Aerial maintenance device and method for a direct-drive wind turbine generator system deflector

Abstract

This invention relates to the field of wind power generation technology, and discloses an aerial maintenance device and method for a direct-drive wind turbine fairing. The maintenance device includes a rotor-side lifting assembly and a nacelle-side lifting assembly. Both the rotor-side and nacelle-side lifting assemblies are connected to lifting chains. The rotor-side lifting assembly is used to lift one-third of the fairing assembly to the rotor side via the lifting chains, and the nacelle-side lifting assembly is used to lift one-third of the fairing assembly to the nacelle side via the lifting chains. This invention solves the problems of cumbersome installation, high resource consumption, low efficiency, and high cost existing technologies.

Description

Technical Field

[0001] This invention relates to the field of wind power generation technology, specifically to an aerial maintenance device and method for the fairing of a direct-drive wind turbine generator set. Background Technology

[0002] Among the various components of a wind turbine, the fairing plays a crucial role. Structurally, the fairing is a protective layer that safeguards the hub and related components from external damage. Functionally, the fairing is a thin-shell structure that ensures the normal operation of the wind turbine and enables more efficient utilization of wind energy. It has a significant impact on the stability of the wind turbine, the wind energy utilization rate of the wind turbine, and the aerodynamic performance of the blades.

[0003] When performing aerial maintenance on wind turbine fairings, it is often necessary to have a crane vessel involved to remove the blades and replace the fairing in the air. However, this method has problems such as complicated installation, high resource consumption, low efficiency, and high cost. The disadvantages are particularly obvious in the scenario of aerial maintenance of fairings for direct-drive wind turbines.

[0004] The process is safe, efficient, and convenient, significantly reducing problem-solving costs. Summary of the Invention

[0005] To overcome the shortcomings of existing technologies, this invention provides an aerial maintenance device and method for the fairing of a direct-drive wind turbine generator, which solves the problems of cumbersome installation, high resource consumption, low efficiency, and high cost in existing technologies.

[0006] The technical solution adopted by the present invention to solve the above problems is:

[0007] An aerial maintenance device for a direct-drive wind turbine fairing includes a rotor-side hoisting assembly and a nacelle-side hoisting assembly. Both the rotor-side and nacelle-side hoisting assemblies are connected to lifting chains. The rotor-side hoisting assembly is used to hoist 1 / 3 of the fairing assembly to the rotor side via the lifting chains, and the nacelle-side hoisting assembly is used to hoist 1 / 3 of the fairing assembly to the nacelle side via the lifting chains.

[0008] As a preferred technical solution, the wind turbine side hoisting assembly includes an electric hoist, a hoisting support rod, and a hoisting strap. Both ends of the hoisting support rod are connected to a hoisting seat, and each hoisting seat is connected to the electric hoist via the hoisting strap. The electric hoist is connected to the hoisting chain.

[0009] As a preferred technical solution, the support rod of the hanging seat is provided with a limiting ring.

[0010] As a preferred technical solution, the nacelle-side hoisting assembly includes a frame beam and an L-shaped tie rod connected to the frame beam. The L-shaped tie rod is used to connect to the end face of the generator on the wind turbine side.

[0011] As a preferred technical solution, the cabin-side hoisting assembly further includes positive and negative helical tie rods, a slewing cantilever connected to the frame beam, and a limiting block connected to the slewing cantilever.

[0012] As a preferred technical solution, the frame beam includes a bottom frame, diagonal bracing beams, horizontal connecting beams, and vertical beams. The bottom frame is a rectangular structure formed by a bottom frame front beam, a bottom frame rear beam, and two bottom frame side beams. The bottom of the vertical beam is connected to the bottom frame front beam and the slewing cantilever, respectively. The top of the vertical beam is connected to the positive and negative spiral tie rods, the top of the diagonal bracing beams, and the horizontal connecting beams. The bottom of the diagonal bracing beams is connected to the bottom frame rear beam, and the bottom frame side beams are connected to the L-shaped tie rods.

[0013] As a preferred technical solution, it also includes a turnbuckle adjusting rod for connecting to the 1 / 3 housing assembly.

[0014] As a preferred technical solution, the system also includes a barge and a guy rope, wherein the barge is used to connect to the 1 / 3 housing assembly via the guy rope.

[0015] A method for aerial maintenance of a direct-drive wind turbine fairing, employing the aforementioned aerial maintenance device for a direct-drive wind turbine fairing, includes the following steps:

[0016] S1, the wind turbine generator set stops operating, and the rotor-side hoisting components and nacelle-side hoisting components are transported to the top of the turbine rotor;

[0017] S2, use one barge to transport 1 / 3 of the casing assembly to below the turbine rotor, and place another barge at a position M meters away from the center of the tower; where 50≤M≤150;

[0018] S3, lower the wind turbine side hoisting assembly and the nacelle side hoisting assembly to the barge and connect them to the prefabricated hoisting points of the cover assembly;

[0019] S4, personnel on the barge located M meters from the center of the tower pull 1 / 3 of the cover assembly using guy ropes at the bow and stern to control the air attitude of the cover assembly during the lifting process;

[0020] S5, adjust the size of the control cover connecting flange by adjusting the turnbuckle adjustment rod to complete the connection with the wheel hub body;

[0021] S6, dismantle the wind turbine side hoisting components and the nacelle side hoisting components, and clean the construction auxiliary tools inside the hub;

[0022] S7, the wind turbine is locked after rotating 120° clockwise;

[0023] S8. Repeat steps S1 to S7 to complete the aerial reassembly of the remaining 1 / 3 of the housing assembly.

[0024] S9, after the installation of the three sets of 1 / 3 shell components is completed, remove the wind turbine side hoisting components, the nacelle side hoisting components, and the auxiliary tools for construction inside the hub, and transfer them to the unit platform;

[0025] S10, Reinstall the auxiliary components that were removed during the internal construction of the hub, and restore the operation of the wind turbine generator set.

[0026] Compared with the prior art, the present invention has the following advantages:

[0027] This invention enables aerial replacement and maintenance of the fairing without the need for large wind turbine lifting vessels or blade removal. The maintenance device is modular, lightweight, portable, and easy to assemble. The replacement and maintenance scheme is optimized, and the replacement process is safe, efficient, and convenient, significantly reducing problem-solving costs. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure for air-to-air replacement of the fairing of the present invention;

[0029] Figure 2 A schematic diagram of the assembly structure for the wheel hub and engine nacelle side hoisting components;

[0030] Figure 3 A schematic diagram of the hoisting of the 1 / 3 enclosure assembly;

[0031] Figure 4 This is a schematic diagram of the wind turbine side hoisting assembly structure;

[0032] Figure 5 Schematic diagram of the connection structure for the specially designed lifting bracket for the wind turbine side lifting components;

[0033] Figure 6 This is a schematic diagram of the nacelle-side hoisting assembly structure.

[0034] Figure 7 Diagram showing the tightening and fixing of the L-shaped tie rods on the bottom frame beam;

[0035] Figure 8 for Figure 7 A sectional view;

[0036] Figure 9 A schematic diagram of the cantilevered state of the cabin-side hoisting assembly;

[0037] Figure 10 This is a diagram showing the installation sequence of the 1 / 3 housing assembly.

[0038] The attached diagram shows the following components and their corresponding names: 1. Electric hoist; 3. Hoist support rod; 4. Hoist; 5. Hollow threaded sleeve; 6. Slewing cantilever; 7. Positive and negative spiral tie rods; 8. L-shaped tie rod; 9. Bottom frame side beam; 10. Bottom frame front beam; 11. Bottom frame rear beam; 12. Diagonal brace beam; 13. Horizontal connecting beam; 14. Limiting block; 15. Set screw; 16. Turnbuckle adjusting rod; 17. Lifting strap; 18. Vertical beam; 19. Shackle; 22. Generator; 23. Barge; 25. 1 / 3 housing assembly; 26. Hub; 31. Limiting ring; 50. Wind turbine side lifting assembly; 56. Lifting chain; 57. Guy rope; 60. Nacelle side lifting assembly. Detailed Implementation

[0039] The present invention will be further described in detail below with reference to the embodiments and accompanying drawings, but the embodiments of the present invention are not limited thereto.

[0040] Example 1

[0041] like Figures 1 to 10 As shown, this invention is an aerial maintenance device and method for a direct-drive wind turbine fairing, which allows for aerial replacement and maintenance of the fairing without the need for a large wind turbine lifting vessel or blade removal. It is safe, fast, and efficient, significantly reducing replacement and maintenance costs.

[0042] The present invention adopts the following technical solution:

[0043] Electric hoist 1 was used as the lifting equipment for replacing and maintaining parts.

[0044] Both the rotor-side lifting assembly 50 and the nacelle-side lifting assembly 60 are connected to lifting chains 56. The fairing is divided into three groups (each group consists of two blades), with two groups of fairing components having pre-drilled passage holes for the electric hoist 1 chain, which are installed in a predetermined order. The upper and lower passages of the electric hoist 1 chain on the nacelle side are the gap space between the generator 22 and the blades.

[0045] During construction, two transport barges 23 are used. One barge 23 is responsible for transporting 1 / 3 of the casing assembly to the bottom of the wind turbine; the other barge 23 is used to pull the wind ropes 57 to control the aerial attitude of 1 / 3 of the casing assembly.

[0046] The cabin-side hoisting assembly 60 consists of a bottom frame beam, a diagonal brace beam 12, a slewing cantilever 6, and an L-shaped tie rod 8.

[0047] The cabin-side hoisting component 60 adopts a split, lightweight design, and the disassembled parts are transported to the top of the cabin cover by the unit elevator and manpower for assembly.

[0048] The nacelle-side hoisting assembly 60 is connected to the outer rotor nacelle-side reinforcing plate fixing hole of the direct-drive generator 22, and the wind turbine side is fixed with an L-shaped tie rod 8.

[0049] The cabin-side hoisting assembly 60 uses a slewing cantilever 6, and the slewing cantilever 6 uses positive and negative spiral tie rods 7 to adjust the cantilever tension.

[0050] The slewing angle of the slewing cantilever 6 on the side of the cabin is limited by the slewing limit block 14.

[0051] The frame beam includes a bottom frame, diagonal bracing beams 12, and vertical beams 18. The bottom frame is a rectangular structure formed by a front bottom frame beam 10, a rear bottom frame beam 11, and two side bottom frame beams 9. The bottom of the vertical beam 18 is connected to the front bottom frame beam 10 and the slewing cantilever 6, respectively. The top of the vertical beam 18 is connected to the positive and negative spiral tie rods 7 and the top of the diagonal bracing beam 12. The bottom of the diagonal bracing beam 12 is connected to the rear bottom frame beam 11. The side bottom frame beams 9 are connected to the L-shaped tie rods 8. A horizontal connecting beam 13 is also included to connect the two diagonal bracing beams 12.

[0052] The wind turbine side lifting assembly 50 uses a special electric hoist 1 lifting base with a hollow threaded sleeve 5 and a transfer connection between the top open end face of the hub 26 and the hub 26. After the special lifting base is connected to the fixing bolt as a whole, it passes through the hollow threaded sleeve 5 and is fixed with a nut from inside the hub 26, which protects the thread of the transfer connection hole of the top open end face of the hub 26 and reduces the installation risk of the special lifting base.

[0053] Safety rope attachment points are attached to each profile rod of the nacelle-side hoisting assembly 60. The specially designed hoisting support rod 3 is equipped with limiting rings 31 on both sides near the specially designed hoisting base 4. When the electric hoist 1 is transferred from inside the wheel hub 26 to the specially designed hoisting base outside the wheel hub 26, the hoisting strap 17 is limited by the limiting rings 31. The electric hoist 1 is then manually dragged to the bottom of the specially designed hoisting base, and the hoisting strap 17 and shackle 19 are connected.

[0054] The wind turbine side lifting assembly 50 uses a specially designed electric hoist 1 lifting base, which is fixed by the transfer connection hole of the hub 26 at the top open end face of the hub 26.

[0055] The wind turbine side lifting assembly 50 uses a special electric hoist 1 with a hollow threaded sleeve 5 connected to the transfer threaded hole of the hub 26 at the top open end face of the hub 26. The special lifting seat 4 is connected to the fixing bolt as a whole and passes through the hollow threaded sleeve 5. It is then fixed with a nut from inside the hub 26 to protect the thread of the transfer connection hole of the hub 26 at the top open end face of the hub 26 and reduce the installation risk of the special lifting seat.

[0056] The specially designed support rod 3 is equipped with limiting rings 31 on both sides near the specially designed support 4. When the electric hoist 1 is transferred from inside the hub 26 to the specially designed support outside the hub 26, the sling 17 is limited by the limiting rings 31. The electric hoist 1 is dragged to the bottom of the specially designed support by manpower, and the sling 17 and shackle 19 are connected.

[0057] The four electric hoists 1 have synchronous control and individual control functions, enabling synchronous lifting of the cover assembly and individual control of hole position adjustment during aerial docking.

[0058] The 1 / 3 housing assembly is equipped with turnbuckles to adjust the gap between the mating surfaces when the 1 / 3 housing assembly is connected, thereby improving the connection efficiency.

[0059] Before replacing and maintaining the generator fairing of a direct-drive wind turbine generator in mid-air, prepare the necessary materials and vessels according to the following steps, and install each hoisting device component according to the corresponding instructions. Some steps can be carried out simultaneously according to the on-site construction schedule.

[0060] Step 1: Retract the blades, stop the wind turbine from rotating, and adjust it to the inverted Y position. Protect and clean the working parts inside the wind turbine, and remove and protect small parts that may affect construction.

[0061] Step 2: Transport the wind turbine side hoisting assembly 50 and the nacelle side hoisting assembly 60 to their respective installation locations via the elevator inside the tower 24, and install the wind turbine side hoisting assembly 50 and the nacelle side hoisting assembly 60 according to the design drawings of the hoisting assemblies.

[0062] Step 3: The electric hoist 1 on the wind turbine side is hung on the middle of the limiting ring 31 of the special hanging support rod 3 using the sling 17, and the electric hoist 1 is pulled to the bottom of the special hanging support 4 by manpower. The sling 17, shackle 19, etc. are then connected to complete the installation of the electric hoist 1.

[0063] Step 4: According to the design drawings of the nacelle side hoisting assembly, firmly connect the bottom frame rear beam 11, bottom frame side beam 9, bottom frame front beam 10, L-shaped tie rod 8 to the generator 22, and use set screws 15 to tighten the bottom frame side beam 9 and L-shaped tie rod 8 to make the frame beam and generator 22 securely fixed.

[0064] Step 5: Connect the power supply and control lines to the four electric hoists on the wind turbine side and the nacelle side, and perform synchronous and individual action tests.

[0065] Step 6: Use one barge 23 to transport 1 / 3 of the casing assembly 25 to below the turbine rotor, and position another barge 23 approximately 100 meters from the center of the tower 24. Figure 1 ).

[0066] Step 7: Lower the wind turbine side hoisting assembly 50 and the nacelle side hoisting assembly 60 to the 1 / 3 of the cover assembly 25 transport ship using the hoist chain, and securely connect them to the prefabricated hoisting points of the cover assembly 25.

[0067] Step 8: At a distance of approximately 100 meters from the generator set, personnel on barge 23 pull on the guy ropes 57 of the 1 / 31 cover assembly 25 at the bow and stern to control the air attitude of the cover assembly 25 during the lifting process.

[0068] Step 9: Use the control box 21 of electric hoist 1 to control electric hoist 1 to synchronously lift it to the position where the guide shield is installed. Figure 2 ).

[0069] Step 10: Adjust the size of the control cover connecting flange by adjusting the turnbuckle adjusting rod 16 to complete the connection with the wheel hub 26 body.

[0070] Step 11: Remove the hoisting components 60 on the side of the wheel hub 26 and the side of the engine compartment, and clean out all construction auxiliary tools inside the wheel hub 26.

[0071] Step 12: After rotating the blades 120° clockwise (i.e., adjusting them to the inverted Y position), lock the wind turbine.

[0072] Step 13: Repeat steps 1 to 12 to complete the aerial reassembly of the remaining 1 / 3 of the casing assembly 25.

[0073] Step 14: After the installation of the three sets of 1 / 3 enclosure components 25 is completed, remove the turbine-side hoisting components 50, the nacelle-side hoisting components 60, and the internal construction tools of the hub 26, and transfer them to the unit platform.

[0074] Step 15: Reinstall the accessories that were removed during the internal construction of wheel hub 26.

[0075] Step 17: After rotating the blades 120° clockwise (i.e., adjusting them to the inverted Y position), the wind turbine generator set will resume operation.

[0076] This invention addresses practical problems encountered during the operation of wind turbine generator sets by designing a dedicated replacement and maintenance device to solve the problem of aerial replacement and maintenance of wind turbine generator fairings. It enables aerial replacement and maintenance of fairings without the involvement of large wind turbine generator lifting vessels or the removal of blades. The maintenance device is modular, lightweight, portable, and easy to assemble. The replacement and maintenance scheme is optimized, and the replacement process is safe, efficient, and convenient, significantly reducing the cost of handling the problem.

[0077] As described above, the present invention can be implemented well.

[0078] All features disclosed in all embodiments of this specification, or steps in all methods or processes implied in the disclosure, may be combined and / or extended or replaced in any way, except for mutually exclusive features and / or steps.

[0079] The above description is merely a preferred embodiment of the present invention and does not constitute any form of limitation to the present invention. Based on the technical essence of the present invention and within the spirit and principles of the present invention, any simple modification, equivalent replacement and improvement of the above embodiment shall still fall within the scope of protection of the technical solution of the present invention.

Claims

1. A method for aerial maintenance of the fairing of a direct-drive wind turbine generator set, characterized in that, An aerial maintenance device for a direct-drive wind turbine fairing is adopted, including a rotor-side hoisting assembly (50) and a nacelle-side hoisting assembly (60). Both the rotor-side hoisting assembly (50) and the nacelle-side hoisting assembly (60) are connected to a lifting chain (56). The rotor-side hoisting assembly (50) is used to hoist 1 / 3 of the fairing assembly (25) to the rotor side via the lifting chain (56), and the nacelle-side hoisting assembly (60) is used to hoist 1 / 3 of the fairing assembly (25) to the nacelle side via the lifting chain (56). It also includes a turnbuckle adjusting rod (16) for connection with the 1 / 3 housing assembly (25); It also includes a barge (23) and a guy rope (57), the barge (23) being used to connect to the 1 / 3 housing assembly (25) via the guy rope (57); The aforementioned method for in-flight maintenance of the fairing includes the following steps: S1, the wind turbine generator set stops operating, and the rotor-side hoisting assembly (50) and nacelle-side hoisting assembly (60) are transported to the top of the turbine rotor; S2, using one barge (23) to transport 1 / 3 of the casing assembly (25) to below the turbine rotor, and another barge (23) to be positioned at a distance of M meters from the center of the tower; where 50≤M≤150; S3, lower the wind turbine side hoisting assembly (50) and the nacelle side hoisting assembly (60) to the barge (23) and connect them to the prefabricated hoisting points of the 1 / 3 shell assembly (25); S4, personnel on the barge (23) located M meters from the center of the tower pull the 1 / 3 shell assembly (25) at the bow and stern using the wind rope (57) to control the aerial attitude of the 1 / 3 shell assembly (25) during the lifting process; S5, adjust the turnbuckle adjusting rod (16) to control the size of the cover connecting flange and complete the connection with the wheel hub body; S6, remove the wind turbine side hoisting assembly (50) and the nacelle side hoisting assembly (60), and clean the construction auxiliary tools inside the hub; S7, the wind turbine is locked after rotating 120° clockwise; S8, repeat steps S1 to S7 to complete the aerial reassembly of the remaining 1 / 3 of the housing assembly (25); S9. After the installation of the three sets of 1 / 3 shell components (25) is completed, remove the wind turbine side hoisting component (50), the nacelle side hoisting component (60), the hub internal construction auxiliary tools, and transfer them to the unit platform. S10, Reinstall the auxiliary components that were removed during the internal construction of the hub, and restore the operation of the wind turbine generator set.

2. The method for aerial maintenance of the fairing of a direct-drive wind turbine generator set according to claim 1, characterized in that, The wind turbine side hoisting assembly (50) includes an electric hoist (1), a hoisting support rod (3), and a sling (17). Both ends of the hoisting support rod (3) are connected to a hoisting seat (4). Each hoisting seat (4) is connected to the electric hoist (1) through the sling (17). The electric hoist (1) is connected to the hoisting chain (56).

3. The method for aerial maintenance of the fairing of a direct-drive wind turbine generator set according to claim 2, characterized in that, The support rod (3) of the hanging seat is provided with a limiting ring (31).

4. The method for aerial maintenance of the fairing of a direct-drive wind turbine generator set according to claim 3, characterized in that, The nacelle-side hoisting assembly (60) includes a frame beam and an L-shaped tie rod (8) connected to the frame beam. The L-shaped tie rod (8) is used to connect to the end face of the wind turbine-side generator.

5. The method for aerial maintenance of the fairing of a direct-drive wind turbine generator set according to claim 4, characterized in that, The cabin-side hoisting assembly (60) also includes positive and negative spiral tie rods (7), a slewing cantilever (6) connected to the frame beam, and a limiting block (14) connected to the slewing cantilever (6).

6. The method for aerial maintenance of the fairing of a direct-drive wind turbine generator set according to claim 5, characterized in that, The frame beam includes a bottom frame, a diagonal bracing beam (12), a horizontal connecting beam (13), and a vertical beam (18). The bottom frame is a rectangular structure formed by a bottom frame front beam (10), a bottom frame rear beam (11), and two bottom frame side beams (9). The bottom of the vertical beam (18) is connected to the bottom frame front beam (10) and the slewing cantilever (6) respectively. The top of the vertical beam (18) is connected to the positive and negative spiral tie rods (7), the top of the diagonal bracing beam (12), and the horizontal connecting beam (13). The bottom end of the diagonal bracing beam (12) is connected to the bottom frame rear beam (11). The bottom frame side beams (9) are connected to the L-shaped tie rods (8).

Images