Yaw brake assembly for a wind turbine

Abstract

The present invention relates to a yaw brake assembly of a wind turbine. Accordingly, the yaw brake assembly includes a bedplate support frame having an annular flange defining a plurality of recesses formed into a lowermost annular surface of the annular flange and extending at least partially through an axial thickness of the annular flange. Each of the plurality of recesses defines an open outer peripheral side. The yaw brake assembly further includes a plurality of brake pads positioned within the plurality of recesses and configured to engage at least one race of an adjacent yaw bearing. The yaw brake assembly further includes a plurality of actuators for driving the plurality of brake pads to engage the yaw bearing.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to wind turbines, and more particularly to systems and methods for braking yaw rotation of a nacelle of a wind turbine. BACKGROUND

[0002] Wind is considered one of the cleanest and most environmentally friendly sources of energy currently available, and in this regard, wind turbines have received increased 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 to the generator. The rotor assembly and the gearbox are assembled on a bedplate support frame located within the nacelle. The one or more rotor blades use known airfoil principles to capture kinetic energy of the wind. The rotor blades transfer the kinetic energy in the form of rotational energy to a shaft that couples the rotor blades to the gearbox or, in the case of direct drive systems, directly to the generator. The generator then converts the mechanical energy into electrical energy, and the electrical energy can be transmitted to a transformer and / or a converter housed within the tower and subsequently deployed to a utility grid. A modern wind power system typically takes the form of a wind farm having a plurality of such wind turbine generators operable to supply power to a transmission system to provide power to a grid.

[0003] To efficiently generate electrical energy, it is typically desirable for the nacelle of a wind turbine to be oriented in aerodynamic alignment with the wind acting on the wind turbine. This is generally accomplished by rotating the nacelle relative to the tower. However, once aerodynamic alignment is achieved, additional rotation of the nacelle relative to the tower must be resisted. Resistance to additional rotation is typically provided via a yaw brake system.

[0004] Modern wind turbine yaw brake systems are typically cylindrical in nature and are inserted through the bedplate support frame. The yaw brake system typically utilizes the top surface of the yaw bearing as the brake friction surface and utilizes the bedplate support frame as the mounting structure for the brake load actuation unit. However, this configuration has several known drawbacks. For example, during braking of the nacelle, loads are generated in the yaw, axial, torque, and moment directions and can be transmitted to the internal components of the actuation unit, causing damage. Additionally, the circular nature of the brake pads often facilitates spinning of the brake pads during actuation. It is common for spinning of the brake pads to result in reduced effectiveness of the brake, pad edge cracking, looseness, and actuator component wear / damage. Additionally, it has proven to be quite problematic to incorporate a wear sensor into the brake pad for the reason of the possibility of spinning, which results in brake pad servicing being done on schedule rather than when necessary due to actual conditions. Also, since the yaw brake system is typically inserted through the bedplate support frame, servicing the brake pads requires disassembly of the yaw brake system in order to remove and access the brake pads.

[0005] Thus, there is an ongoing need in the art for new and improved systems for controlling yaw rotation of a nacelle of a wind turbine. Accordingly, the present disclosure relates to a yaw brake assembly that overcomes the drawbacks of previous yaw brake assemblies. SUMMARY

[0006] Aspects and advantages of the application will be set forth in the description below, or can be obvious from the description, or can be learned through practice of the application.

[0007] In an aspect, the present disclosure relates to a yaw brake assembly of a wind turbine. The brake assembly can include a yaw bearing. The yaw brake assembly can also include a bedplate support frame having an annular flange disposed adjacent the yaw bearing. The annular flange can define a plurality of recesses formed into a lowermost annular surface of the annular flange and extending at least partially through an axial thickness of the annular flange. Each of the plurality of recesses can define an open outer peripheral side. Additionally, the yaw brake assembly can include a plurality of brake pads positioned within the plurality of recesses. Each of the plurality of brake pads can be configured to engage at least one race of the yaw bearing. Moreover, the yaw brake assembly can include a plurality of actuators for driving the plurality of brake pads to engage the at least one race of the yaw bearing to resist yaw of a nacelle of the wind turbine.

[0008] In an embodiment, the yaw brake assembly can also include a plurality of arm members positioned within a corresponding plurality of holes through the annular flange between the plurality of actuators and the plurality of brake pads. The plurality of arm members can be oriented to transmit force from the plurality of actuators to the plurality of brake pads.

[0009] In embodiments, each of the plurality of brake pads can have a non-circular shape.

[0010] In additional embodiments, each of the plurality of brake pads can have at least one of a polygonal shape, a curvilinear polygonal shape, or a rounded square planform shape.

[0011] In further embodiments, each of the plurality of brake pads can define a maximum length and a maximum width. The maximum length can be greater than the maximum width.

[0012] In embodiments, each open peripheral side of the plurality of recesses can define a circumferential length that is greater than a maximum length of a corresponding brake pad.

[0013] In additional embodiments, only one of the plurality of brake pads can be positioned within each of the plurality of recesses.

[0014] In embodiments, the plurality of recesses and the corresponding plurality of brake pads can be distributed circumferentially about the annular flange in a plurality of adjacent paired sets.

[0015] In additional embodiments, a single actuator can be operably coupled to each of the plurality of paired sets.

[0016] In further embodiments, the plurality of brake pads can be radially aligned with an outer race of the yaw bearing.

[0017] In embodiments, the yaw brake assembly can further include a retaining bracket secured to the outer peripheral side. The retaining bracket can close at least one of the circumferential openings.

[0018] In additional embodiments, at least one of the plurality of brake pads can further include at least one sensor configured to generate a warning related to a wear level of one or more of the plurality of brake pads.

[0019] In further embodiments, the sensor(s) can include a continuity sensor.

[0020] In embodiments, the plurality of brake pads can be accessible from an exterior of the bottom plate support frame via the corresponding circumferential openings.

[0021] In additional embodiments, each of the plurality of brake pads can be formed with at least one extraction feature. The extraction feature can be positioned so as to facilitate removal of each of the brake pads from the corresponding recess.

[0022] In another aspect, the present disclosure is directed to a wind turbine. The wind turbine can include a tower. The wind turbine can also include a nacelle assembled on top of the tower. The nacelle can include a floor support frame. The floor support frame can include an annular flange. The annular flange can define a plurality of recesses formed into a lowermost annular surface of the annular flange and extending at least partially through an axial thickness of the annular flange. Each of the plurality of recesses can define an open outer peripheral side. The wind turbine can include a yaw bearing disposed adjacent to the annular flange. Also, the wind turbine can include a rotor assembled to the nacelle. The rotor can include a rotatable hub having one or more rotor blades secured to the rotatable hub. Additionally, the wind turbine can include a plurality of brake pads positioned within the plurality of recesses. Each of the plurality of brake pads can be configured to engage at least one race of the yaw bearing. The wind turbine can also include a plurality of actuators for driving the plurality of brake pads to engage the at least one race of the yaw bearing in order to resist yaw of the nacelle of the wind turbine. It should be appreciated that the system can further include any of the additional steps and / or features described herein.

[0023] In another aspect, the present disclosure is directed to a method for servicing a yaw brake assembly of a wind turbine. The method can include accessing at least one brake pad of a plurality of brake pads via an open outer peripheral side of a recess defined by at least one of the plurality of recesses formed into a lowermost annular surface of an annular flange of a floor support frame and extending at least partially through an axial thickness of the annular flange, wherein the lowermost annular surface is disposed adjacent to a yaw bearing of the wind turbine. The method can also include passing the at least one brake pad through the open outer peripheral side of the recess while maintaining a corresponding actuator of a plurality of actuators in an assembled configuration. It should be appreciated that the system can further include any of the additional steps and / or features described herein.

[0024] These and other features, aspects, and advantages of the present application 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 application and help to explain the principles of the application. BRIEF DESCRIPTION OF DRAWINGS

[0025] A complete and enabling disclosure of the application, including its best mode, directed to one of ordinary skill in the art following in the specification accompanied by the drawings, in which:

[0026] Figure 1 FIG. 1 illustrates a perspective view of one embodiment of a wind turbine in accordance with the present disclosure;

[0027] Figure 2The figure shows a perspective interior view of one embodiment of the nacelle of a wind turbine according to the present disclosure;

[0028] Figure 3 The illustration is a top view of one embodiment of a yaw bearing for a wind turbine according to the present disclosure;

[0029] Figure 4 The illustration is a perspective view of a portion of a wind turbine tower according to this disclosure;

[0030] Figure 5 The figure shows a perspective view of a base plate support frame used in conjunction with a yaw brake assembly according to this disclosure.

[0031] Figure 6 The figure shows a perspective view of the assembled portion of the yaw brake assembly according to this disclosure;

[0032] Figure 7A and Figure 7B The illustration is based on this disclosure. Figure 5 A cross-sectional view of a portion of the base plate support frame;

[0033] Figure 8 The illustration is based on this disclosure. Figure 5 Bottom view of the lowest annular surface portion of the base plate support frame;

[0034] Figure 9 The figure shows a bottom perspective view of a portion of an embodiment of a yaw braking assembly according to the present disclosure;

[0035] Figure 10 The figure shows a bottom view of an embodiment of the brake pad of the yaw braking assembly according to the present disclosure;

[0036] Figure 11 The figure shows a bottom view of an embodiment of the brake pad of the yaw braking assembly according to the present disclosure;

[0037] Figure 12A and Figure 12B The figures illustrate a side view and a perspective view of an embodiment of a brake pad used in conjunction with a yaw braking assembly according to the present disclosure; and

[0038] Figure 13 The diagram shows a flowchart of a method for repairing a yaw brake assembly according to the present disclosure.

[0039] The repeated use of reference characters in this specification and drawings is intended to indicate the same or similar features or elements of the invention. Detailed Implementation

[0040] Reference will now be made in detail to embodiments of the application, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the application, not limitation of the application. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present application without departing from the scope or spirit of the application. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present application encompass such modifications and variations as come within the scope of the appended claims and their equivalents.

[0041] As used herein, the terms "first," "second," and "third" can be used interchangeably to distinguish between components of like kind, and are not intended to denote a location or importance of the individual components.

[0042] Unless otherwise defined, the terms "coupled," "fixed," "attached to" and like terms mean both direct coupling, fixation, or attachment and indirect coupling, fixation or attachment through one or more intermediary components or features unless otherwise specified.

[0043] Approximating language can be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is directed. Accordingly, a value modified by a term or terms, such as "about" and "substantially," will not be limited to the precise value specified. In at least some instances, the approximating language can correspond to the precision of an instrument for measuring the value or the precision of the measurement techniques employed to construct or manufacture the components and / or systems. For example, the approximating language can refer to being within 10% of a stated value. In at least some instances, the approximating language can be construed as referring to the degree of expected variation inherent in the instruments used to measure the value or the degree of variation that would be expected by one of ordinary skill in the art to occur in the manufacturing or production process.

[0044] Herein and throughout the specification and claims, range limitations are combined and / or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, a range of "between A and B" or "between about A and B" can include A and B unless context or language indicates otherwise. The same applies to ranges containing endpoints, for example, a range of "from A to B" or "from about A to B" can include A and B unless context or language indicates otherwise.

[0045] Generally, the present disclosure relates to a yaw brake assembly of a wind turbine. In particular, the yaw brake assembly of the present disclosure can include a bedplate support frame having an annular flange. The annular flange can be formed with a plurality of recesses formed into a lowermost annular surface of the annular flange. The recesses can extend at least partially through an axial thickness of the flange and can define openings in an outer peripheral side of the annular flange. In other words, each of the recesses can have two open sides through which a corresponding brake pad can pass. One opening can be located in the lowermost annular surface of the annular flange and can facilitate engagement of the brake pad with a braking friction surface, such as a yaw bearing. A second opening can be located in the outer peripheral side of the annular flange and can facilitate access to the brake pad without requiring disassembly of the yaw brake assembly.

[0046] The brake pads inserted into each of the recesses can have a non-circular shape. For example, the brake pads can have a polygonal shape, a curvilinear polygonal shape, or a rounded square planform shape. In instances where the brake pads are formed with a non-circular shape, the brake pads can interface with the recesses so as to transfer loads generated during braking to the bedplate support frame, rather than to an actuator member of the yaw brake assembly. It should be appreciated that, as a result of the brake pads interfacing with the recesses, the brake pads can be prevented from spinning during a braking operation. This, in turn, can improve braking effectiveness of the yaw brake assembly and can facilitate inclusion of a wear sensor with the brake pads.

[0047] Reference is now made to the drawings, Figure 1 A perspective view illustrating one embodiment of a wind turbine 100 in accordance with 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 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 outward 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 can include more or less than three rotor blades 112. Each rotor blade 112 can be spaced about the hub 110 to facilitate rotating the rotor 108 to enable kinetic energy from the wind to be converted into usable mechanical energy and, subsequently, electrical energy. For example, the hub 110 can be rotatably coupled to an electric generator 118 Figure 2 located within the nacelle 106 to allow electrical energy to be generated.

[0048] The wind turbine 100 may also include a turbine controller 114 centrally located within the nacelle 106. However, in other embodiments, the turbine controller 114 may be located within any other component of the wind turbine 100 or at a location external to the wind turbine. Furthermore, the turbine controller 114 may be communicatively coupled to any number of components of the wind turbine 100 to control those components. Accordingly, the turbine controller 114 may include a computer or other suitable processing unit. Thus, in several embodiments, the turbine controller 114 may include suitable computer-readable instructions that, when executed, configure the turbine controller 114 to perform various functions, such as receiving, transmitting, and / or executing wind turbine control signals.

[0049] Now for reference Figure 2 Illustration Figure 1 The diagram shows a simplified internal view of one embodiment of the nacelle 106 of the wind turbine 100. As shown, a generator 118 can be coupled to a rotor 108 to generate electrical power 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 a hub 110 for rotation with the hub. The rotor shaft 122 may be rotatably supported by a main bearing. The rotor shaft 122 can then be rotatably coupled to the high-speed shaft 124 of the generator 118 via a gearbox 126, which is connected to a base support frame 136 via one or more torque arms 142. As generally understood, the rotor shaft 122 can 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 can then be configured to convert the low-speed, high-torque input into a high-speed, low-torque output to drive the high-speed shaft 124 and thus the generator 118. In one embodiment, the gearbox 126 may be configured with multiple gear ratios to produce varying rotational speeds of the high-speed shaft for a given low-speed input, or vice versa.

[0050] Each rotor blade 112 can also include a pitch control mechanism 120 configured to rotate each rotor blade 112 about its pitch axis 116. The pitch control mechanism 120 can include a pitch controller configured to receive at least one pitch setpoint command from the turbine controller 114. Moreover, each pitch control mechanism 120 can 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 embodiments, the pitch drive motor 128 can be coupled to the pitch drive gearbox 130 such that the pitch drive motor 128 applies a mechanical force to the pitch drive gearbox 130. Similarly, the pitch drive gearbox 130 can be coupled to the pitch drive pinion 132 for rotation therewith. The pitch drive pinion 132, in turn, can 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 embodiments, rotation of the pitch drive motor 128 drives the pitch drive gearbox 130 and the pitch drive pinion 132, thereby rotating the pitch bearing 134 and the rotor blade(s) 112 about the pitch axis 116.

[0051] The wind turbine 100 can also include one or more yaw drive mechanisms 138 communicatively coupled to the controller 114. Each yaw drive mechanism(s) 138 can be configured to change the angle of the nacelle 106 relative to the wind by engaging a yaw bearing 140 of the wind turbine 100. The yaw bearing 140 can couple the tower 102 and the nacelle 106 at a yaw bearing interface 146. For example, as shown in FIG. 1, the yaw bearing 140 can be coupled to the tower 102 at a first end 148 and to the nacelle 106 at a second end 150. In such embodiments, the yaw drive mechanism 138 can be configured to rotate the nacelle 106 about the yaw axis 142 by engaging the yaw bearing 140 at the first end 148 and the second end 150. Figure 3As shown in FIG. 1, yaw bearing 140 can include an inner race 148 and an outer race 150. As such, inner race 148 of yaw bearing 140 can be fitted to floor support frame 136, while outer race 150 of yaw bearing 140 can be fitted to tower 102, or vice versa. Fitting can be facilitated by use of suitable mechanical fasteners, such as a combination of nuts and bolts, screws, nails, rivets, or other suitable mechanical fastening devices, or by a suitable adhesive, or by suitable fitting techniques, such as welding or brazing. In an exemplary embodiment, inner race 148 can have an inner race hole pattern 152 that corresponds to a matching hole pattern in floor support frame 136. Similarly, outer race 150 can have an outer race hole pattern 154 that corresponds to a matching hole pattern on top of tower 102. In an exemplary embodiment, rotation of yaw bearing 140, such as rotation of inner race 148 relative to outer race 150, can cause nacelle 106 to rotate relative to tower 102. It should be appreciated that, in at least one embodiment, yaw bearing 140 can be formed with a single race 148, 150, and tower 102 can act as the other race.

[0052] As Figure 4 As depicted in FIG. 1, in an embodiment, a reference system can be defined with respect to wind turbine 100. In such an embodiment, an axis (A) can be defined that is substantially parallel to a centerline of tower 102 and perpendicular to support surface 104. Axis (A) can define an axial direction of wind turbine 100, such that the term "axially" refers to a position, dimension, translation, or movement along or with respect to axis (A). This axis can intersect with a plane (R). As used herein, plane (R) can be oriented substantially perpendicular to axis (A) and can define a radial direction. As such, the term "radially" refers to a position, dimension, translation, or movement along or with respect to a radius. Additionally, an arc (C) can be defined along plane (R) so as to define a circumferential position, dimension, translation, or movement.

[0053] Referring now to Figures 5-12B wherein a plurality of embodiments of a yaw brake assembly 300 are shown. As Figure 5 As shown in FIG. 1, floor support frame 136 can include an annular flange 302. As Figure 2 As depicted in FIG. 1, annular flange 302 can be disposed adjacent to yaw bearing 140 along yaw bearing interface 146. As particularly illustrated in Figure 7A As shown in FIG. 1, in an embodiment, annular flange 302 can define a plurality of recesses 304 formed into a lowermost annular surface 306 of annular flange 302. The plurality of recesses 304 can extend at least partially through an axial thickness (AT ). Each of the plurality of recesses 304 can define an open outer periphery 308. In other words, each of the recesses 304 can define an opening in an outer periphery 310 of the annular flange 302. In embodiments, the yaw brake assembly 300 can further include a plurality of brake pads 312 positioned within the plurality of recesses 304. The plurality of brake pads 312 can be configured to engage at least one race 148, 150 of the yaw bearing 140. For example, in at least one embodiment, the plurality of brake pads 312 can be radially aligned with the outer race 150 of the yaw bearing 140. Additionally, the yaw brake assembly 300 can include a plurality of actuators 314 for driving the plurality of brake pads 312 to engage the yaw bearing 140 and resist yaw of the nacelle 106 of the wind turbine 100.

[0054] As particularly depicted in Figure 7A and Figure 7B , in at least one embodiment, the yaw brake assembly 300 can include a plurality of arm members 316 positioned within a corresponding plurality of holes 318 through the annular flange 302. The holes 318 can be positioned between the plurality of actuators 314 and the plurality of brake pads 312. In embodiments, the plurality of arm members 316 can be oriented to transfer force from the plurality of actuators 314 to the plurality of brake pads 312. In other words, the plurality of arm members 316 can operably couple the plurality of brake pads 312 to the corresponding plurality of actuators 314.

[0055] In embodiments, the brake pads 312 can include a wear layer 320 coupled to a support plate 322. The wear layer 320 can be configured to engage the yaw bearing 140 and increase friction with the yaw bearing. As such, the wear layer 320 can be any suitable material selected based on wear characteristics and heat resistance. The support plate 322 can be a rigid / semi-rigid material, such as steel, configured to improve the ability of the wear layer 320 to resist structural loads.

[0056] In at least one embodiment, such as depicted in Figure 5 and Figures 8-12B , the plurality of brake pads 312 can have a non-circular shape. Additionally, in embodiments, the plurality of recesses 304 can be formed to conform to the non-circular shape of the plurality of brake pads 312. For example, as depicted in Figure 8 , the brake pads 312 can be formed with a polygonal shape or a rounded square planform shape. In such embodiments, the linear perimeter edges of the plurality of brake pads 312 can be configured to engage corresponding edges of the plurality of recesses 304. As depicted in Figure 9 and Figure 10As depicted, in at least one embodiment, the plurality of brake pads 312 may be formed in a curved polygonal shape. In other words, in such an embodiment, the brake pads 312 may be generally rectangular, but may be formed to conform to the periphery of the plurality of recesses 304. It should be appreciated that the yaw brake assembly 300 may include brake pads 312 with different planar shapes.

[0057] It should also be appreciated that forming a plurality of recesses 304 that conform to the non-circular shape of the plurality of brake pads 312 can facilitate the transfer of braking load from the brake pads 312 to the base plate support frame 136 by excluding the spin or rotation of the brake pads 312. Accordingly, only one of the plurality of brake pads 312 may be positioned within each of the plurality of recesses 304. In other words, in at least one embodiment, the number of recesses 304 may be equal to the number of brake pads 312.

[0058] In such Figure 5 and Figure 8 In at least one embodiment depicted, a plurality of recesses 304 and corresponding plurality of brake pads 312 may be circumferentially distributed around the annular flange 302 in a plurality of adjacent pairs. In, for example... Figure 5 and Figure 6 In at least one embodiment depicted, a single actuator 314 may be operatively coupled to each of a plurality of paired kits 324. In such an embodiment, the number of actuators 314 may be half the number of brake pads 312 and recesses 304. It should be appreciated that using a single actuator 314 to drive paired kits 324 can reduce the cost and complexity of the yaw brake assembly 300. It should be further appreciated that, in at least one embodiment, a combination of single brake pads 312 and paired kits 324 can be utilized to increase the required braking force for the wind turbine 100.

[0059] In an embodiment, each of the plurality of brake pads 312 may be defined with a maximum length (M). L ) and maximum width (M W In such as Figure 10 In at least one embodiment described herein, the maximum length (M) L It can be greater than the maximum width (M) W In an alternative embodiment, the maximum width (M) W It can be greater than the maximum length (M) L In yet another embodiment, the maximum length (M) L ) and maximum width (M W () can have the same length.

[0060] In an embodiment, each open outer peripheral side 308 of the plurality of recesses 304 may define a circumferential length (C) sufficient to allow the corresponding brake pad 312 to pass through.L ) can be implemented without requiring rotation or disassembly of the brake pad 312. For example, in at least one embodiment, the circumferential length (C L ) of the opening in the outer peripheral side 310 of the annular flange 302 can be greater than the maximum length (M L ) of the corresponding brake pad 312. It should be appreciated that the ability to pass the brake pad 312 through the open outer peripheral side 308 of the recess 304 can facilitate utilization of brake pads 312 having pad surface areas that can be greater than the actuator piston area. In other words, the brake pad 312 can be greater than the aperture 318. It should be further appreciated that utilization of brake pads 312 having greater areas can facilitate more controlled pad pressure and, as a result, can lead to more desirable reliability and wear characteristics.

[0061] As depicted in Figure 6 and Figure 8 , in embodiments, the yaw brake assembly 300 can include a retaining bracket 326. The retaining bracket 326 can be secured to the outer peripheral side 310 of the annular flange 302. The retaining bracket 326 can enclose at least one of the open outer peripheral sides 308 of the plurality of recesses 304. In such embodiments, the retaining bracket(s) 326 can be the only member of the wind turbine 100 that must be removed in order to access the brake pad 312. In embodiments, the plurality of brake pads 312 can be accessible from outside of the bed support frame 136 via the corresponding open outer peripheral sides 308 of the plurality of recesses 304. For example, the yaw brake assembly 300 can allow for replacement of the brake pad 312 on-tower, within the nacelle 106. In such embodiments, this maintenance can be implemented without requiring disengagement of the actuator 314 from the bed support frame 136. It should be appreciated that the ability to service the yaw brake assembly 300 while the yaw brake assembly 300 remains substantially installed can reduce the cost and complexity of the service operation.

[0062] In embodiments such as Figure 8 , Figure 12A and Figure 12BIn the depicted embodiment, at least one of the plurality of brake pads 312 can include at least one sensor 328 configured to generate a warning related to a wear level of one or more of the plurality of brake pads 312. The sensor(s) 328 can be configured to detect when the thickness of the wear layer 320 can be less than a predetermined threshold. In such an embodiment, the sensor(s) 328 can generate a warning when the thickness of the wear layer 320 crosses the threshold. The warning can include a signal to the controller 114, a light, a sound, or other suitable means selected to warn an operator of the wear level of one or more of the plurality of brake pads 312. For example, in at least one embodiment, the sensor(s) 328 can be a continuity sensor. As the thickness of the wear layer 320 decreases, the sensor(s) 328 can be brought into contact with the yaw bearing 140, causing a disruption in the continuity of the sensor(s) 328. It should be appreciated that including the sensor(s) 328 can allow for performing maintenance activities or scheduling maintenance activities based on the actual wear of the brake pads 312, rather than based on a predetermined schedule. This, in turn, can preclude performing maintenance activities that are out of sync with the wear state of the brake pads 312.

[0063] In further embodiments, each of the plurality of brake pads 312 can be formed with at least one extraction feature 330. The extraction feature 330 can be positioned to facilitate removal of each of the brake pads 312 from the corresponding recess 304. For example, as shown in Figure 10 As shown in the depicted embodiment, the support plate 322 can be formed with at least one protrusion 332. The protrusion 332 can define a suitable feature, such as a hole, a dimple, a notch, and / or a ridge, that can be engaged with a tool to affect extraction of the brake pad 312 through the open peripheral side 308 of the corresponding recess 304. In embodiments such as Figure 11 In additional embodiments, the support plate 322 can be formed to define a threaded hole 334. In such embodiments, a tool, a fastener, or other similar implement can be threaded into the threaded hole 334 and utilized to extract the brake pad 312 through the open peripheral side 308 of the corresponding recess 304.

[0064] Referring now to Figure 13 , a flow diagram illustrating one embodiment of a method 400 for servicing a brake assembly of a wind turbine is shown. The method 400 can be implemented using the assembly 300 of the present disclosure, for example, as discussed above with reference to Figures 1-12B For purposes of illustration and discussion, the method 400 will be described with reference to the assembly 300 of the present disclosure, as shown in Figure 13Depicts steps performed in a particular order. One of ordinary skill in the art will understand that various steps of the method 400 or any of the methods disclosed herein can be adapted, modified, rearranged, performed simultaneously, and / or modified in various ways without deviating from the scope of the disclosure, using the disclosure provided herein.

[0065] As shown at (402), the method 400 can include accessing at least one brake pad of a plurality of brake pads via an open peripheral side of a recess defined by at least one of the plurality of recesses formed into a lowermost annular surface of an annular flange of a bedplate support frame and extending at least partially through an axial thickness of the annular flange. The lowermost annular surface can be disposed adjacent to a yaw bearing of a wind turbine. As shown at (404), the method 400 can also include passing the at least one brake pad through the open peripheral side of the recess while maintaining a corresponding actuator of a plurality of actuators in an assembled configuration.

[0066] Furthermore, those skilled in the art will recognize that the various features of the various embodiments can be interchanged, i.e., swapped, between the various embodiments. Similarly, various method steps and features described, as well as other known equivalents, can be mixed and matched by those skilled in the art to construct additional systems and techniques in accordance with the principles of this disclosure. Of course, it is to be understood that not necessarily all objects or advantages can be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein can be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as can be taught or suggested herein.

[0067] This written description uses examples to disclose the application, including the best mode, and also to enable any person skilled in the art to practice the application, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the application is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent

[0068] Further aspects of the application are provided by the subject matter of the following clauses:

[0069] Clause 1. A yaw brake assembly of a wind turbine, the yaw brake assembly comprising: a yaw bearing; a bedplate support frame comprising an annular flange arranged adjacent to the yaw bearing, the annular flange defining a plurality of recesses formed into a lowermost annular surface of the annular flange and extending at least partially through an axial thickness of the annular flange, each of the plurality of recesses defining an open outer peripheral side; a plurality of brake pads positioned within the plurality of recesses, each of the plurality of brake pads configured to engage at least one race of the yaw bearing; and a plurality of actuators for driving the plurality of brake pads to engage the at least one race of the yaw bearing so as to resist yaw of a nacelle of the wind turbine.

[0070] Clause 2. The yaw brake assembly of any preceding clause, further comprising: a plurality of arm members positioned within a corresponding plurality of holes through the annular flange between the plurality of actuators and the plurality of brake pads, the plurality of arm members oriented to transmit force from the plurality of actuators to the plurality of brake pads.

[0071] Clause 3. The yaw brake assembly of any preceding clause, wherein each of the plurality of brake pads has a non-circular shape.

[0072] Clause 4. The yaw brake assembly of any preceding clause, wherein each of the plurality of brake pads has at least one of a polygonal shape, a curvilinear polygonal shape, or a rounded square planform shape.

[0073] Clause 5. The yaw brake assembly of any preceding clause, wherein each of the plurality of brake pads defines a maximum length and a maximum width, the maximum length being greater than the maximum width.

[0074] Clause 6. The yaw brake assembly of any preceding clause, wherein each open outer peripheral side of the plurality of recesses defines a circumferential length that is greater than the maximum length of the corresponding brake pad.

[0075] Clause 7. The yaw brake assembly of any preceding clause, wherein only one of the plurality of brake pads is positioned within each of the plurality of recesses.

[0076] Clause 8. The yaw brake assembly of any preceding clause, wherein the plurality of recesses and the corresponding plurality of brake pads are distributed circumferentially around the annular flange in a plurality of adjacent paired sets.

[0077] Clause 9. The yaw brake assembly of any preceding clause, wherein a single actuator is operably coupled to each of the plurality of paired sets.

[0078] Clause 10. The yaw brake assembly of any preceding clause, wherein the plurality of brake pads are radially aligned with an outer race of the yaw bearing.

[0079] Clause 11. The yaw brake assembly of any preceding clause, further comprising a retaining bracket secured to the outer peripheral side, the retaining bracket closing at least one of the circumferential openings.

[0080] Clause 12. The yaw brake assembly of any preceding clause, wherein at least one of the plurality of brake pads further comprises at least one sensor configured to generate a warning related to a wear level of one or more of the plurality of brake pads.

[0081] Clause 13. The yaw brake assembly of any preceding clause, wherein the at least one sensor comprises a continuity sensor.

[0082] Clause 14. The yaw brake assembly of any preceding clause, wherein the plurality of brake pads are accessible from an exterior of the bed support frame via the corresponding circumferential openings.

[0083] Clause 15. The yaw brake assembly of any preceding clause, wherein each of the plurality of brake pads is formed with at least one extraction feature positioned to facilitate removal of each of the brake pads from the corresponding recess.

[0084] Clause 16. A wind turbine comprising: a tower; a nacelle assembled atop the tower and including a bed support frame, the bed support frame including a bed support frame having an annular flange disposed adjacent to a yaw bearing, the annular flange defining a plurality of recesses formed into a lowermost annular surface of the annular flange and extending at least partially through an axial thickness of the annular flange, each of the plurality of recesses defining an open outer peripheral side, the yaw bearing disposed adjacent to the annular flange; a rotor assembled to the nacelle, the rotor including a rotatable hub having one or more rotor blades secured to the rotatable hub; and a plurality of brake pads positioned within the plurality of recesses, each of the plurality of brake pads configured to engage at least one race of the yaw bearing; and a plurality of actuators for driving the plurality of brake pads to engage the at least one race of the yaw bearing so as to resist yaw of the nacelle of the wind turbine.

[0085] Clause 17. The wind turbine of any preceding clause, wherein each of the plurality of brake pads comprises at least one of a polygonal shape, a curvilinear polygonal shape, or a rounded square planform shape.

[0086] Clause 18. The wind turbine of any preceding clause, wherein each of the plurality of brake pads defines a maximum length and a maximum width, the maximum length being greater than the maximum width.

[0087] Clause 19. The wind turbine of any preceding clause, wherein each circumferential opening defines a circumferential length that is greater than a maximum length of a corresponding brake pad of the plurality of brake pads.

[0088] Clause 20. A method for servicing a yaw brake assembly of a wind turbine, the method comprising: accessing at least one brake pad of a plurality of brake pads via an open peripheral side of a recess defined by at least one of a plurality of recesses formed into a lowermost annular surface of an annular flange of a bedplate support frame and extending at least partially through an axial thickness of the annular flange, wherein the lowermost annular surface is disposed adjacent to a yaw bearing of the wind turbine; and passing the at least one brake pad through the open peripheral side of the recess while maintaining a corresponding actuator of a plurality of actuators in an assembled configuration.

Claims

1. A yaw braking assembly for a wind turbine, the yaw braking assembly comprising: Yaw bearing; A base plate support frame includes an annular flange arranged adjacent to the yaw bearing, the annular flange defining a plurality of recesses formed in the lowest annular surface of the annular flange and extending at least partially through the axial thickness of the annular flange, each of the plurality of recesses defining an open outer peripheral side. A plurality of brake pads, the plurality of brake pads being positioned within the plurality of recesses, each of the plurality of brake pads being configured to engage at least one race of the yaw bearing; as well as Multiple actuators for driving multiple brake pads to engage at least one race of the yaw bearing in order to resist yaw of the nacelle of the wind turbine. Each of the plurality of recesses defines an opening on the outer peripheral side of the annular flange.

2. The yaw braking assembly according to claim 1, characterized in that, The yaw braking assembly further includes: Multiple arm components are positioned within corresponding holes passing through the annular flange between the multiple actuators and the multiple brake pads, the multiple arm components being oriented to transmit force from the multiple actuators to the multiple brake pads.

3. The yaw braking assembly according to claim 1, characterized in that, Each of the plurality of brake pads has a non-circular shape.

4. The yaw braking assembly according to claim 1, characterized in that, Each of the plurality of brake pads has at least one of a polygonal shape, a curved polygonal shape, or a rounded square planar shape.

5. The yaw braking assembly according to claim 1, characterized in that, Each of the plurality of brake pads is defined with a maximum length and a maximum width, wherein the maximum length is greater than the maximum width.

6. The yaw braking assembly according to claim 1, characterized in that, Each open peripheral side of the plurality of recesses defines a circumferential length greater than the maximum length of the corresponding brake pad.

7. The yaw braking assembly according to claim 1, characterized in that, Only one of the plurality of brake pads is located within each of the plurality of recesses.

8. The yaw braking assembly according to claim 7, characterized in that, The plurality of recesses and corresponding plurality of brake pads are distributed circumferentially around the annular flange in a plurality of adjacent pairs of kits.

9. The yaw braking assembly according to claim 8, characterized in that, A single actuator is operatively coupled to each of the plurality of paired kits.

10. The yaw braking assembly according to claim 1, characterized in that, The plurality of brake pads are radially aligned with the outer race of the yaw bearing.

11. The yaw braking assembly according to claim 1, characterized in that, The yaw braking assembly further includes: A retaining bracket fixed to the outer peripheral side, the retaining bracket closing at least one of the circumferential openings.

12. The yaw braking assembly according to claim 1, characterized in that, At least one of the plurality of brake pads further includes at least one sensor configured to generate a warning related to the wear level of one or more of the plurality of brake pads.

13. The yaw braking assembly according to claim 12, characterized in that, The at least one sensor includes a continuity sensor.

14. The yaw braking assembly according to claim 1, characterized in that, Multiple brake pads can be accessed from the outside of the base plate support frame via corresponding circumferential openings.

15. The yaw braking assembly according to claim 1, characterized in that, Each of the plurality of brake pads is formed with at least one extraction feature, the extraction feature being positioned to facilitate the removal of each of the brake pads from the corresponding recess.

16. A wind turbine, comprising: Tower; The nacelle, mounted atop the tower, includes a base plate support frame comprising a base plate support frame having an annular flange defining a plurality of recesses formed in the lowest annular surface of the annular flange and extending at least partially through the axial thickness of the annular flange, each of the plurality of recesses defining an open outer peripheral side. A yaw bearing, the yaw bearing being arranged adjacent to the annular flange; A rotor, the rotor being assembled into the nacelle, the rotor including a rotatable hub having one or more rotor blades fixed to the rotatable hub; as well as A plurality of brake pads, the plurality of brake pads being positioned within the plurality of recesses, each of the plurality of brake pads being configured to engage at least one race of the yaw bearing; as well as Multiple actuators for driving multiple brake pads to engage at least one race of the yaw bearing in order to resist yaw of the nacelle of the wind turbine. Each of the plurality of recesses defines an opening on the outer peripheral side of the annular flange.

17. The wind turbine according to claim 16, characterized in that, Each of the plurality of brake pads includes at least one of a polygonal shape, a curved polygonal shape, or a rounded square planar shape.

18. The wind turbine according to claim 16, characterized in that, Each of the plurality of brake pads is defined with a maximum length and a maximum width, wherein the maximum length is greater than the maximum width.

19. The wind turbine according to claim 18, characterized in that, Each circumferential opening defines a circumferential length greater than the maximum length of the corresponding brake pad among the plurality of brake pads.

20. A method for servicing a yaw brake assembly of a wind turbine, the method comprising: At least one brake pad is approached via an open peripheral side of a plurality of recesses defined by at least one of the recesses, the recesses being formed in the lowest annular surface of an annular flange of a base plate support frame and extending at least partially through the axial thickness of the annular flange, wherein the lowest annular surface is arranged adjacent to the yaw bearing of the wind turbine; and The at least one brake pad is passed through the open outer peripheral side of the recess, while the corresponding actuator of the plurality of actuators is held in the assembled configuration. Each of the plurality of recesses defines an opening on the outer peripheral side of the annular flange.

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