Method for repairing bearing pedestal of wind turbine generator on tower
By using a combination of jacking components and pads in wind turbine units, in-situ repair of wind turbine bearing housings was achieved, solving the problem of axial positioning failure of the transmission chain, significantly reducing downtime and cost, and ensuring positioning accuracy.
Patent Information
- Application Number
- CN202511771362.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-28
- Publication Date
- 2026-01-06
AI Technical Summary
During the operation of wind turbine units, the outer ring of the rear bearing and the mating surface of the rear bearing housing are prone to slippage, which leads to friction and wear on the end face of the stop, resulting in failure of the axial positioning of the transmission chain. The entire unit needs to be removed from the tower for replacement, which is time-consuming and costly.
The first and second jacking components are arranged in the wind turbine. By controlling their extension and retraction, the main shaft and bearing are moved forward and backward to form a preset gap. A pad is fixed at the stop, and the bearing housing is repaired in situ by combining threaded holes and screws.
No need to remove the tower to replace the drive chain, the repair time is shortened to less than 3 days, the cost is reduced by more than 95%, the bearing outer ring and stop fit accuracy is ensured, the axial positioning error is less than 0.1mm, and the positioning accuracy of the drive chain is restored.
Smart Images
Figure CN121273571A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of wind turbine maintenance technology, specifically to a method for repairing wind turbine bearing seats on towers. Background Technology
[0002] During wind turbine operation, slippage is prone to occur on the mating surface between the outer ring of the rear bearing and the rear bearing housing. This causes relative movement between the end face of the outer ring and the stop face of the rear bearing housing, leading to frictional wear on the stop face. When the wear on the stop face becomes severe, it can cause the entire drivetrain's axial positioning to fail. In this case, the entire drivetrain must be removed from the tower, and the main shaft sleeve must be disassembled and replaced. This replacement operation takes 7-10 days and costs over 500,000 yuan per instance, severely impacting the unit's normal operating efficiency and imposing a high maintenance cost burden. Summary of the Invention
[0003] The purpose of this application is to provide a method for repairing wind turbine bearing housings on the tower, which enables the bearing housings to be repaired without having to be taken off the tower.
[0004] To achieve the above objectives, the technical solution adopted in this application is as follows: In a first aspect, this application discloses a method for repairing the bearing seat of a wind turbine tower, comprising: A first jacking assembly is arranged between the front bearing housing and the wind turbine locking disc, and a second jacking assembly is arranged between the rear bearing housing and the torque arm of the gearbox. The wind turbine locking disc is connected to the gearbox via a main shaft, and the main shaft is connected to the bearings in the front and rear bearing housings respectively. The first pushing component is extended and the second pushing component is shortened, so that the main shaft and the bearing connected to the main shaft move forward, forming a preset gap between the outer ring of the bearing and the stop of the bearing seat. A shim is fixed on the side of the stop near the outer ring of the bearing, and the thickness of the shim is determined according to the actual wear of the stop. The second push assembly is extended while the first push assembly is shortened, causing the spindle and the bearing connected to the spindle to move backward and reset.
[0005] Furthermore, the number of pads is multiple, and the multiple pads are evenly arranged along the circumferential direction of the stop.
[0006] Furthermore, after the spindle and the bearing connected to the spindle are moved back to their original positions, the method further includes: machining multiple threaded holes around the end face of the stop, the positions of the threaded holes corresponding to the positions of the pad, and the threaded holes penetrating the bearing seat stop to the pad, with the ends not exceeding the end face of the pad near the bearing; and using screws to connect with the threaded holes and tighten them to achieve a fixed connection between the pad and the bearing seat stop.
[0007] Furthermore, when controlling the first jacking component to extend and the second jacking component to shorten, or when controlling the second jacking component to extend and the first jacking component to shorten, the displacement of the left and right sides of the main shaft is monitored in real time by a dial indicator to ensure synchronization; there are two dial indicators, which are respectively fixed on the left and right sides of the front bearing seat, and the dial indicator head is in perpendicular contact with and abuts against the rear side of the wind turbine locking plate.
[0008] Furthermore, when the main shaft and the bearing connected to the main shaft move forward to the target position, a support structure is fixed between the front bearing housing and the impeller locking disc to prevent the main shaft from moving backward.
[0009] Furthermore, before fixing the pad to the side of the stop near the outer ring of the bearing, the process includes: cleaning the end face of the stop and applying a metal repair agent, installing the pad coated with the metal repair agent to the side of the stop near the outer ring of the bearing and clamping it in place, and completing the initial fixing of the pad after the metal repair agent has cured.
[0010] Furthermore, the first jacking assembly includes two first hydraulic jacks, and the second jacking assembly includes two second hydraulic jacks; the two first hydraulic jacks are symmetrically arranged on the left and right sides of the main shaft and are correspondingly installed on the left and right sides of the front bearing seat; the two second hydraulic jacks are symmetrically arranged on the left and right sides of the main shaft and are correspondingly installed on the left and right sides of the rear bearing seat.
[0011] This application has the following unexpected and beneficial effects: 1. The repair method provided in this application eliminates the need to remove the entire transmission chain from the tower and replace the main shaft sleeve, avoiding the lengthy 7-10 day construction period of traditional solutions. Repair time is reduced to less than 3 days, significantly reducing unit downtime losses. Furthermore, it eliminates the high costs of tower removal and component replacement, keeping the cost of a single repair below 20,000 yuan, a cost reduction of over 95% compared to traditional solutions (over 500,000 yuan).
[0012] 2. This application customizes the pad thickness based on the actual wear of the stop, and combined with the synchronous displacement control of the first and second jacking components, it can achieve millimeter-level wear compensation, ensure the fitting accuracy between the bearing outer ring and the stop, and the axial positioning error is less than 0.1mm, thus restoring the original positioning accuracy of the transmission chain.
[0013] 3. The pad described in this application adopts a dual fixing method of initial fixing with metal repair agent and mechanical locking with screws. Combined with the surface treatment process of the stop end face, it ensures that the pad and the stop are firmly connected, avoids loosening or displacement during use, and improves the wear resistance and impact resistance of the repaired part. Attached Figure Description
[0014] To more clearly illustrate the specific embodiments of this application or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application.
[0015] Figure 1 A schematic flowchart illustrating the method for repairing wind turbine bearing housings on towers, as provided in this application embodiment.
[0016] Figure 2 This is a schematic diagram of the wind turbine drive train provided in an embodiment of this application.
[0017] Figure 3 This is a schematic diagram illustrating the disassembly of the cover plate provided in an embodiment of this application.
[0018] Figure 4 A schematic diagram showing the arrangement of the first and second jacking components provided in the embodiments of this application.
[0019] Figure 5 This is a schematic diagram showing the state of the spindle and the bearing connected to the spindle as provided in the embodiments of this application when they are moved to the target position.
[0020] Figure 6 This is a schematic diagram of the installation of the pad provided in an embodiment of this application.
[0021] Figure 7 This is a schematic diagram showing the distribution of threaded holes provided in an embodiment of this application.
[0022] Figure 8 This is a schematic diagram of screw installation provided in an embodiment of this application.
[0023] In the diagram, 1-front bearing housing, 2-rear bearing housing, 3-wind turbine locking disc, 4-gearbox, 41-torsion arm, 5-main shaft, 6-bearing, 7-first jacking assembly, 8-second jacking assembly, 9-stop, 10-pad, 11-threaded hole, 12-screw, 13-dial indicator, 14-support structure, 15-end cover, 16-sleeper, 17-metal repair agent. Detailed Implementation
[0024] The embodiments of this application will be described below with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. This application can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be understood that the preferred embodiments are only for illustrating this application and are not intended to limit the scope of protection of this application.
[0025] In one embodiment, see Figure 1 As shown, this application provides a method for repairing the bearing seat of a wind turbine tower, which includes: See Figure 2 and Figure 4 As shown, a first jacking assembly 7 is arranged between the front bearing housing 1 and the impeller locking disc 3, and a second jacking assembly 8 is arranged between the rear bearing housing 2 and the torque arm 41 of the gearbox 4. The impeller locking disc 3 is connected to the gearbox 4 via a main shaft 5, that is, the impeller locking disc 3 is fixed on the main shaft 5, the main shaft 5 is connected to the gearbox 4, and the main shaft 5 is correspondingly connected to the bearings 6 in the front bearing housing 1 and the rear bearing housing 2.
[0026] By controlling the first pushing component 7 to extend and the second pushing component 8 to shorten, the main shaft 5 and the bearing 6 connected to the main shaft 5 move forward, forming a preset gap between the outer ring of the bearing 6 and the stop 9 of the bearing seat, thus providing operating space for the subsequent fixing of the pad 10.
[0027] A pad 10 is fixed on the side of the stop 9 near the outer ring of the bearing 6. The thickness of the pad 10 is determined according to the actual wear of the stop 9, thus achieving precise compensation for the wear.
[0028] The second push assembly 8 is extended while the first push assembly 7 is shortened, causing the main shaft 5 and the bearing 6 connected to the main shaft 5 to move back to their original positions, ensuring that the outer ring of the bearing 6 is in close contact with the pad 10.
[0029] The repair method provided in this embodiment achieves smooth forward movement and repositioning of the shaft system (main shaft 5 and bearing 6) through the coordinated operation of the first jacking component 7 and the second jacking component 8. Combined with the customized pad 10, the bearing seat stop 9 is repaired in situ, which has significant technical advantages: it eliminates the need to remove the entire transmission chain from the tower and replace the main shaft sleeve, avoiding the long construction period of 7-10 days in the traditional solution, shortening the repair time to less than 3 days, and greatly reducing unit downtime losses; it saves the high costs of tower hoisting and component replacement, and the cost of a single repair can be controlled below 20,000 yuan, which is more than 95% lower than the cost of the traditional solution (over 500,000 yuan). At the same time, the thickness of the customized pad 10 is based on the actual wear of the stop 9, and with the synchronous displacement control of the first jacking component 7 and the second jacking component 8, millimeter-level wear compensation can be achieved, ensuring the fitting accuracy between the outer ring of the bearing 6 and the stop 9, with an axial positioning error of less than 0.1mm, effectively restoring the original positioning accuracy of the transmission chain and ensuring stable operation of the unit.
[0030] Furthermore, when performing the shaft system rearward repositioning, observe whether the outer ring end face of the rear bearing 6 and the added pad 10 inside the stop 9 of the rear bearing housing 2 fit tightly. Use a 0.1mm feeler gauge to check along the circumference. If 60% cannot be inserted, it means that the requirement is met. When the outer ring end face of the bearing 6 and the pad 10 inside the stop 9 are completely fitted tightly, the first push assembly 7 at the front bearing housing 1 is completely depressurized and removed.
[0031] Measure and record the positions of the locking pins on the left and right sides of the front bearing housing 1 and the distance between the end face of the front bearing housing 1 and the wind turbine locking plate 3. Reset the elastic support pads and mounting bolts to their original installation positions. Remove the jack and sleepers between the rear bearing housing 2 and the torque arm 41, and the dial indicator at the front bearing housing 1.
[0032] In a preferred embodiment of this invention, there are multiple pads 10, which are evenly arranged along the circumference of the stop 9. The evenly arranged multiple pads 10 can distribute the axial force transmitted by the outer ring of the bearing 6 to various points around the circumference of the stop 9, avoiding overload on a single pad 10 that could lead to deformation or increased wear, and ensuring the stability of the transmission chain after repair.
[0033] For example, the number of pads 10 is preferably 8 to 12, and they are evenly distributed at equal angles along the circumference of the stop 9. The central angle error between adjacent pads 10 does not exceed ±1°, so as to ensure the uniformity of force on each pad 10.
[0034] As a preferred embodiment of this example, see Figure 7 and Figure 8 As shown, after the spindle 5 and the bearing 6 connected to the spindle 5 are moved back to their original positions, the method further includes: machining multiple threaded holes 11 on the circumference of the end face of the stop 9, the positions of the threaded holes 11 corresponding to the positions of the pad 10, and the threaded holes 11 penetrating the bearing seat stop 9 to the pad 10, with the ends not exceeding the end face of the pad 10 near the bearing 6; and using screws 12 to connect with the threaded holes 11 and tighten them to achieve a fixed connection between the pad 10 and the bearing seat stop 9.
[0035] In this preferred embodiment, the mechanical locking of the threaded hole 11 and the screw 12, combined with the chemical bonding of the metal repair agent 17, forms a dual fixing structure that combines chemical and mechanical properties. This significantly improves the connection strength between the pad 10 and the stop 9, effectively resists the risk of loosening caused by vibration and impact during unit operation, and ensures the long-term stability of the repaired part.
[0036] Among them, thread hole processing and screw installation do not require large equipment and can be completed with portable tools, which meets the needs of working in the narrow space on the tower. The steps are clear and easy to operate, without adding extra workload to the operation and maintenance personnel.
[0037] For example, the number of threaded holes 11 is the same as the number of pads 10, preferably 8 to 12, and they are evenly distributed along the circumference of the stop 9. The threaded holes 11 are drilled to a depth of 28 mm and tapped to a depth of 25 mm, using M8 thread. The screws 12 are internal hexagonal set screws (model M8×25). Before assembly, thread-locking agent is applied to the surface of the screws 12. After tightening, the tail end of the screws 12 does not extend beyond the outer surface of the bearing seat stop 9 to avoid interfering with the operation of the bearing.
[0038] When drilling, cover the bearing with a clean cloth to protect it and prevent metal shavings from entering the bearing raceway.
[0039] As a preferred embodiment of this example, see Figure 4 As shown, when the first jacking component 7 is extended and the second jacking component 8 is shortened (i.e., the main shaft 5 moves forward), or when the second jacking component 8 is extended and the first jacking component 7 is shortened (i.e., the main shaft 5 moves backward to reset), the displacement of the left and right sides of the main shaft 5 is monitored in real time by a dial indicator 13 to ensure synchronization. There are two dial indicators 13, which are fixed on the left and right sides of the front bearing seat 1, respectively. The dial indicator heads of the dial indicators 13 are in perpendicular contact with the rear side of the wind turbine locking plate 3 and abut against it to ensure accurate monitoring data.
[0040] By using dial indicators 13 on both sides for real-time synchronous monitoring, the displacement deviation on both sides during the forward / reset of the spindle 5 can be accurately controlled, ensuring that the deviation is ≤0.1mm. This effectively avoids secondary damage such as bearing 6 jamming and transmission chain coaxiality failure caused by shaft misalignment, laying the foundation for subsequent repair accuracy.
[0041] The dial indicator 13 has a monitoring accuracy of up to 0.01 mm. Combined with the smooth adjustment of the first jacking component 7 or the second jacking component 8, it can achieve fine control of shaft displacement, accurately match the millimeter-level wear compensation of the pad, and ensure that the outer ring of the bearing 6 fits tightly with the pad 10, thus meeting the axial positioning accuracy requirements.
[0042] For example, the dial indicator 13 is a magnetic base dial indicator with a range of 0~10mm and an accuracy of 0.01mm. During installation, ensure that the magnetic base is firmly attached, the indicator head is perpendicular to the rear side of the wind turbine locking plate 3, and the preload is 0.5~1mm. During displacement adjustment, the difference in readings between the two dial indicators must be kept ≤0.05mm. If the difference exceeds this value, the extension / retraction speed of the corresponding push assembly must be adjusted immediately until synchronization is achieved.
[0043] As a preferred embodiment of this example, see Figure 5As shown, when the main shaft 5 and the bearing 6 connected to the main shaft 5 move forward to the target position, a fixed support structure 14 is formed between the front bearing seat 1 and the wind turbine locking plate 3 to form a rigid limit, preventing the main shaft 5 from accidentally moving backward during subsequent operations such as the installation of the pad block 10 and the curing of the metal repair agent 17.
[0044] The support structure 14 forms a reliable axial limit, which can effectively counteract the backward movement caused by the weight of the main shaft 5 and slight vibration of the unit, avoid changes in the already adjusted gap, eliminate the need to continuously maintain the pressure of the first jacking component 7, and reduce operational risks.
[0045] For example, the support structure 14 is preferably a combination of two symmetrically arranged sleepers and metal pads. Each support structure is symmetrically distributed between the front bearing seat 1 and the impeller locking plate 3 along the axis of the main shaft 5, and the support structure 14 and the contact surface must fit tightly without any loose gaps. After installation, the stability of the support structure 14 needs to be checked to ensure that the main shaft 5 does not move axially and does not affect the normal monitoring of the dial indicator 13 and the subsequent adjustment operation of the jacking assembly.
[0046] In a preferred embodiment of this invention, before fixing the pad 10 to the side of the stop 9 near the outer ring of the bearing 6, the method further includes: (See below) Figure 6 As shown, the end face of the stop 9 is first thoroughly cleaned to remove surface oil, rust and impurities, ensuring that the repair surface is clean and dry. Then, metal repair agent 17 is evenly applied to the end face of the stop 9 and the mating surface of the pad 10. The pad 10 coated with metal repair agent 17 is then precisely installed on the side of the stop 9 near the outer ring of the bearing 6 and clamped in place. After the metal repair agent 17 has completely cured, the initial fixation between the pad 10 and the stop 9 is completed.
[0047] In this preferred embodiment, the cleaning process eliminates the influence of impurities on the surface of the stop 9 on the bonding effect. The metal repair agent 17 fills the tiny gaps between the stop 9 and the pad 10, forming a tight chemical bond structure, providing a stable foundation for subsequent mechanical locking and preventing loosening during long-term operation. The metal repair agent combines filling and bonding properties, further compensating for microscopic surface defects after wear on the stop 9, resulting in a tighter fit between the pad 10 and the end face of the stop 9. Combined with the precisely customized thickness of the pad 10, this improves the accuracy of millimeter-level wear compensation.
[0048] Specifically, the end face of stop 9 is cleaned using a combination of soaking in a high-efficiency cleaning agent and wiping with a brush. After cleaning, it is wiped a second time with anhydrous ethanol to ensure that the surface is free of oil and residue. Metal repair agent 17 is a wear-resistant industrial metal repair agent, with a coating thickness controlled between 0.1 and 0.3 mm, and it must evenly cover the entire bonding surface without bubbles or missed areas. Spacer 10 is temporarily fixed using a special clamp or wooden wedge. During the curing process, a hot air gun is used to circulate heat around stop 9 to accelerate curing efficiency, ensuring that the curing time does not exceed 2 hours. After curing, spacer 10 is checked to ensure it is not loose or displaced.
[0049] In a preferred embodiment of this invention, the first jacking assembly 7 includes two first hydraulic jacks, and the second jacking assembly 8 includes two second hydraulic jacks; the two first hydraulic jacks are symmetrically arranged on the left and right sides of the main shaft 5 and are correspondingly installed on the left and right sides of the front bearing seat 1; the two second hydraulic jacks are symmetrically arranged on the left and right sides of the main shaft 5 and are correspondingly installed on the left and right sides of the rear bearing seat 2.
[0050] In this preferred embodiment, the symmetrically arranged double jack structure enables the jacking force to be applied evenly to both sides of the shaft system, effectively avoiding secondary damage such as spindle bending and bearing jamming caused by excessive force on one side, and ensuring a smooth and stable process of shaft system forward movement / reset.
[0051] Specifically, the first hydraulic jack is a 30t-50t specification, and the second hydraulic jack is a 20t specification, both equipped with pressure stabilizing devices. During installation, ensure that the jack base and bearing seat end face are tightly fitted, and that the jack rod axis is parallel to the main shaft axis 5. See [link / reference]. Figure 4 As shown, to prevent the jack rod from damaging the wind turbine locking plate or the torque arm, sleepers 16 are arranged between the jack rod and the wind turbine locking plate 3, and between the jack rod and the torque arm 41. During the jacking process, the pressure / depression speed of the two jacks in the same component is kept consistent to ensure synchronous extension and contraction.
[0052] Furthermore, before performing the repair, see Figure 2 As shown, remove the two cover plates 15 of the front bearing housing 1 and the rear bearing housing 2, and place the removed cover plates 15 on the spindle 5. Be careful to protect the paint surface of the spindle 5 with a soft cloth. The rear cover plate 15 of the rear bearing housing 2 should be placed close to the expansion sleeve of the gearbox 4, leaving as much space as possible for future operations. After removing the cover plates, loosen the elastic support mounting bolts on both sides of the torque arm 41 of the gearbox 4 one by one.
[0053] The embodiments of this application have been described in detail above with reference to the accompanying drawings. However, this application is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this application. Furthermore, unless otherwise specified, the embodiments and features described in the embodiments of this application can be combined with each other.
Claims
1. A method of on-site repair of a wind turbine generator bearing pedestal, characterized in that, The utility model relates to a wind turbine bearing seat and gear box torsion arm locking device, comprising: A first pushing assembly is arranged between the front bearing seat and the wind wheel locking disc, and a second pushing assembly is arranged between the rear bearing seat and the torsion arm of the gear box, the wind wheel locking disc is drivingly connected with the gear box through a main shaft, and the main shaft is correspondingly connected with bearings in the front bearing seat and the rear bearing seat; The first pushing assembly is controlled to be elongated, the second pushing assembly is controlled to be shortened, the main shaft and the bearings connected with the main shaft are moved forward, and a preset gap is formed between the outer ring of the bearing and the stopper of the bearing seat; A spacer is fixed on the side of the stopper close to the outer ring of the bearing, and the thickness of the spacer is determined according to the actual wear of the stopper; The second pushing assembly is controlled to be elongated, and the first pushing assembly is controlled to be shortened, so that the main shaft and the bearings connected with the main shaft are moved backward to reset.
2. The on-shaft repair method of a wind turbine main shaft bearing housing according to claim 1, characterized in that: The number of the spacers is multiple, and the multiple spacers are uniformly arranged along the circumferential direction of the stopper.
3. The on-shaft repair method of a wind turbine main shaft bearing housing according to claim 2, characterized in that: After the main shaft and the bearings connected with the main shaft are moved backward to reset, a plurality of threaded holes are formed on the circumferential direction of the end face of the stopper, the positions of the threaded holes correspond to the positions of the spacers, the threaded holes penetrate through the stopper of the bearing seat to the spacers, and the end face of the end portion does not exceed the end face of the side of the spacer close to the bearing; a screw is connected with the threaded hole and is screwed, so that the spacer and the stopper of the bearing seat are fixedly connected.
4. The on-shaft repair method of a wind turbine main shaft bearing housing according to claim 1, characterized in that: When the first pushing assembly is controlled to be elongated and the second pushing assembly is controlled to be shortened, or when the second pushing assembly is controlled to be elongated and the first pushing assembly is controlled to be shortened, the displacement of the left and right sides of the main shaft is monitored in real time by using a dial gauge to ensure synchronization. The number of the dial gauges is two, the left and right sides of the front bearing seat are respectively fixed with the two dial gauges, and the heads of the dial gauges are vertically contacted and abutted with the rear side of the wind wheel locking disc.
5. The on-shaft repair method of a wind turbine main shaft bearing housing of claim 1, wherein: When the main shaft and the bearings connected with the main shaft are moved forward to the target position, a supporting structure is fixed between the front bearing seat and the wind wheel locking disc to prevent the main shaft from moving backward.
6. The on-shaft repair method of a wind turbine main shaft bearing housing of claim 1, wherein: Before the spacer is fixed on the side of the stopper close to the outer ring of the bearing, the end face of the stopper is cleaned and coated with a metal repair agent, the spacer coated with the metal repair agent is installed on the side of the stopper close to the outer ring of the bearing and is clamped, and the preliminary fixation of the spacer is completed after the metal repair agent is solidified.
7. The on-shaft repair method of a wind turbine main shaft bearing housing of claim 1, wherein: The first pushing assembly comprises two first hydraulic jacks, and the second pushing assembly comprises two second hydraulic jacks. The two first hydraulic jacks are symmetrically arranged on the left and right sides of the main shaft and are correspondingly installed on the left and right sides of the front bearing seat. The two second hydraulic jacks are symmetrically arranged on the left and right sides of the main shaft and are correspondingly installed on the left and right sides of the rear bearing seat.