A unit tower maintenance device

Abstract

The utility model relates to a kind of wind turbine tower maintenance device, belong to unit maintenance equipment technical field.The device includes support assembly, first support platform, second support platform and power component.Support assembly is installed in the both ends of unit base, provides mounting position for lifting mechanism;First support platform includes first support, for connecting and supporting the shaft extension end of unit;Second support platform includes second support, for connecting and supporting the non-shaft extension end of unit;Power component is installed on first support platform, includes movement driving device and rotary driving device, respectively for exerting force along the axial direction of unit and rotating force around the axial direction of unit to unit.The first support platform is segmented, includes three modules;Second support platform is segmented, includes two modules, and the positioning accuracy is strengthened with joint pin between module and locked with fastener.The utility model has reasonable structure, can realize the maintenance operation of unit on tower, improve maintenance efficiency, reduce maintenance cost.

Description

Technical Field

[0001] This utility model belongs to the field of wind turbine generator operation and maintenance technology, specifically relating to a special device for high-altitude on-site maintenance of wind turbine towers. Background Technology

[0002] With the rapid development of the wind power industry, the maintenance and repair of wind turbines have become increasingly important. Wind power is a crucial pillar of the renewable energy system, and ensuring the high reliability and availability of wind turbines is essential for reducing the cost per kilowatt-hour. As the core energy conversion component of a wind turbine, the generator has a relatively high failure rate and frequent maintenance needs. Proper maintenance avoids the enormous costs associated with replacing a faulty generator from the tower. Internal generator maintenance, especially the repair or replacement of the rotor, stator, bearings, or shaft, sometimes requires the safe and precise removal of the heavy generator rotor from the stator cavity. This work is one of the most technically challenging and risky aspects of generator maintenance.

[0003] However, existing wind turbine maintenance equipment still faces numerous challenges when performing generator rotor removal operations within the nacelle on the tower. First, existing equipment presents high risks and difficulties during operation, especially at high altitudes, posing significant safety hazards. Second, existing equipment lacks precision control; the air gap between the stator and rotor is typically only a few millimeters, requiring constant concentricity during removal, which struggles to meet the precise positioning and smooth movement requirements of generator rotor removal operations. Third, many maintenance tasks require large hoisting equipment, leading to high costs and significant weather-related limitations, impacting maintenance efficiency. Fourth, existing equipment often has limited functionality and lacks integrated design, failing to simultaneously meet multiple functional requirements such as support, movement, and rotation, resulting in frequent tooling changes and low efficiency. Finally, the nacelle space is limited; the generator is typically tightly integrated into the drivetrain, surrounded by other equipment, leaving extremely limited axial and radial space for large tooling or rotor movement, severely restricting maintenance space. Modern high-power wind turbine generator rotors weigh several tons, and the motors are generally installed at an angle, placing extremely high demands on the load-bearing capacity, stability, and balance control of the tooling. Generator failures result in huge downtime losses, and traditional rotor removal methods are time-consuming, indirectly prolonging downtime and incurring high downtime costs.

[0004] Therefore, there is an urgent need to develop a maintenance device specifically for the removal of generator rotors from the nacelle of wind turbine towers. This device should be characterized by safe operation, high precision control, no need for large hoisting equipment, high efficiency, and high degree of integration, in order to solve the problems existing in the current technology. Utility Model Content

[0005] The technical problem to be solved by this utility model is to provide a tower maintenance device for wind turbines, which addresses the technical problems of high risk and difficulty in operation, insufficient precision control, high cost and low efficiency due to the need for large hoisting equipment, and lack of dedicated, efficient and reliable integrated equipment when performing generator rotor removal operations in the nacelle of the wind turbine tower.

[0006] The technical solution adopted by this utility model to solve its technical problem is as follows: A tower maintenance device for a generator unit is provided. The generator unit includes a base, a shaft, a stator, and a rotor. The tower maintenance device includes a support assembly, a first support platform, a second support platform, and a power assembly. The support assembly is installed at both ends of the base, providing installation positions for a lifting mechanism. The first support platform includes a first bracket for connecting and supporting the shaft extension end of the generator unit. The second support platform includes a second bracket for connecting and supporting the non-shaft extension end of the generator unit. The power assembly is installed on the first support platform and includes a moving drive device and a rotating drive device, respectively used to apply a force along the axial direction of the generator unit and a rotational force around the axial direction of the generator unit.

[0007] Preferably, the first support platform is segmented, comprising a first module, a second module, and a third module, and the second support platform is segmented, comprising a fourth module and a fifth module. The modules are reinforced with interlocking pins to enhance positioning accuracy and are locked together with fasteners.

[0008] Furthermore, the first module and the second module are provided with through grooves on their side walls or bottoms, and guide members are provided in the grooves. The first bracket is slidably connected to the first support platform through the guide members.

[0009] Furthermore, the first module is provided with a sliding bearing, the third module is provided with a first mounting base, the mobile drive device is fixed to the first support platform through the first mounting base, and the output end of the mobile drive device passes through the first bracket and is connected to the sliding bearing.

[0010] Preferably, the second module is provided with a second mounting base, the rotary drive device is fixed to the first support platform through the second mounting base, and the output end of the rotary drive device is provided with a connector for connecting to the unit shaft.

[0011] Furthermore, a guide is provided at the bottom of the second support platform, and the second bracket slides along the guide.

[0012] Furthermore, a baffle is provided at the end of the second support platform away from the unit axis to restrict the second bracket from sliding out of the second support platform.

[0013] Preferably, the shaft extension end of the unit is provided with a first bearing sleeve, the first bracket is connected to the first bearing sleeve, and the non-shaft extension end of the unit is provided with a second bearing sleeve, the second bracket is connected to the second bearing sleeve.

[0014] Furthermore, the support assembly includes a crossbeam, a cantilever, and a support arm. The cantilever is mounted on both sides of the base, the crossbeam connects the two sides of the cantilever, and one end of the support arm is connected to the cantilever and the other end is connected to the base.

[0015] Furthermore, the second support platform is equipped with a tool holder assembly, which is used for repairing the non-shaft extension end, including turning and welding operations.

[0016] The beneficial effects of this utility model are as follows: Through the integrated and modular design of a dedicated tooling system, stable and controllable rotor extraction operations are achieved, ensuring the rotor moves smoothly and at a constant speed along the preset centerline, significantly reducing maintenance costs and downtime. The segmented support platform design and the application of the guiding structure overcome the spatial limitations within the wind turbine nacelle, improving operational efficiency and enabling efficient deployment and operation within the confined space of the nacelle, solving the problem of large equipment being unable to enter or operate. The weight reduction and split design of the device, along with the integrated drive and maintenance system, significantly reduce the labor intensity of maintenance personnel and improve working conditions. Simultaneously, the rotary structure design with the bearing sleeve as the rotating support position reduces tooling investment and disassembly / adjustment workload, improving overall maintenance efficiency. Compared with existing technologies, the tower maintenance device provided by this utility model eliminates the need for large hoisting equipment, reducing maintenance costs. Furthermore, the application of a high-efficiency drive module ensures stable torque transmission, guaranteeing the concentricity of the stator and rotor during maintenance, thus improving maintenance quality and safety. Attached Figure Description

[0017] The accompanying drawings are provided to further illustrate the present application and form part of the specification. They are used together with the embodiments of the present application to explain the application and do not constitute a limitation thereof. In the drawings:

[0018] Figure 1 This is an assembly diagram of the tower maintenance device for the unit in this application.

[0019] Figure 2 This is a schematic diagram showing the connection between the tower maintenance device and the rotor of the unit in this application.

[0020] Figure 3 This is a schematic diagram of the support assembly for the tower maintenance device of the unit in this application.

[0021] Figure 4 This is a schematic diagram of the first support platform of the tower maintenance device for the unit in this application.

[0022] Figure 5 This is another schematic diagram of the first support platform of the tower maintenance device for the unit in this application.

[0023] Figure 6 This is a schematic diagram of the first support platform of the tower maintenance device for the unit in this application, which is equipped with a power assembly.

[0024] Figure 7 This is a schematic diagram of the second support platform of the tower maintenance device for the unit in this application.

[0025] Figure 8 This is a schematic diagram of the tool holder assembly mounted on the second support platform of the tower maintenance device for the unit in this application. Detailed Implementation

[0026] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0027] In this specification, identical parts are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, and the terms "bottom surface," "top surface," "inner," and "outer" refer to directions towards or away from a specific component, respectively. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more.

[0028] The present application will be further described below with reference to the accompanying drawings and embodiments.

[0029] In one embodiment provided in this application, such as Figure 1 , Figure 2 As shown, a tower maintenance device for a generator unit is suitable for tower maintenance of a generator unit including a base 1, generator shaft, stator, and rotor 2. The tower maintenance device includes a support assembly 3, a first support platform 4, a second support platform 5, and a power assembly. A first bearing sleeve 21 is provided at the shaft extension end of the generator unit, and a first support 45 is connected to the first bearing sleeve 21. A second bearing sleeve 22 is provided at the non-shaft extension end of the generator unit, and a second support 53 is connected to the second bearing sleeve 22. This connection method ensures the stability and safety of the generator unit during maintenance.

[0030] The power unit is installed on the first support platform 4. The power unit includes a moving drive device 6 and a rotating drive device 7. The moving drive device 6 applies a force along the axial direction of the unit and can be used for rotor 2 extraction operations. The rotating drive device 7 applies a rotational force around the axial direction of the unit and can be used for maintenance operations such as turning and welding.

[0031] like Figure 3 As shown, there are at least two sets of support assemblies 3, respectively installed at both ends of the base 1, namely the shaft extension end and the non-shaft extension end, providing installation positions for the lifting mechanism, which can be a manual hoist. The support assembly 3 includes a crossbeam 31, a cantilever 32, and a support arm 33. The cantilever 32 is installed on both sides of the base 1 through lifting holes. The crossbeam 31 connects the two cantilever 32s and is fixed by welding or fasteners. One end of the support arm 33 is connected to the cantilever 32, and the other end is connected to the end cover of the base 1, forming a triangular support. This structural design allows the support assembly 3 to be stably installed on the base 1, providing reliable support for subsequent maintenance operations. For example, a manual hoist installed on the crossbeam 31 can be used to lift the rotor 2.

[0032] like Figure 4 , Figure 5 , Figure 6 As shown, the first support platform 4 includes a first bracket 45, which is used to connect to and support the shaft extension end of the unit. The first support platform 4 is segmented, including a first module 41, a second module 42, and a third module 43. The modules are reinforced with interlocking pins to enhance positioning accuracy and are locked with fasteners. The side walls of the first module 41 and the second module 42 are provided with through grooves, and guide members are installed within the grooves. The first bracket 45 is slidably connected to the first support platform 4 via the guide members. This design allows the first bracket 45 to slide smoothly on the first support platform 4, facilitating position adjustment. In another embodiment, the bottom of the first module 41 and the second module 42 of the first support platform 4 is provided with through grooves, instead of grooves on the side walls. Guide members are installed within the grooves, and the first bracket 45 is slidably connected to the first support platform 4 via the guide members. This design allows the first bracket 45 to slide more stably on the first support platform 4, reducing the impact of lateral forces.

[0033] The first module 41 is provided with a sliding bearing 44, and the third module 43 is provided with a first mounting base 46. The moving drive device 6 is fixed to the first support platform 4 via the first mounting base 46. The output end of the moving drive device 6 passes through the first bracket 45 and connects to the sliding bearing 44. In one possible embodiment, the output end of the moving drive device 6 is a screw. The first bracket 45 is provided with a screw-type flange nut. The screw passes through the flange nut and connects to the sliding bearing 44. During operation, the moving drive device 6 drives the screw to rotate and moves the first bracket 45. It should be noted that the transmission method includes, but is not limited to, threaded transmission, gear transmission, and hydraulic transmission. This embodiment does not represent a limitation on the technical solution of this application. The second module 42 is provided with a second mounting base 47. The rotary drive device 7 is fixed to the first support platform 4 via the second mounting base 47. The output end of the rotary drive device 7 is provided with a connector 71 for connecting to the unit shaft.

[0034] like Figure 7 As shown, the second support platform 5 includes a second bracket 53, which is used to connect to and support the non-shaft extension end of the unit. The second support platform 5 is segmented, comprising a fourth module 51 and a fifth module 52. The modules are reinforced with interlocking pins for improved positioning accuracy and secured with fasteners. A guide is provided at the bottom of the second support platform 5, along which the second bracket 53 slides. A baffle 54 is provided at the end of the second support platform 5 furthest from the unit's shaft to prevent the second bracket 53 from sliding off the second support platform 5. Figure 8 As shown, the second support platform 5 is also provided with a tool holder assembly 55, which is used to perform repair work on the non-shaft extension end. The repair work includes turning and welding operations.

[0035] In practical applications, the operation process of the maintenance device on the unit tower is as follows:

[0036] First, install the shaft extension end of the unit. Install the cantilever 32 through the lifting hole, and fix the crossbeam 31 by spot welding or threading. Hang the hand chain hoist on the crossbeam 31. Remove the end cover at this end and install the support arm 33. After lifting the rotor 2 with the hand chain hoist, install the first support platform 4. Fix the first module 41, second module 42, and third module 43 of the first platform in sequence with fasteners. During installation, pay attention to using positioning pins for alignment to ensure the installation accuracy and overall rigidity of the first support platform 4. Install guides on both sides or the bottom of the first support platform 4. Slide the first bracket 45 into the first support platform 4 and fix it to the first bearing sleeve 21 at the shaft extension end with bolts. Then install the power assembly. Fix the first mounting base 46 to the third module 43 with fasteners. Install the sliding bearing 44 on the first module 41. Install the moving drive device 6 on the first mounting base 46. Connect the output end of the moving drive device 6 through the first bracket 45 to the sliding bearing 44. After this end is installed, release the hand chain hoist.

[0037] Next, install the non-shaft extension end of the unit. Similarly, install the cantilever 32 through the lifting holes, and spot weld or thread the crossbeam 31. Hang a hand-operated hoist on the crossbeam 31. Remove the end cover at this end and install the support arm 33. After lifting the rotor 2 with the hand-operated hoist, install the second support platform 5. Secure the fourth module 51 and the fifth module 52 with fasteners, paying attention to alignment using positioning pins during installation. Install guides at the bottom of the second support platform 5, slide the second bracket 53 into the second support platform 5, and bolt it to the second bearing sleeve 22 at the non-shaft extension end. Install a baffle 54 at the end of the second support platform 5 away from the unit shaft. Since the unit is tilted, the baffle 54 prevents the second bracket 53 from sliding out of the second support frame due to gravity or other reasons. After this end is installed, release the hand-operated hoist.

[0038] After checking the uniformity of the air gap using an air gap test strip, apply lubricating oil to the entire sliding surface. Slowly start the motor by connecting the handwheel or motor in the moving drive device 6 to the frequency converter, and push the rotor 2 out at a uniform speed. After reaching the predetermined position, fix the two end supports to their respective support planes.

[0039] In another embodiment, when machining, welding, or other finishing operations are required, a rotary drive device 7 can be selectively installed. On the first support platform 4 at the shaft extension end, a second mounting base 47 is installed on the second module 42 of the first support platform 4 using fasteners. The rotary drive device 7 is installed on the second mounting base 47. The output end of the rotary drive device 7 is connected to the unit shaft via a connector 71. In one embodiment, the connector 71 can be a transition plate and a universal joint coupling. At the non-shaft extension end, a tool holder assembly 55 is installed on the second support platform 5. In one embodiment, the tool holder assembly 55 includes a tool holder and a tool holder support. The tool holder support frame is installed on the second support platform 5, and then the tool holder is installed on the tool holder support frame.

[0040] In another embodiment, the tool holder assembly 55 of the second support platform 5 features an adjustable height design to accommodate machine shafts of different heights. The tool holder assembly 55 includes a base, a column, and a tool holder. The column height is adjustable, and the tool holder can rotate on the column to accommodate machining requirements at different angles.

[0041] In another embodiment, this location can also be used to install a laser head moving guide rail or similar device from a laser cladding equipment.

[0042] During turning operations, the rotary drive unit 7 is started by the frequency converter, driving the rotor 2 to rotate, thereby turning the end of the rotor 2 without weft strips, the outer diameter of the fan, or various stops on the shaft. During welding operations, the tool holder support can be equipped with laser cladding guides for easy repair of shaft stops. During finishing operations, after the rotor 2 is pulled out, the maintenance space is increased, making it easier to repair the ends of the stator and rotor 2, slot wedges, bearing components, etc.

[0043] In addition, in maintenance situations where it is not necessary to remove the rotor 2, such as the maintenance of bearings and shaft extension positions, the first support platform 4 and the second support platform 5 can also be equipped with special roller supports after separation to complete the maintenance task. The applicable range of maintenance conditions is very wide.

[0044] In the embodiments disclosed in this application, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this utility model according to the specific circumstances.

[0045] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A tower maintenance device for a generating unit, the generating unit comprising a base, a shaft, a stator, and a rotor, characterized in that, The unit tower maintenance device includes: Support assemblies: The support assemblies are respectively installed at both ends of the base, providing installation positions for the lifting mechanism. First support platform: includes a first bracket, which is used to connect to and support the shaft extension end of the unit. Second support platform: includes a second bracket, which is used to connect to and support the non-shaft extension end of the unit. Power assembly: The power assembly is mounted on the first support platform. The power assembly includes a moving drive device and a rotating drive device, which are used to apply a force along the axial direction of the unit and a rotational force about the axial direction of the unit, respectively.

2. An en-route maintenance apparatus for an aircraft engine as claimed in claim 1, characterized in that: The first support platform is segmented, comprising a first module, a second module, and a third module. The second support platform is segmented, comprising a fourth module and a fifth module. The modules are reinforced with interlocking pins to enhance positioning accuracy and are secured with fasteners.

3. An en-route maintenance apparatus for an aircraft engine as claimed in claim 2, characterized in that: The first module and the second module are provided with through grooves on their side walls or bottoms. Guide members are provided in the grooves. The first bracket is slidably connected to the first support platform through the guide members. After the first bracket slides to a preset position, it is locked with fasteners.

4. An en-route maintenance apparatus for an aircraft engine as claimed in claim 3, characterized in that: The first module is provided with a sliding bearing, the third module is provided with a first mounting base, the mobile drive device is fixed to the first support platform through the first mounting base, and the output end of the mobile drive device passes through the first bracket and is connected to the sliding bearing.

5. The en route maintenance apparatus of claim 3, wherein: The second module is provided with a second mounting base, and the rotary drive device is fixed to the first support platform through the second mounting base. The output end of the rotary drive device is provided with a connector for connecting to the unit shaft.

6. The en route maintenance apparatus of claim 1, wherein: The second support platform is provided with a guide at its bottom. The second bracket slides along the guide and is locked with fasteners after sliding to a preset position.

7. An en route maintenance apparatus for a turbine engine as defined in claim 1 wherein: A baffle is provided at the end of the second support platform away from the unit axis to prevent the second bracket from sliding out of the second support platform.

8. The unit tower maintenance device as described in claim 1, characterized in that: The unit is provided with a first bearing sleeve at the shaft extension end, and the first bracket is connected to the first bearing sleeve. The unit is provided with a second bearing sleeve at the non-shaft extension end, and the second bracket is connected to the second bearing sleeve.

9. An en route maintenance apparatus for a turbine engine as defined in claim 1 wherein: The support assembly includes a crossbeam, a cantilever, and a support arm. The cantilever is mounted on both sides of the base, the crossbeam connects the two sides of the cantilever, and one end of the support arm is connected to the cantilever, while the other end is connected to the base.

10. An en route maintenance apparatus for a turbine engine as defined in claim 1 wherein: The second support platform is equipped with a tool holder assembly, which is used to perform repair work on the non-shaft extension end, including turning and welding operations.

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