Replacement tools and methods for active stator parts

Abstract

To provide replacement tools and methods for active stator parts.SOLUTION: The present disclosure relates to methods and tools for mounting and / or removing active parts of a stator of an electrical machine, e.g. a generator. The present disclosure also relates to rotors, stators and generators. The method comprises removing one or more active rotor parts of a rotor of an electrical machine when the rotor is in a removal starting position, arranging a replacement tool in a gap left by the removed active rotor parts, rotating the rotor to an alignment position such that the replacement tool is radially aligned with an active stator part to be removed, picking the active stator part to be removed with the replacement tool, rotating the rotor to an extraction position, and removing the active stator part from the rotor.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present disclosure relates to methods and tools for mounting and / or removing one or more active components of an electrical machine stator, such as a stator of a direct drive wind turbine generator. The present disclosure also relates to rotors, stators, and generators of electrical machines.

Background Art

[0002] Electrical machines such as motors and generators generally comprise a rotor structure and a stator structure. A large generator may be, for example, a permanent magnet generator (PMG). The rotor of an electrical machine rotates relative to the stator. The rotor may be an inner structure and the stator may be an outer structure. Thus, in this case the stator, for example, radially surrounds the rotor. Alternatively, the configuration may be opposite, i.e., the rotor radially surrounds the stator, for example.

[0003] Such generators can be used, for example, in wind turbines. A wind turbine generally comprises a rotor having a rotor hub and a plurality of blades. The rotor is configured to rotate under the influence of wind on the blades. The rotation of the rotor shaft directly drives the generator rotor (“direct drive type”) or is driven using a gearbox.

[0004] A direct drive wind turbine generator can have, for example, a diameter of 6 to 10 meters (236 to 328 inches), for example a length of 2 to 3 meters (79 to 118 inches), and can rotate at a low speed, for example in the range of 2 to 20 rpm (revolutions per minute). Alternatively, the permanent magnet generator may also be coupled to a gearbox that increases the rotational speed of the generator, for example, to 50 to 500 rpm or more.

[0005] In permanent magnet excited generators (PMGs), the permanent magnets (PMs) are generally located in the rotor (although they can also be arranged alternately in the stator structure), while the winding elements (e.g., coils) are usually contained within the stator (although they can also be arranged alternately in the rotor structure). Permanent magnet generators are generally considered reliable and require less maintenance than other types of generators. This is a key reason why permanent magnet generators are used in offshore wind turbines, particularly direct-drive offshore wind turbines.

[0006] Multiple permanent magnets may be provided in a permanent magnet module, which may be mounted to the rotor as a single component. A permanent magnet module may be defined as a unit having multiple permanent magnets, so that the magnets can be mounted and dismounted together. Such a module may have a module base having a shape suitable for housing or supporting multiple permanent magnets that can be fixed to a base. The base may be configured to be fixed to a rotor structure, such as a rotor rim, so that the magnets are fixed together to the rotor rim through the module base. The use of a permanent magnet module can facilitate the manufacture of the rotor. Similarly, stator coils may be grouped together in a coil module. The coil module may be fixed to a generator structure, such as a stator rim.

[0007] In large electrical machinery such as permanent magnet generators in direct-drive wind turbines, accessing damaged coils within the stator can be difficult. For example, if the coil to be replaced is located near the front (windward) side of the wind turbine tower or nacelle, the damaged coil may strike the tower or nacelle when removed. Similarly, if the replacement coil is located in a hard-to-reach stator gap, installing the coil can require considerable time and effort.

[0008] A simpler method for replacing a damaged coil in the stator might be to remove several coils from their proper positions until the damaged coil is reached. The new coil can then be installed from its proper position, and the previously removed working coil can be reinstalled. Installing and removing coils from their proper positions may involve inserting and pulling coils from the top or upper (radial) portion of the generator. However, this can still be quite time-consuming. [Overview of the project]

[0009] One aspect of the present disclosure provides a method for removing an active stator component of an electromachine. The method includes removing one or more active rotor components from a rotor when the rotor of the electromachine is in a removal start position, and positioning a replacement tool in the gap formed by removing the active rotor components. The method further includes rotating the rotor to an alignment position so that the replacement tool is radially aligned with the active stator component to be removed, and picking the active stator component to be removed with the replacement tool. The method further includes rotating the rotor to a pull-out position and removing the active stator component from the rotor.

[0010] In this embodiment, the replacement tool may be releasably mounted on the rotor and transported to a circumferential position on which the damaged active component of the stator rests. The damaged active component may be located in a position that is particularly difficult to access, or where its removal is particularly complex. Once picked by the tool, the damaged component can be removed from a position that may be relatively easy to access.

[0011] In this way, the active components of the stator can be replaced efficiently. The integrity of the components does not need to be considered, and the operator can replace the active stator components in a safer manner.

[0012] In a further embodiment, a method is provided for mounting an active stator component to an electromachine. The method includes positioning the active stator component on a replacement tool attached to a rotor while the rotor is in a mounting start position. The method further includes rotating the rotor to an insertion position where the replacement tool is radially aligned with a gap in the stator on which the active stator component is mounted. The method further includes inserting the active stator component into the gap.

[0013] This method may be performed after the withdrawal method described above, or it may be performed independently of the withdrawal method.

[0014] In yet another embodiment, a replacement tool is provided. The replacement tool comprises a retaining portion configured to hold an active stator component. The replacement tool further comprises an anchoring portion configured to fix the replacement tool to the rotor.

[0015] The replacement tool can be used in any of the above methods, including a combination of both methods.

[0016] In a further embodiment, a stator is provided. The stator comprises a stator frame, a stator rim, and a plurality of active stator components attached to the stator rim. The stator frame comprises one or more recesses, each having one or more movable elements. The movable elements are configured to push the active stator components out of the stator frame. For example, a coil, coil assembly, or coil module may be radially pushed toward the rotor by a movable element housed within a recess. The stator may be a stator for a direct-drive wind turbine. The stator may be configured to be radially surrounded by a rotor.

[0017] In yet another embodiment, a stator is provided. The stator comprises a stator frame, a stator rim, and a plurality of active stator components attached to the stator rim. The stator frame comprises one or more protrusions, each having one or more movable elements. The movable elements are configured to push the active stator components out of the stator frame. For example, coils may be radially pushed toward the rotor by movable elements housed within the protrusions. The stator may be a stator for a direct-drive wind turbine. The stator may be configured to be radially surrounded by the rotor. In some examples, the active stator components may be coils, coil assemblies, or coil modules.

[0018] In a further embodiment, a rotor is provided. The rotor comprises a rotor rim and a plurality of removable rotor elements mounted on the rotor rim. During use, the rotor elements face the stator. The height of the rotor elements is substantially equal to or greater than the height of the active stator components so that one or more of the active stator components can rotate with the rotor when held by the rotor. The height can be measured radially. The rotor may be a rotor for a direct-drive wind turbine. The rotor may be configured to radially surround the stator. The rotor elements may be active rotor components. The rotor elements may be assemblies of active rotor components and spacers. In some examples, the active rotor components may be permanent magnet modules.

[0019] In this embodiment, the height of the rotor elements may be such that a tool configured to hold active stator components can be placed in the rotor gap after removing the rotor, for example, one or more rotor elements, in order to pull out and / or insert the active stator components by rotating the rotor.

[0020] In yet another aspect, an electromechanical machine is provided. The electromechanical machine includes a rotor, a stator, and a radial air gap between the rotor and the stator. The stator includes a plurality of active stator components. The rotor includes a rotor rim and a plurality of rotor elements removably attached to the rotor rim. The height of the rotor elements is substantially equal to or greater than the height of the active stator components such that one or more of the active stator components can rotate with the rotor when held by the rotor. In some examples, the active rotor components may be permanent magnet modules. In some examples, the active stator components may be coils.

[0021] Here, height is measured radially. The electromechanical machine may be a generator, particularly a generator for a wind turbine, more particularly a generator for a direct drive wind turbine. In some examples, the rotor can surround the stator.

Brief Description of the Drawings

[0022] [Figure 1] A diagram schematically showing a perspective view of an example of a wind turbine. [Figure 2] A diagram showing an example of a hub and nacelle of a wind turbine. [Figure 3] A diagram schematically showing a rear view of an example of an electromechanical machine. The electromechanical machine may be a generator for a direct drive wind turbine. [Figure 4] A diagram schematically showing details of the electromechanical machine of FIG. 3 with a segment removed. [Figure 5] A diagram schematically showing an example of a flowchart of a method for removing active components of a stator. [Figure 6] A diagram schematically showing some aspects of the method of FIG. 5. [Figure 7] A diagram schematically showing some aspects of the method of FIG. 5. [Figure 8] A diagram schematically showing some aspects of the method of FIG. 5. [Figure 9A]A diagram schematically showing two examples of a stator. [Figure 9B] A diagram schematically showing two examples of a stator. [Figure 10] A diagram schematically showing an example of a flowchart of a method for mounting active components of a stator. [Figure 11] A diagram schematically showing some aspects of the method of FIG. 10. [Figure 12] A diagram schematically showing some aspects of the method of FIG. 10. [Figure 13] A diagram schematically showing an example of a tool for removing and / or mounting active components from / onto a stator.

Embodiments for Carrying out the Invention

[0023] Here, embodiments of the present invention will be referred to in detail, and one or more examples thereof are shown in the drawings. Each example is provided as an illustration of the present invention, not as a limitation thereof. In fact, it will be apparent to those skilled in the art that various modifications and changes can be made to the present invention without departing from the scope or spirit of the present invention. For example, features illustrated or described as part of one embodiment can be used in conjunction with another embodiment to bring about further embodiments. Therefore, the present invention is intended to cover such modifications and changes within the scope of the appended claims and their equivalents.

[0024] Figure 1 is a perspective view of an example of a wind turbine 10. In this example, the wind turbine 10 is a horizontal-axis wind turbine. Alternatively, the wind turbine 10 may be a vertical-axis wind turbine. In this example, the wind turbine 10 includes a tower 15 extending from a support system 14 on the ground 12, a nacelle 16 mounted on the tower 15, and a rotor 18 coupled to the nacelle 16. The rotor 18 includes a rotatable hub 20 and at least one rotor blade 22 coupled to the hub 20 and extending outward from the hub 20. In this example, the rotor 18 has three rotor blades 22. In an alternative embodiment, the rotor 18 includes more or fewer than three rotor blades 22. The tower 15 can be fabricated from tubular steel to define a cavity (not shown in Figure 1) between the support system 14 and the nacelle 16. In an alternative embodiment, the tower 15 is any suitable type of tower having any suitable height. In alternative configurations, the tower may be a hybrid tower comprising concrete and tubular steel sections. Alternatively, the tower may be a partially or fully lattice tower.

[0025] The rotor blades 22 may be spaced apart around the hub 20 to facilitate the rotation of the rotor 18 and to allow kinetic energy to be transferred from the wind to usable mechanical energy, and subsequently to electrical energy. The rotor blades 22 are fitted to the hub 20 by coupling the blade root portion 24 to the hub 20 with a plurality of load transfer regions 26. The load transfer regions 26 may have hub load transfer regions and blade load transfer regions (neither of which are shown in Figure 1). The load induced on the rotor blades 22 is transferred to the hub 20 via the load transfer regions 26.

[0026] In this example, the rotor blades 22 can have lengths ranging from about 15 meters (m) to about 90 meters or more. The rotor blades 22 may have any suitable length that allows the wind turbine 10 to function as described herein. For example, non-limiting examples of blade lengths include lengths of 20 m or less, 37 m, 48.7 m, 50.2 m, 52.2 m, or more than 91 m. When wind strikes the rotor blades 22 from the wind direction 28, the rotor 18 rotates around the rotor axis 30. As the rotor blades 22 rotate and are subjected to centrifugal force, the rotor blades 22 are also subjected to various forces and moments. Thus, the rotor blades 22 can be deflected and / or rotated from a neutral or non-deflected position to a deflected position.

[0027] Furthermore, the pitch angle of the rotor blades 22, i.e., the angle that determines the orientation of the rotor blades 22 relative to the wind direction, is modified by the pitch system 32, and the load and power generated by the wind turbine 10 can be controlled by adjusting the angular position of at least one rotor blade 22 relative to the wind vector. The pitch axis 34 of the rotor blades 22 is also shown. During the operation of the wind turbine 10, the pitch system 32 can specifically modify the pitch angle of the rotor blades 22 so that the angle of attack of (part of) the rotor blades is reduced, thereby facilitating a reduction in rotational speed and / or facilitating a stall of the rotor 18.

[0028] In this example, the blade pitch of each rotor blade 22 is controlled individually by the wind turbine controller 36 or the pitch control system 80. Alternatively, the blade pitch for all rotor blades 22 may be controlled simultaneously by the control system.

[0029] Furthermore, in this example, as the wind direction 28 changes, the yaw direction of the nacelle 16 can be rotated around the yaw axis 38, thereby positioning the rotor blades 22 relative to the wind direction 28.

[0030] In this example, the wind turbine controller 36 is shown as being concentrated within the nacelle 16, but the wind turbine controller 36 may be a distributed system located throughout the wind turbine 10, on the support system 14, within the wind power plant, and / or in a remote control center. The wind turbine controller 36 includes a processor 40 configured to carry out the methods and / or steps described herein. Furthermore, many of the other components described herein include processors.

[0031] As used herein, the term “processor” is not limited to integrated circuits referred to as computers in the prior art, but broadly includes controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits, and other programmable circuits, and these terms are used interchangeably herein. It should be understood that processors and / or control systems may also include memory, input channels, and / or output channels.

[0032] Figure 2 is an enlarged cross-sectional view of a portion of the wind turbine 10. In this example, the wind turbine 10 includes a nacelle 16 and a rotor 18 rotatably coupled to the nacelle 16. More specifically, the hub 20 of the rotor 18 is rotatably coupled to an electric generator 42 positioned within the nacelle 16 by a main shaft 44, a gearbox 46, a high-speed shaft 48, and a coupling 50. In this example, the main shaft 44 is positioned at least partially coaxial with the longitudinal axis (not shown) of the nacelle 16. The rotation of the main shaft 44 drives the gearbox 46, which in turn drives the high-speed shaft 48 by converting the relatively slow rotational motion of the rotor 18 and the main shaft 44 into the relatively fast rotational motion of the high-speed shaft 48. The latter is connected to the generator 42 to produce electrical energy with the help of the coupling 50. Furthermore, a transformer 90 and / or appropriate electronic equipment, switches, and / or an inverter can be placed in the nacelle 16 to convert the electrical energy generated by the generator 42, which has a voltage of 400V to 1000V, into electrical energy having a medium voltage (10 to 35kV). The electrical energy is then conducted from the nacelle 16 to the tower 15 via power cables.

[0033] The gearbox 46, generator 42, and transformer 90 may be supported by the main support structure frame of the nacelle 16, or optionally embodied as the main frame 52. The gearbox 46 may include a gearbox housing connected to the main frame 52 by one or more torque arms 103. In this example, the nacelle 16 also includes a main front support bearing 60 and a main rear support bearing 62. Furthermore, the generator 42 may be mounted to the main frame 52 by isolation support means 54, in particular to prevent vibrations of the generator 42 from being introduced into the main frame 52 and thereby causing a noise emission source.

[0034] Optionally, the main frame 52 is configured to bear the weight of the components of the rotor 18 and nacelle 16, as well as the entire load caused by the wind and rotational load, and further to introduce these loads into the tower 15 of the wind turbine 10. The rotor shaft 44, generator 42, gearbox 46, high-speed shaft 48, coupling 50, and any associated fastening, support, and / or fixing devices, including but not limited to support 52, front support bearing 60, and rear support bearing 62, may be referred to as the drivetrain 64.

[0035] In some examples, the wind turbine may be a direct-drive wind turbine without a gearbox 46. The generator 42 operates at the same rotational speed as the rotor 18 in the direct-drive wind turbine. Therefore, they generally have a much larger diameter than the generators used in wind turbines with a gearbox 46 in order to provide a similar amount of power as wind turbines with a gearbox.

[0036] The nacelle 16 may also include a yaw drive mechanism 56 that can be used to rotate the nacelle 16 and, consequently, the rotor 18 around the yaw axis 38, thereby controlling the viewpoint of the rotor blades 22 with respect to the wind direction 28.

[0037] To properly position the nacelle 16 with respect to the wind direction 28, the nacelle 16 may also include at least one weather measurement system, which may include a wind vane and an anemometer. The weather measurement system 58 can provide the wind turbine controller 36 with information, which may include wind direction 28 and / or wind speed. In this example, the pitch system 32 is at least partially located within the hub 20 as a pitch assembly 66. The pitch assembly 66 includes one or more pitch drive systems 68 and at least one sensor 70. Each pitch drive system 68 is coupled to each rotor blade 22 (shown in Figure 1) to modulate the pitch angle of the rotor blade 22 along the pitch axis 34. Only one of the three pitch drive systems 68 is shown in Figure 2.

[0038] In this example, the pitch assembly 66 includes a hub 20 and at least one pitch bearing 72 coupled to each rotor blade 22 (shown in Figure 1) to rotate each rotor blade 22 around a pitch axis 34. The pitch drive system 68 includes a pitch drive motor 74, a pitch drive gearbox 76, and a pitch drive pinion 78. The pitch drive motor 74 is coupled to the pitch drive gearbox 76 so that the pitch drive motor 74 imparts mechanical force to the pitch drive gearbox 76. The pitch drive gearbox 76 is coupled to the pitch drive pinion 78 so that the pitch drive pinion 78 is rotated by the pitch drive gearbox 76. The pitch bearing 72 is coupled to the pitch drive pinion 78 so that the rotation of the pitch drive pinion 78 causes the rotation of the pitch bearing 72.

[0039] The pitch drive system 68 is coupled to the wind turbine controller 36 to adjust the pitch angle of the rotor blades 22 upon receiving one or more signals from the wind turbine controller 36. In this example, the pitch drive motor 74 is any suitable motor driven by a power and / or hydraulic system that enables the pitch assembly 66 to function as described herein. Alternatively, the pitch assembly 66 may include any suitable structure, configuration, arrangement, and / or component, but is not limited to, a hydraulic cylinder, spring, and / or servo mechanism. In a particular embodiment, the pitch drive motor 74 is driven by energy extracted from a stored energy source (not shown) that supplies the rotational inertia and / or energy of the hub 20 to the components of the wind turbine 10.

[0040] The pitch assembly 66 may also include one or more pitch control systems 80 for controlling the pitch drive system 68 in accordance with control signals from the wind turbine controller 36 in certain priority situations and / or during rotor overspeed. In this example, the pitch assembly 66 includes at least one pitch control system 80 communicably coupled to each pitch drive system 68 in order to control the pitch drive system 68 independently of the wind turbine controller 36. In this example, the pitch control system 80 is coupled to the pitch drive system 68 and the sensor 70. During normal operation of the wind turbine 10, the wind turbine controller 36 can control the pitch drive system 68 to adjust the pitch angle of the rotor blades 22.

[0041] According to one embodiment, for example, a power generator 84 comprising a battery and an electric capacitor is located in or within the hub 20 and coupled to the sensor 70, the pitch control system 80, and the pitch drive system 68 to provide a power source to these components. In this example, the power generator 84 provides a continuous power source to the pitch assembly 66 during the operation of the wind turbine 10. In an alternative embodiment, the power generator 84 provides power to the pitch assembly 66 only during power loss events of the wind turbine 10. Power loss events may include power grid loss or depletion, malfunction of the wind turbine 10's electrical system, and / or failure of the wind turbine controller 36. During a power loss event, the power generator 84 operates to provide power to the pitch assembly 66 so that the pitch assembly 66 can operate during the power loss event.

[0042] In this example, the pitch drive system 68, sensor 70, pitch control system 80, cable, and power generator 84 are each positioned within a cavity 86 defined by the inner surface 88 of the hub 20. In an alternative embodiment, the components may be positioned relative to the outer surface of the hub 20 and coupled directly or indirectly to the outer surface.

[0043] Figure 3 schematically shows a rear view of an example of the electromachine 100. Figure 4 schematically shows a portion of the electromachine of Figure 3 without segment 145. As seen in the examples of Figures 3 and 4, the electromachine 100 comprises a rotor 130, a stator 120, and a radial air gap 116 between the rotor 130 and the stator 120.

[0044] In this example, the electric machine is a generator for a wind turbine, particularly a direct-drive wind turbine. The illustrated rear of the generator may face the leeward side of the wind turbine rather than the rotor of the wind turbine. In other examples, the electric machine 100 may be a generator for a wind turbine with a gearbox, a general-purpose generator, or a motor.

[0045] In the examples of Figures 3 and 4, the generator has an annular cover 140 on its rear (the wind turbine rotor is located in front of the generator). The annular cover 140 has several segments 145, one of which is removed in Figure 4. In this figure, the rotor rim 131 and the stator rim 121 can be seen. In the illustrated example, the rotor 130 radially surrounds the stator 120. In other examples, the stator may radially surround the rotor.

[0046] The stator 120 comprises a stator rim 121 and a plurality of active stator components 122. The rotor 130 comprises a rotor rim 131 and a plurality of active rotor components 132. The active stator components 122 may be one or more permanent magnets, one or more permanent magnet modules, one or more coils, or one or more coil modules. Similarly, the active rotor components 132 may be one or more permanent magnets, one or more permanent magnet modules, one or more coils, or one or more coil modules. For example, the active stator components 122 may be coils, and the active rotor components 132 may be permanent magnet modules. In other examples, both the active stator components 122 and the active rotor components 132 may be coils. A radial air gap 116 separates the active rotor components 132 from the active stator components 122. Referencing a coil can include simply referring to a coil, or referring to a coil and a coil support, such as a coil tooth.

[0047] As shown in Figures 3 and 4, the annular cover 140 can be attached to the flange 150 of the circumferential cover of the rotor 130. The annular cover 140 may extend in a radial plane substantially perpendicular to the axial direction 105, and the circumferential cover (not shown) may radially surround the stator. The flange 150 can be understood as a side portion of the circumferential cover of the rotor. Removable fasteners such as bolts or screws can be used to join the annular cover 140 to the flange 150. An axial gap may be provided between the annular cover 140 and the active components of the stator 122 and rotor 132.

[0048] The annular cover 140 may comprise multiple segments 145. As seen in the example in Figure 4, removing the segments 145 may allow access to some active components of the rotor and / or stator. The annular cover 140 can protect the active components of the rotor and / or stator. In other examples, such a cover 140 may not be present.

[0049] In one aspect of this disclosure, a method 200 is provided, which is suitable for removing an active component 122 of a stator 120 of an electromachine 100. Method 200 is schematically shown in Figure 5.

[0050] In some examples, the electromechanical device may be a generator, particularly a generator for a wind turbine, or more specifically, a generator for a direct-drive wind turbine.

[0051] Active components used throughout this disclosure can be considered as magnetically and / or electrically active rotor or stator components. In some examples, multiple active stator components 122 may be multiple coils, and multiple active rotor components 132 may be multiple permanent magnet modules. The active component 122 to be removed may be a coil. Along with the coil, teeth supporting the coil may be removed.

[0052] The method includes removing one or more active rotor components 132 of the rotor 130 of the electromachine 100 when the rotor is in the removal start position in block 210. When one or more active components 132, for example, one or more permanent magnet modules, are removed, the components may be adjacent to each other in the circumferential direction 115. This can be seen in Figure 6, where two adjacent active components of the rotor 132 are removed. The removed components 132 leave a gap 160 in the rotor.

[0053] The starting position for removing the rotor can be selected according to its suitability for removing the active components of the rotor 132. For example, the rotor 130 may be rotated to a first position so that one or more active components of the rotor 132 to be removed are easily accessible. Relatively easy access may be, for example, from the upper side or upper portion of the nacelle. If the rotor is already in the appropriate position, it is not necessary to rotate the rotor.

[0054] The method may further include removing a portion of a side cover, for example, a side cover 145, to allow access to the active rotor component 132. In some examples, the side cover may be a segment 145 of an annular cover 140. By removing the side cover 145, an opening can be formed that allows removal of one or more active components of the rotor 132 (and / or stator 122) in the axial direction 105.

[0055] Additionally or alternatively, the method may include removing a portion of a circumferential cover (not shown) to allow access to the active rotor components 132. The circumferential cover may cover the rotor 130 along the axial direction 105 and the tangential or circumferential direction 115. The flange 150 may be an extension of the circumferential cover extending to the rear side (downstream side) of the generator. By removing a portion of the circumferential cover, one or more active rotor components 132 may be removed in the radial direction 110 and the axial direction 105. One or more active stator components 122 may also be removed in a similar manner.

[0056] In some examples, the rotor 130 may have multiple spacers 133. The spacers 133 may be positioned circumferentially 115 between the rotor rim or circumferential cover of the rotor and multiple active components of the rotor 132. The spacers 133 may be attached to the rotor rim 131, and the active components of the rotor 132 may be attached radially to the spacers 133, for example. The spacers 133 may have a width in the circumferential direction 115 that is substantially equal to the width of the active components of the rotor 132 in the circumferential direction 115, as shown in Figure 4, for example. Similarly, the spacers 133 may have an axial length in the axial direction 105 that is substantially equal to the length of the active components of the rotor 132 in the axial direction 105. The height of the spacers 133 in the radial direction 110 may be less than, substantially equal to, or greater than the height of the active rotor components 132 in the radial direction 110. In Figure 4, the height of the spacers 133 in the radial direction 110 is greater than the height of the active components of the rotor 132.

[0057] If spacers 133 are present on the rotor 130, removing the active rotor component 132 may further include removing one or more spacers radially adjacent to the active rotor component 132 by 110. Thus, for example, when the rotor 130 is in the first position, one or more spacers 133 and one or more active components of the rotor 132 can be removed.

[0058] One or more spacers 133 and one or more active components of the rotor 132 may be removed together, i.e., in a single operation, or separately. For example, one or more spacers 133 may be removed first, and one or more active components 132 may be removed thereafter. Removal can be performed in the axial direction 105 and / or radial direction 110. In Figure 6, removal may be performed in the axial direction 105 through the opening left by the previously separated segment 145.

[0059] The method further includes positioning the replacement tool 101 in the block 220 in the gap 160 left by the removed active rotor component 132. If the spacer 133 has also been removed, the replacement tool may be housed in the gap 160 left by the removed spacer 133 and the active component 132. The replacement tool 101 is configured to hold the active stator component 122, for example, a coil, or a coil and coil teeth.

[0060] The use of spacers 133, and if used, their height (radial dimension 110) can be selected according to the height (radial dimension 110) of the active components of the stator 122 and rotor 132. For example, if the height of the active rotor component 132 is smaller than the height of the active stator component 122, more space may be required to accommodate the replacement tool 101, and therefore spacers can be used. The rotor diameter can also be increased in some examples to create more radial space 110 for accommodating the spacers 133 and replacement tool 101.

[0061] Alternatively, or in addition to the use of spacers, the height (radial dimension 110) of the active rotor component 132 can be increased. For example, the height of the permanent magnet module, particularly its base (i.e., the component configured to be mounted to the rotor rim 131 or spacer), can be increased. In some examples, the diameter of the rotor can also be increased. By using one or more of the aforementioned options, one or more pull-out tools 101 can have sufficient radial free space to be positioned for pulling out the active rotor component 132.

[0062] Taking the above into consideration, a rotor 130 can be provided, comprising a rotor rim 131 and a plurality of removable rotor elements attached to the rotor rim 131. During use, the rotor elements face the stator. The height of the rotor elements is substantially equal to or greater than the height of the active stator components 122 so that one or more of the active stator components 122 can rotate with the rotor when held by the rotor 130. The height can be measured along the radial direction 110.

[0063] In this way, as described throughout this disclosure, sufficient space can be provided in the rotor 130, particularly in the radial direction 110, for arranging the tool 101.

[0064] In some examples, the rotor element is an active rotor component 132, such as a permanent magnet module.

[0065] In some other examples, the rotor element comprises an assembly of an active rotor component and a spacer. For example, the rotor element may be an active rotor component 132 mounted on a spacer 133 such that the active component is attached to the rotor rim by the spacer.

[0066] Such rotors may be included in electromechanical devices, such as generators. Rotors and generators may be suitable for wind turbines, particularly direct-drive wind turbines.

[0067] The replacement tool 101 can be introduced axially into the gap 160. Alternatively, the tool 101 may be introduced radially into the gap 160. When it reaches a desired position, for example, a desired axial position, the replacement tool 101 can be fixed in place. For example, the tool 101 can be releasably attached to the rotor rim, for example, through nuts and bolts. The tool 101 can also clamp a part of the rotor, for example, the rotor rim. The replacement tool 101 attached to the rim and rotor cover can be seen in Figure 7. In this example, the rotor cover can be fixed directly to the rotor rim and form an integral part with the rotor rim, i.e., the rotor cover rotates with the rotor rim. Multiple replacement tools 101 can be placed in the gap 160 and fixed to the rotor 130 in particular along the axial direction 105. For example, two replacement tools 101 can be placed axially in the gap 160 so that the longitudinal end of the active stator component 122 can later be gripped by the replacement tools 101.

[0068] The method further includes rotating the rotor to a aligning position in block 230 so that the replacement tool 101 is radially aligned with the active stator component 122 to be removed. In some examples, the active stator component 122 to be removed may be a coil. The active component 122 may be located in a circumferential position of the stator 120 that is difficult to access, i.e., the active component of the stator 122 may be difficult to pull out from that position. For example, in the case of a direct-drive generator of a wind turbine, the active stator component 122 may be located near the tower or wind turbine blades. If removed directly from such a position, the active component 122 may collide with the tower or blades.

[0069] The method further includes picking the active stator component 122 to be removed with the replacement tool 101 in block 240. The method may further include pushing the active stator component 122 so that it is pulled out toward the replacement tool 101 by a movable element 155. The movable element 155 may be configured for this purpose. The movable element 155 can move the active component 122 radially outward 111. The movable element 155 can advance radially outward 111 for this purpose. The movable element 155 that pushes the active stator component 122 toward the tool 101 can be seen in Figure 8.

[0070] The active stator component 122 may first need to be separated from the stator rim 121. For example, before displacing the active component 122 radially outward 111 using the movable element 155, one or more bolts connecting the active component 122 to the stator rim 121 may need to be removed.

[0071] The movable element 155 may already be incorporated into the stator 120, for example, into a recess 135 (see Figure 9A) or protrusion 125 (see Figure 9B) of the stator. For example, if a particular circumferential region of the stator 120 is known to be problematic for replacing an active component 122 mounted therein, one or more extrusion elements 155 can be positioned together with these components of the stator. The protrusion and / or recess may be provided on the stator frame 142.

[0072] In some examples, the stator 120 may have one or more recesses 135 that can house one or more extruded elements 155. The recesses may extend partially or entirely along the axial length of the stator. In the first case, there may be multiple recesses along the axial direction 105. For example, two recesses may be provided along the axial direction at two different axial positions. The extruded elements 155 may be housed in each recess.

[0073] Similarly, one or more recesses 135 may be provided along the circumferential direction 115. For example, the stator 120 may have three or four recesses provided at approximately equal intervals along the circumferential direction. Each of the recesses may extend along the overall or partial axial length of the stator. One or more extruded elements 155 can be positioned at specific axial locations within each recess.

[0074] In some other examples, the stator 120 may have one or more protrusions 125 that can house one or more extrusion elements 155. The protrusions 125 may extend partially or entirely along the axial length of the stator. In the first case, there may be multiple protrusions along the axial direction 105. For example, two protrusions may be provided along the axial direction at two different axial positions. The extrusion elements 155 may be housed inside or beneath each protrusion.

[0075] Similarly, one or more protrusions 125 may be provided along the circumferential direction 115. For example, the stator 120 may have three or four protrusions provided at approximately equal intervals along the circumferential direction. Each of the protrusions may extend along the partial or overall axial length of the stator. One or more extruded elements 155 can be positioned at specific axial locations within each protrusion.

[0076] The dimensions of the recesses 135 or protrusions 125 can be selected according to the dimensions of the extruded element 155. The circumferential spacing between adjacent protrusions or recesses in the circumferential direction may be substantially the same along the circumferential direction 115. This may be important for proper load distribution in the stator.

[0077] The movable element 155 may be fixedly or removably connected to the protrusion or recess. The movable element 155 may be retractable. In some examples, the movable element 155 may be a rod, a screw, such as a worm screw, or any suitable element or tool that can push the active stator component 122 out of the stator rim 121.

[0078] In some examples, the replacement tool 101 does not need to move radially 110 to pick up the active stator part 122. The tool does not need to be configured to move radially 110. The movable element 155 can push the active part toward the replacement tool 101, and the tool 101 can grip the active part 122. The replacement tool may have a clamp or clamping portion for this purpose, for example. The active stator part 122 may be clamped by the tool. For example, the tool may clamp two opposing circumferential recesses of the part 122 with the tool 101. In some other examples, the replacement tool 101, for example, a portion of the tool, can move radially (inward, see arrow 114 in Figure 8) to pick up the active part 122. In these examples, the tool 101 is configured to move radially.

[0079] The method further includes rotating the rotor 130 to the pull-out position in block 250 and removing the active stator component 122 from the rotor 130 in block 260. In some examples, the active component 122 may be removed axially 105. The replacement tool 101 may then be separated or left attached for mounting the new active stator component 122. In some examples, the pull-out position may be the removal start position. In other examples, the pull-out position may be different from the removal start position.

[0080] In this method, other active components, such as other active stator components 122, do not need to be pulled out to reach the damaged active component 122. Rather, the replacement tool 101 is moved from a first removal starting position to a second alignment position where the damaged active component 122 is located, and then moved to a pull-out position, such as the first position. Therefore, this method may be easier and more efficient to implement than other methods for removing or replacing active stator components 122 in locations that are difficult to access or operate.

[0081] The new active stator component 122 can be joined to the replacement tool 101, and the above steps can be carried out in reverse order for installation. These steps are shown below. These may be carried out after block 260 of method 200, or independently. These are shown below as separate methods 300, but the replacement method may be carried out together with the removal method 200.

[0082] Another aspect of this disclosure provides a method 300 for mounting an active stator component 122 to a stator 120 of an electromachine 100. Method 300 is schematically shown in Figure 10. The electromachine 100 may be a generator, more particularly a generator for a wind turbine, and more particularly a generator for a direct-drive wind turbine.

[0083] Figure 12 shows the stator gap 65 in which the active stator component 122 is installed.

[0084] The method includes positioning the active stator component 122 on the replacement tool 101 attached to the rotor 130 while the rotor is in the mounting start position in block 310. This step is shown in Figure 11. The rotor's mounting start position may correspond to the pull-out position of method 200 or a different position. In some examples, the active stator component 122 may be a coil, and the active rotor component 132 may be a permanent magnet module. If method 300 is not performed as a continuation of method 200, it may be necessary to remove one or more active rotor components 132 and optionally one or more spacers 133 to form a gap 160 in the rotor and position the tool 101. The rotor may be rotated to the mounting start position or may already be in the mounting start position.

[0085] The method further includes rotating the rotor in block 320 to the insertion position so that the replacement tool 101 is radially aligned with the gap 165 of the stator into which the active stator component 122 is mounted. Such a position is achieved in Figure 12. If these methods are performed sequentially, the insertion position may be the alignment position of method 200.

[0086] The method further includes inserting the active stator component 122 into the gap 65 in block 330. In some examples, a movable element 155 can pick up the active component 122 from the replacement tool 101 and move it toward the stator rim 121. The movement may be radial 110, particularly radially inward (see arrow 114 in Figure 8).

[0087] The movable element 155 may be the same as the one used to pull out the active stator component 122 in method 200.

[0088] Once positioned correctly, the active components of the stator 122 can be attached to the stator rim 121, for example, using nuts and bolts.

[0089] The method may further include rotating the rotor 130 to the mounting end position and removing the replacement tool 101. In some examples, the mounting end position may be the mounting start position. Before removing the tool 101, it may be necessary to separate the replacement tool 101 from the rotor circumferential cover. In some examples, the tool 101 may be pulled out axially 105.

[0090] When the rotor gap 160 between adjacent active components in the circumferential direction of the rotor 132 is released, one or more active rotor components 132 can be placed in the gap to fill the gap 160 (see Figure 4). For example, one or more permanent magnet modules can be mounted on the rotor rim 131. Any covers 145 that were removed to access the active components 122, 132 can be reattached to the generator (see Figure 3).

[0091] In this way, the active stator component 122 can be replaced conveniently and efficiently.

[0092] In another aspect of this disclosure, a replacement tool 101 is provided. The replacement tool is configured to hold an active stator component 122 in an electromachine. The replacement tool 101 can be used in method 200, method 300, and a combination of methods 200 and 300.

[0093] An example of the replacement tool 101 is schematically shown in Figure 13. The replacement tool 101 comprises a holding portion 410 and an anchor portion 420. The holding portion is configured to hold the active stator component 122. The anchor portion is configured to fix the replacement tool 101 to the rotor 130, for example, to the circumferential cover of the rotor.

[0094] The retaining portion 410 may comprise two substantially parallel arms 411, 411' extending from the base 414. The parallel arms 411, 411' may be configured to surround the active stator component 122. The height of the arms 431 may be designed to be approximately the same as the height of the active stator component 122.

[0095] In some examples, the height 431 of the arms 411, 411' may be adjustable. For example, the arms may be telescopic.

[0096] The retaining portion 410 may include two opposing inward projections 412, 412' configured to hold or clamp the active stator component 122. For example, each arm 411, 411' may have inward projections 412, 412' for this purpose. When mounted on the rotor 130, the arms may extend radially 110, and the projections may extend tangentially 115.

[0097] As shown in Figure 13, the protrusions can be located on or near the end 415 of the replacement tool 101 opposite the anchor portion 420. The protrusions 412, 412' can be configured to fit into recesses that the active stator component 122 may have. In some examples, the recesses in the active component 122 may be accessible to the tool 101 only after the active component 122 has been displaced radially (outward).

[0098] The holding portion 410 may include a base 414 from which arms 411, 411' can extend. When the active stator component 122 is picked, the base 414 may come into contact with the upper (radially outward) side of the active component 122.

[0099] The anchor portion 420 may have one or more grippers 421, 421' for gripping the rotor 130, for example, a portion of the rotor's circumferential cover. The grippers may be clamps or any suitable components for releasably connecting the tool 101 to the rotor. In some examples, the grippers may extend from the base portion 414.

[0100] Although only a few examples are disclosed herein, other alternative forms, modifications, uses, and / or equivalents thereof are possible. Furthermore, all possible combinations of the examples described are also covered. Accordingly, the scope of this disclosure should not be limited by any particular example, but should be determined solely by a fair reading of the appended claims. [Explanation of Symbols]

[0101] 10 Wind Turbines 12 Ground 14 Support System 15 Towers 16 Nacer 18 rotors 20 Hubs 22 rotor blades 24. Blade base 26 Load transfer region 28 Wind direction 30 rotor shaft 32 Pitch System 34 Pitch axis 36 Wind Turbine Controller 38 Yaw axis 40 processors 42 Electric Generators 44 Main shaft, rotor shaft 46 Gearbox 48 High-speed shaft 50 Couplings 52 Main frame, support 54 Separation support means 56 Yaw drive mechanism 58 Weather Measurement Systems 60 Main forward support bearing 62 Main rear support bearing 64 Drivetrain 65 stator gap 66 Pitch Assembly 68 Pitch Drive System 70 sensors 72 pitch bearing 74 Pitch drive motor 76 Pitch Drive Gearbox 78 Pitch Drive Pinion 80 Pitch Control System 84 Power Generators 86 Hollow 88 Inner self 90 Transformer 100 Electrical machinery 101 Replacement tools, drawer tools 103 Torque Arm 105 Axis 110 Radial 111 Radial outward direction 114 Arrow 115 Tangential direction, circumferential direction 116 Radial air gap 120 stator 121 Stator Rim 122 Active Stator Components 125 Convex part 130 rotors 131 Rotary Rim 132 Active rotor parts 133 Spacer 135 recess 140 Ring Cover 142 Stator Frame 145 segments, side cover 150 flange 155 Movable elements, extrusion elements 160 rotor gap 165 Gap 200 Removal Method 300 ways 410 Holding part 411 Arm 411' Arm 412 Inner protrusion 412' Inner protrusion 414 Base 415 End 420 Anchor section 421 Grippa 421' Grippa 431 Height

Claims

1. When the rotor (130) of the electromechanical machine (100) is in the removal start position, removing one or more active rotor components (132) of the rotor (130) (210); Placing an exchange tool (101) in a gap (160) formed by removing the active rotor component (132) (220); Rotating the rotor (130) to an alignment position so that the exchange tool (101) is radially aligned (110) with the active stator component (122) to be removed (230); Radially picking the active stator component (122) to be removed by the exchange tool (101) (240); Rotating the rotor (130) to a withdrawal position (250); Removing the active stator component (122) from the rotor (130) (260) and a method (200) including this.

2. The method (200) according to claim 1, further including removing a side cover (145) to enable access to the active rotor component (132).

3. The method (200) according to claim 1, wherein the active rotor component (132) and / or the active stator component (122) are removed axially (105).

4. The method (200) according to claim 1, wherein removing the active rotor component (132) (210) further includes removing one or more spacers (133) radially adjacent to the active rotor component (132).

5. The method (200) according to claim 1, further including pushing out the active stator component (122) so as to be pulled out toward the exchange tool (101) by a movable element (155).

6. The method (200) according to claim 1, wherein the movable element (155) is incorporated into the stator (120), particularly a recess (135) or a protrusion (125) of the stator (120).

7. The method (200) according to claim 1, wherein the active stator component (122) is clamped by the exchange tool (101).

8. The method (200) according to claim 1, wherein the withdrawal position is the removal start position.

9. The method (200) according to claim 1, wherein the electromechanical machine (100) is a generator, in particular a generator (42) for a wind turbine (10), more particularly a generator (42) for a direct drive wind turbine.

10. During the rotor (130) being in the mounting start position, arranging (310) an active stator component (122) on an exchange tool (101) attached to the rotor (130), wherein the exchange tool (101) is arranged within a rotor gap (160) suitable for receiving one or more active rotor components (132) of the rotor (130), the arranging (310); Rotating (320) the rotor (130) to an insertion position such that the exchange tool (101) is radially (110) aligned with a gap (165) of a stator (120) in which the active stator component (122) is to be mounted; Radially inserting (330) the active stator component (122) into the gap (165); A method (300) comprising the above.

11. A rotor (130) comprising a rotary rim (131) and a plurality of removable rotor elements attached to the rotary rim (131), wherein in use, the rotor elements face a stator (122), and a height measured in the radial direction of the rotor elements is substantially equal to or greater than a height measured in the radial direction of the active stator component (122) such that after the active stator component (122) is picked up by the exchange tool (101) arranged in a rotor gap (160) suitable for receiving one or more active rotor components (132) of the rotor (130), the rotor elements can rotate with the rotor (130).

12. The rotor (130) according to claim 11, wherein the rotor element is an active rotor component (132).

13. The rotor (130) according to claim 11, wherein the rotor element comprises an assembly of an active rotor component (132) and a spacer (133).

14. The rotor (130) according to claim 11, wherein the active rotor component (132) is a permanent magnet module.

15. An electromechanical machine (100) comprising the rotor (130) according to claim 11.

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