Method for assembling a drivetrain for a wind turbine, wind turbine and its assembly kit

Abstract

The present invention relates to a method for assembling a drivetrain for a wind turbine, as well as a wind turbine and an assembly kit thereof. A first fixing member is fastened to the first planetary carrier of the first gear stage, and a second fixing member is fastened to the gearbox housing. Each gear stage of the gearbox unit is pre-assembled, and the first planetary carrier is fixed to the gearbox housing via the first and second fixing members. The first ring gear is further fixed to the gearbox housing by a fastening member. Next, the pre-assembled gearbox unit is aligned with the main shaft and moved into a predetermined position relative to each other. The gearbox housing is mounted to the main bearing housing, and the first planetary carrier is released and moved into a predetermined position axially relative to the flange of the main shaft. Then, the first planetary carrier is mounted to the flange, and the first and second fixing members are removed.

Description

Technical Field

[0001] The present invention relates to a method for assembling a drivetrain for a wind turbine, the drivetrain comprising a main shaft, a gearbox and a generator. The main shaft is configured to be connected at one end to a rotor hub and at an opposite end to a gearbox input, and the generator further comprises a gearbox output configured to be connected to a generator rotor. The method comprises the steps of preparing the gearbox for installation, aligning the gearbox with the main shaft, and moving the gearbox into position and fastening it to the main shaft.

[0002] The invention also relates to a wind turbine comprising the drivetrain. Background Art

[0003] In recent years, it is known that wind turbines have increased tower height and rotor diameter to capture more energy from the wind, thereby increasing the power capacity of wind turbines. As a result, the size and weight of each component have increased, since the main shaft and the main frame need to support the increased weight of the rotor. Consequently, increased torque and loads are transmitted from the main shaft to the gearbox and further to the generator. The design of wind turbine drivetrains has also evolved towards more integrated drivetrain arrangements.

[0004] During assembly, the main shaft and the gearbox are aligned with each other and moved into position. High tolerances are required at the time of component design. A known problem is that, as disclosed in CN103042378B, the main shaft and the gearbox must be accurately aligned during assembly. This is difficult to achieve using an overhead crane and is time-consuming.

[0005] CN204621527U discloses an assembly stand for assembling a main shaft and a gearbox, where the main shaft rests on a first support and the gearbox rests on a second support. A linear actuator on the first support is used to move the main shaft into place relative to the gearbox. CN103244363B also discloses an assembly stand for assembling a main shaft and a gearbox, where the main shaft rests on a first support and the gearbox rests on a second support. A tensioning device attached to the opposite end of the gearbox is connected to the main shaft through a central hole in the gearbox.

[0006] These two solutions disclose an expansion sleeve that extends around the outer surface of the main shaft and is connected to the input end of the gearbox. The main shaft and gearbox are then locked together by the expansion sleeve. The expansion sleeve requires very precise alignment between the main shaft and the gearbox.

[0007] EP3018341B1 discloses another assembly stand for assembling a main shaft and gearbox, in which the main shaft and gearbox are placed on individual supports and then moved into place. The main shaft and gearbox are fastened together by press-fit or shrink-disc couplings. Such couplings are known to fail due to misalignment.

[0008] CN110802380B discloses an assembly method for planetary gears in a wind turbine gearbox, where the individual gear parts are assembled vertically. Details on how the gearbox is installed are not provided. CN113909842B discloses an alternative assembly method in which the gear stages of the gearbox are mounted directly to the main shaft. The main shaft is positioned vertically, and then the gear parts are lowered into place and fastened to the main shaft. During gear synchronization adjustment, the first gear stage is fixed to the main shaft, and the second gear stage is fixed to the first gear stage. Once the adjustment is complete, the fixing devices are removed. However, this solution requires removing the main shaft containing the gearbox from the nacelle during maintenance or replacement. [Overview of the project]

[0009] One objective of the present invention is to solve the problems of the prior art described above.

[0010] One objective of the present invention is to provide a method, wind turbine, and assembly kit that reduces the risk of damaging potential contact surfaces during assembly and enables a simpler assembly process.

[0011] One object of the present invention is to provide a method, wind turbine, and assembly kit that can accommodate a compact drivetrain.

[0012] One object of the present invention is achieved by the method for assembling a wind turbine drivetrain according to claim 1. The drivetrain comprises at least a main shaft unit and a gearbox unit having at least one gear stage, and the method is: - A step of providing a main shaft having a rotor end and a gearbox end, - A step of providing a gearbox having a main shaft end and a generator end, - A step of aligning the main shaft unit and the gearbox unit relative to each other, - A step of moving the main shaft end of the gearbox and the gearbox end of the main shaft to relative positions, - Includes the step of connecting the main shaft unit to the gearbox unit,

[0013] When it moves to a predetermined position, the first planetary carrier of the gearbox moves axially from a retracted position to an extended position, and in the extended position, the first planetary carrier is connected to the flange of the main shaft at the end of the gearbox. This provides an improved method for assembling a wind turbine drivetrain, the drivetrain comprising at least a main shaft unit and a gearbox unit. Since the input planetary carrier is fixed in a retracted assembly position and then guided to contact the main shaft, the method reduces the risk of misalignment between the main shaft and the gearbox unit during assembly. This method is suitable for assembling compact drivetrains, such as integrated drivetrains without bearings supporting the first planetary carrier.

[0014] Here, the term "move to a relative position" should be understood as two units moving toward each other to their assembly positions. This can be achieved by moving only one of the two units, or by moving both units.

[0015] First, the main shaft unit and the gearbox unit are aligned with respect to each other at least in the axial or circumferential direction, preferably in both the axial and circumferential directions. The main shaft unit may be positioned in a stationary position and the gearbox unit in a movable position, or conversely, the main shaft unit may be positioned in a movable position and the gearbox unit in a stationary position. Alternatively, both the main shaft unit and the gearbox unit may be positioned in separate movable positions relative to each other. This method allows assembly to be carried out in the vertical or horizontal direction.

[0016] The planetary carrier of the first gear stage (see first planetary carrier) is positioned in a retracted position within the gearbox unit. When in the retracted position, the gearbox unit and the main shaft unit move relative to each other to their assembly positions. During this movement, the ring gear of the first gear stage (see first ring gear) may move to contact the main bearing housing. This allows the local bearing housing end of the ring gear to contact the local gearbox end of the main bearing housing. Optionally, the gearbox end of the main bearing housing may have a recess molded to guide the ring gear end of the ring gear into place. Furthermore, the local main shaft end of the first planetary carrier may be guided into a recess at the local gearbox end of the main shaft. This allows the main shaft and gearbox to be guided into place during assembly.

[0017] In one embodiment, the first planetary carrier is fixed to other gearbox components, preferably the gearbox housing, before moving the gearbox unit and the main shaft unit into place.

[0018] In the retracted position, the first planetary carrier can be fastened to another part of the gearbox unit. Preferably, the other gearbox part may be the gearbox housing. Optionally, the first planetary carrier may be rotated to a certain angular position and then fixed in the assembled position relative to the other gearbox part. Thus, the first planetary carrier can be fixed within the gearbox to restrict its movement during alignment. This allows for easier alignment of each flange and the first planetary carrier.

[0019] In one embodiment, the first planetary carrier is fixed to the other gearbox portion by attaching several temporary fixing devices to the first planetary carrier and the other gearbox portion. The first planetary carrier can be fastened by one or more temporary fasteners. These temporary fasteners may be connected between the first planetary carrier and the other gearbox components, or positioned between the first planetary carrier and the other gearbox components. The number of temporary fasteners (e.g., standardized or custom-made fasteners) may depend on the size and configuration of the first gear stage. The fasteners can be installed before moving the main shaft unit and gearbox unit into place. The fasteners can be removed while or after connecting the main shaft to the gearbox. This allows the first planetary carrier to be fixed axially and / or radially during assembly.

[0020] In one embodiment, at least one first fixing member is attached to the first planetary carrier, and at least one second fixing member is attached to another gearbox portion, and the first planetary carrier is fixed to the other gearbox portion by engaging the first fixing member and the second fixing member to form at least one pair of temporary fixing devices.

[0021] The fixing device can be formed by a single fixing member (e.g., a bracket or wedge) that can be configured to fix the first planetary carrier to other gearbox parts. Alternatively, the fixing device can be formed by a pair of fixing members. These fixing members can be molded to engage or interact with each other when installed. The fixing members may be formed as female and male elements, or as plug and socket elements. This facilitates the fixing of the first planetary carrier.

[0022] Preferably, the first fixing member can be attached to the first planetary carrier, and the second fixing member can be attached to other gearbox parts. When the first and second fixing members are engaged, they can fix the first planetary carrier in the assembled position. For example, as will be described later, the first fixing member may be a rod, and the second fixing member may be a bushing. This allows each pair of fixing members to be easily attached to the first planetary carrier and other gearbox parts, respectively.

[0023] In one embodiment, when moved to a predetermined position, the gearbox housing of the gearbox is fastened to the main bearing housing by a first fastening member.

[0024] Once positioned, the gearbox housing can be connected to the main bearing housing using one or more fastening members (see first fastening member). The first fastening member can be connected to the gearbox housing or the main bearing housing before the main shaft unit and gearbox unit are moved into place. Alternatively, once the main shaft and gearbox are moved into place, the first fastening member can be inserted through either the main bearing housing or the gearbox housing and then connected to the gearbox housing and the main bearing housing, respectively. This ensures a secure connection between the main bearing housing and the gearbox housing.

[0025] For example, the first fastening member may be an elongated bolt having a threaded portion at one end or both ends. The bolt may be fastened at one end or both ends by a nut and / or an internal threaded portion.

[0026] In one embodiment, the second fastening member is inserted into the flange and at least partially fastened to the first planetary carrier, and the first planetary carrier moves axially by tightening the second fastening member.

[0027] The flange of the main shaft and the local main shaft end of the first planetary carrier can move towards each other until the main shaft unit and the gearbox unit reach the assembly position. When the first planetary carrier is in the retracted position, a gap is formed between the local end face of the flange and the opposite local end face of the first planetary carrier. This reduces the risk of damage to the interface between the main shaft and the first planetary carrier during assembly.

[0028] The main shaft end of the first planetary carrier may be guided to engage with the gearbox end of the main shaft during movement. This allows the first planetary carrier to be guided to a predetermined position relative to the main shaft during assembly.

[0029] One or more fastening members (refer to the second fastening member) can be loosely connected to the main shaft end of the gearbox. The second fastening member can be inserted through the flange of the main shaft. Then, by tightening the second fastening member, the first planetary carrier may be pulled axially towards the flange and pulled to the extended position. Further, the second fixing member can be released relative to the first fixing member to enable movement of the first planetary carrier. This allows the first planetary carrier to move axially, so that the end face of the flange comes into contact with the opposite end face of the first planetary carrier. Accordingly, a reliable connection is formed between the flange and the first planetary carrier.

[0030] For example, the second fastening member may be a bolt having threaded portions at one or both ends. The bolt may be fastened at one or both ends by a nut and / or female threaded portion.

[0031] In one embodiment, the method further includes the step of pre-assembling each gear stage of the gearbox in the vertical direction.

[0032] Each gear stage of the gearbox unit may be pre-assembled before the gearbox unit can be aligned with the main shaft unit and moved into place. Pre-assembly of the gear stages can be performed vertically or horizontally, depending on the gearbox configuration. This allows the components of the gearbox unit to be pre-assembled under controlled conditions with minimal load. For example, the gearbox unit can be assembled using known assembly methods.

[0033] If the gearbox unit is pre-assembled horizontally, it can be easily moved during assembly to align with the main shaft. If the gearbox unit is pre-assembled vertically, it can be rotated during assembly to align with the main shaft unit.

[0034] In this method, it is advantageous to pre-assemble the gearbox unit in a vertical position to minimize gravitational load. This allows the first planetary carrier to be more easily secured to the other gearbox parts in the retracted position.

[0035] In one embodiment, the first ring gear of the gearbox is fixed to the gearbox housing before the main shaft end and the gearbox end are moved to a predetermined position.

[0036] The ring gear of the first gear stage (see first ring gear) can slide above the first fastener member before moving the main shaft unit and gearbox unit into their predetermined positions. Alternatively, the first fastener member can be inserted through the first ring gear after the main shaft unit and gearbox unit have been moved into their predetermined positions, before being connected to the gearbox housing and main bearing housing, respectively. This allows the ring gear to be fixed in an angular position via the first fastener member.

[0037] Preferably, the first fastener member can be connected to the gearbox housing. The ring gear can then rotate to an angular position and slide above the first fastener member. Alternatively, the ring gear can be positioned relative to the gearbox housing, and the first fastener member can then be inserted through the ring gear and connected to the gearbox housing. This allows the ring gear to be fixed radially, resulting in easier alignment between the gearbox housing and the main bearing housing.

[0038] The nut can be temporarily attached to the opposite end of the first fastening member until the main shaft and gearbox are aligned. This allows the gearbox components to be held in place during handling.

[0039] In one embodiment, the main shaft and gearbox are assembled and / or disassembled on-site and in the uptower, and the gearbox is optionally pre-assembled at another location.

[0040] This method allows the assembly of the main shaft unit and gearbox unit described above to be performed on-site and up-tower. Here, the term "up-tower" should be understood as assembly performed while the main shaft and gearbox unit are inside the nacelle. Here, the term "on-site" should be understood as assembly performed at the wind turbine installation site. This allows for cost savings by enabling the individual transport of drivetrain components. It also allows for cost savings by enabling repair or replacement of the main shaft or gearbox at the top of the wind turbine tower.

[0041] Furthermore, this method allows gearbox units to be pre-assembled off-site and / or down-tower. Here, the term “down-tower” should be understood as pre-assembly performed at ground level relative to the wind turbine tower. Here, the term “off-site” should be understood as pre-assembly performed at a separate location, such as a factory or assembly site.

[0042] One object of the present invention is achieved by an assembly kit for use in assembling a wind turbine drivetrain as described in claim 10. The assembly kit is - At least one first fixing member configured to be attached to the first planetary carrier of the gearbox, - comprising at least one second fixing member configured to be attached to another gearbox part, preferably the gearbox housing, The first fixing member is formed to engage with the second fixing member to form at least one pair of temporary fixing devices for securing the first planetary carrier to the other gearbox portion.

[0043] This provides an assembly kit for use during the assembly of a wind turbine drivetrain. The kit allows the planetary carrier of the first gear stage to be fixed in a retracted position. Furthermore, the kit allows the first planetary carrier to be moved axially to contact the flange of the main shaft. The kit can be removed and reused to assemble another main shaft and gearbox, or to assemble other drivetrain configurations.

[0044] The assembly kit comprises at least one pair of fixing members configured to engage with each other to fix the first planetary carrier axially and / or radially relative to other gearbox parts. The first fixing member is attached to or positioned on the first planetary carrier of the gearbox. The second fixing member is attached to or positioned on other gearbox parts, such as the gearbox housing. The configuration and shape of the first and second fixing members may be adapted to the configuration of the gearbox. The first and second fixing members are then removed during or after the connection of the main shaft to the gearbox. For example, the fixing members can be removed after the bearing housing and the gearbox housing have been connected.

[0045] In one embodiment, the first fixing member is a rod having a first end and a second end on the opposite side, the first end being configured to be fastened to a mounting point on the first planetary carrier.

[0046] The first fixing member can preferably be molded to be attached to the first planetary carrier at a dedicated mounting point. The first fixing member may be a rod, and the mounting point may be a mounting hole in the first planetary carrier. One end of the rod and the corresponding mounting hole may be equipped with a screw coupling, which allows the rod to be fastened to the planetary carrier when inserted. The first fixing member can be inserted from outside the gearbox housing, which facilitates the fixing of the first fixing member.

[0047] In one embodiment, the second fixing member is a bushing having a hole, a first end and a second end on the opposite side, the second end being configured to be fastened to a mounting point on another gearbox portion.

[0048] The second fixing member can be molded to be attached to another gearbox portion, preferably the gearbox housing, at a dedicated mounting point. The second fixing member may be a bushing, and the mounting point may be a mounting hole or through hole in the other gearbox portion. The mounting points for the first and second fixing members can preferably be aligned with each other in the axial direction. This allows the first fixing member to engage with the second fixing member to form a pair of fixing members.

[0049] The mounting point corresponding to the second fixing member may be equipped with a screw coupling. Alternatively, the second fixing member can be attached at one end to another gearbox portion using fasteners such as bolts or screws. Alternatively, or in addition to the above, the second fixing member can be directly attached to the first fixing member at the other end. This facilitates the fixing of the second fixing member.

[0050] The first planetary carrier, upon installation, rests on the other end of the second fixing member or simply contacts the other end of the second fixing member. The local length of the second fixing member can be selected according to the nominal axial position of the first planetary carrier relative to other gearbox parts. This allows the first planetary carrier to be fixed in a predetermined retracted axial position using the second fixing member.

[0051] The second fixing member can be inserted through the first fixing member and one end can be fastened to the first planetary carrier. The second fixing member can be fastened to the first fixing member at the other end, for example, using a nut. This allows the second fixing member to be released, for example by unfastening the nut, so that it can move axially relative to the first fixing member. This allows the first planetary carrier to move axially between a retracted position and an extended position.

[0052] In one embodiment, at least one of the first and second fixing members is accessible from outside the gearbox and is configured to be removed and / or inserted from the outside.

[0053] The first and / or second fixing members are accessible from outside the gearbox, preferably via dedicated mounting points in the gearbox housing. This facilitates the removal and insertion of each fixing member.

[0054] The first and / or second fixing members can be removed and / or inserted using external tools or by hand. Optionally, the first and second fixing members can be removed and / or inserted as a pair and then fastened to the first planetary carrier and other gearbox components, respectively.

[0055] One object of the present invention is achieved by the wind turbine described in claim 14. The wind turbine comprises a wind turbine tower, a nacelle located at the top of the wind turbine tower, and a rotor of at least one wind turbine blade positioned relative to the nacelle, wherein the rotor is connected to a drivetrain within the wind turbine, the drivetrain comprises a main shaft connected to a gearbox having at least one gear stage, and the main shaft and gearbox are assembled according to the method described above.

[0056] This provides a wind turbine in which the main shaft unit and gearbox unit can be assembled using the method described above. Disassembly of the main shaft unit and gearbox unit can be performed in the reverse order. This allows for on-site, preferably on-site and up-tower, assembly and / or disassembly during replacement or repair. Assembly can also be performed off-site, after which the assembled main shaft and gearbox unit can be transported to the wind turbine installation site.

[0057] The main shaft unit and / or gearbox unit can be positioned on an assembly stand during assembly, and the assembly stand may include means for moving the main shaft unit and gearbox unit to relative positions. Alternatively, the main shaft unit and gearbox unit can be moved to relative positions using a hoist or crane system. Optionally, one main shaft unit or gearbox unit may be placed on a fixed support structure, while the other main shaft unit or gearbox unit is placed on a movable support structure or suspended from a hoist or crane system. This allows for controlled movement of one or both units.

[0058] In one embodiment, the first planetary carrier of the gearbox is provided with at least one dedicated mounting element for fastening a first fixing member, and the other gearbox portion of the gearbox is provided with at least one dedicated mounting element for fastening a second fixing member.

[0059] Other gearbox components, such as the gearbox housing, may have dedicated mounting points adapted to receive the second fixing member. Furthermore, the first planetary carrier may have dedicated mounting points adapted to receive the first fixing member. The number of dedicated mounting points may depend on the configuration of the first gear stage. The mounting points can be formed during the manufacture of the other gearbox components and / or the first planetary carrier. Alternatively, the mounting points can be machined onto the other gearbox components and / or the first planetary carrier.

[0060] The mounting points may preferably be arranged so that the first and second fixing members can be inserted and removed from outside the gearbox. This allows access to the fixing members during installation or removal. [Brief explanation of the drawing]

[0061] The present invention will be described with reference to the drawings for illustrative purposes only. [Figure 1] An exemplary embodiment of a wind turbine is shown. [Figure 2] An exemplary embodiment of the assembly kit according to the present invention is shown. [Figure 3] This shows a planetary carrier having a first fixing member fastened to a dedicated mounting point. [Figure 4] This shows a gearbox housing having second fixing members fastened to each dedicated mounting point. [Figure 5] This shows the first step of pre-assembling the gearbox in a vertical position. [Figure 6] The second step involves pre-assembling the gearbox in a vertical position. [Figure 7] This shows the first step in assembling the main shaft and gearbox, with the pre-assembled gearbox rotating in a horizontal position. [Figure 8] This shows the second step of assembling the main shaft and gearbox in a horizontal position. [Figure 9]This shows the third step: assembling the main shaft and gearbox in a horizontal position. [Figure 10] This shows the fourth step: assembling the main shaft and gearbox in a horizontal position. [Figure 11] Step 5 shows the assembly of the main shaft and gearbox in a horizontal position.

[0062] The following describes each drawing in turn. Different parts and locations shown in the drawings are indicated by the same reference numerals in different drawings. Not all parts and locations shown in a particular drawing are necessarily described in conjunction with that drawing. [Modes for carrying out the invention]

[0063] Figure 1 shows an exemplary embodiment of a wind turbine 1. The wind turbine 1 comprises a wind turbine tower 2, a nacelle 3 located at the top of the wind turbine tower 2, and a rotor connected to a drivetrain within the nacelle 3. The rotor comprises a hub 4 and at least one wind turbine blade 5 connected to the hub 4. Here, three wind turbine blades 5 are shown, but the hub 4 can be connected to two, four, or more wind turbine blades.

[0064] Although wind turbine 1 is shown as an onshore wind turbine, wind turbine 1 may also be an offshore wind turbine 1.

[0065] The drivetrain 6 of the wind turbine 1 is mechanically connected to the rotor. Here, the hub 4 is mechanically connected to the input interface of the gearbox 7 to transmit torque to the gear stages of the gearbox 7. In particular, the hub 4 can be directly connected to the input of the gearbox via a bolt connection or a shaft connection.

[0066] The output interface of the gearbox 7 is mechanically connected to the rotor of the generator 8. The generator 8 further comprises a generator stator positioned relative to the generator rotor. Each of the generator stator and generator rotor comprises a plurality of pole units configured to interact with each other via at least one magnetic field. The rotation of the generator rotor relative to the generator stator generates an electrical output current in the generator 8.

[0067] Figure 2 shows an exemplary embodiment of an assembly kit according to the present invention. The assembly kit includes one or more temporary fastening devices 9 for securing the first planetary carrier of the gearbox to other gearbox parts, such as the gearbox housing.

[0068] Each pair of temporary fixing devices 9 comprises a first fixing member 10 molded to engage with a second fixing member 11. Here, the first fixing member 10 is molded as a rod having a first end 12 and a second end 13 on the opposite side. The second end 13 has a threaded portion molded to engage with the threaded portion on the opposite side of a nut 15. Furthermore, the second end 13 has a bolt head 14 for rotating the first fixing member 10.

[0069] Here, the second fixing member 11 is formed as a bushing having a through hole 18 extending from the first end 16 to the second end 17. The second end 17 of the second fixing member 11 is formed as a flange.

[0070] The flange is provided with a plurality of first holes 19 for receiving the first fastener 20. The first fastener 20 is used to fasten the second fixing member 11 to other gearbox parts. The flange is further provided with a plurality of second holes 21 for receiving the second fastener 22. The second fastener 22 is used to remove the second fixing member 11 from other gearbox parts.

[0071] Figure 3 shows the first planetary carrier 23 of the input gear stage (see first gear stage), which has a dedicated mounting point 24 for fastening the first fixing member 10. The mounting point 24 is molded to receive and engage with the first end 12 of the first fixing member 10. The mounting point 24 and the first end 12 together form a screw connection or a press-fit connection.

[0072] Figure 4 shows a gearbox housing portion 26 having a dedicated mounting point 25 for fastening the second fixing member 11. The second fixing member 11 is fastened to the gearbox housing portion 26 by a second fastener 20.

[0073] The dedicated mounting point 25 is different from the main mounting point for mounting the next gear. These main mounting points may be arranged in a line circumferentially.

[0074] Figure 5 shows the first step of pre-assembling the gearbox 7 in a vertical position. The gear components and gearbox housing of the output gear stage of the gearbox 7 are assembled using a gearbox assembly frame or table (not shown). Subsequently, the gear components and gearbox housing of the intermediate gear stage 30 of the gearbox 7 are assembled and interconnected with the preceding gear stage. This process is repeated for each intermediate gear stage.

[0075] The gearbox housing portion 26 of the input gear stage 29 is positioned and interconnected with the gearbox housing portion of the preceding gear stage 30. Here, the ring gear and gearbox housing portion of the preceding gear stage are interconnected with the gearbox housing 26 by a plurality of fasteners fastened to the main mounting point.

[0076] The second fixing member 11 can be fastened to the gearbox housing portion 26 before or after the gearbox housing portion 26 is installed.

[0077] The input planetary carrier (see first planetary carrier) 23 of the input gear stage 29, the sun gear, and the sun shaft are assembled and positioned on the gearbox housing portion 26. Next, the first planetary carrier 23 rotates to align the second fixing member 11 with its designated mounting point 24. Next, the first fixing member 10 is inserted into and fastened to the first planetary carrier 23 to prevent radial movement. Next, the nut 15 is fastened to the first fixing member 10 to prevent axial movement. This fixes the first planetary carrier 23 in the retracted position.

[0078] Figure 6 shows the second step of pre-assembling the gearbox 7 in a vertical position. The input ring gear (see first ring gear) 28 is slid into place relative to the sun gear and gearbox housing portion 26. Multiple first fastener members 27 are inserted into mounting holes on the first ring gear 28 and fastened to the gearbox housing portion 26.

[0079] The first ring gear 28 may optionally be temporarily fixed in place to prevent axial movement during the assembly of the main shaft and gearbox 7.

[0080] Figure 7 shows the first step in assembling the main shaft and gearbox, with the pre-assembled gearbox 7 rotated to a horizontal position. The main shaft is further rotated to a horizontal position.

[0081] Figure 8 shows the second step of assembling the main shaft 31 and gearbox in a horizontal position. The main shaft 31 has a rotor end 32 and a gearbox end 33. The gearbox 7 has a main shaft end 34 and a generator end 35.

[0082] The main shaft unit 31 and the gearbox unit 7 are aligned relative to each other. The main shaft end 34 of the gearbox 7 and the gearbox end 33 of the main shaft 31 move toward each other until they are in relative positions.

[0083] Here, the main shaft 31 is surrounded by a main bearing housing 36 which rests on a set of fixed supports 37. The gearbox 7 is suspended by a crane wire 39 connected to a crane unit (not shown) for moving the gearbox 7 to a predetermined position relative to the main shaft 31. Alternatively, the gearbox 7 may be mounted on a set of movable supports 38 for moving the gearbox 7 to a predetermined position relative to the main shaft 31.

[0084] Figure 9 shows the third step of assembling the main shaft 31 and gearbox 7 in a horizontal position. Once moved to the predetermined position, the gearbox housing portion 26 and ring gear 28 are connected to the main bearing housing 36 by fastening the first fastening member 27 to the main bearing housing 36.

[0085] Figure 10 shows the fourth step of assembling the main shaft 31 and gearbox 7 in the horizontal position. The second fastener member 41 is inserted through the main mounting hole in the flange 42 of the main shaft 31. The second fastener member 41 is loosely fastened to the main mounting point at the main shaft end 34. The nut 15 is loosened or removed, and the second fastener member 41 is tightened. This causes the first planetary carrier 23 to move axially from the retracted position to the extended position. In the extended position, the main shaft end 34 contacts the gearbox end 33.

[0086] Figure 11 shows the fifth and final step of assembling the main shaft 31 and gearbox 7 in a horizontal position. Once the main shaft end 34 and gearbox end 33 are connected to each other by the second fastening member 41, the remaining nut 15 is removed.

[0087] The first fixing member 10 is loosened and removed by engaging the bolt head 14. The first fastener 20 is further loosened and removed. The second fixing member 11 is finally removed by applying tensile force to the second fastener member 22.

Claims

1. A method for assembling a drivetrain (6) for a wind turbine (1), wherein the drivetrain (6) comprises at least a main shaft (31) unit and a gearbox (7) unit having at least one gear stage, and the method is as follows: - A step of providing a main shaft (31) having a rotor end (32) and a gearbox end (33), - A step of providing a gearbox (7) having a main shaft end (34) and a generator end (35), - A step of aligning the main shaft (31) unit and the gearbox (7) unit with respect to each other, - A step of moving the main shaft end (34) of the gearbox (7) and the gearbox end (33) of the main shaft (31) to relative positions to each other, - The process includes the step of connecting the main shaft (31) unit to the gearbox (7) unit, A method characterized in that, upon moving to a predetermined position, the first planetary carrier (23) of the gearbox (7) moves further axially from a retracted position to an extended position, and in the extended position, the first planetary carrier (23) is connected to the flange (42) of the main shaft (31) at the gearbox end (33).

2. The method according to claim 1, characterized in that the first planetary carrier (23) is fixed to other gearbox parts, preferably the gearbox housing (26), before moving the gearbox (7) unit and the main shaft (31) unit to their predetermined positions.

3. The method according to 2, characterized in that the first planetary carrier (23) is fixed to the other gearbox portion by attaching several temporary fixing devices (9) to the first planetary carrier (23) and the other gearbox portion.

4. The method according to claim 3, characterized in that at least one first fixing member (10) is attached to the first planetary carrier (23), at least one second fixing member (11) is attached to the other gearbox portion, and the first planetary carrier (23) is fixed to the other gearbox portion by engaging the first fixing member (10) and the second fixing member (11) to form at least one pair of temporary fixing devices (9).

5. The method according to any one of claims 1 to 4, characterized in that when moved to a predetermined position, the gearbox housing (26) of the gearbox (7) is fastened to the main bearing housing (36) by the first fastening member (27).

6. The method according to any one of claims 1 to 5, characterized in that the second fastening member (41) is inserted into the flange (42) and at least partially fastened to the first planetary carrier (23), and the first planetary carrier (23) moves axially by tightening the second fastening member (41).

7. The method according to any one of claims 1 to 6, further comprising the step of pre-assembling each gear stage of the gearbox (7) in the vertical direction.

8. The method according to any one of claims 1 to 7, characterized in that the first ring gear (28) of the gearbox (7) is fixed to the gearbox housing (26) before the main shaft end (34) and the gearbox end (33) move to predetermined positions.

9. The method according to any one of claims 1 to 8, characterized in that the main shaft (31) and the gearbox (7) are assembled and / or disassembled on-site and uptower, and the gearbox (7) is optionally pre-assembled at another location.

10. An assembly kit for use in assembling a wind turbine drivetrain according to any one of claims 1 to 9, - At least one first fixing member (10) configured to be attached to the first planetary carrier (23) of the gearbox (7), - comprising at least one second fixing member (11) configured to be attached to another gearbox portion, preferably the gearbox housing (26), The assembly kit is characterized in that the first fixing member (10) is molded to engage with the second fixing member (11) to form at least one pair of temporary fixing devices (9) for fixing the first planetary carrier (23) to the other gearbox portion.

11. The assembly kit according to claim 10, characterized in that the first fixing member (10) is a rod having a first end (12) and a second end (13) on the opposite side, the first end (12) being configured to be fastened to a mounting point (24) on the first planetary carrier (23).

12. The assembly kit according to claim 10 or 11, characterized in that the second fixing member (11) is a bushing having a hole (18), a first end (16) and a second end (17) on the opposite side, the second end (17) being configured to be fastened to a mounting point (25) on the other gearbox portion.

13. The assembly kit according to claim 11 or 12, characterized in that at least one of the first fixing member (10) and the second fixing member (11) is accessible from outside the gearbox (7) and is configured to be removed and / or inserted from the outside.

14. A wind turbine comprising a wind turbine tower (2), a nacelle (3) positioned on top of the wind turbine tower (2), and a rotor having at least one wind turbine blade (5) positioned relative to the nacelle (3), wherein the rotor is connected to a drivetrain (6) in the wind turbine (1), and the drivetrain (6) comprises at least a main shaft (31) connected to a gearbox (7) having at least one gear stage, and the main shaft (31) and the gearbox (7) are assembled according to the method described in any one of claims 1 to 9.

15. The wind turbine according to claim 14, wherein the first planetary carrier (23) of the gearbox (7) is provided with at least one dedicated mounting element (24) for fastening the first fixing member (10), and the other gearbox portion of the gearbox (7) is provided with at least one dedicated mounting element (25) for fastening the second fixing member (11).

Images