Replacement system for internal parts of hub of wind generating set and use method of replacement system

Abstract

The invention discloses a wind generating set hub internal part replacement system and a use method thereof, and belongs to the field of wind generating set tools. The system comprises a support frame and a platform, a screw sleeve is arranged at one end of the support frame and is used for sleeving and locking the connecting bolt; the platform is arranged at the other end of the supporting frame and used for installing hoisting equipment such as a winch. The method comprises the steps that the supporting frame is installed on the connecting bolts, and a platform is built; a winch is mounted on the platform; fixed anchor points with fixed pulleys are arranged on the inner wall or the outer wall of the upper part of the hub; and a winch steel wire rope bypasses the fixed pulley to vertically hoist the component. Existing high-strength bolts in the hub serve as a force bearing foundation, an internal operation and hoisting system is constructed, and disassembly-free wind wheel replacement of core components such as a variable-pitch gearbox is achieved. Depending on a large external crane is eliminated, and the method has the advantages of being low in operation cost, short in period, high in safety, free of limitation of external site environment, modularized in tool, high in universality and the like.

Description

Technical Field

[0001] This invention relates to the field of tooling technology for wind turbine generator sets, specifically to a system for replacing internal components of a wind turbine generator hub and its usage method. Background Technology

[0002] Direct-drive wind turbines are widely used due to their simple structure and high reliability. Their hubs integrate important components such as pitch gearboxes, pitch control cabinets, and external fairings (including the fairing top cover). When these components fail, the limited operating range and insufficient rated load of the cranes built into the nacelle prevent direct lifting and replacement of heavy components. Current technology, except for some components that can be disassembled into smaller parts, generally employs a method of using a large ground crane to first disassemble and lift the entire wind turbine (including the hub and blades), weighing tens of tons, to the ground. Then, the faulty components are replaced on the ground, and finally, the entire turbine is lifted and reassembled. This operating mode has significant drawbacks: firstly, the daily rental and operation costs of large cranes are high, typically reaching tens of thousands of yuan; secondly, the disassembly and installation process is complex, resulting in downtime of 4 to 6 days per unit, causing significant power generation losses; and thirdly, the total cost is often as high as 200,000 to 300,000 yuan, making it uneconomical. Furthermore, this method is severely limited by on-site geographical and meteorological conditions. For example, the site must meet the requirements for crane operating space and foundation, and continuous low wind speeds are required during operation. This makes implementation extremely difficult or even impossible in special sites such as mountainous areas and offshore locations. Therefore, there is an urgent need for an efficient and low-cost operating solution that allows for component replacement directly inside the hub without disassembling the wind turbine. Summary of the Invention

[0003] The present invention aims to overcome the shortcomings of the prior art and provide a system for replacing internal components of a wind turbine hub and its usage method.

[0004] The technical solution adopted in this invention is as follows: A system for replacing internal components of a wind turbine hub includes: a support frame and a platform; One end of the support frame is set as a threaded sleeve, which is fitted onto the end of the connecting bolt connecting the hub and the generator, and locked with a nut; The platform is located at the other end of the support frame and is equipped with lifting equipment for hoisting components.

[0005] Furthermore, the support frame comprises multiple supports, each mounted on a different connecting bolt.

[0006] Furthermore, the multiple support frames include straight braces and diagonal braces. The straight braces directly support one side of the platform via connecting bolts, while the diagonal braces support the side of the platform away from the connecting bolts, thus keeping the platform stable in the axial direction of the wheel hub.

[0007] Furthermore, the lifting equipment includes winches and fixed anchor points.

[0008] Furthermore, the fixed anchor point is set on the upper inner or outer wall of the hub and is equipped with a fixed pulley for lifting the inner components of the hub or the components below the anchor point.

[0009] Furthermore, the platform is detachably connected to the support frame by bolts, and the winch is detachably fixed to the platform by bolts.

[0010] Furthermore, multiple fixed anchor points are provided to match different stopping angles of the wheel hub and different orientation components.

[0011] Furthermore, the platform has a diagonal anchor point on the side of the hub near the connecting bolt in the axial direction.

[0012] Furthermore, a method for using a wind turbine hub internal component replacement system includes the following steps: S1: Install a support frame on the generator connecting bolt inside the hub. One end of the support frame is provided with a threaded sleeve, which is fitted onto the connecting bolt and locked with a nut. S2: Build a platform at the other end of the support frame; S3: Install lifting equipment on the platform; S4: Set fixed anchor points inside the wheel hub and configure a pulley system; S5: Using lifting equipment and pulley blocks, the internal components of the wheel hub are lifted and replaced.

[0013] Furthermore, the lifting equipment is a winch; During hoisting, the winch's wire rope passes through the pulley block, with its free end extending vertically downwards and connecting to the component to be replaced; the component is lifted and lowered by operating the winch.

[0014] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: Reduced operating costs and time: This system integrates the entire operation scenario into the wheel hub, eliminating reliance on large ground-based crawler cranes or truck cranes. By utilizing the readily available high-strength load-bearing structure of the wheel hub and generator connection bolts, an internal operating platform and lifting system are built. This transforms complex operations that previously required disassembling the entire wind turbine, using large cranes, taking 4-6 days, and costing 200,000-300,000 yuan, into standardized procedures completed directly inside the wheel hub. Operation time can be shortened to 1-2 days, with the main costs being tooling and labor. The overall cost per operation is significantly reduced, resulting in substantial economic benefits.

[0015] Enhancing operational safety and reliability: The system adopts a modular and detachable design, allowing all components to be transported through the engine room passageway. Installation eliminates the need for high-risk operations such as hot work and welding. The support frame is bolted to the main structure using specialized threaded sleeves, ensuring reliable load-bearing capacity and effectively protecting the threads of critical bolts from damage. Internally designed fixed anchor points and pulley systems ensure controllable lifting paths and precise vertical lifting force, preventing the risk of components being pulled at an angle or colliding in confined spaces, thus improving the safety and controllability of the operation.

[0016] Traditional large crane operations are limited by wind speed, ground bearing capacity, site space, and high access costs. This solution is not constrained by these external conditions and can be carried out at any time when the wind turbine is normally shut down. It is especially suitable for wind farms in mountainous areas, offshore areas, and areas with complex terrain where crane access is difficult or the operating costs are extremely high, thus enhancing the responsiveness and flexibility of wind turbine operation and maintenance.

[0017] The core components of the system, including the support frame, platform, and winch, all utilize standardized interfaces and detachable connections. By adjusting the number and length of the support frame and the specifications of the platform, it can be quickly adapted to the hub structures of different direct-drive wind turbine models, achieving tooling standardization. Furthermore, after component replacement, the platform can be converted into a fully functional aerial work platform for inspection, cleaning, maintenance, and other operations inside the hub, improving the overall utilization rate of the equipment and enabling rapid deployment and efficient reuse. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall decorative structure of the present invention; Figure 2 This is a schematic diagram of the connecting bolts and platform structure of the present invention; Figure 3 This is a partial structural diagram of the present invention.

[0019] Marked in the image: 1-Support frame; 2-Platform; 3-Screw sleeve; 4-Connecting bolt; 5-Nut; 6-Lifting equipment; 7-Straight brace; 8-Diagonal brace; 9-Winch; 10-Fixed anchor point; 11-Wheel hub; 12-Diagonal anchor point. Detailed Implementation

[0020] The present invention will now be described in detail with reference to the accompanying drawings.

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0022] Example 1 In this embodiment, as Figure 1-3 As shown, a system for replacing internal components of a wind turbine hub includes: a support frame and a platform; One end of the support frame is set as a threaded sleeve, which is fitted onto the end of the connecting bolt connecting the hub and the generator, and locked with a nut; The platform is located at the other end of the support frame and is equipped with lifting equipment for hoisting components.

[0023] The system mainly consists of a support frame and a platform.

[0024] Support Frame Setup: The support frame is made of high-strength structural steel, with a threaded sleeve machined at one end. The internal thread of this sleeve perfectly matches the thread specification of the connecting bolts used to fix the generator to the hub. During installation, the sleeve is directly screwed in or fitted onto the protruding end of the connecting bolt, and then tightened on the outside of the sleeve using a special high-strength nut. The key to this setup is that the sleeve, acting as a transitional connector, directly bears the load from the support frame and transfers it to the connecting bolts. Since the connecting bolts themselves are critical components used to withstand the enormous torque and gravity loads of the wind turbine, their strength and safety margin are extremely high, making this a completely reliable foundation. Simultaneously, the sleeve effectively avoids direct hard contact or welding between the support frame and the connecting bolt threads, protecting the integrity of the threads of this critical component—the generator-hub connecting bolts—preventing damage during tooling assembly and disassembly, and ensuring the safety of the wind turbine's main structure.

[0025] Platform Setup and Functions: The platform is typically a rectangular or square steel frame structure covered with anti-slip steel plates. It is fixed to the other end of the support frame by welding or high-strength bolts. When the support frame is secured to the connecting bolts on the edge of the wheel hub using bolt sleeves, the platform extends suspended into the space inside the wheel hub, forming a stable working surface at height. The core function of this platform is as a mounting base for lifting equipment.

[0026] Integration of lifting equipment: Lifting equipment for hoisting components, such as manual hoists, electric hoists, or winches, is installed on the platform. This lifting equipment can directly lift small tools or parts, and more importantly, it can serve as a traction power source, working in conjunction with other lifting points inside the hub to form a complete lifting system.

[0027] The beneficial effects of this embodiment are: it provides a work system construction scheme based entirely on the existing internal structure (connecting bolts) of the wheel hub. It does not rely on external large cranes, nor does it damage the wheel hub structure. Through a clever "sleeve-bolt" connection method, it safely transfers the work load to the most reliable load-bearing structure, laying the most critical foundational load-bearing platform for solving the problem of replacing large internal components of the wheel hub.

[0028] Furthermore, the support frame comprises multiple supports, each mounted on a different connecting bolt.

[0029] Based on the above embodiments, the number and distribution of support frames are optimized to cope with larger loads or more complex platform stability requirements that may be encountered in actual operations.

[0030] The support frame consists of multiple pieces. In actual operation, different connecting bolts are selected as installation points based on the size of the platform, the weight of the part to be replaced, and the distribution of the connecting bolts on the edge of the wheel hub. For example, on a rectangular platform, 3-4 adjacent connecting bolts may be evenly selected on one side near the edge of the wheel hub, and independent support frames may be installed on each of them.

[0031] The advantages of using multiple support frames for distributed load-bearing are: Load Dispersion: The total load generated by the platform and operations is distributed across multiple connecting bolts, significantly reducing the load on individual bolts and further enhancing the overall safety margin of the system.

[0032] Enhanced system rigidity: Multi-point support makes the connection between the platform and the hub structure more rigid, effectively suppressing platform vibration and deformation when subjected to eccentric loads or dynamic loads (such as the swaying of components during lifting).

[0033] Highly adaptable: The number and position of the support frame can be flexibly adjusted according to the specific space inside the wheel hub and the distribution of bolts, so as to build a platform that is most suitable for the current working scenario.

[0034] Furthermore, the multiple support frames include straight braces and diagonal braces. The straight braces directly support one side of the platform via connecting bolts, while the diagonal braces support the side of the platform away from the connecting bolts, thus keeping the platform stable in the axial direction of the wheel hub.

[0035] The multiple support frames are designed for two functional types: straight bracing and diagonal bracing.

[0036] Straight brace: One end of the straight brace is connected to the connecting bolt via a threaded sleeve, and the other end is directly connected to and supports the near end of the platform (the side closest to the wheel hub edge). It mainly bears the vertical pressure from the platform and a small amount of radial force.

[0037] Diagonal brace: The upper end of the diagonal brace (away from the hub end) is connected to the side of the platform away from the connecting bolt (i.e., the far end or cantilever end of the platform), while the lower end is connected to another or the same connecting bolt via another threaded sleeve (located below the platform connection point). The core function of the diagonal brace is to provide axial (along the hub axis) constraint.

[0038] When lifting operations or placing heavy objects at the far end of the platform, a tilting moment is generated that causes the far end of the platform to rotate downwards. Without diagonal bracing, this moment would be entirely resisted by the bending stress at the connection between the straight brace and the bolt, which could easily lead to connection failure or excessive platform deflection. With the addition of diagonal bracing, this tilting moment is converted into axial tensile or compressive force on the diagonal bracing. The diagonal bracing, with its strong tensile / compressive resistance, directly transmits this moment back to the connecting bolts of the hub, thereby maintaining the platform's axial (forward / backward) stability and greatly enhancing the system's reliability and safety under complex stress conditions.

[0039] Specifically, such as Figure 3 As shown, the platform uses two straight supports on both sides and one diagonal support in the middle to form a triangular structure, which makes the platform stable.

[0040] Furthermore, the lifting equipment includes winches and fixed anchor points.

[0041] Winches: As the power unit of the system, they provide stable traction. They are usually low-speed, high-torque models with reliable braking systems to achieve smooth and precise lifting and lowering of heavy components. At the same time, winches require less space and are suitable for use in the limited space of a wheel hub.

[0042] Fixed anchor points: serving as the system's guide and the base for installing fixed pulleys, they do not provide power but are used to change the direction of force on the wire rope, converting the horizontal or inclined traction of the winch into a vertical or specific directional lifting force.

[0043] The lifting function is modularized into a power unit and a guiding unit. The winch is centralized on the platform for easy operation and control; the fixed anchor points are flexibly arranged on the top of the inner cavity or the outer wall of the hub according to the location of the lifting target. This separate design allows for flexible planning of the lifting path, overcoming the limitations of the narrow space and numerous obstacles inside the hub, and enabling heavy objects to be vertically lifted in or out through narrow maintenance openings.

[0044] Furthermore, the fixed anchor point is set on the upper inner or outer wall of the hub and is equipped with a fixed pulley for lifting the inner components of the hub or the components below the anchor point.

[0045] In this embodiment, the fixing anchor points are located on the upper inner and outer walls of the wheel hub. Specifically, the existing reinforcing rib structure inside the wheel hub, pre-drilled process holes, or special clamps (such as inner support clamps) can be used without damaging the structure, or one or more sturdy points can be selected on the outer wall of the wheel hub. A fixed pulley is installed at each fixing anchor point.

[0046] During hoisting, the winch's wire rope is extended from the winch on the platform, extends upwards, passes through the fixed pulley groove fixed to the inner wall of the upper part of the hub, and then extends vertically downwards. Its free end is connected to the internal component of the hub to be replaced (such as a pitch gearbox) via a hook or sling. At this time, the fixed pulley plays a crucial guiding role, converting the roughly horizontal pulling force output by the winch into a vertically upward lifting force. Optimized force transmission: ensuring that the final lifting force acts directly above the component, avoiding the additional friction and collision risks caused by oblique pulling.

[0047] Furthermore, the winch is detachably fixed to the platform by bolts.

[0048] In this embodiment, the winch is detachably fixed to the platform by bolts. Specifically, a mounting base plate or beam with standard hole spacing is pre-installed on the platform's steel structure, and the winch base has corresponding mounting holes. High-strength bolts and anti-loosening washers are used for fastening.

[0049] The winch can be installed as an independent module on the platform and then moved to the platform for securing, reducing the overall lifting weight and difficulty. It can be quickly disassembled after operation, facilitating transfer to the next wind turbine. If the winch requires maintenance or upgrades, it can be easily removed without affecting the main structure of the platform.

[0050] Furthermore, the platform is detachably connected to the support frame via bolts.

[0051] In this embodiment, the platform is detachably connected to the support frame via bolts. The top of the support frame is designed with a connecting flange or connecting plate, and the corresponding bottom of the platform also has a corresponding connecting structure, all secured by a set of high-strength bolts. This reduces transportation and handling difficulties: the support frame and platform can be disassembled into modules of suitable size and weight, easily inserted into the hub through the existing manhole or maintenance door of the nacelle, without requiring structural modifications to the wind turbine. Furthermore, considering the differences in the internal space and bolt distribution diagrams of different wind turbine hub models, standardized support frame modules and several specifications of platform modules can be designed, allowing for combinations to adapt to various turbine models and improving the versatility of the tooling.

[0052] Furthermore, multiple fixed anchor points are provided to match different stopping angles of the wheel hub and different orientation components.

[0053] In this embodiment, multiple fixed anchor points are provided. These multiple anchor points can be arranged at different positions on the top of the hub cavity, depending on the distribution of lifting lugs on the component or the need for balanced lifting. When using multiple fixed anchor points, multiple sets of pulley blocks and wire ropes can be used.

[0054] Specifically, fixed anchor points are arranged in a circumferential array on the outer wall of the hub inspection hole. In this embodiment, three fixed anchor points are provided on the outer wall of the hub inspection hole, with a circumferential interval of 120 degrees, which also corresponds to the angle of the three blades of the wind turbine. This ensures that there are fixed anchor points available at the top when the hub is stopped at different angles.

[0055] For example, when replacing a pitch gearbox with a larger length dimension, a fixed anchor point can be set at each end of its length to achieve two-point hoisting. This method can: Keep components stable: prevent components from tilting or rotating in the air during single-point hoisting, and facilitate alignment of components with the installation reference surface.

[0056] Distribute load: Distribute the weight of the component to multiple stress points on the top of the hub to avoid local stress concentration.

[0057] Achieving complex posture adjustment: By controlling the lifting speed of different lifting points separately, the component can be rotated or leveled slightly in the air, greatly simplifying the difficulty of installation and positioning.

[0058] Furthermore, the platform has a diagonal anchor point on the side of the hub near the connecting bolt in the axial direction.

[0059] The diagonal anchor point is a high-strength lug or through hole with a pin hole located on the side of the platform hub near the connecting bolt in the axial direction. It is used to connect a diagonal cable or tie rod.

[0060] The installers use a steel wire rope (or a special adjustable-length tie rod), with one end connected to the inclined anchor point on the platform via a shackle, and the other end connected to an anchor point outside the wheel hub. This connection to the external fixed structure helps balance the torque generated by the lifting equipment during hoisting, preventing excessive eccentric torque on the support frame and connecting bolts, protecting critical connection points, and extending the service life and reliability of the entire tooling system.

[0061] Example 2 A method for using a wind turbine hub internal component replacement system includes the following steps: S1: Install the support brackets: The operator enters the hub and selects the appropriate number (usually 3-4) and positions of generator connection bolts. After cleaning the nut at one end of the support bracket, screw it into or fit it onto the connection bolts, and use a special wrench to tighten the outer locking nut to the specified torque to ensure that each support bracket is securely installed.

[0062] S2: Platform Setup: Transport the prefabricated platform modules to the support frame, align the platform with the connecting part at the top of the support frame, and use high-strength bolts to fasten it to all the support frames to form a stable overall working platform.

[0063] S3: Install the lifting equipment: Transport the winch to the platform and secure it to the platform in the designed position using bolts. Connect the winch's power and control cables.

[0064] S4: Set up fixed anchor points and pulley blocks: According to the hoisting plan for the part to be replaced, install fixed anchor points at selected positions on the upper inner wall of the hub. Install fixed pulleys at each anchor point. Lead out the wire rope from the winch, pass it through each fixed pulley in sequence, and finally lower the free end of the wire rope vertically to the vicinity of the part to be replaced.

[0065] S5: Lifting and Replacement Operation: Reliably connect the free end of the wire rope to the component to be replaced using shackles, lifting slings, etc. Clean up the connecting pipes and cables around the component. Operate the winch to slowly and steadily lift the faulty component, move it out of the installation position, and properly place it in an open area inside the hub or transfer it out through the hub inspection hole. Subsequently, lift the new component to the installation position, accurately align it, and install and secure it. Disassemble the system modules in reverse order to complete the replacement operation.

[0066] This method transforms the complex, high-risk, and costly operation that originally required large cranes and the dismantling of wind turbines into a standardized, modular, and step-by-step process completed entirely inside the wind turbine hub. This shortens the operation time, reduces operating costs, and the operation is unaffected by external weather conditions.

[0067] The above description is merely a preferred embodiment of the invention and is not intended to limit the invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A wind turbine hub internals replacement system, characterized by, The utility model relates to a support frame and platform for hoisting and replacing the components in the hub of a wind turbine, comprising: a support frame and a platform; one end of the support frame is provided with a threaded sleeve which is sleeved on the end of the connecting bolt connecting the hub and the generator and locked by a nut; the platform is arranged at the other end of the support frame and is provided with a hoisting device for hoisting and replacing the components.

2. A wind turbine hub internal component replacement system according to claim 1, wherein, the support frame comprises a plurality of supports which are arranged at different connecting bolts respectively.

3. A wind turbine hub internal component replacement system according to claim 2, wherein, the plurality of supports comprise straight supports and inclined supports, the straight supports directly support one side of the platform through the connecting bolts, and the inclined supports support the other side of the platform away from the connecting bolts, so that the platform is kept stable in the axial direction of the hub.

4. The wind turbine hub internal component replacement system of claim 1, wherein, the hoisting device comprises a winch and fixed anchor points.

5. A wind turbine hub internal component replacement system according to claim 4, wherein, the fixed anchor points are arranged on the inner wall or outer wall of the upper part of the hub and are provided with a fixed pulley for hoisting the components inside the hub or below the anchor points.

6. A wind turbine hub internal component replacement system according to claim 4, wherein, the platform is detachably connected to the support frame by bolts, and the winch is detachably fixed to the platform by bolts.

7. A wind turbine hub internal component replacement system according to claim 5, wherein, the fixed anchor points are arranged in multiple to match different parking angles of the hub and different components in different directions.

8. A wind turbine hub internal component replacement system according to claim 1, wherein, the platform is provided with inclined anchor points on the side close to the connecting bolt in the axial direction of the hub.

9. A method of using a wind turbine hub component replacement system according to any one of claims 1-8, wherein the method comprises: the utility model relates to a support frame and platform for hoisting and replacing the components in the hub of a wind turbine, comprising: S1: a support frame is arranged on the generator connecting bolt inside the hub, one end of the support frame is provided with a threaded sleeve which is sleeved on the connecting bolt and locked by a nut; S2: a platform is built at the other end of the support frame; S3: a hoisting device is arranged on the platform; S4: fixed anchor points are arranged inside the hub and a pulley block is arranged; S5: the components inside the hub are hoisted and replaced by the hoisting device and the pulley block.

10. A method of using a wind turbine hub internals replacement system according to claim 9, wherein, the hoisting device is a winch; during hoisting, the steel wire rope of the winch passes through the pulley block, the free end of the steel wire rope extends vertically downward and is connected to the component to be replaced, and the hoisting and lowering of the component are realized by operating the winch.

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