Method for replacing offshore wind turbine gearbox in air

Abstract

The invention relates to the field of aerial replacement of offshore wind turbine gearboxes, in particular to a method for aerial replacement of offshore wind turbine gearboxes, which comprises the following steps of: hoisting all components of an auxiliary hoisting unit and a main hoisting unit to an operation transport ship by using a port crane; the auxiliary hoisting unit and the main hoisting unit are sequentially installed on the offshore wind turbine cabin main body, the traction winch mechanism is arranged according to the arrangement positions of the auxiliary hoisting unit and the main hoisting unit assembly, and then the guide pulley mechanism is arranged on one side of the traction winch mechanism. And then the gear box main body is hoisted and replaced through the main hoisting unit, so that the requirement for aerial replacement of the offshore wind turbine gear box can be met without the help of a large wind power installation platform, and the gear box main body can be replaced only through cooperation of an operation transport ship when the gear box is replaced. And large ships for long-distance transportation are not needed, so that the maintenance cost can be effectively reduced, and the construction period is easy to control.

Description

Technical Field

[0001] The invention relates to the technical field of aerial replacement of offshore wind turbine gearboxes, and in particular to a method for aerial replacement of offshore wind turbine gearboxes. Background Art

[0002] Offshore wind turbines are the core equipment for offshore wind power generation, usually composed of towers, nacelles, blades and generators. Among them, the gearbox, as a key component in the nacelle, generally has a service life of 10 to 15 years. However, the gearbox may need to be replaced due to wear, failure and other reasons during operation, especially in offshore environments. The replacement operation faces many challenges.

[0003] The traditional method of replacing gearboxes relies on large wind power installation platforms and heavy lifting equipment, and its installation method is relatively cumbersome. It is suitable for towers with a height of 100 meters and requires a 600T crane, which not only occupies a large area but also has high rental costs. In addition, the long-distance transportation efficiency of the large wind power installation platform equipped with a 600T crane is low, resulting in a long gearbox replacement period and low replacement efficiency. Summary of the invention

[0004] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a method for aerial replacement of an offshore wind turbine gearbox.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions: A method for replacing an offshore wind turbine gearbox in mid-air comprises the following steps: S1. Initial configuration of equipment: Use the port crane to lift the modular lifting system components to the operating transport ship, and set up the traction winch mechanism and guide pulley mechanism on the operating transport ship; S2. Remove the external protective structure of the main body of the offshore wind turbine nacelle and use the crane inside the nacelle to lift it to the operating transport ship; S3. Install the auxiliary hoisting unit and the main hoisting unit in stages, and use the traction winch mechanism and the guide pulley mechanism to assist the traction and hoisting work throughout the process: a. The auxiliary crane support base is hoisted and installed, and the auxiliary crane support base is accurately positioned and installed on the second limit mounting frame of the shaft body through the first support rod mounting foot and the first support rod; b. Install the middle connection mechanism of the auxiliary crane, including the cantilever arm and its winch, and the first guide pulley frame, and install the auxiliary crane lifting mechanism through the cantilever arm; c. Assembly and debugging of auxiliary crane lifting mechanism; d. Use the auxiliary lifting unit to lift the components of the main lifting unit into the cabin, dismantle the gearbox limit unit, dismantle the upper mounting plate, the limit connecting column, and the second gearbox mounting unit, and accurately position the third support rod on the lower mounting plate; S4. Replacement of the gearbox: The disassembled old gearbox body is moved out of the engine room through the main lifting unit, and then the new gearbox body is lifted into the engine room through the main lifting unit, and the first gearbox installation unit is used to ensure the accurate installation position; S5. Dismantle the main hoisting unit and the auxiliary hoisting unit in sequence, use the crane inside the cabin to restore the protective structure, and complete the replacement of the gearbox.

[0006] Preferably, a cavity for installing the gearbox body is provided inside the offshore wind turbine nacelle body, a gearbox installation area for installing the gearbox body is provided on the bottom wall of the offshore wind turbine nacelle body, and gearbox limiting unit installation grooves are symmetrically provided on both sides of the offshore wind turbine nacelle body located at the gearbox installation area, and gearbox limiting units are installed at the gearbox limiting unit installation grooves; A blade connecting shaft is arranged on one side of the gear box installation area inside the offshore wind turbine cabin main body, a first shaft limit mounting frame is installed at one end of the blade connecting shaft inside the offshore wind turbine cabin main body, and a second shaft limit mounting frame is installed at the other end, a plurality of first support rod mounting holes are symmetrically opened on both sides of the first shaft limit mounting frame, a plurality of second support rod mounting holes are symmetrically opened on both sides of the second shaft limit mounting frame, and an auxiliary crane mounting port is opened on the offshore wind turbine cabin main body above the second shaft limit mounting frame.

[0007] Preferably, a gearbox limit mounting plate is provided at one end of the gearbox body, a first lifting ring hole plate is symmetrically provided at the upper portion of the gearbox limit mounting plate, limit mounting protrusions are symmetrically provided at both sides of the gearbox limit mounting plate, and a second lifting ring hole plate is symmetrically provided at the upper portion of the end of the other side of the gearbox body away from the gearbox limit mounting plate; An internal crane is installed on the bottom wall of the inner cavity of the offshore wind turbine cabin main body and located on one side of the first limiting mounting frame of the shaft body.

[0008] Preferably, the gearbox limiting unit comprises a lower mounting plate, the lower mounting plate is mounted at the gearbox limiting unit mounting groove, a first gearbox mounting unit is arranged at the middle of the upper surface of the lower mounting plate, and an upper mounting plate is mounted above the lower mounting plate; A second gearbox mounting unit is arranged in the middle of the bottom surface of the upper mounting plate, a plurality of limit connecting columns are symmetrically installed on both sides of the second gearbox mounting unit, and the limit mounting protrusion is installed between the second gearbox mounting unit and the first gearbox mounting unit.

[0009] Preferably, the auxiliary hoisting unit comprises an auxiliary hoist support base, an auxiliary hoist middle connection mechanism, an auxiliary hoist lifting mechanism, a ladder and a hook assembly; The auxiliary crane support base includes a first connecting seat, and the bottom of the two side ends of the first connecting seat body is symmetrically provided with first support rod mounting feet, and the bottom of the first support rod mounting feet is provided with a plurality of first support rods, and the first ladder mounting plate for mounting the ladder is symmetrically provided on the side wall of the central column of the first connecting seat; A first connection plate is provided on the top of the first connection seat, the middle connection mechanism of the auxiliary crane is installed at the first connection plate, and a plurality of third lifting ring orifice plates are evenly provided on the inner wall of the middle column of the first connection seat; The auxiliary crane middle connection mechanism includes a second connection seat, a third connection plate is arranged on the top of the second connection seat, a second connection plate is arranged on the bottom of the second connection seat, the second connection plate is installed at the first connection plate, a second ladder mounting plate for mounting the ladder is symmetrically arranged on the outer wall of the second connection seat, and a cantilever arm is fixedly connected to the middle of the outer wall of the second connection seat; A first guide pulley frame is arranged at the end of one side of the cantilever arm away from the second connecting seat, a winch is installed on the upper surface of the cantilever arm and close to the second connecting seat, and a plurality of fourth hanging ring holes are evenly arranged on the top of the inner wall of the second connecting seat column.

[0010] Preferably, the auxiliary crane hoisting mechanism comprises an auxiliary crane main mounting frame, a first rotary drum assembly is arranged at the bottom of the auxiliary crane main mounting frame, the first rotary drum assembly is mounted on the third connecting plate, and a first driving assembly for driving the first rotary drum assembly to rotate is installed on one side of the bottom frame of the auxiliary crane main mounting frame; An auxiliary crane boom is rotatably arranged on the top of the auxiliary crane main mounting frame, an operating platform is arranged on one side of the auxiliary crane main mounting frame, a first boom hydraulic drive assembly for driving the auxiliary crane boom to move is arranged on the other side of the auxiliary crane main mounting frame away from the operating platform, an output end of the first boom hydraulic drive assembly is connected to the bottom of the auxiliary crane boom, and a first hydraulic station assembly is arranged on the operating platform; A plurality of fifth lifting ring holes are evenly arranged in the middle of the upper surface of the auxiliary crane arm, an auxiliary crane winch assembly is arranged on the upper surface of one end of the auxiliary crane arm close to the auxiliary crane main mounting frame, and a hook assembly is installed at the other end of the auxiliary crane arm away from the auxiliary crane main mounting frame; The hook assembly comprises a second guide pulley frame and a first hook mechanism, wherein the first hook mechanism is connected to the second guide pulley frame by winding a steel wire rope; The second guide pulley frame is installed at the other end of the auxiliary crane arm away from the auxiliary crane main mounting frame, and the second guide pulley frame includes a first guide pulley symmetrically arranged for rotation up and down, a first hook is arranged at the bottom of the first hook mechanism, and a second guide pulley is rotatably arranged on the first hook mechanism.

[0011] Preferably, the main hoisting unit comprises a main hoist support base, a main hoist lifting mechanism, a third guide pulley frame, and a second hook mechanism, and the main hoist support base is installed at the first support rod mounting hole and the lower mounting plate; The main crane support base includes a third connecting seat, a fourth connecting plate for installing the main crane lifting mechanism is arranged on the top of the central column of the third connecting seat, and a plurality of sixth lifting ring hole plates are evenly arranged on the top of the inner wall of the central column of the third connecting seat; A second support rod mounting foot is symmetrically arranged on one side of the bottom of the third connecting seat body, and a third support rod mounting foot is symmetrically arranged on the other side, a plurality of second support rods are symmetrically installed on the bottom of the second support rod mounting foot, the second support rod is installed at the first support rod mounting hole, a plurality of third support rods are symmetrically installed on the bottom of the third support rod mounting foot, and the third support rod is installed at the lower mounting plate; The main crane hoisting mechanism comprises a main crane main mounting frame, a second rotary drum assembly is arranged at the bottom of the main crane main mounting frame, the second rotary drum assembly is installed at the fourth connecting plate, a second driving assembly for driving the second rotary drum assembly is installed on the bottom frame of the main crane main mounting frame, and a second hydraulic station assembly is installed on a side plate of the main crane main mounting frame; A main crane boom is rotatably arranged on the top of the main crane main mounting frame, and a second boom hydraulic drive assembly for driving the main crane boom to rotate is arranged on the main crane main mounting frame, and the top output end of the second boom hydraulic drive assembly is connected to the bottom of the main crane boom; A plurality of seventh lifting eye hole plates are symmetrically arranged in the middle part of the upper surface of the main crane arm, a main crane winch assembly is installed on the upper surface of one end of the main crane arm close to the main mounting frame of the main crane, and a third guide pulley frame is arranged at the other end, and the third guide pulley frame is connected to the second hook mechanism through a steel wire rope.

[0012] Preferably, the third guide pulley frame is provided with a plurality of third guide pulleys symmetrically rotating up and down, the second hook mechanism is provided with a fourth guide pulley symmetrically rotating up and down, and the second hook mechanism is provided with a second lifting ring at the bottom of the fourth guide pulley.

[0013] The beneficial effects of the present invention are as follows: in the present invention, an auxiliary lifting unit and a main lifting unit are sequentially installed on the main body of the offshore wind turbine nacelle, and then the main lifting unit is used to lift and replace the gear box main body. In this way, the need for aerial replacement of the offshore wind turbine gear box can be realized without the aid of a large wind power installation platform. When replacing the gear box, the gear box main body only needs to be replaced with the cooperation of an operating transport ship, and there is no need to use a large ship for long-distance transportation. This can effectively reduce maintenance costs and the construction period is easy to control. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 A schematic diagram of the structure in which the main hoisting unit and the auxiliary hoisting unit are installed on the main body of the offshore wind turbine nacelle; Figure 2 Structural diagram of the top protection mechanism removed from the main body of the offshore wind turbine nacelle; Figure 3 This is a structural diagram of an offshore wind turbine nacelle with only the auxiliary lifting unit installed; Figure 4 This is a construction diagram of the main hoisting unit lifting the gearbox body; Figure 5 It is a structural schematic diagram of an offshore wind turbine nacelle body without a gearbox body installed; Figure 6 It is a structural schematic diagram of an offshore wind turbine nacelle body without a partially enlarged gearbox body installed; Figure 7 This is a partially enlarged structural diagram of the interior of the main body of the offshore wind turbine nacelle; Figure 8 It is a structural schematic diagram of the gearbox body; Fig. 9 It is a structural schematic diagram of the gear box limit unit; Fig.10 This is a structural schematic diagram of the auxiliary hoisting unit installed on the main body of the offshore wind turbine nacelle from the inner side; Fig.11 This is a structural schematic diagram of the auxiliary hoisting unit installed on the main body of the offshore wind turbine nacelle from an outer perspective; Fig.12 It is a structural schematic diagram of the second limit mounting frame of the shaft body without the auxiliary lifting unit installed; Fig.13 It is a schematic diagram of the overall structure of the auxiliary lifting unit; Fig.14 This is a schematic diagram of the structure after the auxiliary lifting unit is disassembled; Fig.15 It is a structural schematic diagram of the auxiliary crane support base; Fig.16 This is a partially enlarged structural diagram of the auxiliary crane support base; Fig.17 It is a structural schematic diagram of the middle connection mechanism of the auxiliary crane; Fig.18 It is a structural schematic diagram of a partial enlargement of the middle connecting mechanism of the auxiliary crane; Fig.19 It is a structural schematic diagram of the auxiliary crane lifting mechanism; Fig. 20 is a structural schematic diagram of a first hook assembly; Fig.21 It is a schematic diagram of the overall structure of the main hoisting unit; Fig. 22 This is a schematic diagram of the structure of the main crane support base; Fig.23 A partially enlarged structural diagram of the main crane support base; Fig.24 This is a schematic diagram of the structure of the main crane hoisting mechanism; Fig.25 is a structural schematic diagram of the third guide pulley frame and the second hook mechanism; Fig.26 is a structural schematic diagram of the third guide pulley frame; Fig. 27 It is a structural schematic diagram of the second hook mechanism.

[0015] In the figure: 01, offshore wind turbine nacelle body; 011, gearbox installation area; 012, gearbox limit unit installation slot; 013, fan blade connecting shaft; 014, shaft body first limit mounting bracket; 0141, first support rod mounting hole; 015, shaft body second limit mounting bracket; 0151, second support rod mounting hole; 016, auxiliary crane installation port; 02, auxiliary lifting unit; 03, main lifting unit; 04, gearbox body; 041, gearbox limit mounting plate; 0411, first lifting ring hole plate; 0412, limit mounting protrusion; 042, second lifting ring hole plate; 05, gearbox limit unit; 051, lower mounting plate; 052, first gearbox mounting unit; 053, upper mounting plate; 054, limit connecting column; 055, second gearbox mounting unit; 06, crane in engine room; 07, guide pulley mechanism; 08, traction winch mechanism; 09, operation transport ship; 1, auxiliary crane support base; 11, first connecting seat; 111, first connecting plate; 112, third lifting ring hole plate; 12, first support rod mounting foot; 13, first support rod; 14, first ladder mounting plate; 2, auxiliary crane middle connecting mechanism; 21, second connecting seat; 22, second ladder mounting plate; 23, second connecting plate; 24, third connecting plate; 25, cantilever arm; 251, winch; 252, first guide pulley frame; 26, fourth lifting ring plate; 3, auxiliary crane lifting mechanism; 31, auxiliary crane main mounting frame; 32, first rotary drum assembly; 33, first drive assembly; 34, operating platform; 35, first hydraulic station assembly; 36, first boom hydraulic drive assembly; 37, auxiliary crane boom; 371, fifth lifting ring plate; 372, auxiliary crane winch assembly; 4, ladder; 5, hook assembly; 51, second guide pulley frame; 511, first guide pulley; 52, first hook mechanism; 521, second guide pulley; 522, first hook; 6, main crane support base; 61 , the third connecting seat; 611, the fourth connecting plate; 612, the sixth lifting ring hole plate; 62, the second support rod mounting foot; 63, the third support rod mounting foot; 64, the second support rod; 65, the third support rod; 7, the main crane lifting mechanism; 71, the main crane main mounting frame; 72, the second boom hydraulic drive assembly; 73, the second rotating drum assembly; 74, the second drive assembly; 75, the second hydraulic station assembly; 76, the main crane boom; 761, the seventh lifting ring hole plate; 762, the main crane winch assembly; 8, the third guide pulley frame; 81, the third guide pulley; 9, the second hook mechanism; 91, the fourth guide pulley; 92, the second lifting ring. DETAILED DESCRIPTION

[0016] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0017] Reference Figure 1-27 , a method for aerial replacement of an offshore wind turbine gearbox, comprising the following steps: S1. Use the port crane to hoist all the components of the auxiliary hoisting unit 02 and the main hoisting unit 03 onto the operation transport ship 09, and set the traction winch mechanism 08 according to the positions of the auxiliary hoisting unit 02 and the main hoisting unit 03 components, and then set the guide pulley mechanism 07 on one side of the traction winch mechanism 08. After all the components are hoisted, the operation transport ship 09 travels to the side of the offshore wind turbine where the gearbox needs to be replaced; S2. The staff climbs to the top of the offshore wind turbine, removes the protective shell on the top of the offshore wind turbine nacelle body 01, and then starts the nacelle crane 06 inside the nacelle itself, and uses the nacelle crane 06 to lift the side panels and top protective panels of the nacelle to the operation transport ship 09; During the lifting process of all the protective plates, the steel wire rope of the traction winch mechanism 08 is passed through the guide pulley mechanism 07 and then hung on the protective plates. In this way, when the crane 06 in the engine room is lifted downward, the steel wire rope of the traction winch mechanism 08 is used to assist the traction, so as to ensure that all the protective plates can be lifted to the operating transport ship 09 below. After all the protective plates of the offshore wind turbine nacelle body 01 are removed, the gearbox body 04 replacement operation can begin. First, the auxiliary hoisting unit 02 is hoisted to the inside of the offshore wind turbine nacelle body 01, and then the main hoisting unit 03 is installed; S3, when hoisting the auxiliary hoisting unit 02, first hoist and assemble the auxiliary crane support base 1, then hoist and assemble the auxiliary crane middle connection mechanism 2, then hoist the ladder 4 for installation, and finally hoist the auxiliary crane lifting mechanism 3 for assembly, and during the hoisting process, use the traction winch mechanism 08 for auxiliary traction; When hoisting the auxiliary crane support base 1, use the crane 06 in the cabin to first hoist the first support rods 13 on all the operating transport ships 09 to the inside of the cabin, and then remove the fixing components at all the second support rod mounting holes 0151 on the second limit mounting frame 015 of the shaft body. In this process, each time a fixing component is removed, a first support rod 13 is installed. After all the first support rods 13 are installed in place, use the crane 06 in the cabin to hoist the first connecting seat 11 as a whole into the cabin, and the third lifting ring plate 112 is used to fix the lifting wire rope, and then the first support rod mounting foot 12 is installed on the first support rod 13. Finally, at the position of each first support rod 13, an M52 nut is installed, and the torque is gradually applied; After installing the auxiliary crane support base 1, when installing the auxiliary crane middle connection mechanism 2, first use the crane 06 in the engine room to lift the second connection seat 21 and the cantilever arm 25 on the operating transport ship 09 into the engine room in sequence, and then the operator uses the crane 06 in the engine room to install the second connection seat 21 to the auxiliary crane installation port 016, and make it located above the first connection seat 11. During the installation process, ensure that the first connection plate 111 is aligned with the second connection plate 23, and then connect them through the fixing components; After installing the second connecting seat 21, the cantilever arm 25 is hoisted to one side of the auxiliary crane installation port 016 by the crane 06 in the engine room, ensuring that the cantilever arm 25 faces the side of the operating transport ship 09. The winch 251 is a 1.08T model, and then it is assembled with the first guide pulley frame 252 to the cantilever arm 25. After assembling the cantilever arm 25, the ladder 4 on the operating transport ship 09 is hoisted into the engine room by the crane 06 in the engine room, and then the ladder 4 is installed on the first ladder mounting plate 14 and the second ladder mounting plate 22; After the ladder 4 is installed, when installing the auxiliary crane hoisting mechanism 3, first pass the steel wire rope on the winch 251 through the first guide pulley frame 252, connect the passed steel wire rope to all components of the auxiliary crane hoisting mechanism 3 on the operating transport ship 09, and the winch 251 cooperates with the traction winch mechanism 08 to traction and lift all components of the auxiliary crane hoisting mechanism 3 to the foundation platform at the bottom of the offshore wind turbine; After all components of the auxiliary crane hoisting mechanism 3 are hoisted to the foundation platform at the bottom of the offshore wind turbine, the auxiliary crane main mounting frame 31 is first hoisted into the cabin by the crane 06 in the cabin, and hoisted through the fifth lifting ring plate 371, and then the auxiliary crane main mounting frame 31 is hoisted into the cabin and installed on the second connecting seat 21, and the first rotary drum assembly 32 is aligned with the third connecting plate 24 and connected. After the fixing parts of the connection are installed, the auxiliary crane winch assembly 372, the first hydraulic station assembly 35, and the hook assembly 5 can be hoisted into the cabin in sequence, and then the wire rope is threaded on the auxiliary crane winch assembly 372 in the cabin; Using the same method, the auxiliary crane winch assembly 372 and the hook assembly 5 with the steel wire rope threaded are installed on the auxiliary crane boom 37 through the crane 06 in the cabin. The operator can climb to the top of the shell of the offshore wind turbine cabin body 01 through the ladder 4, and climb to the operating platform 34 to complete the installation of the auxiliary crane winch assembly 372, and then install the first hydraulic station assembly 35 on the operating platform 34. After the auxiliary lifting unit 02 is installed, the control cabinet wiring and the connection between the first hydraulic station assembly 35 and the first boom hydraulic drive assembly 36 can be completed, the auxiliary crane winch assembly 372 is energized, and the steel wire rope is tightened; Then, it is tested whether the first rotary drum assembly 32 is rotating normally when driven by the first driving assembly 33; S4. After installing the auxiliary lifting unit 02 and confirming that the test is correct, the auxiliary lifting unit 02 can be used to lift the various components of the main lifting unit 03 that cannot be lifted by the crane 06 in the cabin. Before lifting the main lifting unit 03, first remove the gear box limit units 05 located on both sides of the gear box body 04 for clamping the limit installation protrusions 0412, remove all the limit connection columns 054 on the upper installation plate 053, and then use the crane 06 in the cabin to lift the upper installation plate 053 to one side for placement. After disassembly and assembly are completed, ensure that only the installation plates 051 on both sides are installed in the gear box limit unit installation grooves 012 on both sides. At this time, the components of the main lifting unit 03 can be started to be lifted. When lifting all the components of the main lifting unit 03, the auxiliary lifting unit 02 is used to cooperate with the traction winch mechanism 08 to complete it; First, lift the main crane support base 6 into the cabin. During this process, first lift all the second support rods 64 and the third support rods 65 into the cabin through the auxiliary crane lifting mechanism 3, and then install all the second support rods 64 at the first support rod mounting hole 0141 in turn, and install the third support rod 65 at the mounting hole of the lower mounting plate 051. The nut used when installing the second support rod 64 is M48, and the nut used when installing the third support rod 65 is M42, and the torque is applied step by step. After all the installations are completed, the third connecting seat 61 can be lifted into the cabin through the sixth lifting ring plate 612 by the auxiliary crane lifting mechanism 3, the second support rod mounting foot 62 is installed at the second support rod 64, and the third support rod mounting foot 63 is installed at the third support rod 65. After fixing them with matching nuts, the main crane lifting mechanism 7 can be installed. When installing the main crane hoisting mechanism 7, the main crane main mounting frame 71 is first hoisted into the engine room through the auxiliary crane hoisting mechanism 3, and then the second hydraulic station assembly 75, the main crane winch assembly 762 and the steel wire rope required for the main crane winch assembly 762 are hoisted into the engine room in sequence; After all the components are hoisted into the cabin, the main crane main mounting frame 71 is first installed on the third connecting seat 61, and the fourth connecting plate 611 is aligned with the second rotary drum assembly 73 and then installed through the fixing components. Then, the operator in the cabin threads the steel wire rope on the main crane winch assembly 762, and then hoists the main crane winch assembly 762 with the steel wire rope to the main crane boom 76 for installation. Finally, the main crane winch assembly 762 is hoisted to the platform on one side of the main crane main mounting frame 71 for installation. After the installation of the main hoisting unit 03 is completed, the control cabinet wiring is completed, the second hydraulic station assembly 75 and the second boom hydraulic drive assembly 72 are connected, the main crane winch assembly 762 is powered on, and the second drive assembly 74 drives the second rotary drum assembly 73 to rotate normally. After the main crane winch assembly 762 is powered on, the wire rope is released. The main crane winch assembly 762 is pulled by two wire ropes. After the two wire ropes are released, they are wound around the third guide pulleys 81 on both sides of the third guide pulley frame 8 on the front side of the main crane boom 76, and then wound around the two fourth guide pulleys 91 on the second hook mechanism 9. Finally, the end of the wire rope is hung on the head of the main crane boom 76 boom frame. At this point, the main crane is installed. S5. Before using the main hoisting unit 03 to hoist the gearbox body 04, the auxiliary hoisting mechanism 3 is rotated by the first rotary drum assembly 32 so that the auxiliary hoisting mechanism 3 is rotated to a state parallel to the fan blades to facilitate the operation of the main hoist; When hoisting the gearbox body 04 out of the cabin of the offshore wind turbine cabin body 01, first set the jack below the gearbox body 04, then connect the lifting rope on the second lifting ring 92 to the first lifting ring hole plate 0411 and the second lifting ring hole plate 042, then the gearbox body 04 is separated from the fan blade connecting shaft 013 by the lifting of the main crane lifting mechanism 7 in cooperation with the jack, and after the gearbox body 04 is separated, connect the wire rope of the traction winch mechanism 08 to the gearbox body 04, and then use the main crane lifting mechanism 7 to cooperate with the auxiliary traction of the traction winch mechanism 08 to slowly move the gearbox body 04 out of the offshore wind turbine cabin body 01 and place it on the operation transport ship 09; After the gearbox body 04 is hoisted onto the operation transport ship 09, the gearbox body 04 can be disassembled and replaced with a new gearbox body 04. After the steel wire rope of the second hoisting ring 92 and the steel wire rope of the traction winch mechanism 08 are connected to the new gearbox body 04, the replaced gearbox body 04 can be hoisted into the cabin again through the main crane hoisting mechanism 7, and installed in the gearbox installation area 011, and then connected to the fan blade connecting shaft 013; After installing and replacing the new gearbox body 04, the main hoisting unit 03 can be disassembled, and the components disassembled from the main hoisting unit 03 are hoisted to the operation transport ship 09 through the auxiliary crane lifting mechanism 3 and the traction winch mechanism 08. After all the components of the main hoisting unit 03 are disassembled and placed on the operation transport ship 09, the gearbox limit unit 05 that was originally disassembled is reassembled to fix the gearbox body 04; S6. After the main lifting unit 03 is disassembled, the components of the auxiliary lifting unit 02 are removed from top to bottom in sequence through the crane 06 in the cabin and the traction winch mechanism 08, and placed on the operating transport ship 09. Finally, the protective shell on the outside of the offshore wind turbine cabin body 01 is lifted from the operating transport ship 09 and transported back to the cabin for installation through the crane 06 in the cabin. After the outer shell of the offshore wind turbine cabin body 01 is completely installed, the operator can evacuate from the offshore wind turbine cabin body 01, and then return to the operating transport ship 09, wait for the offshore wind turbine test to run normally, and then return to the port.

[0018] Among them, the wire rope is made of stainless steel, the weight of each component of the auxiliary lifting unit 02 is less than 1000kg, and the weight of each component of the main lifting unit 03 is less than 5000kg.

[0019] In addition, the torque value when installing the M52 nut in S3 is 8200N.M, the torque value when installing the M42 nut in S4 is 4200N.M, and the torque value when installing the M48 nut in S4 is 6300N.M.

[0020] Moreover, a cavity for installing the gearbox body 04 is provided inside the offshore wind turbine nacelle body 01, a gearbox installation area 011 for installing the gearbox body 04 is provided on the bottom wall of the offshore wind turbine nacelle body 01, and gearbox limiting unit installation grooves 012 are symmetrically provided on both sides of the gearbox installation area 011 of the offshore wind turbine nacelle body 01, and gearbox limiting units 05 are installed at the gearbox limiting unit installation grooves 012; A blade connecting shaft 013 is arranged on one side of the gear box installation area 011 inside the offshore wind turbine cabin body 01, a first shaft limit mounting frame 014 is installed at one end of the blade connecting shaft 013 inside the offshore wind turbine cabin body 01, and a second shaft limit mounting frame 015 is installed at the other end, a plurality of first support rod mounting holes 0141 are symmetrically opened on both sides of the first shaft limit mounting frame 014, a plurality of first support rod mounting holes 0141 are symmetrically opened on both sides of the second shaft limit mounting frame 015, and an auxiliary crane mounting port 016 is opened on the upper side of the second shaft limit mounting frame 015 of the offshore wind turbine cabin body 01.

[0021] At the same time, a gear box limit mounting plate 041 is provided at one end of the gear box main body 04, a first lifting ring hole plate 0411 is symmetrically provided on the upper part of the gear box limit mounting plate 041, and limit mounting protrusions 0412 for mounting on the gear box limit unit 05 are symmetrically provided on both sides of the gear box limit mounting plate 041, and a second lifting ring hole plate 042 is symmetrically provided on the upper part of the end of the gear box main body 04 away from the gear box limit mounting plate 041, and the limit mounting protrusions 0412 cooperate with the gear box limit unit 05 to limit the gear box main body 04.

[0022] An internal crane 06 is installed on the bottom wall of the inner cavity of the offshore wind turbine cabin body 01 and located on one side of the first limiting mounting frame 014 of the shaft.

[0023] The gearbox limiting unit 05 includes a lower mounting plate 051, which is mounted at the gearbox limiting unit mounting groove 012, a first gearbox mounting unit 052 is disposed in the middle of the upper surface of the lower mounting plate 051, and an upper mounting plate 053 is mounted above the lower mounting plate 051; A second gear box mounting unit 055 is arranged in the middle of the bottom surface of the upper mounting plate 053, and a plurality of limiting connecting columns 054 are symmetrically installed on both sides of the second gear box mounting unit 055 of the upper mounting plate 053, and a limiting mounting protrusion 0412 is installed between the second gear box mounting unit 055 and the first gear box mounting unit 052, and the mounting hole on the lower mounting plate 051 located on the side of the first gear box mounting unit 052 is used for the installation of the third support rod 65.

[0024] And the auxiliary hoisting unit 02 includes an auxiliary crane support base 1, an auxiliary crane middle connection mechanism 2, an auxiliary crane lifting mechanism 3, a ladder 4, and a hook assembly 5; The auxiliary crane support base 1 includes a first connecting seat 11, and first support rod mounting feet 12 are symmetrically arranged at the bottom of both ends of the first connecting seat 11, and a plurality of first support rods 13 are arranged at the bottom of the first support rod mounting feet 12, and a first ladder mounting plate 14 for mounting the ladder 4 is symmetrically arranged on the side wall of the central column of the first connecting seat 11; A first connection plate 111 is provided on the top of the first connection seat 11, the auxiliary crane middle connection mechanism 2 is installed on the first connection plate 111, and a plurality of third lifting ring orifice plates 112 are evenly provided on the inner wall of the middle column of the first connection seat 11; The auxiliary crane middle connection mechanism 2 includes a second connection seat 21, a third connection plate 24 is arranged on the top of the second connection seat 21, a second connection plate 23 is arranged on the bottom of the second connection seat 21, the second connection plate 23 is installed at the first connection plate 111, and a second ladder mounting plate 22 for mounting the ladder 4 is symmetrically arranged on the outer wall of the second connection seat 21, and a cantilever arm 25 is fixedly connected to the middle of the outer wall of the second connection seat 21; A first guide pulley frame 252 is provided at the end of the cantilever arm 25 away from the second connecting seat 21, a winch 251 is installed on the upper surface of the cantilever arm 25 and close to the second connecting seat 21, and a plurality of fourth hanging ring plates 26 are evenly arranged on the top of the inner wall of the second connecting seat 21 column.

[0025] Meanwhile, the auxiliary crane hoisting mechanism 3 includes an auxiliary crane main mounting frame 31, a first rotary drum assembly 32 is arranged at the bottom of the auxiliary crane main mounting frame 31, the first rotary drum assembly 32 is mounted on the third connecting plate 24, and a first driving assembly 33 for driving the first rotary drum assembly 32 to rotate is installed on one side of the bottom frame of the auxiliary crane main mounting frame 31; An auxiliary crane arm 37 is rotatably arranged on the top of the auxiliary crane main mounting frame 31, an operating platform 34 is arranged on one side of the auxiliary crane main mounting frame 31, and a first arm hydraulic driving component 36 for driving the auxiliary crane arm 37 to move is arranged on the other side of the auxiliary crane main mounting frame 31 away from the operating platform 34, the output end of the first arm hydraulic driving component 36 is connected to the bottom of the auxiliary crane arm 37, and a first hydraulic station component 35 is arranged on the operating platform 34; A plurality of fifth lifting ring holes 371 are evenly arranged in the middle of the upper surface of the auxiliary crane arm 37, an auxiliary crane winch assembly 372 is arranged on the upper surface of one end of the auxiliary crane arm 37 close to the auxiliary crane main mounting frame 31, and a hook assembly 5 is installed at one end of the auxiliary crane arm 37 away from the auxiliary crane main mounting frame 31; The hook assembly 5 comprises a second guide pulley frame 51 and a first hook mechanism 52, and the first hook mechanism 52 is connected to the second guide pulley frame 51 by winding a steel wire rope; The second guide pulley frame 51 is installed at the other end of the auxiliary crane arm 37 away from the auxiliary crane main mounting frame 31, and the second guide pulley frame 51 includes a first guide pulley 511 symmetrically arranged to rotate up and down, a first hook 522 is arranged at the bottom of the first hook mechanism 52, and a second guide pulley 521 is rotatably arranged on the first hook mechanism 52.

[0026] The main hoisting unit 03 includes a main hoist support base 6, a main hoist lifting mechanism 7, a third guide pulley frame 8, and a second hook mechanism 9. The main hoist support base 6 is installed at the first support rod mounting hole 0141 and the lower mounting plate 051; The main crane support base 6 includes a third connecting seat 61, a fourth connecting plate 611 for installing the main crane lifting mechanism 7 is arranged at the top of the central column of the third connecting seat 61, and a plurality of sixth lifting ring hole plates 612 are evenly arranged at the top of the inner wall of the central column of the third connecting seat 61; A second support rod mounting foot 62 is symmetrically arranged on one side of the bottom of the third connecting seat 61, and a third support rod mounting foot 63 is symmetrically arranged on the other side. A plurality of second support rods 64 are symmetrically installed at the bottom of the second support rod mounting foot 62, and the second support rod 64 is installed at the first support rod mounting hole 0141. A plurality of third support rods 65 are symmetrically installed at the bottom of the third support rod mounting foot 63, and the third support rod 65 is installed at the lower mounting plate 051. The main crane hoisting mechanism 7 comprises a main crane main mounting frame 71, a second rotary drum assembly 73 is arranged at the bottom of the main crane main mounting frame 71, the second rotary drum assembly 73 is installed at the fourth connecting plate 611, a second driving assembly 74 for driving the second rotary drum assembly 73 is installed on the bottom frame of the main crane main mounting frame 71, and a second hydraulic station assembly 75 is installed on a side plate of the main crane main mounting frame 71; A main crane arm 76 is rotatably arranged on the top of the main crane main mounting frame 71, and a second arm hydraulic drive assembly 72 for driving the main crane arm 76 to rotate is arranged on the main crane main mounting frame 71, and the top output end of the second arm hydraulic drive assembly 72 is connected to the bottom of the main crane arm 76; A plurality of seventh lifting eye hole plates 761 are symmetrically arranged in the middle of the upper surface of the main crane arm 76, and a main crane winch assembly 762 is installed on the upper surface of one end of the main crane arm 76 close to the main crane main mounting frame 71, and a third guide pulley frame 8 is arranged at the other end, and the third guide pulley frame 8 is connected to the second hook mechanism 9 through a wire rope.

[0027] Moreover, the third guide pulley frame 8 is symmetrically rotatably provided with a plurality of third guide pulleys 81 , the second hook mechanism 9 is symmetrically rotatably provided with a fourth guide pulley 91 , and the second hook mechanism 9 is provided with a second lifting ring 92 at the bottom of the fourth guide pulley 91 .

[0028] At the same time, when choosing to go out to sea for operations, you should choose wind speeds below level 5 and temperatures between -20℃ and 45℃.

[0029] In addition, the auxiliary hoisting unit 02 is first installed through the crane 06 in the cabin, and then the main hoisting unit 03 is installed by the auxiliary hoisting unit 02, so that the work of hoisting the 35t gearbox body 04 can be realized, ensuring that the hoisted components are within the safe lifting range of the hoisting equipment.

[0030] In the present invention, an auxiliary lifting unit 02 and a main lifting unit 03 are sequentially installed on the offshore wind turbine nacelle body 01, and then the gear box body 04 is lifted and replaced through the main lifting unit 03. In this way, the need for aerial replacement of the offshore wind turbine gearbox can be realized without the aid of a large wind power installation platform. When replacing the gearbox, the gear box body 04 only needs to be replaced with the cooperation of the operating transport ship 09, and there is no need to use a large ship for long-distance transportation. This can effectively reduce maintenance costs and make the construction period easy to control.

[0031] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A method for replacing an offshore wind turbine gearbox in mid-air, characterized in that: The steps include: S1. Initial configuration of equipment: Use the port crane to lift the modular lifting system components to the operating transport ship, and set up the traction winch mechanism and guide pulley mechanism on the operating transport ship; S2. Remove the external protective structure of the main body of the offshore wind turbine nacelle and use the crane inside the nacelle to lift it to the operating transport ship; S3. Install the auxiliary hoisting unit and the main hoisting unit in stages, and use the traction winch mechanism and the guide pulley mechanism to assist the traction and hoisting work throughout the process: a. The auxiliary crane support base is hoisted and installed, and the auxiliary crane support base is accurately positioned and installed on the second limit mounting frame of the shaft body through the first support rod mounting foot and the first support rod; b. Install the middle connection mechanism of the auxiliary crane, including the cantilever arm and its winch, and the first guide pulley frame, and install the auxiliary crane lifting mechanism through the cantilever arm; c. Assembly and debugging of auxiliary crane lifting mechanism; d. Use the auxiliary lifting unit to lift the components of the main lifting unit into the cabin, dismantle the gearbox limit unit, dismantle the upper mounting plate, the limit connecting column, and the second gearbox mounting unit, and accurately position the third support rod on the lower mounting plate; S4. Replacement of the gearbox: The disassembled old gearbox body is moved out of the engine room through the main lifting unit, and then the new gearbox body is lifted into the engine room through the main lifting unit, and the first gearbox installation unit is used to ensure the accurate installation position; S5. Dismantle the main hoisting unit and the auxiliary hoisting unit in sequence, use the crane inside the cabin to restore the protective structure, and complete the replacement of the gearbox.

2. A method for aerial replacement of an offshore wind turbine gearbox according to claim 1, characterized in that: A cavity for installing the gearbox body is provided inside the offshore wind turbine nacelle body, a gearbox installation area for installing the gearbox body is provided on the bottom wall of the offshore wind turbine nacelle body, and gearbox limiting unit installation grooves are symmetrically provided on both sides of the offshore wind turbine nacelle body located at the gearbox installation area, and gearbox limiting units are installed at the gearbox limiting unit installation grooves; A blade connecting shaft is arranged on one side of the gear box installation area inside the offshore wind turbine cabin main body, a first shaft limit mounting frame is installed at one end of the blade connecting shaft inside the offshore wind turbine cabin main body, and a second shaft limit mounting frame is installed at the other end, a plurality of first support rod mounting holes are symmetrically opened on both sides of the first shaft limit mounting frame, a plurality of second support rod mounting holes are symmetrically opened on both sides of the second shaft limit mounting frame, and an auxiliary crane mounting port is opened on the offshore wind turbine cabin main body above the second shaft limit mounting frame.

3. A method for aerial replacement of an offshore wind turbine gearbox according to claim 2, characterized in that: A gearbox limit mounting plate is arranged at one end of the gearbox body, a first lifting ring hole plate is symmetrically arranged on the upper part of the gearbox limit mounting plate, and limit mounting protrusions are symmetrically arranged on both sides of the gearbox limit mounting plate, and a second lifting ring hole plate is symmetrically arranged on the upper part of the other end of the gearbox body away from the gearbox limit mounting plate; An internal crane is installed on the bottom wall of the inner cavity of the offshore wind turbine cabin main body and located on one side of the first limiting mounting frame of the shaft body.

4. A method for aerial replacement of an offshore wind turbine gearbox according to claim 2, characterized in that: The gearbox limiting unit comprises a lower mounting plate, the lower mounting plate is mounted at the gearbox limiting unit mounting groove, a first gearbox mounting unit is arranged at the middle of the upper surface of the lower mounting plate, and an upper mounting plate is mounted above the lower mounting plate; A second gearbox mounting unit is arranged in the middle of the bottom surface of the upper mounting plate, a plurality of limit connecting columns are symmetrically installed on both sides of the second gearbox mounting unit, and the limit mounting protrusion is installed between the second gearbox mounting unit and the first gearbox mounting unit.

5. The method for aerial replacement of an offshore wind turbine gearbox according to claim 1, characterized in that: The auxiliary hoisting unit includes an auxiliary hoist support base, an auxiliary hoist middle connection mechanism, an auxiliary hoist lifting mechanism, a ladder and a hook assembly; The auxiliary crane support base includes a first connecting seat, and the bottom of the two side ends of the first connecting seat body is symmetrically provided with first support rod mounting feet, and the bottom of the first support rod mounting feet is provided with a plurality of first support rods, and the first ladder mounting plate for mounting the ladder is symmetrically provided on the side wall of the central column of the first connecting seat; A first connection plate is provided on the top of the first connection seat, the middle connection mechanism of the auxiliary crane is installed at the first connection plate, and a plurality of third lifting ring orifice plates are evenly provided on the inner wall of the middle column of the first connection seat; The auxiliary crane middle connection mechanism includes a second connection seat, a third connection plate is arranged on the top of the second connection seat, a second connection plate is arranged on the bottom of the second connection seat, the second connection plate is installed at the first connection plate, a second ladder mounting plate for mounting the ladder is symmetrically arranged on the outer wall of the second connection seat, and a cantilever arm is fixedly connected to the middle of the outer wall of the second connection seat; A first guide pulley frame is arranged at the end of one side of the cantilever arm away from the second connecting seat, a winch is installed on the upper surface of the cantilever arm and close to the second connecting seat, and a plurality of fourth hanging ring holes are evenly arranged on the top of the inner wall of the second connecting seat column.

6. A method for aerial replacement of an offshore wind turbine gearbox according to claim 5, characterized in that: The auxiliary crane hoisting mechanism comprises an auxiliary crane main mounting frame, a first rotary drum assembly is arranged at the bottom of the auxiliary crane main mounting frame, the first rotary drum assembly is mounted on the third connecting plate, and a first driving assembly for driving the first rotary drum assembly to rotate is installed on one side of the bottom frame of the auxiliary crane main mounting frame; An auxiliary crane boom is rotatably arranged on the top of the auxiliary crane main mounting frame, an operating platform is arranged on one side of the auxiliary crane main mounting frame, a first boom hydraulic drive assembly for driving the auxiliary crane boom to move is arranged on the other side of the auxiliary crane main mounting frame away from the operating platform, an output end of the first boom hydraulic drive assembly is connected to the bottom of the auxiliary crane boom, and a first hydraulic station assembly is arranged on the operating platform; A plurality of fifth lifting ring holes are evenly arranged in the middle of the upper surface of the auxiliary crane arm, an auxiliary crane winch assembly is arranged on the upper surface of one end of the auxiliary crane arm close to the auxiliary crane main mounting frame, and a hook assembly is installed at the other end of the auxiliary crane arm away from the auxiliary crane main mounting frame; The hook assembly comprises a second guide pulley frame and a first hook mechanism, wherein the first hook mechanism is connected to the second guide pulley frame by winding a steel wire rope; The second guide pulley frame is installed at the other end of the auxiliary crane arm away from the auxiliary crane main mounting frame, and the second guide pulley frame includes a first guide pulley symmetrically arranged for rotation up and down, a first hook is arranged at the bottom of the first hook mechanism, and a second guide pulley is rotatably arranged on the first hook mechanism.

7. A method for aerial replacement of an offshore wind turbine gearbox according to claim 1, characterized in that: The main hoisting unit comprises a main hoist support base, a main hoist lifting mechanism, a third guide pulley frame, and a second hook mechanism, wherein the main hoist support base is installed at the first support rod mounting hole and the lower mounting plate; The main crane support base includes a third connecting seat, a fourth connecting plate for installing the main crane lifting mechanism is arranged on the top of the central column of the third connecting seat, and a plurality of sixth lifting ring hole plates are evenly arranged on the top of the inner wall of the central column of the third connecting seat; A second support rod mounting foot is symmetrically arranged on one side of the bottom of the third connecting seat body, and a third support rod mounting foot is symmetrically arranged on the other side, a plurality of second support rods are symmetrically installed on the bottom of the second support rod mounting foot, the second support rod is installed at the first support rod mounting hole, a plurality of third support rods are symmetrically installed on the bottom of the third support rod mounting foot, and the third support rod is installed at the lower mounting plate; The main crane hoisting mechanism comprises a main crane main mounting frame, a second rotary drum assembly is arranged at the bottom of the main crane main mounting frame, the second rotary drum assembly is installed at the fourth connecting plate, a second driving assembly for driving the second rotary drum assembly is installed on the bottom frame of the main crane main mounting frame, and a second hydraulic station assembly is installed on a side plate of the main crane main mounting frame; A main crane boom is rotatably arranged on the top of the main crane main mounting frame, and a second boom hydraulic drive assembly for driving the main crane boom to rotate is arranged on the main crane main mounting frame, and the top output end of the second boom hydraulic drive assembly is connected to the bottom of the main crane boom; A plurality of seventh lifting eye hole plates are symmetrically arranged in the middle part of the upper surface of the main crane arm, a main crane winch assembly is installed on the upper surface of one end of the main crane arm close to the main mounting frame of the main crane, and a third guide pulley frame is arranged at the other end, and the third guide pulley frame is connected to the second hook mechanism through a steel wire rope.

8. A method for aerial replacement of an offshore wind turbine gearbox according to claim 7, characterized in that: The third guide pulley frame is provided with a plurality of third guide pulleys symmetrically rotating up and down, the second hook mechanism is provided with a fourth guide pulley symmetrically rotating up and down, and the second hook mechanism is provided with a second lifting ring at the bottom of the fourth guide pulley.

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