System and method for coupling a hub of a wind turbine to a main shaft

Abstract

A system and method for coupling a hub of a wind turbine to a main shaft is provided. Accordingly, a plurality of fasteners are disposed within corresponding through holes of the hub of the wind turbine. At least one circumferential ridge segment is disposed radially adjacent to head sections of the plurality of fasteners so as to resist torque applied to each of the plurality of fasteners. A connection mechanism is utilized to secure the plurality of fasteners within the plurality of through holes so as to limit axial translation of the plurality of fasteners prior to coupling of the hub to the main shaft.

Description

Technical Field

[0001] The present disclosure relates generally to wind turbines, and more particularly to mounting systems and methods for coupling a hub to a main shaft of a wind turbine. Background Art

[0002] Wind power is considered 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 a rotor with a rotatable hub, to which one or more rotor blades are fixed. The rotor is also mechanically coupled to a main shaft that drives the gearbox. The gearbox then drives the generator. The main shaft, gearbox, and generator are mounted on a bedplate support frame that is positioned within the nacelle. 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 to rotate a shaft that connects the rotor blades to the gearbox, or if a gearbox is not used, the shaft directly connects the rotor blades to the generator. The generator then converts the mechanical energy into electrical energy, which can be transferred to a converter and / or transformer housed within the tower and subsequently deployed to the utility grid.

[0003] In conventional wind turbines, threaded fasteners are typically secured in threaded fastener holes formed in the hub body and corresponding holes in the main shaft to secure the hub to the main shaft. However, the hub body is typically a cast component formed from a relatively soft cast material compared to the material of the threaded fasteners. Consequently, it is common for the threaded fasteners to experience significant preload loss due to loosening of the hub threads. Therefore, some wind turbines have adopted through-fasteners to avoid this loss of preload due to loosening of the hub threads.

[0004] While the use of through-fasteners can eliminate the loss of preload due to loosening of the hub threads, the utilization of through-fasteners can create additional challenges. Specifically, the hub is typically mounted to the main shaft after the nacelle has been installed atop the tower. As such, the connection of the hub to the nacelle is completed at a considerable height above the ground (e.g., approximately 150 meters). Because the hub is typically suspended at a considerable height above the ground during installation, safety restrictions prevent personnel from accessing the hub before the hub is coupled to the main shaft. As such, personnel are unable to insert and align the fasteners before the hub is coupled to the main shaft. Additionally, not allowing access to the suspended hub can also hinder personnel's ability to provide counter-torque to the fasteners during the coupling operation.

[0005] Therefore, the art is continually seeking new and improved systems and methods that address the aforementioned problems.Accordingly, the present disclosure relates to an improved mounting system and method for coupling a hub to a main shaft of a wind turbine. Summary of the Invention

[0006] 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.

[0007] In one aspect, the present disclosure relates to a method for coupling a hub of a wind turbine to a main shaft. The method may include inserting a plurality of fasteners into corresponding plurality of through-holes formed in the hub. The plurality of through-holes may be arranged in a circular array about the rotational axis of the hub. Each of the plurality of fasteners may include a head segment and a shank segment. The method may also include positioning at least one circumferential ridge segment radially adjacent to the head segment of the plurality of fasteners. The method may include aligning the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through-hole. The method may include limiting axial translation of the plurality of fasteners within the plurality of through-holes via a connection mechanism between the plurality of fasteners and the hub. The method may also include positioning the hub adjacent to the main shaft of the wind turbine. Additionally, the method may include inserting each of the plurality of fasteners into corresponding plurality of receiving holes in the through-holes and the main shaft of the wind turbine. Furthermore, the method may include resisting torque applied to the shaft segment via contact between the head segment and the circumferential ridge segment(s) to secure each of the plurality of fasteners within the through-holes and the corresponding plurality of receiving holes in the main shaft.

[0008] In an embodiment, positioning the ridge segment(s) may further include machining a U-shaped channel on the hub. The U-shaped channel may include at least one radially inner circumferential ridge segment disposed adjacent to the radially inner faces of the head segments of the plurality of fasteners. The U-shaped channel may further include at least one radially outer circumferential ridge segment disposed adjacent to the radially outer faces of the head segments of the plurality of fasteners. The radially inner circumferential ridge segment and the radially outer circumferential ridge segment may define an axial plane coplanar with the axial faces of the head segments of the plurality of fasteners.

[0009] In an embodiment, limiting axial translation of the plurality of fasteners via the connection mechanism may further include coupling at least one retaining ring segment to the hub.The retaining ring segment(s) may be positioned adjacent to an axial face of the head segments of the plurality of fasteners opposite the shank segments.

[0010] In an embodiment, the retaining ring segment(s) and the circumferential ridge segment(s) may be a unitary component. Positioning the circumferential ridge segment(s) may further comprise coupling the unitary component to the hub radially adjacent the head segment and adjacent an axial face of the head segment.

[0011] In additional embodiments, the retaining ring segment(s) are spring members or further include elastomeric members configured to contact axial surfaces of the head sections of the plurality of fasteners. Limiting axial translation may also include absorbing shock during an installation procedure while maintaining alignment of the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through-hole.

[0012] In another aspect, the present disclosure relates to a mounting system for coupling a hub of a wind turbine to a main shaft. The mounting system may include a plurality of fasteners arranged in corresponding through-holes, the corresponding through-holes being arranged in a circular array around the axis of rotation of the hub. Each of the plurality of fasteners may include a head segment and a shank segment. The head segment may have a cross-sectional area that is greater than the cross-sectional area of ​​the shank segment. The head segment may distribute torque loads to the hub when the hub is coupled to the main shaft. The mounting system may also include (multiple) circumferential ridge segments arranged radially adjacent to the head segments of the plurality of fasteners so as to resist torque applied to each of the plurality of fasteners. In addition, the mounting system may include a connecting mechanism that secures the plurality of fasteners within the plurality of through-holes so as to limit axial translation of the plurality of fasteners before the hub is coupled to the main shaft.

[0013] In another aspect, the present disclosure relates to a mounting system for coupling a hub of a wind turbine to a main shaft. The mounting system may include a plurality of fasteners arranged within corresponding through-holes, the corresponding through-holes being arranged in a circular array about the hub's rotational axis. Each of the plurality of fasteners may include a head section and a shank section. The head section may have a cross-sectional area greater than the cross-sectional area of ​​the shank section. The shank section may have a first end and a second end disposed opposite the first end. The first end may define a first threaded portion configured to be received by the main shaft of the turbine. The mounting system may also include a connection mechanism that secures the plurality of fasteners within the plurality of through-holes to limit axial translation of the plurality of fasteners before the hub is coupled to the main shaft. The connection mechanism may include a threaded portion in each of the through-holes. The threaded portion may have a longitudinal length less than the longitudinal length of the through-hole. The connection mechanism may also include a second threaded portion defined by the second ends of the plurality of fasteners. The second threaded portion may be configured to engage a corresponding threaded portion of the through-hole. The second threaded portion may be configured to resist torque transmitted to the first threaded portion.

[0014] Technical Solution 1. A method for coupling a hub of a wind turbine to a main shaft, the method comprising:

[0015] inserting a plurality of fasteners into a corresponding plurality of through-holes formed in the hub, the plurality of through-holes being arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners including a head section and a shank section;

[0016] positioning at least one circumferential ridge segment radially adjacent to the head sections of the plurality of fasteners;

[0017] aligning a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of the corresponding through-hole;

[0018] limiting axial translation of the plurality of fasteners in the plurality of through-holes via a connection mechanism between the plurality of fasteners and the hub;

[0019] positioning the hub adjacent the main shaft of the wind turbine;

[0020] inserting each of the plurality of fasteners within the through-hole through a corresponding plurality of receiving holes of the main shaft of the wind turbine; and

[0021] Torque applied to the shaft segment of at least one of the plurality of fasteners is resisted via contact between the head segment and the at least one circumferential ridge segment to secure the at least one fastener within the throughbore and the corresponding plurality of receiving holes of the spindle.

[0022] Technical Solution 2. The method according to Technical Solution 1, wherein positioning the at least one circumferential ridge segment further comprises machining a U-shaped channel on the hub, the U-shaped channel comprising:

[0023] at least one radially inner circumferential ridge segment disposed adjacent to the radially inner faces of the head sections of the plurality of fasteners; and

[0024] At least one radially outer circumferential ridge segment is disposed adjacent to the radially outer faces of the head segments of the plurality of fasteners, wherein the radially inner circumferential ridge segment and the radially outer circumferential ridge segment define an axial plane that is coplanar with the axial faces of the head segments of the plurality of fasteners.

[0025] Technical Solution 3. The method according to Technical Solution 1 is characterized in that limiting the axial translation of the multiple fasteners via a connecting mechanism further includes connecting at least one retaining ring segment to the hub, and the at least one retaining ring segment is positioned to be adjacent to the axial surface of the head segment of the multiple fasteners opposite to the handle segment.

[0026] Technical Solution 4. The method according to Technical Solution 3 is characterized in that the retaining ring segment and the at least one circumferential ridge segment are integral components, and wherein positioning the at least one circumferential ridge segment further includes connecting the integral component to the hub radially adjacent to the head segment and adjacent to the axial surface of the head segment.

[0027] Technical Solution 5. The method according to Technical Solution 3, characterized in that the retaining ring segment is a spring component or further includes an elastomeric component, the spring component or the elastomeric component is configured to contact the axial surfaces of the head segments of the plurality of fasteners, and wherein limiting axial translation further includes:

[0028] Shock is absorbed during an installation procedure while maintaining the alignment of the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through-hole.

[0029] Technical Solution 6. A mounting system for coupling a hub of a wind turbine to a main shaft, the mounting system comprising:

[0030] a plurality of fasteners disposed within corresponding through-holes arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners comprising a head section and a shank section, the head section having a cross-sectional area greater than a cross-sectional area of ​​the shank section, wherein the head section distributes torque loads to the hub when the hub is coupled to the spindle;

[0031] at least one circumferential ridge segment disposed radially adjacent to the head sections of the plurality of fasteners so as to resist torque applied to each of the plurality of fasteners; and

[0032] A connecting mechanism secures the plurality of fasteners within the plurality of through-holes to limit axial translation of the plurality of fasteners before the hub is coupled to the spindle.

[0033] Technical Solution 7. The mounting system according to Technical Solution 6, wherein the at least one circumferential ridge segment comprises a U-shaped channel, and the U-shaped channel comprises:

[0034] at least one radially inner circumferential ridge segment disposed adjacent to the radially inner faces of the head sections of the plurality of fasteners; and

[0035] At least one radially outer circumferential ridge segment is disposed adjacent to the radially outer faces of the head segments of the plurality of fasteners, wherein the radially inner circumferential ridge segment and the radially outer circumferential ridge segment define an axial plane that is coplanar with the axial faces of the head segments of the plurality of fasteners.

[0036] Technical Solution 8. The installation system according to Technical Solution 7 is characterized in that the connection mechanism includes at least one retaining ring segment spanning the U-shaped channel, and the at least one retaining ring segment is connected to the radially inner circumferential ridge segment and the radially outer circumferential ridge segment.

[0037] Technical Solution 9. The mounting system according to Technical Solution 6, characterized in that the at least one circumferential ridge segment is formed integrally with the hub.

[0038] Technical Solution 10. The installation system according to Technical Solution 6 is characterized in that the connecting mechanism includes at least one retaining ring segment connected to the hub, and the at least one retaining ring segment is positioned to be adjacent to the axial surface of the head segment of the multiple fasteners opposite to the handle segment.

[0039] Technical Solution 11. The installation system according to Technical Solution 10 is characterized in that the retaining ring segment further includes an elastomeric component configured to contact the axial surface of the head section of the multiple fasteners, the elastomeric component is configured to absorb impact during the installation process, and the elastomeric component is further configured to maintain the longitudinal axis of each of the multiple fasteners aligned with the longitudinal axis of the corresponding through hole.

[0040] Technical Solution 12. The installation system according to Technical Solution 10 is characterized in that the retaining ring segment is a spring component configured to contact the axial surface of the head segment of the multiple fasteners, the spring component is configured to absorb impact during the installation process, and the spring component is further configured to maintain the longitudinal axis of each of the multiple fasteners aligned with the longitudinal axis of the corresponding through hole.

[0041] Technical Solution 13. The mounting system according to Technical Solution 10 is characterized in that the retaining ring segment is coupled to the at least one circumferential ridge segment.

[0042] Technical Solution 14. The mounting system according to Technical Solution 10 is characterized in that the retaining ring segment and the at least one circumferential ridge segment are an integral component, and the integral component is connected to the hub.

[0043] Technical Solution 15. The mounting system according to Technical Solution 6, wherein the head section includes a square head and an integral washer disposed between the square head and the handle section, wherein:

[0044] The square head has a width greater than or equal to 175% of the diameter of the shank segment and less than or equal to 225% of the diameter of the shank segment;

[0045] the integral washer having a diameter greater than or equal to 150% and less than or equal to 200% of the diameter of the shank segment; and

[0046] The integral washer has a height greater than or equal to 10% and less than or equal to 20% of the diameter of the shank segment.

[0047] Technical Solution 16. The mounting system according to Technical Solution 6 is characterized in that the handle segment includes an alignment portion arranged adjacent to the head segment, the alignment portion maintains the longitudinal axis of each of the multiple fasteners aligned with the longitudinal axis of the corresponding through hole, and the alignment portion has a diameter greater than 98% of the diameter of the through hole and less than 100% of the diameter of the through hole.

[0048] Technical Solution 17. The installation system according to Technical Solution 6 is characterized in that the connecting mechanism further includes a bushing surrounding a portion of the handle segment, the bushing being further configured to absorb impact during an installation procedure and configured to maintain alignment of the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through hole.

[0049] Technical Solution 18. The installation system according to Technical Solution 6 is characterized in that the installation system further includes at least one alignment pin, which is fixed in at least one of the through holes, and the at least one alignment pin has a length greater than the length of the multiple fasteners.

[0050] Technical Solution 19. The installation system according to Technical Solution 6 is characterized in that the connecting mechanism is at least one of epoxy resin or brazing.

[0051] Technical Solution 20. A mounting system for coupling a hub of a wind turbine to a main shaft, the mounting system comprising:

[0052] a plurality of fasteners disposed within corresponding through-holes arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners comprising a head segment and a shank segment, the head segment having a cross-sectional area greater than a cross-sectional area of ​​the shank segment, the shank segment having a first end and a second end disposed opposite the first end, the first end defining a first threaded portion configured to be received by the spindle of the turbine;

[0053] a connecting mechanism that secures the plurality of fasteners within the plurality of through-holes to limit axial translation of the plurality of fasteners before the hub is coupled to the spindle, the connecting mechanism comprising:

[0054] a threaded portion in each of the through holes, the threaded portion having a longitudinal length that is less than a longitudinal length of the through hole, and

[0055] A second threaded portion is defined by the second ends of the plurality of fasteners, wherein the second threaded portion is configured to engage the corresponding threaded portion of the through hole, the second threaded portion being configured to resist torque transmitted to the first threaded portion.

[0056] 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

[0057] A complete and enabling disclosure of the invention, including the best mode thereof, to one skilled in the art is set forth in the specification which proceeds with reference to the accompanying drawings in which:

[0058] Figure 1 illustrates a perspective view of one embodiment of a wind turbine according to the present disclosure;

[0059] Figure 2 illustrates a perspective interior view of one embodiment of a nacelle of a wind turbine according to the present disclosure;

[0060] Figure 3 illustrates a front view of one embodiment of a nacelle of a wind turbine without a hub according to the present disclosure;

[0061] Figure 4 illustrates a side view of one embodiment of a nacelle and hub of a wind turbine according to the present disclosure, particularly illustrating a mounting system for coupling the hub of the wind turbine to a main shaft;

[0062] Figure 5 illustrates a front cross-sectional view of one embodiment of a hub of a wind turbine according to the present disclosure;

[0063] Figure 6 illustrates a perspective view of one embodiment of a fastener for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0064] Figure 7 illustrates a perspective cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0065] Figure 8 illustrates a perspective cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0066] Figure 9 illustrates a perspective cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0067] Figure 10 illustrates a side cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0068] Figure 11 illustrates a side cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to one embodiment of the present disclosure;

[0069] Figure 12 illustrates a side cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0070] Figure 13 illustrates a side cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0071] Figure 14 illustrates a side cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0072] Figure 15 illustrates a side cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0073] Figure 16 illustrates a side cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure;

[0074] Figure 17 illustrates a side cross-sectional view of one embodiment of a mounting system for coupling a hub of a wind turbine to a main shaft according to the present disclosure; and

[0075] Figure 18 A flow chart illustrating one embodiment of a method for coupling a hub of a wind turbine to a main shaft according to the present disclosure.

[0076] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0077] 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 by way of illustration of the present invention, not limitation. In fact, 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, features illustrated or described as part of one embodiment may be used together with another embodiment to produce yet another embodiment. 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.

[0078] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to denote the position or importance of individual components.

[0079] Unless otherwise specified herein, the terms "coupled," "fixed," "attached," and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment through one or more intermediate members or features.

[0080] Approximating language, as used herein throughout the specification and claims, is applicable to modifying any quantitative expression that may vary without causing a change in the basic function to which it is related. Thus, a value modified by one or more terms such as "about," "approximately," "substantially," and "substantially" is not limited to the precise value specified. In at least some instances, approximating language may correspond to the precision of an instrument used to measure the value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximating language may refer to being within a 10 percent margin.

[0081] Here and throughout the specification and claims, range limitations are combined and interchangeable, and unless context or language indicates otherwise, such ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0082] In general, the present disclosure relates to systems and methods for coupling a hub of a wind turbine to a main shaft. In particular, the present disclosure may include an array of through-holes arranged in the hub. A corresponding number of fasteners may be inserted through each of the through-holes. Inserting the fasteners into the through-holes may cause the heads of the fasteners to contact at least one circumferential ridge segment. The circumferential ridge segment(s) may be positioned radially adjacent to the head segment and configured to resist torque applied to each of the fasteners. In other words, the circumferential ridge segment(s) may prevent the fasteners from rotating when the hub is secured to the main shaft of the wind turbine by nuts or other fasteners. It should be appreciated that because the heads of the fasteners are prevented from rotating by the circumferential ridge segments, it may not be necessary for personnel to enter the hub segment to hold the heads in place before the hub segment is coupled to the main shaft.

[0083] In addition to preventing the fastener from rotating without human intervention, the fastener can also be retained in the through-hole before being coupled to the spindle. Specifically, the connecting mechanism prevents axial movement of the fastener before the fastener is secured to the spindle. In other words, during the lifting and installation of the hub, the connecting mechanism prevents the fastener from moving out of the through-hole or otherwise falling out without human intervention. For example, in at least one embodiment, the fastener can be secured in the through-hole by coupling at least one retaining ring segment to the hub. The (multiple) retaining ring segments can be substantially perpendicular to the (multiple) circumferential ridge segments and can affect the axial face of the fastener. In additional embodiments, the connecting mechanism may include a bushing, epoxy, braze, and / or a threaded portion of the fastener. It should be appreciated that retaining the fastener in the through-hole while maintaining alignment of the fastener during the lifting and installation operations can eliminate the need for personnel to enter the suspended hub to insert the fastener before securing the fastener to the spindle.

[0084] Referring now to the accompanying drawings, Figure 1 A perspective view of one embodiment of a wind turbine 100 according to the present disclosure is illustrated. As shown, the wind turbine 100 generally includes a tower 102 extending from a foundation 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 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.

[0085] Now refer to Figure 2 , diagram 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 electrical power from rotational energy generated by the rotor 108. For example, as shown in the illustrated embodiment, the rotor 108 may include a main shaft 122 coupled to the hub 110 for rotation therewith. The main shaft 122 may be rotatably supported by main bearings 144. The main 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 by one or more torque arms 142. As generally understood, the main 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 126 may then be configured to convert the low speed, high torque input to a high speed, low torque output to drive the generator shaft 124 and, therefore, the generator 118 .

[0086] Now refer to Figure 3 , illustrates a front view of one embodiment of a nacelle 106 of a wind turbine 100 according to the present disclosure without a hub 110. As shown, the main shaft 122 may be formed with a receiving surface 128. The main shaft 122 may also include a plurality of receiving holes 130 defined by the receiving surface 128. In at least one embodiment, the plurality of receiving holes 130 may be centered about the axis of rotation (R S ) are arranged in a circular array. The receiving surface 128 and the plurality of receiving holes 130 can be configured to receive the hub 110 and provide a secure mounting of the hub 110.

[0087] Now refer to Figures 4-17 , presents a mounting system 200 for coupling the hub 110 of the wind turbine 100 to the main shaft 122 according to the present disclosure. Figure 4 In the embodiment shown in FIG, the mounting system 200 may include a plurality of fasteners 202. The fasteners 202 may be disposed in corresponding through holes 204 ( Figure 5 ) Figure 5 As shown in FIG, the through hole 204 may be oriented around the rotation axis (R H) are arranged in a circular array. The mounting system 200 may also include at least one circumferential ridge segment 206. The circumferential ridge segment(s) 206 may be arranged radially adjacent to the plurality of fasteners 202. The circumferential ridge segment(s) 206 may resist torque applied to each of the plurality of fasteners 202. The mounting system 200 may also include a connecting mechanism 208. The connecting mechanism 208 may secure the plurality of fasteners 202 within the plurality of through-holes 204. In an embodiment, the connecting mechanism 208 may limit axial translation of the plurality of fasteners 202 before the hub 110 is coupled to the spindle 122. It should be appreciated that axial translation includes any movement of the fasteners 202 relative to the through-holes 204 generally along the axis (A).

[0088] like Figure 6 As particularly depicted in FIG, the fastener 202 of the mounting system 200 may include a head section 210 and a shank section 212. For example, the fastener 202 may be a bolt that, along with a corresponding plurality of nuts, may be configured to secure the hub 110 to the spindle 122. In embodiments, the head section 210 may distribute torque loads to the hub 110 when the hub 110 is coupled to the spindle 122. At least a portion of the shank section 212 may be threaded. In at least one embodiment, the head section 210 may have a cross-sectional area that is greater than a cross-sectional area of ​​the shank section 212.

[0089] like Figures 6-17 , in at least one embodiment, the fastener 202 of the mounting system 200 can be formed such that the head section 210 includes a square head 214. In additional embodiments, the head section 210 can include an integral washer 216 disposed between the square head 214 and the shank section 212. In embodiments, the head section 210 can include at least one contact surface 218. The contact surface(s) 218 ​​can be configured to increase friction between the fastener 202 and the hub 110. For example, the contact surface(s) 218 ​​can be formed with a plurality of ridges, protrusions, and / or teeth configured to interface with the hub 110 and increase friction therebetween.

[0090] To distribute loads to the hub 110 during coupling, in an embodiment, the square head 214 may have a width (W) that is greater than or equal to the shank segment diameter (D S ) and less than or equal to the shank segment diameter (D S ). For example, in at least one embodiment, the width (W) may be greater than the handle segment diameter (D S ). Similarly, the width (W) may be less than the handle segment diameter (D S ). In embodiments where the fastener 202 includes an integral washer 216, the integral washer 216 may have a diameter (DW ), diameter (D W ) is greater than or equal to the handle section diameter (D S ) and less than or equal to the shank segment diameter (D S ). For example, in at least one embodiment, the integral washer 216 may have a diameter greater than the handle segment diameter (D S ) is 170% of the diameter (D W The integral washer may also have a diameter smaller than the handle segment diameter (D S ) is 175% of the diameter (D W In at least one embodiment, the integral gasket may have a height (H W ), height (H W ) is greater than or equal to the handle section diameter (D S ) and less than or equal to the shank segment diameter (D S ). For example, in at least one embodiment, the height (H W ) can be smaller than the handle section diameter (D S ) of 15%.

[0091] In such Figure 6 、 Figure 9 as well as Figure 16 In the embodiment depicted in FIG, the fastener 202 may include an alignment portion 220 disposed adjacent to the head section 210. The alignment portion 220 may have a length that is less than the length of the handle section 212. The alignment portion 220 may establish and maintain the longitudinal axis (L) of the fastener 202. A ) and the longitudinal axis (L A In at least one embodiment, the alignment portion 220 may be formed with a diameter greater than the handle segment diameter (D S ) diameter (D A In an embodiment, the alignment portion 220 may have a diameter (D A ), diameter (D A ) is larger than the diameter of the through hole (D H ) and is smaller than the diameter of the through hole (D H ) (for example, greater than the diameter of the through hole (D H ) and is smaller than the diameter of the through hole (D H ). It will be appreciated that machining the alignment portion 220 to a specified accuracy can facilitate maintaining the alignment of the fastener 202 without requiring the same high degree of accuracy throughout the length of the fastener 202. It will be further appreciated that manufacturing the entire fastener 202 to the same tolerances as required for the alignment portion 220 can unnecessarily increase the cost of the mounting system 200.

[0092] like Figure 5 、 Figures 7-13 as well as Figure 16 , in an embodiment, the mounting system 200 can include a plurality of circumferential ridge segments 206. The circumferential ridge segment(s) 206 can be arranged radially adjacent to the head section 210 of the fastener 202 to resist torque applied to the fastener 202 during coupling of the hub 110 to the spindle 122. In other words, the circumferential ridge segment(s) 206 can prevent the fastener 202 from rotating in response to a nut or other similar fastener being threaded and torqued onto the shank section 212.

[0093] In such Figure 5 In at least one embodiment depicted in FIG, the circumferential ridge segment(s) 206 may include a plurality of circumferential ridge segments 206 arranged in radial alignment with the through-hole 204. In additional embodiments, the circumferential ridge segment(s) 206 may form a radial axis of rotation (R) around the hub 110. H ) continuous ridge. Figure 5 and Figure 8 , the circumferential ridge segment(s) 206 may form at least one radially outer circumferential ridge segment 222. The radially outer circumferential ridge segment(s) 222 may be disposed adjacent to a radially outer face 224 of the head segment 210. In additional embodiments, the circumferential ridge segment(s) 206 may form at least one radially inner circumferential ridge segment 226. The radially inner circumferential ridge segment(s) 226 may be disposed adjacent to a radially inner face 228 of the head segment 210. It should be appreciated that the terms "radially inner" and "radially outer" refer to distances from the axis of rotation (R) of the hub 110. H ) distance. As such, the radially inner circumferential ridge segment(s) 226 may be positioned about the axis of rotation (R H ) and the plurality of through holes 204. Similarly, the plurality of through holes 204 may be positioned about the rotation axis (R H ) and between (multiple) radially outer circumferential ridge segments 222.

[0094] In an embodiment, the circumferential ridge segments 206 may be integrally formed with the hub 110. For example, the circumferential ridge segments 206 may be formed during the manufacture (e.g., casting and / or additive manufacturing) of the hub 110. In an embodiment, the circumferential ridge segments 206 may protrude from the surface of the hub 110. In an alternative embodiment, the circumferential ridge segments 206 may be formed by machining recesses 230 into the surface of the hub 110. In an embodiment, such as by Figure 10 、 Figure 12 as well as Figure 13In the additional embodiment depicted, the circumferential ridge segment(s) 206 may be separate components coupled to the hub 110. It should be appreciated that the circumferential ridge segment(s) 206 may have a height and / or depth relative to the hub 110 that is sufficient to secure the fastener 202 in a specified orientation.

[0095] In such Figure 7 、 Figure 9 、 Figure 11 as well as Figure 16 In the embodiment depicted in FIG, the mounting system 200 may include a plurality of circumferential ridge segments 206 as a U-shaped channel. The U-shaped channel may include a plurality of radially inner circumferential ridge segments 226 disposed adjacent to a radially inner face 228 of the head section 210 of the fastener 202. The U-shaped channel may also include a plurality of radially outer circumferential ridge segments 222 disposed adjacent to a radially outer face 224 of the head section 210 of the fastener 202. In embodiments such as Figure 11 and Figure 16 In the embodiment particularly depicted in FIG, the radially inner circumferential ridge segment 226 and the radially outer circumferential ridge segment 222 may define an axial plane (A P ), axial plane (A P ) is coplanar with the axial faces 232 of the head sections 210 of the plurality of fasteners 202.

[0096] Now refer to Figures 7-17 The mounting system 200 may further include a connection mechanism 208 configured to retain the fasteners 202 in the through-holes 204 when the hub 110 is lifted to the nacelle 106 and coupled to the main shaft 122. In at least one embodiment, the connection mechanism 208 may further at least temporarily secure the fasteners 202 in the corresponding through-holes so as to maintain the longitudinal axis (L) of the fasteners 202. A ) and the longitudinal axis (L A ). In additional embodiments, connection mechanism 208 may also provide shock absorption capabilities to mounting system 200. The shock absorption capabilities may allow for a certain degree of axial movement in the event that fastener 202 accidentally strikes main shaft 122 or another component of wind turbine 100 during installation operations. By allowing for a certain degree of axial movement of fastener 202, the shock absorption capabilities of mounting system 200 may reduce the likelihood of damaging at least one of fasteners 202 due to accidental contact. It should be appreciated that during the lifecycle of wind turbine 100, it may be necessary to remove one or more of fasteners 202. As such, connection mechanism 208 may be configured to allow for removal of fastener 202 after hub 110 is coupled to main shaft 122. For example, in at least one embodiment, connection mechanism 208 may be removed after hub 110 is installed on wind turbine 100.

[0097] refer to Figures 7-11 、 Figure 13 as well as Figure 16 In at least one embodiment, the connection mechanism 208 can include at least one retaining ring segment 234 coupled to the hub 110. The retaining ring segment(s) 234 can be positioned adjacent to the axial face 232 of the head section 210 of the fastener 202 opposite the shank section 212. In an embodiment, the retaining ring segment(s) 234 can be arranged so as to be axially aligned about the axis of rotation (R) of the hub 110. H ) form a circumferential ring. The circumferential ring can be formed by a plurality of retaining ring segments 234. However, in alternative embodiments, the retaining ring segments 234 can be a unitary structure forming a single uninterrupted ring. The retaining ring segment(s) 234 can be formed from sheet metal, wood, plastic, a composite material, and / or other materials suitable for resisting axial movement of the fastener 202. The retaining ring segment(s) 234 can be coupled to the hub 110 via a plurality of retaining ring fasteners 236. In additional embodiments, the retaining ring segment(s) 234 can be coupled to the hub 110 via an adhesive, a braze, a magnetic coupling, and / or a mechanical coupling, such as a twist lock.

[0098] like Figures 7-9 、 Figure 11 as well as Figure 16 As depicted in FIG, in an embodiment, the retaining ring segment(s) 234 of the connection mechanism 208 may be coupled to the circumferential spine segment(s) 206. Figure 7 and Figure 8 In at least one embodiment depicted in FIG, the retaining ring segment(s) 234 may be coupled to the radially outer circumferential ridge segment(s) 222. Figure 9 and Figure 16 In the alternative embodiment depicted in FIG, the retaining ring segment 234 may be coupled to the radially inner circumferential ridge segment(s) 226. The retaining ring segment(s) 234 may extend from the corresponding circumferential ridge segment(s) 206 to define a radial width (W R ), radial width (W R ) at least partially covers the axial surface 232 of the head section 210.

[0099] like Figure 11As particularly depicted in FIG, in embodiments, the retaining ring segment(s) 234 may be coupled to both the radially inner circumferential ring segment 226 and the radially outer circumferential ring segment 222. As such, in embodiments, the retaining ring segment(s) 234 may span the U-shaped channel. It should be appreciated that spanning the U-shaped channel does not necessitate complete coverage of the axial face 232 of the head section 210. For example, in embodiments in which multiple retaining ring segments 234 may be employed, each of the retaining ring segments 234 may have a circumferential width that is less than the width (W) of the square head section 214. It should be further appreciated that coupling the retaining ring segment(s) 234 to both the radially inner circumferential ring segment 226 and the radially outer circumferential ring segment 222 may increase the stiffness of the retaining ring segment(s) 234 without necessitating a corresponding increase in the axial thickness of the retaining ring segment(s) 234. This, in turn, may allow for the utilization of retaining ring segment(s) 234 that are axially thinner than retaining ring segment(s) 234 coupled to a single circumferential spine segment(s) 206 .

[0100] In such Figure 13 , the retaining ring segment(s) 234 may also include an elastomeric member 238. The elastomeric member 238 may be positioned to contact the axial face 232 of the head section 210 of the fastener 202. In at least one embodiment, the elastomeric member 238 may be configured to absorb shock during the installation process. For example, in the event that the fastener 202 contacts the spindle 122 prior to being inserted into the corresponding receiving hole 130, the elastomeric member 238 may allow a certain degree of axial movement of the fastener 202, thereby reducing the risk of damaging the fastener 202. The elastomeric member 238 may also be configured to maintain the longitudinal axis (L) of each of the fasteners 202. A ) and the corresponding longitudinal axis (L A ) alignment. In additional embodiments, the impact absorption and alignment maintaining functions of the elastomeric member 238 can be performed or enhanced by forming the retaining ring segment(s) 234 as spring members. In at least one embodiment, a spring member can be provided in place of the elastomeric member 238 to contact the axial face 232 of the head section 210. It should be appreciated that maintaining the respective longitudinal axis (L A ) can facilitate receiving the fastener 202 by the corresponding receiving hole 130.

[0101] In such Figure 10In the embodiment depicted in FIG, the retaining ring segment(s) 234 and the circumferential ridge segment(s) 206 may be formed as a monolithic component 240. The monolithic component 240 may be coupled to the hub 110. The monolithic component 240 may perform any of the functions discussed herein with respect to the circumferential ridge segment(s) 206 and the retaining ring segment(s) 234 and have any of the properties discussed herein with respect to the circumferential ridge segment(s) 206 and the retaining ring segment(s) 234. For example, the monolithic component 240 may not only resist torque applied to each of the plurality of fasteners 202, but may also limit axial translation of the fasteners 202. The monolithic component may be formed from sheet metal, wood, plastic, composite materials, and / or other materials suitable for facilitating coupling of the hub 110 to the main shaft 122 of the wind turbine 100.

[0102] like Figure 12 , in an embodiment, the connection mechanism 208 of the mounting system 200 may include a bushing 242 surrounding a portion of the shank section 212 of the fastener 202. The bushing 242 may be configured to at least temporarily secure the fastener 202 within the through hole 204. In an embodiment, the bushing 242 may be configured to absorb shock during the installation process of coupling the hub 110 to the spindle 122. In an embodiment, the bushing 242 may be configured to maintain the corresponding longitudinal axis (L A ) alignment, as previously discussed. Bushing 242 can be formed of an elastomeric material. In additional embodiments, bushing 242 can be sized to establish a press fit between fastener 202 and corresponding through-hole 204.

[0103] In such Figure 14 In additional embodiments depicted in , the connecting mechanism 208 may be at least one of an epoxy or a braze. In such embodiments, the connecting mechanism 208 may be configured to secure and align the fastener 202 in the corresponding through-hole 204. In embodiments, such a connecting mechanism 208 may be configured to resist torque transmitted to the shank segment 212 during the coupling operation. In alternative embodiments, the connecting mechanism 208 may secure the fastener 202, while the (multiple) circumferential ridge segments 206 may be used to resist torque. To facilitate future maintenance operations, the connecting mechanism 208 in the form of an epoxy or a braze may form a temporary connection between the fastener 202 and the hub 110. For example, in embodiments, the fastener 202 may be released by applying a solvent and / or heat to the epoxy or the braze.

[0104] Now refer to Figure 15, depicts another embodiment of a mounting system 200 according to the present disclosure. As depicted, the shank section 212 of the fastener 202 may include a first end 244 and a second end 246 disposed opposite the first end 244. The first end 244 may define a first threaded portion 248 configured to be received by the main shaft 122 of the wind turbine 100. In such an embodiment, the connection mechanism 208 may include a threaded portion 250 in each of the through-holes 204. The threaded portion 250 may have a longitudinal length (L3) that is less than the longitudinal length (L4) of the through-holes 204. The connection mechanism 208 may also include a second threaded portion 252 defined by the second end 246 of the fastener 202. The second threaded portion 252 may be configured to engage a corresponding threaded portion 250 of the through-hole 204. The engagement of the threaded portions 250, 252 may limit axial translation of the fastener 202 before the hub 110 is coupled to the main shaft 122.

[0105] Still refer to Figure 15 , the second threaded portion 252 can also be configured to resist torque transferred to the first threaded portion 248. In at least one embodiment, the thread pattern of the second threaded portion 252 can be opposite to the thread pattern of the first threaded portion 248. The opposing thread patterns of the first threaded portion 248 and the second threaded portion 252 can facilitate the connection mechanism 208 to resist torque applied to the first threaded portion 248 (such as during coupling of a nut to the first threaded portion). As such, the mounting system 200 may not require the circumferential ridge segment 206 to resist torque applied to the first threaded portion 248.

[0106] In yet another embodiment, the first threaded portion 248 and the second threaded portion 252 of the fastener 202 can have the same thread pattern. In such an embodiment, the threaded portion 250 and the second threaded portion 252 of the through hole 204 can be positioned such that torque applied to the first threaded portion 248 causes the second threaded portion 252 to advance longitudinally within the through hole 204 and disengage from the threaded portion 250 of the through hole 204.

[0107] Now refer to Figure 17, depicts yet another embodiment of a mounting system 200 according to the present disclosure. As depicted, a fastener 202 may be formed with a securing element 254. The securing element 254 may be coupled to the handle section 212 opposite the head section 210. In at least one embodiment, a tool may be coupled to the securing element 254 and used to resist torque applied to the fastener 202 during a coupling operation. For example, in at least one embodiment, the fastener 202 may be received by a corresponding receiving aperture 130, and a securing fastener (not shown) may be threaded onto the handle section 212. When torque is applied to the securing fastener by a tool coupled to the securing element 254, the fastener 202 may be held in place. In at least one embodiment, the securing element 254 may be configured to be received by a tool. For example, the securing element 254 may have a polygonal cross-section (e.g., a hexagonal head, a square head, a triangular head, etc.) and may be secured by a wrench, a socket, or other similar tool. In alternative embodiments, the securing element 254 is configured to receive a tool within a recess. For example, the fixing element 254 can be configured to receive a square driver, a hex key, or a star drill bit. It should be appreciated that since rotation of the fastener 202 can be prevented by a tool coupled to the fixing element 254, in such embodiments, it may not be necessary for the mounting system 200 to include the circumferential ridge segment 206.

[0108] Still refer to Figure 17 In an embodiment, the securing mechanism 208 may include at least one retaining clip 256. The retaining clip(s) 256 may be coupled to the handle section 212. The retaining clip(s) 256 may be positioned adjacent to the hub 110, opposite the head section 210. In an embodiment, at least one recess 258 may be formed in the hub 110 to facilitate recessing of the retaining clip(s) 256. In an alternative embodiment, the retaining clip(s) 256 may be disposed between the hub 110 and the spindle 122. For example, in at least one embodiment, a single retaining clip 256 retains all of the fasteners 202. In such an embodiment, the single retaining clip 256 may serve as a washer or spacer between the hub 110 and the spindle 122. In at least one embodiment, the retaining clip(s) 256 may be configured to allow the fasteners 202 to be extracted from the hub 110 for future maintenance operations.

[0109] Reference again Figure 4In embodiments, the mounting system 200 can include at least one alignment pin 260. The alignment pin(s) 260 can have a length (L2) that is greater than the length (LI) of the fasteners 202. In embodiments, the alignment pin(s) 260 can replace at least one of the fasteners 202 in the through hole 204. In additional embodiments, the alignment pin(s) 260 can be the fasteners 202 that have a greater length (L2) than the other fasteners 202. Due to the greater length (L2) of the alignment pin(s) 260, the alignment pin can contact the main shaft 122 and the receiving hole 130 before the fasteners 202. As such, the alignment pin(s) 260 can be configured to facilitate alignment of the fasteners 202 with the corresponding receiving hole 130. It should be appreciated that the greater length (L2) of the alignment pin(s) 260 relative to the length (LI) of the fasteners 202 can facilitate the alignment pin(s) 260 protecting the fasteners 202 from accidental contact with the main shaft 122 and potential damage to the fasteners 202.

[0110] Referring now to Figure 18 , a flow diagram illustrating one embodiment of a method 300 for coupling a hub of a wind turbine to a main shaft is shown. The method 300 can be implemented using, for example, the mounting system 200 discussed above with reference to Figures 4-17 For purposes of illustration and discussion, Figure 18 the steps are depicted as being performed in a particular order. Those of ordinary skill in the art, using the disclosures provided herein, will appreciate that various of the steps of the method 300, or any of the methods disclosed herein, can be altered, modified, rearranged, performed simultaneously, or modified in various ways without departing from the scope of the present disclosure.

[0111] As shown at (302), method 300 may include inserting a plurality of fasteners into corresponding plurality of through-holes formed in a hub. The plurality of through-holes may be arranged in a circular array about the axis of rotation of the hub. Each of the plurality of fasteners may include a head segment and a shank segment. As shown at (304), method 300 may include positioning at least one circumferential ridge segment radially adjacent to the head segment of the plurality of fasteners. As shown at (306), method 300 may include aligning the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through-hole. As shown at (308), method 300 may include limiting axial translation of the plurality of fasteners in the plurality of through-holes via a connection mechanism between the plurality of fasteners and the hub. As shown at (310), method 300 may include positioning the hub adjacent to a main shaft of the wind turbine. As shown at (312), method 300 may include inserting each of the plurality of fasteners within the through-holes through corresponding plurality of receiving holes of the main shaft of the wind turbine. As shown at (314), method 300 may include resisting torque applied to the shaft segment via contact between the head segment and at least one circumferential spine segment to secure each of the plurality of fasteners within the corresponding plurality of receiving holes of the through hole and the main shaft.

[0112] 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 language of the claims.

[0113] Further aspects of the invention are provided by the subject matter of the following clauses:

[0114] Item 1. A method for coupling a hub of a wind turbine to a main shaft, the method comprising: inserting a plurality of fasteners into corresponding plurality of through-holes formed in the hub, the plurality of through-holes being arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners comprising a head segment and a shank segment; positioning at least one circumferential ridge segment radially adjacent to the head segment of the plurality of fasteners; aligning a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of the corresponding through-hole; limiting axial translation of the plurality of fasteners in the plurality of through-holes via a connection mechanism between the plurality of fasteners and the hub; positioning the hub adjacent to the main shaft of the wind turbine; inserting each of the plurality of fasteners within the through-holes through corresponding plurality of receiving holes of the main shaft of the wind turbine; and resisting torque applied to the shaft segments via contact between the head segment and the at least one circumferential ridge segment so as to secure each of the plurality of fasteners within the through-holes and the corresponding plurality of receiving holes of the main shaft.

[0115] Clause 2. A method according to any preceding clause, wherein positioning at least one ridge segment further comprises machining a U-shaped channel on the hub, the U-shaped channel comprising: at least one radially inner circumferential ridge segment disposed adjacent to a radially inner face of a head segment of a plurality of fasteners; and at least one radially outer circumferential ridge segment disposed adjacent to a radially outer face of a head segment of a plurality of fasteners, wherein the radially inner circumferential ridge segment and the radially outer circumferential ridge segment define an axial plane that is coplanar with an axial face of the head segments of the plurality of fasteners.

[0116] Clause 3. The method of any preceding clause, wherein limiting axial translation of the plurality of fasteners via the connection mechanism further comprises coupling at least one retaining ring segment to the hub, the at least one retaining ring segment positioned adjacent to an axial face of the head segments of the plurality of fasteners opposite the shank segments.

[0117] Clause 4. The method of any preceding clause, wherein the retaining ring segment and the at least one circumferential ridge segment are a unitary component, and wherein positioning the at least one circumferential ridge segment further comprises coupling the unitary component to the hub radially adjacent the head segment and adjacent an axial face of the head segment.

[0118] Clause 5. A method according to any preceding clause, wherein the retaining ring segment is a spring member or further comprises an elastomeric member, the spring member or elastomeric member being configured to contact an axial face of the head segments of the plurality of fasteners, and wherein limiting axial translation further comprises: absorbing shock during an installation procedure while maintaining alignment of the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through-hole.

[0119] Item 6. A mounting system for coupling a hub of a wind turbine to a main shaft, the mounting system comprising: a plurality of fasteners arranged within corresponding through-holes, the corresponding through-holes being arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners comprising a head segment and a shank segment, the head segment having a cross-sectional area greater than a cross-sectional area of ​​the shank segment, wherein the head segment distributes a torque load to the hub when the hub is coupled to the main shaft; at least one circumferential ridge segment arranged radially adjacent to the head segment of the plurality of fasteners so as to resist torque applied to each of the plurality of fasteners; and a connecting mechanism securing the plurality of fasteners within the plurality of through-holes so as to limit axial translation of the plurality of fasteners before the hub is coupled to the main shaft.

[0120] Clause 7. An installation system according to any preceding clause, wherein at least one circumferential ridge segment comprises a U-shaped channel, the U-shaped channel comprising: at least one radially inner circumferential ridge segment disposed adjacent to a radially inner face of a head segment of a plurality of fasteners; and at least one radially outer circumferential ridge segment disposed adjacent to a radially outer face of a head segment of a plurality of fasteners, wherein the radially inner circumferential ridge segment and the radially outer circumferential ridge segment define an axial plane that is coplanar with the axial face of the head segments of the plurality of fasteners.

[0121] Clause 8. The mounting system of any preceding clause, wherein the connection mechanism comprises at least one retaining ring segment spanning the U-shaped channel, the at least one retaining ring segment coupled to the radially inner circumferential ridge segment and the radially outer circumferential ridge segment.

[0122] Clause 9. The mounting system of any preceding clause, wherein at least one circumferential ridge segment is integrally formed with the hub.

[0123] Clause 10. The mounting system of any preceding clause, wherein the connection mechanism comprises at least one retaining ring segment coupled to the hub, the at least one retaining ring segment positioned adjacent to an axial face of the head segments of the plurality of fasteners opposite the shank segments.

[0124] Clause 11. An installation system according to any preceding clause, wherein the retaining ring segment further comprises an elastomeric member configured to contact an axial face of a head segment of the plurality of fasteners, the elastomeric member configured to absorb shock during an installation procedure, the elastomeric member further configured to maintain alignment of a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of a corresponding through-hole.

[0125] Clause 12. The installation system of any preceding clause, wherein the retaining ring segment is a spring member disposed in contact with an axial face of a head section of the plurality of fasteners, the spring member being configured to absorb shock during an installation procedure, the spring member being further configured to maintain alignment of a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of a corresponding through-hole.

[0126] Clause 13. The mounting system of any preceding clause, wherein the retaining ring segment is coupled to at least one circumferential spine segment.

[0127] Clause 14. The mounting system of any preceding clause, wherein the retaining ring segment and the at least one circumferential spine segment are a unitary component coupled to the hub.

[0128] Clause 15. A mounting system according to any preceding clause, wherein the head segment includes a square head and an integral washer disposed between the square head and the handle segment, wherein the square head has a width greater than or equal to 175% and less than or equal to 225% of the handle segment diameter; the integral washer has a diameter greater than or equal to 150% and less than or equal to 200% of the handle segment diameter; and the integral washer has a height greater than or equal to 10% and less than or equal to 20% of the handle segment diameter.

[0129] Clause 16. A mounting system according to any preceding clause, wherein the shank segment includes an alignment portion disposed adjacent to the head segment, the alignment portion maintaining alignment of the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through-hole, the alignment portion having a diameter greater than 98% and less than 100% of the diameter of the through-hole.

[0130] Clause 17. The mounting system of any preceding clause, wherein the connection mechanism further comprises a bushing surrounding a portion of the handle segment, the bushing further configured to absorb shock during an installation procedure and configured to maintain alignment of a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of a corresponding through-hole.

[0131] Clause 18. The mounting system of any preceding clause, further comprising at least one alignment pin secured in at least one of the through-holes, the at least one alignment pin having a length greater than a length of the plurality of fasteners.

[0132] Clause 19. The mounting system of any preceding clause, wherein the connection mechanism is at least one of an epoxy or a braze.

[0133] Item 20. A mounting system for coupling a hub of a wind turbine to a main shaft, the mounting system comprising: a plurality of fasteners arranged within corresponding through-holes, the corresponding through-holes being arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners comprising a head segment and a shank segment, the head segment having a cross-sectional area greater than a cross-sectional area of ​​the shank segment, the shank segment having a first end and a second end disposed opposite the first end, the first end defining a first threaded portion, the first threaded portion being configured to be received by the main shaft of the turbine; a connecting mechanism that secures the plurality of fasteners within the plurality of through-holes so as to limit axial translation of the plurality of fasteners before the hub is coupled to the main shaft, the connecting mechanism comprising: a threaded portion of each of the through-holes, the threaded portion having a longitudinal length less than a longitudinal length of the through-holes, and a second threaded portion defined by the second ends of the plurality of fasteners, wherein the second threaded portion is configured to engage a corresponding threaded portion of the through-hole, the second threaded portion being configured to resist torque transmitted to the first threaded portion.

Claims

1. A method for coupling a hub of a wind turbine to a main shaft, the method comprising: inserting a plurality of fasteners into a corresponding plurality of through-holes formed in the hub, the plurality of through-holes being arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners including a head section and a shank section; positioning at least one circumferential ridge segment radially adjacent to the head sections of the plurality of fasteners; aligning a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of the corresponding through-hole; limiting axial translation of the plurality of fasteners in the plurality of through-holes via a connection mechanism between the plurality of fasteners and the hub, wherein limiting the axial translation of the plurality of fasteners via the connection mechanism further comprises coupling at least one retaining ring segment to the hub, the at least one retaining ring segment positioned adjacent to an axial face of the head segments of the plurality of fasteners opposite the shank segments; positioning the hub adjacent the main shaft of the wind turbine; inserting each of the plurality of fasteners within the through-hole through a corresponding plurality of receiving holes of the main shaft of the wind turbine; and Torque applied to the shaft segment of at least one of the plurality of fasteners is resisted via contact between the head segment and the at least one circumferential ridge segment to secure the at least one fastener within the throughbore and the corresponding plurality of receiving holes of the spindle.

2. The method according to claim 1, characterized in that Positioning the at least one circumferential ridge segment further comprises machining a U-shaped channel on the hub, the U-shaped channel comprising: at least one radially inner circumferential ridge segment disposed adjacent to the radially inner faces of the head sections of the plurality of fasteners; and At least one radially outer circumferential ridge segment is disposed adjacent to the radially outer faces of the head segments of the plurality of fasteners, wherein the radially inner circumferential ridge segment and the radially outer circumferential ridge segment define an axial plane that is coplanar with the axial faces of the head segments of the plurality of fasteners.

3. The method according to claim 1, characterized in that The retaining ring segment and the at least one circumferential ridge segment are a unitary component, and wherein positioning the at least one circumferential ridge segment further comprises coupling the unitary component to the hub radially adjacent the head segment and adjacent the axial face of the head segment.

4. The method according to claim 1, wherein The retaining ring segment is a spring component or further includes an elastomeric component, the spring component or the elastomeric component is configured to contact the axial surfaces of the head sections of the plurality of fasteners, and wherein limiting axial translation further includes: Shock is absorbed during an installation procedure while maintaining the alignment of the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through-hole.

5. A mounting system for coupling a hub of a wind turbine to a main shaft, the mounting system comprising: a plurality of fasteners disposed within corresponding through-holes arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners comprising a head section and a shank section, the head section having a cross-sectional area greater than a cross-sectional area of ​​the shank section, wherein the head section distributes torque loads to the hub when the hub is coupled to the spindle; at least one circumferential ridge segment disposed radially adjacent to the head sections of the plurality of fasteners to resist torque applied to each of the plurality of fasteners; as well as a connecting mechanism that secures the plurality of fasteners within the plurality of through-holes to limit axial translation of the plurality of fasteners before the hub is coupled to the spindle, wherein the connecting mechanism includes at least one retaining ring segment coupled to the hub, the at least one retaining ring segment positioned adjacent to an axial face of the head segments of the plurality of fasteners opposite the shank segments.

6. The mounting system according to claim 5, wherein: The at least one circumferential ridge segment comprises a U-shaped channel comprising: at least one radially inner circumferential ridge segment disposed adjacent to the radially inner faces of the head sections of the plurality of fasteners; and At least one radially outer circumferential ridge segment is disposed adjacent to the radially outer faces of the head segments of the plurality of fasteners, wherein the radially inner circumferential ridge segment and the radially outer circumferential ridge segment define an axial plane that is coplanar with the axial faces of the head segments of the plurality of fasteners.

7. The mounting system according to claim 6, wherein: The connection mechanism includes at least one retaining ring segment spanning the U-shaped channel, the at least one retaining ring segment coupled to the radially inner circumferential ridge segment and the radially outer circumferential ridge segment.

8. The mounting system according to claim 5, wherein: The at least one circumferential ridge segment is integrally formed with the hub.

9. The mounting system according to claim 5, wherein: The retaining ring segment further includes an elastomeric component configured to contact the axial surface of the head sections of the plurality of fasteners, the elastomeric component being configured to absorb shock during an installation procedure, the elastomeric component being further configured to maintain alignment of the longitudinal axis of each of the plurality of fasteners with the longitudinal axis of the corresponding through hole.

10. The mounting system according to claim 5, wherein: The retaining ring segment is a spring member disposed in contact with the axial surface of the head sections of the plurality of fasteners, the spring member being configured to absorb shock during an installation procedure, and the spring member being further configured to maintain alignment of a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of the corresponding through hole.

11. The mounting system according to claim 5, wherein: The retaining ring segment is coupled to the at least one circumferential ridge segment.

12. The mounting system according to claim 5, wherein: The retaining ring segment and the at least one circumferential ridge segment are a unitary component coupled to the hub.

13. The mounting system according to claim 5, wherein: The head section includes a square head and an integral washer disposed between the square head and the handle section, wherein: the square head having a width greater than or equal to 175% of the diameter of the shank segment and less than or equal to 225% of the diameter of the shank segment; the integral washer having a diameter greater than or equal to 150% and less than or equal to 200% of the diameter of the shank segment; and The integral washer has a height greater than or equal to 10% and less than or equal to 20% of the diameter of the shank segment.

14. The mounting system according to claim 5, wherein: The shank section includes an alignment portion disposed adjacent to the head section, the alignment portion maintaining alignment of a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of the corresponding through-hole, the alignment portion having a diameter greater than 98% and less than 100% of the diameter of the through-hole.

15. The mounting system according to claim 5, wherein: The connection mechanism further includes a bushing surrounding a portion of the shank section, the bushing further configured to absorb shock during an installation procedure and configured to maintain alignment of a longitudinal axis of each of the plurality of fasteners with a longitudinal axis of the corresponding through-hole.

16. The mounting system according to claim 5, wherein: The mounting system further includes at least one alignment pin secured in at least one of the through-holes, the at least one alignment pin having a length greater than a length of the plurality of fasteners.

17. The mounting system according to claim 5, wherein: The connection mechanism is at least one of epoxy resin or brazing.

18. A mounting system for coupling a hub of a wind turbine to a main shaft, the mounting system comprising: a plurality of fasteners disposed within corresponding through-holes arranged in a circular array about a rotational axis of the hub, each of the plurality of fasteners comprising a head segment and a shank segment, the head segment having a cross-sectional area greater than a cross-sectional area of ​​the shank segment, the shank segment having a first end and a second end disposed opposite the first end, the first end defining a first threaded portion configured to be received by the spindle of the turbine; a connecting mechanism that secures the plurality of fasteners within the plurality of through-holes to limit axial translation of the plurality of fasteners before the hub is coupled to the spindle, the connecting mechanism comprising at least one retaining ring segment coupled to the hub, the at least one retaining ring segment positioned adjacent to an axial face of the head segments of the plurality of fasteners opposite the shank segments, wherein the connecting mechanism comprises: a threaded portion in each of the through holes, the threaded portion having a longitudinal length that is less than a longitudinal length of the through hole, and A second threaded portion is defined by the second ends of the plurality of fasteners, wherein the second threaded portion is configured to engage the corresponding threaded portion of the through hole, the second threaded portion being configured to resist torque transmitted to the first threaded portion.

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