features of the bushing element and secure the bushing element within the opening; preventing the rotor from rotating; advancing an internal low-speed rotor lock of the wind turbine to engage a first corresponding feature of a rotor lock plate; advancing a pin of the at least one removable rotor lock to an advanced position to engage a second corresponding feature of the rotor lock plate; as well as, The pin is secured in the advanced position by engagement of a locking mechanism.

12. The method according to claim 11, characterized in that The method further comprises: The pin is aligned with the corresponding feature of the rotor lock plate via an alignment system operably coupled to the pin.

13. The method according to claim 11, characterized in that Advancing the pin includes advancing the pin via at least one of a direct-manual engagement system, a hydraulic engagement system, a gear engagement system, or a motorized engagement system operably coupled to the pin.

14. The method according to claim 11, characterized in that The at least one removable rotor lock includes a first removable rotor lock coupled to a first quarter of the bearing housing, the method further comprising: A second removable rotor lock is coupled to an adjacent quadrant of the main bearing housing.

15. The method according to claim 11, characterized in that The method further comprises: The maintenance procedures are performed on the assembled nacelle above the tower.

16. The method according to claim 14, characterized in that The method further comprises: The first and second removable rotor locks are hoisted above the tower through an access hatch located on the underside of the nacelle.

17. A wind turbine repair system comprising: a rotor lock plate circumferentially mounted to a rotor shaft of the wind turbine, the rotor lock plate defining a plurality of openings, each of the plurality of openings having an axis parallel to and offset relative to the rotor shaft; a low speed rotor lock coupled to a platen support frame perpendicular to the rotor lock plate; bearing housing; as well as, A removable rotor lock mounted to the bearing housing, the removable rotor lock comprising: a housing including an opening, a mounting portion, a bushing element positioned within the opening, the bushing securing mechanism oriented to engage corresponding features of the bushing element and secure the bushing element within the opening, the opening extending from a first end to a second end thereof, the mounting portion adapted to be mounted to a bearing housing adjacent a rotor lock plate of the rotor, a pin positioned within the opening, the pin comprising a proximal end and a distal end, the pin being movable within the opening such that the distal end moves toward and engages the rotor lock plate of the rotor; as well as A locking mechanism is provided for locking the pin in place.

18. The wind turbine repair system of claim 17, wherein: The bearing housing further includes mounting points for a removable rotor lock, the mounting points for the removable rotor lock including: a planar surface defining a plurality of fastener openings, the planar surface having a long axis oriented perpendicular to the rotor axis, A pair of mounting ridges are oriented perpendicular to the rotor axis, wherein the flat surface is disposed between the pair of mounting ridges.

19. The wind turbine repair system of claim 17, wherein: The removable rotor lock includes a first removable rotor lock, and the rotor lock mounting point includes a first rotor lock mounting point positioned within a first quarter of the bearing housing, the system further comprising: A second removable rotor lock is coupled to the second rotor lock mounting point positioned within the second quarter of the bearing housing.

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