Adjustable support system for wind turbine main shafts

Abstract

An adjustable support system for supporting and securing a longitudinally extending main shaft within the nacelle of a wind turbine when the gearbox is removed comprises: a crossbeam rigidly mounted within the nacelle and extending over the main shaft; a saddle having an arc-shaped recess for engaging with the main shaft from above and movably connected to the crossbeam; a flexible strap for supporting the main shaft from below by engaging with the main shaft from below; and a lateral saddle adjuster connected to the saddle and configured to adjust the lateral position of the saddle relative to the main shaft.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 512,103, filed on Jul. 6, 2023, the entire content of which is incorporated herein by reference.

[0002] This application relates to an accessory for use in supporting the main shaft of a wind turbine, specifically during the replacement or repair of a gearbox.

Background Art

[0003] A wind turbine includes a tall tower with a rotor having rotor blades mounted at the top, and a hub to which the rotor blades are attached. The hub is attached to one end of a main shaft, which extends substantially horizontally from the hub into the nacelle of the wind turbine. The other end of the main shaft is attached to a gearbox within the nacelle with the gearbox connected to a generator. Wind is captured by the rotor blades, causing the hub to rotate, which in turn rotates the main shaft. This rotation drives the gears and the generator to generate electricity. The main shaft, gearbox, and generator are located within the nacelle at the top of the tower, and the nacelle is essentially a compartment that houses the turbine components.

[0004] To efficiently repair or replace the gearbox, it is necessary to remove the gearbox from the end of the main shaft and lower it to the ground. After repair or when replacement is required, the gearbox is lifted back up to the nacelle and reinstalled on the end of the main shaft.

[0005] However, the gearbox also secures the end of the main shaft. So when the gearbox is first removed, the main shaft may tilt due to the weight of the rotor at the other end of the main shaft, causing the entire rotor to fall to the ground or at least damaging the main shaft, nacelle, and / or rotor.

[0006] To prevent the spindle from tilting, one of two strategies is employed. The first, more elaborate strategy involves removing the rotor from the spindle and lowering it to the ground before removing the gearbox from the spindle. This requires a large crane and considerable time. The second strategy involves using a "spindle fixation device" to lift the spindle to the nacelle and hold it in place before removing the gearbox, thus avoiding the need to remove the rotor. Various spindle fixation devices are known in the art, but generally, among many, they have one or more problems, including being complex to install, difficult to use, not being simple to properly seat on the spindle, being usable with only one type of wind turbine, and / or only being able to support the spindle without fixing its rotation. [Overview of the project] [Problems that the invention aims to solve]

[0007] Despite recent advances, the need for spindle fixtures that address one or more of the problems associated with existing spindle fixtures remains in this field. [Means for solving the problem]

[0008] An adjustable support system for supporting and securing a longitudinally extending main shaft within the nacelle of a wind turbine when the gearbox is removed from the main shaft comprises: a crossbeam rigidly mounted within the nacelle and extending over the main shaft; a saddle having an arc-shaped recess for engaging with the main shaft from above and movably connected to the crossbeam; a flexible strap for supporting the main shaft from below by engaging with the main shaft from below; and a lateral saddle adjuster connected to the saddle and configured to adjust the lateral position of the saddle relative to the main shaft.

[0009] The adjustable support system is relatively easy to install. The adjustability of the support system allows for proper engagement between the saddle and the spindle, thereby ensuring that the spindle is securely fixed and prevented from tilting. Furthermore, the same support system can be used to tilt the spindle, for example, by approximately 0.5° to 1°, facilitating the removal and / or reinstallation of components such as the main bearings and gearbox.

[0010] The crossbeam is rigidly mounted within the nacelle and extends over the main shaft. The crossbeam can be mounted at any convenient and well-supported position within the nacelle, allowing it to extend laterally across the nacelle above the main shaft. In some embodiments, the crossbeam is mounted on longitudinal beams mounted within the nacelle. In some embodiments, the longitudinal beam is located above the main shaft and mounted on pillow blocks within the nacelle. The longitudinal beam may also be mounted on the main bearing or bed plate within the nacelle. In some embodiments, the crossbeam includes a mounting flange to assist in mounting the crossbeam within the nacelle, for example, by using a pinning connection including a pin inserted through at least one opening in the mounting flange and at least one corresponding opening in the structure to which the crossbeam is mounted. The crossbeam may further include a connecting structure to which other components of the adjustable support system can be connected. The connecting structure may also include a mechanism for fastening various components of the adjustable support system. Examples of connecting structures include lugs, rings, buckles, and cam-alongs.

[0011] The saddle has an arc-shaped recess for engaging with the spindle from above. The arc-shaped recess is preferably molded to conform to the curvature of the spindle. In some embodiments, the arc-shaped recess has sufficient depth to prevent the spindle from rolling out of the saddle if the spindle experiences a lateral load. In some embodiments, the arc-shaped recess has a liner that engages with the surface of the spindle. The liner includes a material (e.g., rubber, other elastomer) that provides more friction when the saddle is engaged with the spindle and prevents the spindle from rotating. In some embodiments, the liner material is also sufficiently compressible to provide a better fit of the saddle to the surface of the spindle, which further facilitates the fixing of the spindle.

[0012] The saddle is movably connected to the transverse beam. The movable connection allows the saddle to move with degrees of freedom, thereby facilitating proper positioning of the saddle relative to the spindle for better engagement between the saddle and the spindle. In some embodiments, the saddle is laterally movable along the transverse axis and rotatable about a vertical axis passing through the saddle, in order to allow adjustment of the saddle's position relative to the spindle. In some embodiments, the saddle is laterally movable along the transverse axis, vertically movable along the vertical axis, and / or rotatable about a vertical axis.

[0013] In some embodiments, the movable connection is provided by rigging between the saddle and the crossbeam. In some embodiments, the saddle is attached to the crossbeam solely by rigging. The rigging may consist of any combination of ropes, cables, chains, etc. In some embodiments, chains are used. In some embodiments, the rigging consists of four chains, namely two front chains and two rear chains, extending between the saddle and the front and rear surfaces of the crossbeam.

[0014] Because the saddle is movably connected to the crossbeam, various saddle position adjusters can be used to properly position the saddle relative to the spindle for better engagement between the saddle and the spindle. For this purpose, a lateral saddle adjuster is connected to the saddle. The lateral saddle adjuster is configured to adjust the lateral position of the saddle relative to the spindle. In some embodiments, the lateral saddle adjuster also helps to stabilize the saddle against lateral loads, preventing the spindle from rotating about the vertical axis passing through the main bearing of the wind turbine. In some embodiments, the lateral saddle adjuster comprises an actuator that applies a lateral force to the saddle. Any suitable actuator may be used, for example, a mechanical actuator, a hydraulic actuator, or an electric actuator. In some embodiments, the actuator is a mechanical actuator. The mechanical actuator may comprise, for example, a threaded rod, a crank, a turnbuckle, a linkage, etc. In some embodiments, the mechanical actuator comprises a turnbuckle. Any number of actuators, for example, one, two, three, four, five or more actuators, may be used. In some embodiments, the lateral saddle adjuster comprises at least two actuators, such as turnbuckles, that connect the saddle to the nacelle from both sides of the saddle. By operating the lateral saddle adjuster, the saddle is shifted laterally to one or the other relative to the main shaft, thereby allowing the recess to be properly aligned with the main shaft. The lateral saddle adjuster can connect the saddle to any suitable support structure within the nacelle, such as a longitudinal beam or crane component. In some embodiments, the lateral saddle adjuster connects the saddle to a longitudinal beam located above the main shaft.

[0015] In some embodiments, the adjustable support system further comprises a vertical saddle adjuster. In some embodiments, the vertical saddle adjuster is connected to a crossbeam. The vertical saddle adjuster is configured to move the saddle vertically to fix the main shaft between the saddle and the flexible strap and / or to change the inclination angle of the main shaft within the nacelle. In some embodiments, the vertical saddle adjuster comprises an actuator that applies a vertical force to the saddle. Any suitable actuator may be used, for example, a mechanical actuator, a hydraulic actuator, or an electric actuator. In some embodiments, the actuator is a mechanical actuator. The mechanical actuator may comprise, for example, a threaded rod, a crank, a turnbuckle, a linkage, etc. Any number of actuators, for example, one, two, three, four, five or more actuators, may be used. In some embodiments, the vertical saddle adjuster comprises at least two actuators, for example, threaded rods, located on both longitudinal sides of the crossbeam. In some embodiments, the vertical saddle adjuster comprises threaded rods. In some embodiments, the threaded rod is screwed through a threaded opening in the crossbeam, so that when the threaded rod is rotated, the end of the threaded rod engages with the saddle, causing the saddle to move vertically. In some embodiments, the saddle has a recess into which the threaded rod engages. The recess allows the saddle to rotate and move somewhat laterally when the threaded rod contacts the top of the saddle.

[0016] The adjustable support system further comprises a flexible strap that engages with the spindle from below to support the spindle from below. The flexible strap is wrapped around the underside of the spindle to support the spindle from below. The flexible strap can be attached to any suitably positioned component of the wind turbine within the nacelle, or to an accessory within the nacelle, such as a crossbeam, bed plate, longitudinal beam, crane component, etc. In some embodiments, the flexible strap is connected to a crossbeam. In some embodiments, the flexible strap is connected to a longitudinally facing surface of the crossbeam. In some embodiments, the flexible strap is connected to a connecting ring and / or a fastening mechanism. The fastening mechanism, such as a cam-along, buckle (e.g., turnbuckle, belt buckle), etc., helps to fasten the flexible strap to the surface of the spindle. In some embodiments, the flexible strap is made of a material that is strong enough to support the weight of the spindle, while having sufficient flexibility to conform to the shape of the spindle when the flexible strap is fastened around the lower portion of the spindle. Examples of such materials include thermoplastics (e.g., nylon), rubber, and canvas. In some embodiments, two or more flexible straps are used, for example, one, two, three, or four or more flexible straps. In some embodiments, two flexible straps are used. In some embodiments, the front flexible straps are connected to the front surfaces of the crossbeams on both sides of the main shaft. In some embodiments, the rear flexible straps are connected to the rear surfaces of the crossbeams on both sides of the main shaft. Using flexible straps to support the main shaft from below is convenient and inexpensive, and can be easily adapted to any wind turbine configuration without requiring other more elaborate support structures beneath the main shaft.

[0017] In some embodiments, two or more of the following components work together to simplify the process of securing the spindle: a flexible strap, a movable saddle, a vertical saddle adjuster, and a lateral saddle adjuster, providing adjustability of the saddle and flexible strap through several degrees of freedom. The adjustability of the saddle and the flexibility of the strap allow the saddle and strap to be properly seated on the spindle, thereby ensuring that the spindle is securely fixed and prevented from tilting. Furthermore, using the same support system, the spindle can be tilted, for example, by about 0.5° to 1° to facilitate the removal and / or reinstallation of the gearbox, main bearings, etc.

[0018] Further features will be described or revealed in the following "Modes for Carrying Out the Invention." It should be understood that each feature described herein can be used in any combination with any one or more of the other features described herein, and that each feature does not necessarily depend on the presence of other features, except as is obvious to those skilled in the art.

[0019] For a clearer understanding, a preferred embodiment will be described in detail below, with reference to the attached drawings. [Brief explanation of the drawing]

[0020] [Figure 1] This shows a rear perspective view of an adjustable support system for supporting and securing the longitudinally extending main shaft in relation to other components of the wind turbine nacelle. [Figure 2] Figure 1 shows another rear perspective view illustrating the adjustable support system. [Figure 3] Figure 1 shows a rear perspective view of the adjustable support system with various system components and the nacelle removed. [Figure 4] Figure 3 shows another rear perspective view illustrating the adjustable support system. [Figure 5] Figure 3 shows a front view illustrating the adjustable support system. [Figure 6]Represents a rear view showing the adjustable support system shown in FIG. 3. [Figure 7] Represents a side view showing the adjustable support system shown in FIG. 3. [Figure 8] Represents a front perspective view showing the adjustable support system shown in FIG. 3. [Figure 9] Represents a rear perspective view showing the adjustable support system shown in FIG. 3. [Figure 10] Represents a rear perspective view of an adjustable support system without a flexible strap. [Figure 11] Represents a rear view showing the adjustable support system shown in FIG. 10. [Figure 12] Represents a side view showing the adjustable support system shown in FIG. 10. [Figure 13] Represents a front view showing the adjustable support system shown in FIG. 10.

Mode for Carrying Out the Invention

[0021] The drawings show an adjustable support system 1 for supporting and fixing a main shaft 101 extending longitudinally within a nacelle of a wind turbine when a gearbox is removed from the rear end of the main shaft 101. The main shaft 101 has a rotor hub flange 102 mounted on its front end, and the rotor hub flange 102 is configured to have a rotor hub (not shown) mounted thereon, and the rotor hub has rotor blades mounted thereon. The nacelle includes a bed plate 103 to which various components of the nacelle are mounted, and the bed plate 103 can be mounted on the top of the tower of the wind turbine. A gearbox pillow block 104 is mounted on the bed plate 103.

[0022] During maintenance work on a wind turbine, one or more cranes are typically mounted inside the wind turbine nacelle. The gearbox pillow block 104 is one of several locations where such cranes can be supported. Therefore, maintenance work may include removing the upper portion of the pillow block 104 and replacing the upper portion with a pillow block mount 90, from which various other structures, such as two longitudinal beams 91, can be mounted. The longitudinal beams 91 are used to support the crane components, but can also be used to support components of other fixtures, such as the adjustable support system 1.

[0023] The adjustable support system 1 is firmly mounted to the longitudinal beams 91 and includes transverse beams 5 that extend laterally within the nacelle between the longitudinal beams 91 and over the main axis 101. The transverse beams 5 are pinned to one longitudinal beam 91 at a first end through a first mounting flange 6 and to the other longitudinal beam 91 at a second end through a pair of second mounting flanges 7.

[0024] The saddle 10 is located beneath the crossbeam 5 and is movably mounted to the crossbeam 5, and has an arc-shaped recess 11 that is molded to fit snugly onto the spindle 101 when the saddle 10 engages with the top portion of the spindle 101. The arc-shaped recess 11 is preferably deep enough to restrain the spindle 101 against lateral loads from wind and other forces, thereby preventing the spindle 101 from rolling off the saddle 10. The surface of the recess 11 is fitted with a rubber pad to protect the spindle 101 from damage when the saddle 10 engages with the spindle 101. The saddle 10 is attached to the crossbeam 5 by rigging 15. The rigging may consist of any combination of ropes, cables, chains, etc., but the drawing shows four chains, namely two front chains and two rear chains, extending between the saddle 10 and the front and rear surfaces of the crossbeam 5. Due to the flexibility of the rigging 15, it gives the saddle 10 a range of motion. The rigging 15 allows the saddle 10 to be lifted by the crossbeam 5.

[0025] The adjustable support system 1 also includes two flexible straps 50, including a front flexible strap 50a and a rear flexible strap 50b, although one flexible strap or three or more flexible straps may be used. The flexible straps 50 are wrapped around the spindle 101 to support the spindle 101 from below. The flexible straps 50 are connected to the crossbeam 5. The front flexible strap 50a is connected to the front surface of the crossbeam 5 on both sides of the spindle 101. Similarly, the rear flexible strap 50b is connected to the rear surface of the crossbeam 5 on both sides of the spindle 101. The flexible straps 50 may be connected to connecting rings 51 and / or fastening mechanisms 52 on the surface of the crossbeam 5 (see Figures 1 and 2). The fastening mechanisms 52, such as cam-alongs, buckles (e.g., turnbuckles, belt buckles), etc., help to fasten the flexible straps 50 to the surface of the spindle 101. Although the flexible strap 50 is shown attached to the crossbeam 5, the flexible strap can be attached to any suitably positioned component of the wind turbine within the nacelle, or to an accessory within the nacelle, such as a bed plate, longitudinal beams, or crane components. The flexible strap 50 is preferably made of a material that is flexible enough to conform to the shape of the main shaft 101 when the flexible strap 50 is tightened around the main shaft 101, while being strong enough to support the weight of the main shaft 101. Examples of such materials include thermoplastics (e.g., nylon), rubber, and canvas. Using a flexible strap to support the main shaft from below is convenient and inexpensive, and can be easily adapted to any wind turbine configuration without requiring other more elaborate support structures beneath the main shaft. The flexible strap helps prevent the main shaft from coming off the saddle during specific strong wind events.

[0026] A vertical saddle adjuster 20 is located at the bottom edge of the crossbeam 5, and the vertical saddle adjuster 20 comprises a plate 21 having a front end and a rear end that extend forward and rearward from the crossbeam 5, respectively. The vertical saddle adjuster 20 further comprises a front threaded boss 22a and a rear threaded boss 22b, and a front rod 23a and a rear rod 23b are screwed into the threaded bosses, respectively. The bottom ends of the threaded rods 23a and 23b are seated in the respective recesses on the top surfaces of the front contact block 12a and the rear contact block 12b on the upper surface of the saddle 10. When the arc-shaped recess 11 of the saddle 10 engages with the spindle 101, the threaded rods 23a and 23b are adjusted to press the saddle 10 more snugly against the spindle 101, thereby fixing the spindle 101 in place. Further adjustment of the threaded rods 23a and 23b can be performed by pressing down on the spindle 101, thereby changing the tilt angle of the spindle 101. By reversing the adjustment, it is possible to return the spindle 101 to its original tilt.

[0027] To better laterally align the saddle 10 and the spindle 101, the adjustable support system 1 further comprises a lateral saddle adjuster 30. The lateral saddle adjuster 30 is connected to the saddle 10 and is configured to adjust the lateral position of the saddle 10 relative to the spindle 101. The lateral saddle adjuster 30 also helps to stabilize the saddle 10 against lateral loads, for example under the influence of strong crosswinds, and helps to prevent the spindle 101 from rotating about the vertical axis passing through the main bearing. In various embodiments, the lateral saddle adjuster may comprise any number and type of actuators, e.g., mechanical actuators, hydraulic actuators, electric actuators, etc. Mechanical actuators may comprise cranks, turnbuckles, linkages, etc. The lateral saddle adjuster applies a lateral force to the saddle, causing it to move laterally. In the illustrated embodiment, the lateral saddle adjuster 30 comprises two turnbuckles 31 located on opposing lateral edges of the saddle 10, connected to the longitudinal beam 91 by pinning connectors 32 and to the saddle 10 by pinning connectors 33. By operating the turnbuckles 31, the saddle 10 is shifted laterally in one or the other direction relative to the spindle 101, thereby allowing the recess 11 to be properly aligned with the spindle 101. Operating the turnbuckles 31 is also necessary to help raise and lower the saddle 10.

[0028] The flexible strap, movable saddle, vertical saddle adjuster, and lateral saddle adjuster all work together to simplify the process of securing the spindle with the spindle fixer by providing adjustability of the saddle and flexible strap through several degrees of freedom. The adjustability of the saddle (longitudinal, lateral, and rotational) and the flexibility of the strap allow the saddle and strap to be properly seated on the spindle, thereby ensuring that the spindle is securely fixed and prevented from tilting. Furthermore, using the same support system, the spindle can be tilted, for example, by about 0.5° to 1° to facilitate the removal and / or reinstallation of the gearbox, main bearings, etc.

[0029] Novel features will become apparent to those skilled in the art upon examination of the specification. However, it should be understood that the scope of the claims should not be limited by the embodiments, but rather should be given the broadest possible interpretation consistent with the claims and the expression herein.

Claims

1. An adjustable support system for supporting and securing a longitudinally extending main shaft within the nacelle of a wind turbine when the gearbox is removed from the main shaft, A crossbeam is firmly mounted within the nacelle and extends above the main shaft, A saddle having an arc-shaped recess that engages with the main shaft from above, and which is movably connected to the crossbeam, A flexible strap that engages with the main shaft from below and supports the main shaft from below, An adjustable support system comprising: a lateral saddle adjuster connected to the saddle and configured to adjust the lateral position of the saddle relative to the main shaft.

2. The adjustable support system according to claim 1, wherein the lateral saddle adjuster also helps to stabilize the saddle against lateral loads, thereby preventing the main shaft from rotating about a vertical axis passing through the main bearing of the wind turbine.

3. The adjustable support system according to claim 1 or 2, wherein the lateral saddle adjuster comprises an actuator that applies a lateral force to the saddle.

4. The adjustable support system according to claim 3, wherein the actuator comprises a mechanical actuator.

5. The adjustable support system according to claim 4, wherein the mechanical actuator comprises a turnbuckle.

6. The adjustable support system according to claim 1 or 2, wherein the lateral saddle adjuster comprises at least two turnbuckles connecting the saddle to the nacelle from both sides of the saddle.

7. The adjustable support system according to any one of claims 1 to 6, wherein the lateral saddle adjuster connects the saddle to a longitudinal beam located above the main shaft.

8. The adjustable support system according to any one of claims 1 to 7, further comprising a vertical saddle adjuster connected to the crossbeam, wherein the vertical saddle adjuster is configured to move the saddle in a vertical direction to fix the main shaft between the saddle and the flexible strap, and / or to change the inclination angle of the main shaft within the nacelle.

9. The adjustable support system according to claim 8, wherein the vertical saddle adjuster comprises a threaded rod screwed through a threaded opening in the crossbeam, and by rotating the threaded rod, the end of the threaded rod engages with the saddle, thereby translating the saddle vertically.

10. The adjustable support system according to claim 9, wherein the saddle has a recess into which the threaded rod engages.

11. The adjustable support system according to any one of claims 1 to 10, wherein the saddle is movably connected to the crossbeam by a rigging.

12. The adjustable support system according to any one of claims 1 to 11, wherein the saddle is movable laterally along a transverse axis and rotatable about a vertical axis passing through the saddle, in order to allow adjustment of the position of the saddle relative to the main shaft.

13. The adjustable support system according to any one of claims 1 to 12, wherein the flexible strap is connected to the crossbeam.

14. The transverse beam is mounted on a longitudinal beam installed within the nacelle, and the longitudinal beam is located above the main shaft and mounted on a pillow block within the nacelle. The saddle is movable laterally along a horizontal axis, movable vertically along a vertical axis passing through the saddle, and rotatable about the vertical axis. The lateral saddle adjuster is connected to the saddle and to at least one of the vertical beams. The adjustable support system according to claim 1, wherein the flexible strap is connected to the crossbeam.

15. The adjustable support system according to claim 14, further comprising a vertical saddle adjuster connected to the crossbeam, wherein the vertical saddle adjuster is configured to move the saddle in a vertical direction to fix the main shaft between the saddle and the flexible strap, and / or to change the inclination angle of the main shaft within the nacelle.

16. The adjustable support system according to any one of claims 1 to 15, wherein the arc-shaped recess has sufficient depth to prevent the spindle from rolling out of the saddle when the spindle experiences a lateral load.

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