Integrated system and method for maintaining components of a wind turbine

Abstract

The present invention relates to an integrated system and method for maintaining components of a wind turbine. In particular, an integrated repair system for maintaining components within a nacelle on a tower of a wind turbine. The repair system includes at least one mounting location integrally formed into a bedplate support frame of the wind turbine, and a frame assembly coupled to the bedplate support frame. The frame assembly supports at least one clamping element and at least one jack element. The repair system supports the main shaft on the tower such that the rotor remains mounted on the rotor shaft when the gearbox is moved in the nacelle during the repair process.

Description

Technical Field

[0001] This disclosure relates generally to wind turbines, and more specifically to integrated systems and methods for maintaining components within the nacelle of a wind turbine. Background Technology

[0002] Wind power is considered one of the cleanest and most environmentally friendly energy sources available today, and wind turbines have attracted increasing attention in this regard. A modern wind turbine typically consists of a tower, generator, gearbox, nacelle, and a rotor with one or more rotor blades. The rotor is typically connected to the gearbox via a rotor shaft supported by main bearings, and ultimately to the generator. The main bearings and gearbox are mounted on a base support frame located within the nacelle. Typically, the base support frame is mounted on top of the tower via a yaw bearing. One or more rotor blades harness the kinetic energy of the wind using known airfoil principles. The rotor blades transfer this kinetic energy, in the form of rotational energy, to rotate the rotor shaft that connects the rotor to the gearbox (or, if no gearbox is used, directly to the generator). The generator then converts this mechanical energy into electrical energy that can be deployed to the power grid.

[0003] Typically, the rotor's weight is supported by the rotor shaft and transmitted to the gearbox, and ultimately to the tower. During the lifespan of a wind turbine, it may be necessary to periodically disconnect the gearbox from the rotor shaft. In this case, the rotor's weight can generate a large upward force at the end of the rotor shaft separated from the generator. For example, this large upward force can exceed 700 metric tons. Therefore, disconnecting the gearbox from the rotor shaft usually also requires removing the rotor, which is both expensive and time-consuming.

[0004] In view of the foregoing, the art is constantly seeking new and improved systems and methods for maintaining components inside the nacelle on a wind turbine tower without requiring the removal of the rotor or any part thereof. Summary of the Invention

[0005] The aspects and advantages of the invention will be set forth in the following description, or may be apparent from the description, or may be learned by practicing the invention.

[0006] In one aspect, this disclosure relates to an integrated repair system for maintaining components within a nacelle on a wind turbine tower. The wind turbine may include a rotor having at least one rotor blade mounted to a rotatable hub. The rotor may be operatively coupled to a gearbox via a rotor shaft supported by at least one main bearing. The repair system may include at least one mounting location integrally formed into a base plate support frame of the wind turbine. The system may also include a frame assembly having at least one support leg fixed to the mounting location and defining a passage for receiving the rotor shaft therethrough. The system may further include at least one clamping element positioned within the frame assembly to receive the rotor shaft therein and provide clamping force to the rotor shaft. Furthermore, the system may include at least one jacking element engaging with the frame assembly and the clamping element. The jacking element may operate with the frame assembly to provide support to the rotor shaft and provide movement of the rotor shaft in at least one direction. While the gearbox moves within the nacelle during the repair process, the repair system can support the rotor shaft on the tower, such that the rotor remains mounted on the rotor shaft.

[0007] In one embodiment, the rotor shaft may be coupled to the gearbox via a shrink disc. The shrink disc may define a thickness relative to the rotor shaft. The frame assembly may define a radial separation distance relative to the rotor shaft, which is greater than the thickness defined by the shrink disc. When the frame assembly is coupled to the base plate support frame, the radial separation distance allows the shrink disc to pass along the rotor shaft between the frame assembly and the rotor shaft.

[0008] In another embodiment, the jack element may include a hydraulic actuator or a screw jack. The screw jack may include a threaded stud extending between a first stud end and a second stud end. The second stud end may define a retaining feature and a rounded foot receivable by a corresponding recess of a clamping element.

[0009] In another embodiment, the clamping element may include a removable abrasion-resistant layer.

[0010] In one embodiment, the mounting location may include the web of a base plate support frame having at least one boss. The boss may define a hole with a diameter corresponding to the diameter of at least one fastener. Additionally, the connecting portion of the support leg may include a mating portion having a first portion positioned at a first axial position and a second portion positioned at a second axial position. The distance between the first and second axial positions may correspond to the thickness of the mounting location. The first and second portions may each define a through hole for receiving fasteners.

[0011] In another embodiment, the mounting location may also include at least one reinforcing strut oriented to receive the maximum load generated by the rotor in response to a wind event.

[0012] In another embodiment, the repair system may further include at least one tensioning jack element that engages with and is oriented to press against the base plate supporting the frame in order to secure fasteners within a through hole defined by the mounting position and the mating portion.

[0013] In one embodiment, the mounting location may include a mounting surface having a profile corresponding to the profile of the support leg. The mounting surface may define a plurality of fastener openings for receiving a plurality of threaded fasteners. The plurality of threaded fasteners may be constructed within the corresponding plurality of fastener openings.

[0014] In another embodiment, the repair system may further include a pin-bearing tray having a support surface extending between a first tray end and a second tray end. The first tray end may be removably coupled to a support leg. The repair system may also include a helical feed assembly operably coupled to the second tray end and oriented to move fasteners in an axial direction to engage or disengage the frame assembly and the base plate support frame.

[0015] In another embodiment, the repair system may also include a suspension belt that is coupled to the frame assembly and configured to pass between the rotor shaft and the base plate support frame to counteract the torque of the rotor shaft.

[0016] In one embodiment, the repair system may further include at least one gearbox actuating element. The gearbox actuating element may have a first end received in a recess defined by the frame assembly and a second end oriented to apply an axial force to the gearbox.

[0017] In another embodiment, the repair system may also include an axial support element having a first end connected to the frame assembly and a second end positioned to react with the gearbox support system.

[0018] On the other hand, this disclosure relates to a method for maintaining components within a nacelle on a wind turbine tower. The wind turbine may have a rotor having at least one rotor blade mounted to a rotatable hub. The rotor may be operatively coupled to a gearbox via a rotor shaft supported by at least one main bearing. The method may include receiving the rotor shaft in a passage defined by a frame assembly. The method may also include securing support legs of the frame assembly to mounting positions integrally formed into a base plate support frame of the wind turbine. The method may further include positioning clamping elements within the frame assembly to receive the rotor shaft therein and provide clamping force to the rotor shaft. The method may further include advancing jacking elements operatively coupled to the clamping elements and the frame assembly to position the clamping elements in contact with the rotor shaft. Additionally, the method may include disengaging the rotor shaft from the gearbox. The method may also include utilizing the frame assembly to receive vertical loads generated by the rotor shaft in response to the supported rotor. Furthermore, the method may include transferring the received vertical loads via the frame assembly to the base plate support frame and maintaining components of the wind turbine. It should be understood that the system may further include any additional steps and / or features described herein.

[0019] On the other hand, this disclosure relates to a wind turbine. The wind turbine may include a tower, a nacelle mounted on top of the tower, and a rotor mounted to the nacelle. The rotor may include a rotatable hub having rotor blades fixed thereto. The wind turbine may also include a rotor shaft that operatively connects the rotor to a gearbox located within the nacelle. The wind turbine may also include at least one main bearing supporting the rotor shaft and a base plate support frame located within the nacelle and supporting the main bearing and the gearbox. Additionally, the wind turbine may include an integrated repair system for maintaining components within the nacelle. It should be understood that this system may further include any additional steps and / or features described herein.

[0020] These and other features, aspects, and advantages of the invention will become more readily understood with reference to the following description and the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0021] Technical Solution 1. An integrated repair system for maintaining components inside a nacelle on a wind turbine tower, the wind turbine having a rotor having at least one rotor blade mounted to a rotatable hub, the rotor being operably coupled to a gearbox via a rotor shaft, the repair system comprising:

[0022] At least one mounting location is integrally formed into the base plate support frame of the wind turbine;

[0023] A frame assembly including at least one support leg fixed to the mounting location and defining a passage for receiving the rotor shaft passing through it;

[0024] At least one clamping element, positioned inside the frame assembly, for receiving the rotor shaft therein and providing a clamping force to the rotor shaft; and

[0025] At least one jack element engages with the frame assembly and the at least one clamping element, the at least one jack element being operable together with the frame assembly to provide support to the rotor shaft and to provide movement of the rotor shaft in at least one direction.

[0026] When the gearbox is moved in the nacelle during the repair process, the repair system supports the rotor shaft on the tower, so that the rotor remains mounted on the rotor shaft.

[0027] Technical Solution 2. The repair system according to Technical Solution 1, characterized in that the rotor shaft is connected to the gearbox via a shrink disc, the shrink disc defining a thickness relative to the rotor shaft, wherein the frame assembly defines a radial separation distance relative to the rotor shaft, the radial separation distance being greater than the thickness defined by the shrink disc, the radial separation distance allowing the shrink disc to pass along the rotor shaft between the frame assembly and the rotor shaft when the frame assembly is connected to the base plate support frame.

[0028] Technical Solution 3. The repair system according to Technical Solution 1, characterized in that the at least one jack element is at least a first jack element movable along a first radial direction, and the repair system further includes at least a second jack element engaged with the frame assembly, the second jack element being movable along a second radial direction, the second radial direction being deviated from the first radial direction by at least 90 degrees.

[0029] Technical Solution 4. The repair system according to Technical Solution 1, characterized in that the at least one jack element includes a hydraulic actuator or a screw jack, the screw jack including a threaded stud extending between a first stud end and a second stud end, the second stud end defining a retaining feature and a circular foot receivable by a corresponding recess of the clamping element.

[0030] Technical Solution 5. The repair system according to Technical Solution 1, characterized in that the at least one clamping element further includes a removable wear-resistant layer.

[0031] Technical Solution 6. The repair system according to Technical Solution 1, characterized in that the at least one mounting position includes a web of the base plate support frame having at least one boss, the at least one boss defining a through hole having a diameter corresponding to the diameter of at least one fastener, and wherein the connecting portion of the at least one support leg includes a mating portion, the mating portion including a first portion positioned at a first axial position and a second portion positioned at a second axial position, the distance between the first axial position and the second axial position corresponding to the thickness of the at least one mounting position, the first portion and the second portion each defining a through hole for receiving the at least one fastener.

[0032] Technical Solution 7. The repair system according to Technical Solution 6, characterized in that the at least one mounting location further includes at least one reinforcing strut, the reinforcing strut being oriented to receive the maximum load generated by the rotor in response to a wind event.

[0033] Technical Solution 8. The repair system according to Technical Solution 6, characterized in that it further includes at least one tensioning jack element, which engages with the frame assembly and is oriented to press against the base plate support frame so as to secure the at least one fastener within the through hole defined by the at least one mounting position and the mating portion.

[0034] Technical Solution 9. The repair system according to Technical Solution 1, characterized in that the at least one mounting position includes a mounting surface having a profile corresponding to the profile of the support leg, the mounting surface defining a plurality of fastener openings for receiving a plurality of threaded fasteners, the plurality of threaded fasteners being constructed within the corresponding plurality of fastener openings.

[0035] Technical Solution 10. The repair system according to Technical Solution 1, characterized in that it further comprises:

[0036] A pin-supported pallet having a support surface extending between a first pallet end and a second pallet end, the first pallet end being removably coupled to the at least one support leg; and

[0037] A helical feed assembly, operably coupled to the end of the second tray and oriented to move the at least one fastener in an axial direction, in order to connect or disconnect the frame assembly and the base plate support frame.

[0038] Technical Solution 11. The repair system according to Technical Solution 1, characterized in that it further comprises:

[0039] A suspension belt, which is connected to the frame assembly and configured to pass between the rotor shaft and the base plate support frame, in order to counteract downward forces on the rotor shaft.

[0040] Technical Solution 12. The repair system according to Technical Solution 1, characterized in that it further comprises:

[0041] At least one gearbox actuating element having a first end receiving in a recess defined by the frame assembly and a second end oriented to apply an axial force to the gearbox.

[0042] Technical Solution 13. The repair system according to Technical Solution 1, characterized in that it further comprises:

[0043] An axial support element having a first end connected to the frame assembly and a second end positioned to react with the gearbox support system.

[0044] Technical Solution 14. A method for maintaining components within a nacelle on a wind turbine tower, the wind turbine having a rotor having at least one rotor blade mounted to a rotatable hub, the rotor being operably coupled to a gearbox via a rotor shaft, the method comprising:

[0045] The rotor shaft is received in a passage defined by the frame assembly;

[0046] At least one support leg of the frame assembly is fixed to a mounting position integrally formed into the base plate support frame of the wind turbine.

[0047] At least one clamping element is positioned inside the frame assembly to receive the rotor shaft therein and provide clamping force to the rotor shaft;

[0048] At least one jack element operably connected to the at least one clamping element and the frame assembly is moved forward to position the at least one clamping element in contact with the rotor shaft;

[0049] Separate the rotor shaft from the gearbox;

[0050] The frame assembly is used to receive the vertical load generated by the rotor shaft in response to the supported rotor;

[0051] The received vertical load is transferred to the base plate support frame via the frame assembly; and

[0052] Components for maintaining the wind turbine.

[0053] Technical Solution 15. The method according to Technical Solution 14, characterized in that the wind turbine further includes a shrinking disk surrounding the rotor shaft, the shrinking disk defining a thickness relative to the rotor shaft, the thickness being greater than the outer diameter of the rotor shaft, the method further comprising:

[0054] When the frame assembly is connected to the base plate support frame, the shrink disc passes along the rotor shaft between the rotor shaft and the frame assembly.

[0055] Technical Solution 16. The method according to Technical Solution 14, characterized in that it further includes:

[0056] By attaching a removable wear-resistant layer to the at least one clamping element, the at least one clamping element is made to match the outer diameter of the rotor shaft.

[0057] Technical Solution 17. The method according to Technical Solution 14, characterized in that the at least one mounting position includes a web of the base plate support frame having at least one boss, the at least one boss defining a through hole having a diameter corresponding to the diameter of at least one fastener, and wherein securing the at least one support leg to the mounting position further includes:

[0058] The web plate is engaged with a connecting portion of the at least one supporting leg, wherein the connecting portion includes a mating portion comprising:

[0059] The first part positioned at the first axial position, and

[0060] A second portion positioned at a second axial position, wherein the first portion and the second portion each further define a through hole for receiving the at least one fastener; and

[0061] The at least one fastener is inserted into the through hole to secure the web of the base plate support frame within the mating portion.

[0062] Technical Solution 18. The method according to Technical Solution 14, characterized in that it further includes:

[0063] The end of the rotor shaft is moved radially by moving the at least one jack element forward or retracting it.

[0064] Technical Solution 19. The method according to Technical Solution 14, characterized in that it further comprises:

[0065] The suspension belt passes between the rotor shaft and the base plate support frame;

[0066] Connect the suspension strap to the frame assembly;

[0067] In response to a wind event impacting the rotor, a downward force is generated at the end of the rotor shaft opposite to the rotor; and

[0068] The suspension belt receives the downward force from the end of the rotor shaft.

[0069] Technical Solution 20. A wind turbine, comprising:

[0070] Tower;

[0071] The nacelle installed on top of the tower;

[0072] The rotor is mounted to the nacelle, the rotor including a rotatable hub having one or more rotor blades fixed thereon;

[0073] A rotor shaft that operatively connects the rotor to a gearbox located within the nacelle;

[0074] A base plate support frame positioned within the cabin and supporting the gearbox; and

[0075] An integrated repair system for maintaining components within the cabin, the repair system comprising:

[0076] At least one mounting location, integrally formed into the base plate support frame of the wind turbine,

[0077] A frame assembly including at least one support leg fixed to the mounting location and defining a passage for receiving the rotor shaft passing through it.

[0078] At least one clamping element is positioned inside the frame assembly to receive the rotor shaft therein and provide a clamping force to the rotor shaft.

[0079] At least one jack element engages with the frame assembly and the at least one clamping element, the at least one jack element being operable together with the at least one frame assembly to provide support to the rotor shaft and provide movement of the rotor shaft in at least one direction, wherein when the gearbox moves in the nacelle during the repair process, the repair system supports the spindle on the tower such that the rotor remains mounted on the rotatable hub. Attached Figure Description

[0080] The complete and full disclosure of the invention, including its best mode, for those skilled in the art, is set forth in the description with reference to the accompanying drawings, in which:

[0081] Figure 1A perspective view of one embodiment of a wind turbine according to the present disclosure is shown;

[0082] Figure 2 A perspective view of one embodiment of a simplified interior view of a nacelle of a wind turbine according to the present disclosure is shown.

[0083] Figure 3 A simplified side view of an embodiment of the drivetrain of a wind turbine with an integrated repair system installed according to the present disclosure is shown.

[0084] Figure 4 A simplified top view is shown of a portion of the drivetrain of a wind turbine with an integrated repair system installed according to this disclosure;

[0085] Figure 5 A perspective view of the framework components according to this disclosure is shown;

[0086] Figure 6 A perspective view of an embodiment of a base plate support frame according to the present disclosure is shown;

[0087] Figure 7 A partially enlarged cross-sectional view of an embodiment of the mating portion between the component and the base plate support frame according to this disclosure is shown;

[0088] Figure 8 A partially enlarged cross-sectional view of an embodiment of the mating portion between the component and the base plate support frame according to this disclosure is shown;

[0089] Figure 9 An axial view of an embodiment of the integrated repair system according to the present disclosure is shown;

[0090] Figure 10 A schematic diagram of the components of the integrated repair system according to this disclosure is shown;

[0091] Figure 11 A schematic diagram of the components of the integrated repair system according to this disclosure is shown;

[0092] Figure 12 A perspective view of the integrated repair system according to this disclosure is shown; and

[0093] Figure 13 A flowchart is shown of one embodiment of a method for maintaining components inside a nacelle on a wind turbine tower according to the present disclosure. Detailed Implementation

[0094] Reference will now be made in detail to embodiments of the invention, one or more of which are illustrated in the accompanying drawings. Each example is provided by way of illustrative purposes and not by way of limitation. Indeed, it will be apparent to those skilled in the art that various modifications and variations can be made to the invention without departing from its scope or spirit. For example, a feature shown or described as part of one embodiment may be used in combination with another embodiment to produce yet another embodiment. Therefore, it is intended that the invention cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0095] In general, this disclosure relates to an integrated repair system that allows for the maintenance of components within the nacelle on a wind turbine tower without removing the rotor or rotor blades attached thereto. Therefore, the integrated repair system may include a frame assembly or yoke configured to resist loads at one end of the rotor shaft caused by the weight of the rotor coupled to the other end of the rotor shaft. The frame assembly can be connected via a base plate support frame of the wind turbine to transfer the load from the rotor shaft to the base plate support frame and ultimately to the wind turbine tower. Thus, the integrated repair system may include at least one mounting location integrally formed within the base plate support frame. The mounting location may be formed simultaneously with the manufacture of the base plate support frame and may be configured specifically to support the frame assembly. In other words, the mounting location may be a perpetual feature of the base plate support frame and may not be intended to support any other components of the wind turbine. Therefore, the connection of the frame assembly to the base plate support frame can be achieved without removing other components of the wind turbine or adding temporary support elements (such as crossbeams spanning openings in the base plate support frame).

[0096] To maintain or achieve rotor shaft alignment, the frame assembly of the integrated repair system may include at least one clamping element positioned within the frame assembly. The clamping element may have a curved profile corresponding to the profile of the rotor shaft. At least one jacking element may engage with the frame assembly and the clamping element. The jacking element serves as both the clamping element and ultimately provides support and movement for the rotor shaft. For example, the jacking element may be a screw jack or a hydraulic jack. Thus, an upward vertical load at the end of the rotor shaft can be transferred from the rotor shaft to the frame assembly via the clamping element and the attached jacking element. From the frame assembly, the load can be transferred via the mounting location to the base plate support frame and then to the tower. As the load is transferred to the tower via the integrated repair system, the rotor shaft and gearbox can be separated to allow maintenance or repair of components on the tower without removing the rotor or any of its components.

[0097] Now refer to the attached diagram, Figure 1A perspective view of one embodiment of a wind turbine 100 according to the present disclosure is shown. As shown, the wind turbine 100 generally includes a tower 102 extending from a support surface 104, a nacelle 106 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 may include more or fewer than three rotor blades 112. Each rotor blade 112 may be spaced apart around the hub 110 to allow the rotor 108 to rotate so that kinetic energy from the wind can be converted into usable mechanical energy, and subsequently into electrical energy. For example, the hub 110 may be rotatably coupled to a generator 118 located within the nacelle 106. Figure 2 This allows for the generation of electrical energy.

[0098] Now for reference Figure 2 , showed 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 may be coupled to a rotor 108 to generate electricity from the rotational energy produced 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 therewith. The rotor shaft 122 may be rotatably supported by a main bearing 144. The rotor shaft 122 may then be rotatably coupled to a generator shaft 124 of the generator 118 via a gearbox 126, which is connected to a base support frame 136 by a gearbox support system 142. The coupling of the rotor shaft 122 to the gearbox 126 may be achieved via a retractable disc 146. As generally understood, the rotor shaft 122 may provide a low-speed, high-torque input to the gearbox 126 in response to rotation of the rotor blades 112 and the hub 110. The gearbox 126 can then be configured to convert a low-speed, high-torque input into a high-speed, low-torque output via a plurality of gears 148 to drive the generator shaft 124, and thus the generator 118. It should be understood that the rotor shaft 122 can be considered as the main shaft or low-speed shaft, while the generator shaft 124 can be considered as the high-speed shaft.

[0099] Each rotor blade 112 may also include a pitch adjustment mechanism 120 configured to rotate each rotor blade 112 about its pitch axis 116. Furthermore, each pitch adjustment mechanism 120 may include a pitch drive motor 128 (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox 130, and a pitch drive pinion 132. In this embodiment, the pitch drive motor 128 may be coupled to the pitch drive gearbox 130 such that the pitch drive motor 128 applies mechanical force to the pitch drive gearbox 130. Similarly, the pitch drive gearbox 130 may be coupled to the pitch drive pinion 132 to rotate therewith. The pitch drive pinion 132 may then be rotatably engaged with a pitch bearing 134 connected 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. Therefore, in this embodiment, the rotation of the pitch drive motor 128 drives the pitch drive gearbox 130 and the pitch drive pinion 132, thereby causing the pitch bearing 134 and the rotor blades 112 to rotate about the pitch axis 116. Similarly, the wind turbine 100 may include one or more yaw drive mechanisms 138 communicatively coupled to the controller 114, wherein each yaw drive mechanism 138 is configured to change the angle of the nacelle 106 relative to the wind (e.g., by engaging the yaw bearing 140 of the wind turbine 100).

[0100] Now for reference Figure 3-12 Several embodiments of the integrated repair system (system) 300 according to this disclosure are shown. In particular, as Figure 3As shown, system 300 may include a frame assembly 302 configured to facilitate repair procedures when the weight of rotor 108 provides a downward vertical load (L1) at the end of rotor shaft 122. Frame assembly 302 may include at least one support leg 304. Support leg 304 may be coupled to a base plate support frame 136 of wind turbine 100 to transfer a load (L2) thereon. Therefore, base plate support frame 136 may include at least one mounting position 306. Base plate support frame 136 may be configured to securely engage and support the support leg 304. When fixed to base plate support frame 136, frame assembly 302 may define a passage 308 that receives rotor shaft 122 passing through it. Additionally, system 300 may include at least one clamping element 310 positioned within frame assembly 302 to receive rotor shaft 122 therein and provide clamping force to rotor shaft. In another embodiment, system 300 may also include at least one jack element 312. The jack element 312 can engage with the frame assembly 302 and the clamping element 310. The jack element 312 can provide support to the rotor shaft 122 and provide movement of the rotor shaft 122 in at least one direction. It should be appreciated that the system 300 can support the rotor shaft 122 on the tower when the gearbox 126 is moved during the repair process after the system 300 is installed in the nacelle. It should also be appreciated that the support of the rotor shaft 122 on the tower allows the rotor 108 to remain mounted on the rotor shaft 122 throughout the repair process.

[0101] In one embodiment, such as in Figure 5 , Figure 9 and Figure 12 As specifically depicted, the frame assembly 302 may have a generally U-shaped body to receive the rotor shaft 122 passing through it. In one embodiment, the frame assembly 302 may be an integral structure. Support legs 304 may define connecting portions 314 at a first leg end 316 and a second leg end 318. In one embodiment, the first and second leg ends may be connected to a mounting position 306.

[0102] like Figure 9 As depicted, in one embodiment, the frame assembly 302 may include at least two support legs 304 and a transverse member therebetween. In such an embodiment, each support leg 304 may define a connecting portion 314 at a corresponding first leg end 316. A corresponding second leg end 318 may be connected to the transverse member.

[0103] It should be recognized that, in another embodiment, the frame assembly 302 may have any other suitable shape. For example, in one embodiment, the frame assembly 302 may be generally L-shaped and have a single connecting portion 314 fixed to a single mounting position 306. In another embodiment, the frame assembly 302 may be generally L-shaped and have a single connecting portion 314 fixed to a single mounting position 306 and additional support points for components of the wind turbine 100. In yet another embodiment, the frame assembly 302 may be generally triangular and have a vertex vertically aligned with the axis (A) of the rotor shaft 122.

[0104] Now for reference Figure 6 and Figure 7 In one embodiment, mounting location 306 may be a dedicated feature of the base plate support frame 136. Therefore, in one embodiment, mounting location 306 may include a web 150 of the base plate support frame 136. In one embodiment, the web 150 may be formed with at least one boss 152. The boss 152 may define a through hole 154. In one embodiment, the through hole 154 may have a diameter corresponding to the diameter (D) of at least one fastener 320. F ).

[0105] In one embodiment, the fastener 320 may be a pin, dowel, rod, or other suitable body with sufficient shear strength to transfer an upward vertical load (L2) from the frame assembly 302 to the base plate support frame 136. For example, in one embodiment, the fastener 320 may be a shear pin having a shear strength greater than 500 metric tons (e.g., greater than 1500 metric tons). In one embodiment, the system 300 may include two fasteners 320. By securing the frame assembly 302 to the base plate support frame 136 using only two fasteners 320, the load path and load distribution of the system 300 may be more predictable and / or controllable than in embodiments using more than two fasteners 320.

[0106] Refer again Figure 4 and Figure 5 In embodiments where mounting location 306 includes a through-hole 154 for receiving fastener 320, system 300 may include at least one tension jack element 322. Tension jack element 322 may engage with frame assembly 302 and be oriented to press against base plate support frame 136. In other words, tension jack element 322 may be positioned to apply a vertical force on base plate support frame 136 and frame assembly 302. Therefore, tension jack element 322 can be used to secure fastener 320 within through-hole 154. In one embodiment, at least one tension jack element 322 may be associated with each mounting location 306 of system 300.

[0107] like Figure 3 and Figure 8 As shown, mounting location 306 may include mounting surface 324. In some embodiments, mounting surface 324 may have a profile corresponding to the profile of support leg 304. For example, the corresponding profiles of mounting surface 324 and support leg 304 may be formed with multiple angles, curves, recesses / protrusions and / or flat surfaces, oriented to facilitate load transfer between frame assembly 302 and base plate support frame 136.

[0108] In one embodiment, the mounting surface 324 may define a plurality of fastener openings 326 configured to receive corresponding plurality of fasteners 320. Each fastener 320 may be configured as a threaded fastener, such as a bolt or screw. For example, in one embodiment, the fastener opening 326 may be threaded, such that the fastener 320 can mate with the fastener opening 326 to secure the coupling portion 314 to the mounting position 306. In another embodiment, the fastener opening 326 may be formed without threads and may allow a portion of each of the plurality of fasteners 320 to extend beyond the base plate support frame 136. In such an embodiment, the fastener 320 may be secured in the fastener opening 326 via a fastening element such as a nut, and may form a through-bolt connection.

[0109] In one embodiment, such as Figure 8 As depicted, mounting position 306 may include a mounting surface 324 defining a fastener opening 326 and a protrusion 328 defining a pin recess 330. In such an embodiment, the fastener opening 326 may be configured to receive a fastener 320 configured as a threaded fastener. Furthermore, the pin recess 330 may be configured to receive another fastener 320 configured as a pin.

[0110] In one embodiment, mounting location 306 may further include at least one reinforcing strut 156. When frame assembly 302 is secured to base support frame 136, reinforcing strut 156 may be oriented to support the maximum anticipated load. For example, the load generated by rotor 108 in response to a wind event may vary based on the orientation of the parked rotor blades 112 and the intensity of the wind event. Therefore, the load generated by rotor blades 112 in each possible parking orientation can be modeled across the wind range in which the usable system 300 is located. This model can predict the maximum load vector that needs to be transferred from frame assembly 302 to base support frame 136 based on each calculated load vector. Reinforcing strut 156 may be sized and / or oriented to facilitate the transfer of the maximum modeled load through base support frame 136 to tower 102 without deformation of base support frame 136.

[0111] It should be recognized that the specific features of mounting location 306 facilitate the connection of frame assembly 302 without disassembly or interference with critical bolt joints securing other components within nacelle 106. Furthermore, it should be recognized that the specific features of mounting location 306 facilitate highly integrated connections, resulting in a load transfer from frame assembly 302 to the base plate support frame 136, and thus facilitating a relatively more compact design than that achievable using known methods. The highly integrated nature of system 300 results in minimal disruption to personnel access, improved mission ergonomics, and relatively rapid system deployment, leading to reduced repair time. It should be recognized that critical bolt joints may include connections associated with components of wind turbine 100 directly related to its operation, such as main bearing 144, gearbox 126, yaw drive mechanism 138, pitch adjustment mechanism 120, and / or electrical systems. In contrast, non-critical joints may include connections related to maintainability and / or technician safety, such as ladders, panels, gantry frames, shielding, and / or cable cabling.

[0112] Now for reference Figure 5 and Figure 7 In one embodiment, the connecting portion 314 of the support leg 304 may include a first portion 334 positioned at a first axial position (A1) and a second portion 336 positioned at a second axial position (A2). Therefore, as shown, the distance (D1) between the first axial position (A1) and the second axial position (A2) may correspond to the thickness (T) of the mounting position 306. In one embodiment, the thickness (T) may correspond to the combined thickness of the web 150 and the boss 152 of the base plate support frame 136. For example, in one embodiment, the connecting portion 314 of the support leg 304 may be a straddle mating portion 332. In one embodiment, the first portion 334 and the second portion 336 may each define a through hole 154 for receiving a fastener 320.

[0113] like Figure 4 , Figure 5 and Figure 12 As shown, in one embodiment, system 300 may include a pin-supporting tray 338. The pin-supporting tray 338 may have a support surface 340 extending between a first tray end 342 and a second tray end 344. The support surface 340 may be configured to support fasteners 320 when the frame assembly 302 is separated from the base plate support frame 136. For example, in one embodiment, the support surface 340 may be formed as a hollow semi-cylinder having a radius corresponding to the radius of the fastener 320, in order to hold the fastener 320 therein. It should be recognized that the shear strength of the fastener 320 required to react to an upward vertical load (L2) may require fastener size and / or weight exceeding the lifting / moving capabilities of a wind turbine repair technician.

[0114] In one embodiment, the first tray end 342 may be removably coupled to the support leg 304. Thus, the pin-carrying tray 338 may be coupled to the frame assembly 302 to support the fastener 320, and may be detached from the frame assembly 302 after the fastener 320 is inserted into the through hole 154.

[0115] In one embodiment, the pin-carrying tray 338 may further include a helical feed assembly 346 coupled to the second tray end 344. The helical feed assembly 346 may be oriented to move the fastener 320 in an axial direction to separate the frame assembly 302 and the base plate support frame 136. For example, in one embodiment, the helical feed assembly 346 may include a rod threaded along its length and screwed through a support plate coupled to the second tray end 344. A first end of the rod may be coupled to the fastener 320 and a torque source may be operably coupled to a second end of the rod to axially advance or retract the fastener 320.

[0116] refer to Figure 3-5 and Figure 9 In one embodiment, the rotor shaft 122 is coupled to the gearbox 126 via a shrink disc 146. Therefore, the shrink disc 146 defines a thickness (T) relative to the rotor shaft 122. D Therefore, in one embodiment, the frame assembly 302 defines a thickness (T) relative to the rotor shaft 122 greater than that defined by the shrink disc 146. D The radial separation distance (R) allows the shrink disc 146 to pass along the rotor shaft 122 between the frame assembly 302 and the rotor shaft 122 when the frame assembly 302 is directly connected to the base plate support frame 136.

[0117] In one embodiment, frame assembly 302 may be engaged with base plate support frame 136 before shrink disc 146 becomes loose or otherwise disturbed. Frame assembly 302 may be engaged with base plate support frame 136 at an axial position behind main bearing 144 and in front of shrink disc 146. With frame assembly 302 secured to base plate support frame 136, shrink disc 146 may be released and moved from an axial position between frame assembly 302 and gearbox 126 to an axial position between main bearing 144 and frame assembly 302. It should be appreciated that the ability to move shrink disc 146 along rotor shaft 122 facilitates the resolution of certain repair procedures. For example, shrink disc 146 may be moved in front of frame assembly 302 to address the problem of a damaged rotor shaft to gearbox joint that cannot be properly separated. It should also be appreciated that such a requirement may not be achievable until frame assembly 302 is installed. Therefore, the radial separation distance (R) of frame assembly 302 eliminates the need to remove and subsequently reinstall yoke tools when a damaged joint is discovered.

[0118] Now for reference Figure 3-5 and Figure 9-12 In one embodiment, the clamping element 310 may include a connecting surface 348 and a mating surface 350 radially opposite thereto. The connecting surface 348 may include at least one receiving structure 352 oriented to receive a jack element 312 therein. The receiving structure 352 may include a recess, groove, socket, and / or other suitable structure to facilitate the connection between the clamping element 310 and the jack element 312. In one embodiment, a plurality of receiving structures 352 may be distributed across the connecting surface 348 to receive a corresponding plurality of jack elements 312. For example, in one embodiment, at least two (e.g., four) receiving structures 352 may be positioned to receive a corresponding number of jack elements 312. In one embodiment, the jack element 312 may be secured within the receiving structure 352 by a pin, key, and / or clamp. Therefore, the connection between the clamping element 310 and the jack element 312 may be a removable connection. The separation of clamping element 310 from jack element 312 prevents clamping element 310 from blocking passage 308 defined by frame assembly 302, thereby facilitating the passage of retractable disc 146 along rotor shaft 122 while frame assembly 302 remains connected to base plate support frame 136.

[0119] In one embodiment, the mating surface 350 may be formed with a curvature that generally corresponds to the radius of the rotor shaft 122. Therefore, the mating surface 350 can distribute clamping forces to the rotor shaft 122 without creating stress rise therein. In one embodiment, the mating surface 350 may have a curvature corresponding to the radius of a specific rotor shaft 122 of the wind turbine 100 requiring maintenance.

[0120] like Figure 10 As specifically depicted, in one embodiment, the clamping element 310 may include a wear-resistant layer 354 removably coupled to the mating surface 350. In one embodiment, the wear-resistant layer 354 may be a sacrificial layer. As a sacrificial layer, the wear-resistant layer 354 can be replaced upon wear or damage. In one embodiment, the wear-resistant layer 354 may be formed of a high-friction material to help hold the rotor shaft 122. Furthermore, in one embodiment, the wear-resistant layer 354 may be an adapter formed to facilitate the reception of rotor shafts 122 of various diameters by the clamping element 310. For example, as an adapter, the wear-resistant layer 354 may have an inner radial surface 356 conforming to the diameter of the rotor shaft 122 and an outer radial surface 358 conforming to the curvature of the mating surface 350. It should be appreciated that the ability to receive rotor shafts 122 of varying diameters facilitates the use of the system 300 to serve a variety of different wind turbine models.

[0121] Now for reference Figure 12In one embodiment, the clamping element 310 may surround the rotor shaft 122. For example, in one embodiment, the clamping element may be a clamshell ring. In such an embodiment, the clamping element 310 may include a first clamshell portion 360 and a second clamshell portion 362. The first clamshell portion 360 and the second clamshell portion 362 may be pivotally coupled to each other. As a clamshell ring, the clamping element 310 may completely surround the rotor shaft 122 to secure the rotor shaft 122 therein.

[0122] Refer again Figure 3-5 and Figure 9-12 In one embodiment, the clamping element 310 may be supported by a jack element 312. The jack element 312 may be configured to move radially relative to the frame assembly 302. Therefore, the jack element 312 may move the clamping element 310 radially between the frame assembly 302 and the rotor shaft 122. In other words, in one embodiment, the jack element 312 may advance the clamping element 310 inside the frame assembly 302 in the direction of the axis (A) of the rotor 112.

[0123] like Figure 9 , Figure 11 and Figure 12 As shown, in one embodiment, system 300 may include at least a first jack element 364 movable in a first radial direction (RD1). In one embodiment, system 300 may include at least a second jack element 366 movable in a second radial direction (RD2). The second radial direction (RD2) may deviate from the first radial direction (RD1) by at least 90 degrees. In one embodiment, the first jack element 364 may transfer substantially all of the upward vertical load (L2) to the frame assembly 302. Additionally, in one embodiment, the second jack element 366 may apply a lateral force on the rotor shaft 122.

[0124] In one embodiment, the first jack element 364 and the second jack element 366 can be used to influence the alignment of the rotor shaft 122. Therefore, the system 300 facilitates the repositioning of the rotor shaft. For example, during certain repair procedures, such as gearbox removal or installation, it may be necessary to adjust the vertical or lateral spindle position, such as when various gearbox mounting components need to be released or engaged. By using the system 300, the end of the rotor shaft 122 can be moved vertically by the radial movement of the first jack element 364 and laterally by the radial movement of the second jack element 366. In one embodiment, such movement or alignment of the rotor shaft 122 can be accomplished while the frame assembly 302 supports an upward vertical load (L2).

[0125] Still referencing Figure 12In one embodiment, the jack element 312 may be a hydraulic actuator 370. A portion of the hydraulic actuator 370 may be received within the jack mounting point 368 of the frame assembly 302.

[0126] Refer again Figure 10 and Figure 11 In one embodiment, the jack element 312 may be a screw jack 372. The screw jack 372 may be a linear actuator having a threaded stud 374 (e.g., a screw shaft) extending between a first stud end 376 and a second stud end 378. The threaded stud 374 may be received by a corresponding jack mounting point 368 of the frame assembly 302. In one embodiment, the first stud end 376 may be an engagement portion having a structure for receiving applied torque. The second stud end 378 may define a retaining feature 380 and a circular foot 382 (e.g., a ball foot) receivable by a corresponding recess 352 of the clamping element 310. In one embodiment, the retaining feature 380 may be a region with a reduced diameter (e.g., a groove or neck) formed to engage with a pin, key, and / or clip to secure the second stud end 378 in the receiving structure 352. The circular foot 382 allows for a certain degree of movement between the clamping element 310 and the jack element 312 to facilitate alignment of the clamping element 310 with the rotor shaft 122. It should be appreciated that the combination of the retaining feature 380 and the receiving structure 352 facilitates the rapid removal of the clamping element 310 to remove obstructions from the passage 308.

[0127] Now for reference Figure 5 and Figure 9 In one embodiment, system 300 may be configured to counteract a downward force (L3) on rotor shaft 122 opposite rotor 108. For example, in response to a wind event, rotor 108 may generate a torque about main bearing 144, which is opposed to the torque generated by the weight of rotor 108 and subsequent upward vertical load (L2). Thus, in one embodiment, system 300 may include a suspension belt 384. Suspension belt 384 may be coupled to frame assembly 302 and may pass between rotor shaft 122 and base plate support frame 136.

[0128] In another embodiment, the second radial direction (RD2) may be oriented such that the second jack element 366 can apply vertical and lateral forces to the rotor shaft 122 as needed. In such an embodiment, the second jack element 366 may be positioned to resist downward force (L3) and provide lateral movement to the rotor shaft 122. For example, in one embodiment, at least three jack elements 312 may be circumferentially offset from each other by 120 degrees. It should be appreciated that utilizing the second jack 366 to provide both vertical and lateral support eliminates the need for the suspension belt 384, thereby reducing the cost and complexity of the system 300.

[0129] Refer again Figure 3 and Figure 4 In one embodiment, system 300 may include at least one actuating element 386 having a first end 388 received in a recess defined by frame assembly 302. Actuating element 386 may also include a second end 390 oriented to apply an axial force to gearbox 126. For example, actuating element 386 may be a hydraulic cylinder that applies an axial force to gearbox 126 to disengage gearbox 126 from rotor shaft 122 after retraction disc 146 has loosened. It should be appreciated that the reaction of frame assembly 302 facilitates the use of a shorter hydraulic cylinder than the reaction of components of wind turbine 100 such as main bearing 144. Using a shorter hydraulic cylinder allows for easier access by technicians and is ergonomically sound when maintaining components.

[0130] Still referencing Figure 4 And also refer to Figure 12 In one embodiment, system 300 may include an axial support element 392. The axial support element 392 may have a first end 394 coupled to the frame assembly 302. In one embodiment, the axial support element 392 may further include a second end 396 positioned to react against the gearbox support system 398. In one embodiment, the axial support element 392 may be a retractable threaded stud. The axial support element 392 may be positioned to counteract rotational movement of the frame assembly 302 in response to an upward vertical load (L2).

[0131] refer to Figure 13 The diagram illustrates a flowchart of one embodiment of a method 400 for maintaining components within a nacelle on a wind turbine tower. Method 400 may utilize, for example, the above reference. Figure 1-12 The integrated repair system 300 is described and implemented. Figure 13 The steps performed in a specific order for illustrative and explanatory purposes are described. Using the disclosure provided herein, those skilled in the art will understand that the individual steps of method 400 or any other method disclosed herein may be adapted, modified, rearranged, performed concurrently, or modified in various ways without departing from the scope of this disclosure.

[0132] As shown at 402, method 400 includes receiving a rotor shaft in a passage defined by a frame assembly. As shown at 404, method 400 includes securing at least one support leg of the frame assembly to a mounting position integrally formed into a base plate support frame of the wind turbine. As shown at 406, method 400 includes positioning at least one clamping element inside the frame assembly to receive the rotor shaft therein and provide clamping force to the rotor shaft. As shown at 408, method 400 includes advancing at least one jacking element operably coupled to at least one clamping element and the frame assembly to position at least one clamping element in contact with the rotor shaft. As shown at 410, method 400 includes disengaging the rotor shaft from the gearbox. As shown at 412, method 400 includes receiving a vertical load generated by the rotor shaft in response to a supported rotor using the frame assembly. As shown at 414, method 400 includes transferring the received vertical load to the base plate support frame via the frame assembly. Additionally, as shown at 416, method 400 includes components for maintaining the wind turbine.

[0133] Furthermore, those skilled in the art will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents of each such method and feature, can be mixed and matched by those skilled in the art to construct additional systems and techniques according to the principles of this disclosure. It will be understood, of course, that all such objects or advantages described above are not necessarily achievable according to any particular embodiment. Therefore, for example, those skilled in the art will recognize that the systems and techniques described herein can be implemented or performed in a manner that achieves or optimizes one or a combination of advantages as taught herein, without requiring the achievement of other objects or advantages as taught or revealed herein.

[0134] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any apparatus or system, and performing any incorporated methods. The scope of the invention is defined by the claims and may include other examples that may 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 are not different from the written language of the claims, or if they include equivalent structural elements that are not substantially different from the written language of the claims.

[0135] For the sake of completeness, various aspects of this disclosure are set forth in the following numbered clauses:

[0136] Clause 1. An integrated repair system for maintaining components within a nacelle on a wind turbine tower, the wind turbine having a rotor having at least one rotor blade mounted to a rotatable hub, the rotor being operatively coupled to a gearbox via a rotor shaft supported by at least one main bearing, the repair system comprising: at least one mounting location integrally formed into a base plate support frame of the wind turbine; a frame assembly including at least one support leg fixed to the mounting location and defining a passage for receiving the rotor shaft therethrough; at least one clamping element positioned within the frame assembly to receive the rotor shaft therein and provide clamping force to the rotor shaft; and at least one jacking element engaging with the frame assembly and the at least one clamping element, the at least one jacking element being operable with the frame assembly to provide support to the rotor shaft and provide movement of the rotor shaft in at least one direction, wherein when the gearbox moves within the nacelle during the repair process, the repair system supports the main shaft on the tower such that the rotor remains mounted on the rotor shaft.

[0137] Clause 2. The repair system according to Clause 1, wherein the rotor shaft is coupled to the gearbox via a shrink disc, the shrink disc defining a thickness relative to the rotor shaft, wherein the frame assembly defines a radial separation distance relative to the rotor shaft, the radial separation distance being greater than the thickness defined by the shrink disc, the radial separation distance allowing the shrink disc to pass along the rotor shaft between the frame assembly and the rotor shaft when the frame assembly is coupled to the base plate support frame.

[0138] Clause 3. A repair system pursuant to any of the foregoing clauses, wherein at least one jack element is a first jack element movable in a first radial direction, and the repair system further includes at least a second jack element engaged with a frame assembly, the second jack element being movable in a second radial direction offset from the first radial direction by at least 90 degrees.

[0139] Clause 4. A repair system pursuant to any of the foregoing clauses, wherein at least one jack element comprises a hydraulic actuator or a screw jack, the screw jack comprising a threaded stud extending between a first stud end and a second stud end, the second stud end defining a retaining feature and a round foot receptacle by a corresponding recess of a clamping element.

[0140] Clause 5. A repair system pursuant to any of the foregoing clauses, wherein at least one clamping element further comprises a removable wear-resistant layer.

[0141] Clause 6. A repair system according to any of the foregoing clauses, wherein at least one mounting location includes a web of a base plate support frame having at least one boss, the at least one boss defining a through hole having a diameter corresponding to the diameter of at least one fastener, and wherein a connecting portion of at least one support leg includes a mating portion comprising a first portion positioned at a first axial position and a second portion positioned at a second axial position, the distance between the first axial position and the second axial position corresponding to a thickness to at least one mounting location, the first portion and the second portion each defining a through hole for receiving at least one fastener.

[0142] Clause 7. A repair system pursuant to any of the foregoing clauses, wherein at least one installation location further includes at least one reinforcing strut oriented to accept the maximum load generated by the rotor in response to a wind event.

[0143] Clause 8. The repair system according to any of the foregoing clauses further includes at least one tensioning jack element that engages with the frame assembly and is oriented to press against the base plate support frame in order to secure at least one fastener within a through hole defined by at least one mounting location and mating portion.

[0144] Clause 9. A repair system pursuant to any of the foregoing clauses, wherein at least one mounting location includes a mounting surface having a profile corresponding to the profile of a support leg, the mounting surface defining a plurality of fastener openings for receiving a plurality of threaded fasteners, the plurality of threaded fasteners being constructed within the corresponding plurality of fastener openings.

[0145] Clause 10. The repair system according to any of the foregoing clauses further includes: a pin-bearing pallet having a support surface extending between a first pallet end and a second pallet end, the first pallet end being removably coupled to at least one support leg; and a screw feed assembly operably coupled to the second pallet end and oriented to move at least one fastener in an axial direction to engage or disengage the frame assembly and the base plate support frame.

[0146] Clause 11. The repair system according to any of the foregoing clauses further includes: a suspension belt, which is coupled to the frame assembly and configured to pass between the rotor shaft and the base plate support frame in order to counteract the downward force of the rotor shaft.

[0147] Clause 12. The repair system according to any of the foregoing clauses further includes: at least one gearbox actuating element having a first end receiving in a recess defined by the frame assembly and a second end oriented to apply an axial force on the gearbox.

[0148] Clause 13. The repair system according to any of the foregoing clauses further includes: an axial support element having a first end coupled to the frame assembly and a second end positioned to react with the gearbox support system.

[0149] Clause 14. A method for repairing components within a nacelle on a wind turbine tower, the wind turbine having a rotor having at least one rotor blade mounted to a rotatable hub, the rotor being operatively coupled to a gearbox via a rotor shaft supported by at least one main bearing, the method comprising: receiving the rotor shaft in a passage defined by a frame assembly; securing at least one support leg of the frame assembly to a mounting position integrally formed into a base plate support frame of the wind turbine; positioning at least one clamping element inside the frame assembly to receive the rotor shaft therein and to provide clamping force to the rotor shaft; advancing at least one jacking element operatively coupled to the at least one clamping element and the frame assembly to position the at least one clamping element in contact with the rotor shaft; disengaging the rotor shaft from the gearbox; receiving a vertical load generated by the rotor shaft in response to supporting the rotor using the frame assembly; transferring the received vertical load to the base plate support frame via the frame assembly; and maintaining components of the wind turbine.

[0150] Clause 15. The method according to any of the foregoing clauses, wherein the wind turbine further includes a shrink disc surrounding the rotor shaft, the shrink disc defining a thickness relative to the rotor shaft greater than the outer diameter of the rotor shaft, the method further comprising: passing the shrink disc along the rotor shaft between the rotor shaft and the frame assembly when the frame assembly is coupled to the base plate support frame.

[0151] Clause 16. The method according to any of the foregoing clauses further includes: attaching a removable wear-resistant layer to at least one clamping element such that at least one clamping element conforms to the outer diameter of the rotor shaft.

[0152] Clause 17. The method according to any of the preceding clauses, wherein at least one mounting location includes a web of a base plate support frame having at least one boss defining a through hole having a diameter corresponding to the diameter of at least one fastener, and wherein securing at least one support leg to the mounting location further includes: engaging a connecting portion of the web with at least one support leg, wherein the connecting portion includes a mating portion comprising: a first portion positioned at a first axial location and a second portion positioned at a second axial location, the first portion and the second portion each further defining a through hole for receiving at least one fastener; and inserting at least one fastener into the through hole to secure the web of the base plate support frame within the mating portion.

[0153] Clause 18. The method according to any of the foregoing clauses further includes: moving the end of the rotor shaft in the radial direction by moving forward or retracting at least one jack element.

[0154] Clause 19. The method pursuant to any of the foregoing clauses further includes:

[0155] The suspension belt passes between the rotor shaft and the base plate support frame; the suspension belt is connected to the frame assembly; in response to a wind event impacting the rotor, a downward force is generated at the end of the rotor shaft opposite to the rotor; and the suspension belt is used to receive the downward force at the end of the rotor shaft.

[0156] Clause 20. A wind turbine comprising: a tower; a nacelle mounted on top of the tower; a rotor mounted to the nacelle, the rotor including a rotatable hub having one or more rotor blades fixed thereto; a rotor shaft operably coupled to the rotor to a gearbox located within the nacelle; at least one main bearing supporting the rotor shaft; a base plate support frame located within the nacelle and supporting the main bearing and the gearbox; and an integrated repair system for maintaining components within the nacelle, the repair system comprising: at least one mounting location integrally formed into the base plate support frame of the wind turbine; a frame assembly including at least one rotor blade fixed to the mounting location. A support leg defining a passage for receiving a rotor shaft therethrough; at least one clamping element positioned inside the frame assembly to receive the rotor shaft therein and provide clamping force to the rotor shaft; and at least one jacking element engaging with the frame assembly and the at least one clamping element, the at least one jacking element being operable with the at least one frame assembly to provide support to the rotor shaft and provide movement of the rotor shaft in at least one direction, wherein when the gearbox is moved in the nacelle during the repair process, the repair system supports the spindle on the tower such that the rotor remains mounted on a rotatable hub.

Claims

1. An integrated repair system for maintaining a component within a nacelle on a wind turbine tower, the wind turbine having a rotor with at least one rotor blade mounted to a rotatable hub, the rotor operably coupled to a gearbox via a rotor shaft, the repair system comprising: at least one mounting location integrally formed into a floor support frame of the wind turbine; a frame assembly including at least one support leg secured to the mounting location and defining a passageway receiving the rotor shaft therethrough; a pin carrying tray having a support surface extending between a first tray end and a second tray end, the first tray end removably coupled to the at least one support leg; a screw feed assembly operably coupled to the second tray end and oriented to move the at least one fastener in an axial direction so as to couple or decouple the frame assembly and the floor support frame; at least one clamping element positioned interior to the frame assembly so as to receive the rotor shaft therein and provide a clamping force to the rotor shaft; and at least one jack element engaged with the frame assembly and the at least one clamping element, the at least one jack element operable with the frame assembly to provide support to the rotor shaft and to provide movement of the rotor shaft in at least one direction, wherein the repair system supports the rotor shaft on the tower such that the rotor remains mounted on the rotor shaft when the gearbox is moved in the nacelle during a repair process. the rotor shaft is coupled to the gearbox via a shrink disc defining a thickness relative to the rotor shaft, wherein the frame assembly defines a radial separation distance relative to the rotor shaft, the radial separation distance being greater than the thickness defined by the shrink disc, the radial separation distance allowing the shrink disc to pass along the rotor shaft between the frame assembly and the rotor shaft when the frame assembly is coupled to the floor support frame.

2. The repair system according to claim 1, characterized in that the at least one jack element is at least a first jack element movable in a first radial direction, the repair system further including at least a second jack element engaged with the frame assembly, the second jack element movable in a second radial direction, the second radial direction being offset from the first radial direction by at least 90 degrees.

3. The repair system of claim 1, wherein the at least one jack element includes a hydraulic actuator or a screw jack, the screw jack including a threaded stud extending between a first stud end and a second stud end, the second stud end defining a retaining feature and a circular foot receivable by a corresponding socket of the clamping element.

4. The repair system of claim 1, wherein the at least one clamping element further includes a removable wear layer.

5. The repair system of claim 1, wherein ​ 6. The repair system of claim 1, wherein The at least one mounting location includes a web of the floor support frame having at least one boss, the at least one boss defining a through hole having a diameter corresponding to a diameter of at least one fastener, and wherein the coupling portion of the at least one support leg includes a docking portion including a first portion positioned at a first axial location and a second portion positioned at a second axial location, a distance between the first axial location and the second axial location corresponding to a thickness of the at least one mounting location, the first portion and the second portion each defining a through hole for receiving the at least one fastener.

7. The repair system according to claim 6, characterized in that The at least one mounting location further includes at least one reinforcing strut oriented to accept a maximum load generated by the rotor in response to a wind event.

8. The repair system according to claim 6, characterized in that Further comprising at least one tensioning jack element engaged with the frame assembly and oriented to press against the floor support frame so as to secure the at least one fastener within the through hole defined by the at least one mounting location and the docking portion.

9. The repair system of claim 1, wherein, The at least one mounting location includes a mounting surface having a profile corresponding to the support leg, the mounting surface defining a plurality of fastener openings for receiving a plurality of threaded fasteners configured within the corresponding plurality of fastener openings.

10. The repair system of claim 1, wherein, Further comprising: a suspension band coupled to the frame assembly and configured to pass between the rotor shaft and the floor support frame so as to oppose a downward force on the rotor shaft.

11. The repair system of claim 1, wherein Further comprising: at least one gear box pushing element having a first end portion received in a recess defined by the frame assembly and a second end portion oriented to exert an axial force on the gear box.

12. The repair system of claim 1, wherein, Further comprising: an axial support element having a first end portion coupled to the frame assembly and a second end portion positioned to react against a gear box support system.

13. A method for maintaining components within a nacelle on a wind turbine tower, the wind turbine having a rotor with at least one rotor blade mounted to a rotatable hub, the rotor operably coupled to a gear box via a rotor shaft, the method comprising: receiving the rotor shaft in a passageway defined by a frame assembly; securing at least one support leg of the frame assembly to a mounting location integrally formed into a floor support frame of the wind turbine; positioning at least one clamping element inside the frame assembly so as to receive the rotor shaft therein and provide a clamping force to the rotor shaft; advancing at least one jack element operably coupled to the at least one clamping element and the frame assembly to position the at least one clamping element in contact with the rotor shaft; decoupling the rotor shaft from the gear box; receiving a vertical load generated by the rotor shaft in response to a supported rotor with the frame assembly; transferring the received vertical load to the floor support frame via the frame assembly; and maintaining components of the wind turbine; wherein the at least one mounting location includes a web of the floor support frame having at least one boss, the at least one boss defining a through hole having a diameter corresponding to a diameter of at least one fastener, and wherein securing the at least one support leg to a mounting location further comprises: engaging the web with a coupling portion of the at least one support leg, wherein the coupling portion includes a docking portion, the docking portion including: a first portion positioned at a first axial location, and a second portion positioned at a second axial location, the first portion and the second portion each further defining a through hole for receiving the at least one fastener; and inserting the at least one fastener into the through hole so as to secure the web of the floor support frame within the docking portion.

14. The method of claim 13, wherein, The wind turbine further includes a shrink disk surrounding the rotor shaft, the shrink disk defining a thickness relative to the rotor shaft, the thickness being greater than an outer diameter of the rotor shaft, the method further comprising: passing the shrink disk between the rotor shaft and the frame assembly along the rotor shaft when the frame assembly is coupled to the floor support frame.

15. The method of claim 13, wherein, further comprising: conforming the at least one clamping element to the outer diameter of the rotor shaft by coupling a removable wear layer to the at least one clamping element.

16. The method of claim 13, wherein, further comprising: moving an end of the rotor shaft in a radial direction by advancing or retracting the at least one jack element.

17. The method of claim 13, wherein, further comprising: passing a suspension band between the rotor shaft and the floor support frame; coupling the suspension band to the frame assembly; generating a downward force on an end of the rotor shaft opposite the rotor in response to a wind event impinging on the rotor; and receiving the downward force of the end of the rotor shaft with the suspension band.

18. A wind turbine, comprising: a tower; a nacelle mounted atop the tower; a rotor mounted to the nacelle, the rotor including a rotatable hub having one or more rotor blades secured thereto; a rotor shaft operably coupling the rotor to a gearbox positioned within the nacelle; a floor support frame positioned within the nacelle and supporting the gearbox; and an integrated repair system for maintaining components within the nacelle, the repair system including: at least one mounting location integrally formed into a floor support frame of the wind turbine, a frame assembly including at least one support leg secured to the mounting location and defining a passageway receiving the rotor shaft therethrough, a pin-bearing tray having a bearing surface extending between a first tray end and a second tray end, the first tray end removably coupled to the at least one support leg, a screw feed assembly operably coupled to the second tray end and oriented to move the at least one fastener in an axial direction so as to couple or decouple the frame assembly and the floor support frame, ​ ​ at least one clamping element positioned inside the frame assembly so as to receive the rotor shaft therein and provide a clamping force to the rotor shaft, and at least one jack element engaged with the frame assembly and the at least one clamping element, the at least one jack element operable with the at least one frame assembly to provide support to the rotor shaft and to provide movement of the rotor shaft in at least one direction, wherein the repair system supports the rotor shaft on a tower such that the rotor remains mounted on the rotatable hub when the gearbox is moved in the nacelle during a repair process.

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