Wind turbine bearing turnover support apparatus

Abstract

In a first aspect of the present invention there is provided turnover support apparatus for supporting a wind turbine bearing when turning the bearing in an assembly process. The wind turbine bearing comprises an inner bearing ring configured for attachment to a first wind turbine component and an outer bearing ring configured for attachment to a second wind turbine component. The inner and outer bearing rings are rotatable relative to one another about a bearing axis and in a bearing plane orthogonal to the bearing axis. The turnover support apparatus comprises a bearing cradle configured for attachment to the wind turbine bearing to assist turning the bearing about an axis orthogonal to the bearing axis. The bearing cradle comprises a bearing holding portion on a first side of the cradle. The bearing holding portion comprises an aperture for receiving at least a portion of the outer bearing ring and fixing means for releasably fixing at least one of the inner and / or outer bearing ring to the cradle. The bearing cradle further comprises a curved rocking surface on a second side of the bearing cradle opposite to the first side of the cradle such that, in use, the wind turbine bearing may be supported by the bearing cradle on an underlying floor surface via the curved rocking surface. The curved rocking surface is configured to define a turnover axis at a point of contact between the curved rocking surface and the floor surface about which the cradle and attached bearing are pivotable in use. The curved rocking surface extends out of the bearing plane when the bearing cradle is attached to the wind turbine bearing in use such that the turnover axis is orthogonal to the bearing axis.

Description

[0001] Wind turbine bearing turnover support apparatus

[0002] Technical field

[0003] The present invention relates generally to wind turbines and more particularly to support apparatus for use with a wind turbine bearing in an assembly process.

[0004] Background

[0005] Modern utility-scale wind turbines typically include a plurality of wind turbine bearings to facilitate relative movement between components of the turbine. For example, a turbine may include a yaw bearing to facilitate rotation of a nacelle relative to a tower, and a pitch bearing to facilitate rotation of a wind turbine blade relative to a hub. Such wind turbine bearings may have a diameter greater than 3.5 m in some examples. It follows that manipulating and moving such a bearing during assembly processes can be challenging.

[0006] Assembly processes involving a wind turbine bearing may require access to both sides of the bearing. For example, with reference to a pitch bearing, access to both sides of the bearing may be required for assembling components of the pitch mechanism. An assembly facility therefore typically includes turnover machinery for turning the bearing during an assembly process. For example, such turnover machinery may include a support frame and a plurality of electric or hydraulic actuators, electric motors, or pulley systems to lift and turn over the bearing.

[0007] Turnover machinery is therefore typically expensive and complex, and in some cases may only be configured for use with a specific bearing design or type. Additionally, such machinery may be substantially large and may therefore occupy a significant area of floor space in the assembly facility. Further, turnover machinery may be heavy and is therefore typically fixed in a specific location within the assembly facility, which may not always be optimal for the assembly process flow.

[0008] It is against this background that the present invention has been developed. Summary

[0009] In a first aspect of the present invention there is provided turnover support apparatus for supporting a wind turbine bearing when turning the bearing in an assembly process. The wind turbine bearing comprises an inner bearing ring configured for attachment to a first wind turbine component and an outer bearing ring configured for attachment to a second wind turbine component. The inner and outer bearing rings are rotatable relative to one another about a bearing axis and in a bearing plane orthogonal to the bearing axis. The turnover support apparatus comprises a bearing cradle configured for attachment to the wind turbine bearing to assist turning the bearing about an axis orthogonal to the bearing axis. The bearing cradle comprises a bearing holding portion on a first side of the cradle. The bearing holding portion comprises an aperture for receiving at least a portion of the outer bearing ring and fixing means for releasably fixing at least one of the inner and / or outer bearing ring to the cradle. The bearing cradle further comprises a curved rocking surface on a second side of the bearing cradle opposite to the first side of the cradle such that, in use, the wind turbine bearing may be supported by the bearing cradle on an underlying floor surface via the curved rocking surface. The curved rocking surface is configured to define a turnover axis at a point of contact between the curved rocking surface and the floor surface about which the cradle and attached bearing are pivotable in use. The curved rocking surface extends out of the bearing plane when the bearing cradle is attached to the wind turbine bearing in use such that the turnover axis is orthogonal to the bearing axis.

[0010] The wind turbine bearing may be referred to as a large-diameter bearing. For example, the wind turbine bearing may have a diameter of more than 2 m, in some examples more than 3 m, or in some examples more than 4 m. For example, the turnover support apparatus may be configured for supporting a wind turbine bearing that is a pitch bearing for arrangement between a wind turbine blade and a wind turbine hub. Similarly, the turnover support apparatus may be configured for supporting a wind turbine bearing that is a yaw bearing for arrangement between a wind turbine tower and a wind turbine nacelle.

[0011] Use of the turnover support apparatus described herein facilitates movement of a large wind turbine bearing, in particular turning over a wind turbine bearing from one side to the other, without requiring complex, fixed, hydraulic or electric turnover equipment. For example, in some preferred examples the turnover support apparatus may be entirely mechanical. As such, the turnover support apparatus may be referred to as mechanical turnover support apparatus. Additionally, the turnover support apparatus may be entirely portable, i.e. moveable, such that the apparatus can be moved around in an assembly facility as required. Such flexibility is advantageous in an assembly facility, in particular if the facility is configured for manufacturing various different wind turbine components, such as different bearings for different wind turbines.

[0012] As described below in more detail, in some examples the turnover support apparatus may be configured with various optional features to facilitate supporting and / or storing a wind turbine bearing in a horizontal orientation and / or an upright orientation. The turnover support apparatus may therefore be configured to support the wind turbine bearing in a plurality of different orientations to facilitate access to different sides of the bearing during assembly or the bearing or of other components with the bearing. Further, the turnover support apparatus may therefore enable efficient use of floorspace in an assembly facility, firstly because the apparatus is moveable as described previously, and also because it facilitates storage and arrangement of wind turbine bearings in space-efficient manner.

[0013] As described previously, the curved rocking surface is configured to define a turnover axis about which the cradle and attached bearing are pivotable in use. Accordingly, the curved rocking surface may also be referred to as a curved pivot surface.

[0014] In some examples the inner bearing ring may be an annular ring defining an internal aperture. In some other examples the inner bearing ring may be part of an integrated assembly comprising a bearing plate and the inner bearing ring. In such an example the bearing plate may extend across the internal aperture. It will be appreciated that the turnover support apparatus is configured to support either example of a wind turbine bearing when turning the bearing in an assembly process.

[0015] In some examples, the bearing cradle may be configured to support the wind turbine bearing in a plurality of orientations. For example, the bearing cradle may be configured to support the wind turbine bearing in an upright orientation in which the bearing plane is substantially vertical and the bearing axis is substantially horizontal. The bearing cradle may be configured to support the wind turbine bearing in a horizontal orientation in which the bearing plane is substantially horizontal and the bearing axis is substantially vertical. The bearing cradle may be configured to support the wind turbine bearing in transitioning orientations in which the bearing is moving between the upright orientation and the horizontal orientation. Accordingly, the bearing cradle may be configured to support the wind turbine bearing throughout a turnover process, and may therefore provide a simple means for aiding turning the bearing over during an assembly process. In some examples, the bearing cradle may be configured to support the wind turbine bearing on the underlying floor surface via the curved rocking surface in the upright and transitioning orientations. The cradle may comprise a substantially planar surface at an end of the rocking surface for supporting the wind turbine bearing in the horizontal orientation. The planar surface may be referred to as a planar end surface. It follows that in some preferred examples the bearing cradle may therefore be configured such that the wind turbine bearing can be supported by the bearing cradle in each of the upright and horizontal orientations, and throughout the pivoting motion when transitioning between the upright and horizontal orientations. The substantially planar surface may provide stability for supporting the bearing in the horizontal orientation in use.

[0016] In some examples, the substantially planar surface may be configured to be substantially parallel to the bearing plane when the bearing cradle is attached to the wind turbine bearing in use. Such a configuration helps to ensure that the wind turbine bearing is positioned in the horizontal orientation, i.e. with the bearing plane being substantially horizontal, when the bearing is supported on the underlying floor surface via the planar surface of the bearing cradle. Such a configuration also provides the bearing cradle with a sufficient surface area for contacting the underlying floor surface to ensure stability and spread the load of the bearing cradle and the bearing when the bearing is supported in the horizontal orientation.

[0017] In some examples, the bearing cradle may comprise a substantially planar surface at each end of the rocking surface for supporting the wind turbine bearing in both a first horizontal orientation and in a second horizontal orientation in which the wind turbine bearing is turned over in comparison to the first horizontal orientation. Accordingly, the substantially planar surfaces may be linked via the curved rocking surface. Such a configuration ensures that the wind turbine bearing can be supported in a first horizontal orientation, can then be supported via the curved rocking surface whilst being turned over, and can then be supported in a second horizontal orientation. Accordingly, the apparatus facilitates a simple method for supporting and turning the wind turbine bearing and minimises the equipment required for turning the bearing over.

[0018] In some examples, the bearing cradle may comprise a plurality of retractable support legs. The retractable support legs may be configured to stabilise the bearing cradle and the attached wind turbine bearing in the upright orientation. For example, the retractable support legs may each pivot from a stored position to a stabilising position. Additionally or alternatively, the retractable support legs may extend, for example extend telescopically, from a stored position to a stabilising position. With the retractable support legs in the stabilising position, the wind turbine bearing may be supported in the upright orientation by the bearing cradle on the underlying floor surface via the curved rocking surface and the plurality of retractable support legs. Configuring the bearing cradle in this way to stabilise and support the wind turbine bearing in the upright orientation may be particularly beneficial for storing the bearing before or after an assembly process. For example, with a large diameter bearing, instead of the bearing being stored with its bearing plane parallel to the underlying floor surface, and thereby occupying a substantial area of floor space in the assembly facility, the bearing can instead be stored upright in the bearing cradle, i.e. with the bearing plane substantially orthogonal to the floor surface. This significantly reduces the area of floor space occupied when storing the blade.

[0019] In some examples, the turnover support apparatus may further comprise a plurality of separate support stands in addition to the bearing cradle for supporting the wind turbine bearing in the horizontal orientation. For example, the turnover support apparatus may comprise two separate support stands in addition to the bearing cradle. The bearing cradle and separate support stands may be configured for arrangement with different portions of the wind turbine bearing to form a three-point support assembly to stabilise and maintain the bearing in the horizontal orientation. Accordingly the combination of the bearing cradle and the separate support stands may increase stability of the bearing in the horizontal orientation to facilitate further assembly operations with the bearing in this orientation.

[0020] Further, the support stands may facilitate supporting the wind turbine bearing in the horizontal orientation such that a lifting fixture and lifting apparatus can be disconnected from the bearing. Accordingly, the support stands may therefore enable stable support of the bearing by only the bearing cradle and the separate support stands. This means that the lifting apparatus can be used for other tasks in the assembly facility whilst the bearing is supported horizontally, the lifting apparatus only being needed again for moving, for example turning over, the wind turbine bearing and attached bearing cradle.

[0021] In some examples, each separate support stand may comprise a contact portion for arrangement with the inner bearing ring or the outer being ring. The contact portion may comprise one or more locating pins for insertion into a corresponding bore in the inner or outer bearing ring for aligning and temporarily connecting the support stand to the wind turbine bearing. In some examples, the one or more locating pins may be retractable to facilitate simple alignment of the support stands, in particular the contact portion of the respective support stand, with the inner and / or outer bearing ring without interference from the locating pins. Following correct arrangement of the respective support stand with the inner and / or outer bearing ring, the or each locating pin may then be inserted into the corresponding bore to temporarily fix the support stand relative to the bearing.

[0022] In some examples, the contact portion of each separate support stand may comprise an abutment surface for arrangement against a bearing surface of the wind turbine bearing. In the horizontal orientation, the first bearing surface may be a downwards-facing surface of the wind turbine bearing. Accordingly the abutment surfaces of each separate support stand may be upwards-facing surfaces configured to abut the downwards-facing first bearing surface to thereby support the wind turbine bearing.

[0023] In some examples each separate support stand may comprise a foot portion for stabilising the support stand on the underlying floor surface in use. The foot portion may comprise one or more apertures configured for receiving a lifting device, such as a fork of a forklift or pallet truck, for moving and positioning the support stand. Such a configuration may facilitate simple movement and alignment of the support stand in use.

[0024] In some examples, the aperture of the bearing holding portion may be defined at least in part by a first engagement surface configured to abut a first bearing surface on a first side of the wind turbine bearing when the outer bearing ring is received in the aperture. Accordingly, the first engagement surface may advantageously provide a physical stop feature for aligning the wind turbine bearing in the bearing cradle. In some examples, the first engagement surface may also support the wind turbine bearing, i.e. at least a portion of the outer bearing ring, during attachment of the bearing cradle to the wind turbine bearing.

[0025] The first bearing surface may be defined by the inner bearing ring of the wind turbine bearing in some examples. Additionally or alternatively the first bearing surface may be defined by the outer bearing ring in some examples. In some examples, the first bearing surface may be substantially parallel to the bearing plane. Accordingly, for advantageous arrangement of the first engagement surface with the first bearing surface, in some preferred examples, the first engagement surface may be configured to be substantially parallel to the bearing plane when the bearing is attached to the bearing cradle in use.

[0026] In some preferred examples, the bearing cradle and separate support stands may be configured such that a distance between the first engagement surface and the substantially planar surface of the bearing cradle is substantially the same as a distance between the abutment surface of the support stand and a base surface of the foot portion of the support stand. Such a configuration of the bearing cradle and separate support stands ensures that the wind turbine bearing is flat with the bearing plane being horizontal when the bearing is supported in the horizontal orientation by the bearing cradle and separate support stands.

[0027] In some examples, the bearing cradle may comprise a plurality of cradle sections. For example, each cradle section may define at least part of the curved rocking surface. To support the wind turbine bearing the bearing cradle may be formed of a strong and hard- wearing material such as steel. Accordingly the total weight of the bearing cradle may be substantial. Providing the bearing cradle as a plurality of cradle sections may mean that the individual cradle sections are easier to move, transport and store, when not in use.

[0028] In some examples, the aperture of the bearing cradle may be defined at least in part by each of a first cradle section and a second cradle section. Accordingly the bearing cradle may be configured to receive the outer bearing ring of the wind turbine bearing in an aperture defined in part by each of the first and second cradle sections. Such a configuration may simplify arrangement of the wind turbine bearing in the aperture of the bearing cradle in use because the bearing cradle can be assembled from its constituent parts to form the aperture around at least a portion of the outer bearing ring.

[0029] In some examples, the first cradle section may define a first engagement surface configured to abut a first bearing surface on a first side of the wind turbine bearing. Further, the second cradle section may define a second engagement surface configured to abut a second bearing surface on a second side of the wind turbine bearing. Accordingly, in some examples the fixing means may comprise the first and second engagement surfaces and the bearing cradle may be configured to clamp the wind turbine blade bearing, i.e. at least a portion of one of the inner or outer bearing rings, between the first and second engagement surfaces.

[0030] In some examples, the bearing cradle sections may be entirely separable from one another. In such an example the bearing cradle may comprise releasable fixing means for releasably connecting the cradle sections together. For example, the cradle sections may be separable to facilitate arrangement of the wind turbine bearing, i.e. at least a portion of the outer ring of the wind turbine bearing, in the aperture. For example to attach the bearing cradle to the wind turbine bearing, the cradle may be disassembled into the separate cradle sections and at least a portion of the outer ring may subsequently be arranged with a first cradle section before a second cradle section is arranged with the first cradle section such that at least a portion of the outer bearing ring is thereby received in the aperture and sandwiched between the first and second cradle sections when the first and second cradle sections are connected together.

[0031] In some other examples, the cradle sections may not be entirely separable from one another, but may still be movable relative to one another to facilitate arrangement of the wind turbine bearing with the bearing cradle. For example, first and second cradle sections may be moved relative to one another such that a separation between the first and second engagement surfaces is increased to simplify arrangement of the at least a portion of the outer bearing ring in the aperture of the bearing cradle.

[0032] In some examples, the releasable fixing means for releasably connecting the cradle sections together may comprise one or more removeable bolts. Additionally or alternatively, the releasable fixing means may comprise one or more removeable rods or pins. In some examples, the releasable fixing means may comprise one or more plates or bars spanning across at least a portion of each cradle section such that the cradle sections may be releasably connected to one another via the one or more plates or bars. It follows that the or each plate or bar may be releasably fixed to the cradle sections by one or more removable bolts or pins. Such a configuration may advantageously facilitate quick and simple assembly, disassembly or reconfiguration of the bearing cradle when required.

[0033] In some examples, the or each plate or bar may comprise a plurality of locations, for example bores, for receiving the or each bolt, rod or pin. Accordingly, the plate or bar may facilitate reconfiguration of the bearing cradle into a plurality of different configurations. For example, the bearing cradle may comprise an assembled configuration in which the cradle sections are arranged together to clamp a portion of the wind turbine bearing between the first and second engagement surfaces, and an open configuration in which the cradle sections are releasably connected together with an increased separation between the engagement surfaces of the first and second cradle sections to facilitate arrangement of the bearing in the aperture. In some examples the open configuration of the bearing cradle may comprise one of the first or second cradle sections suspended above the other of the first or second cradle sections, and the first and second engagement surfaces may be oriented substantially horizontally. Accordingly the open configuration may facilitate arrangement of the bearing cradle with the wind turbine bearing when the bearing is in a substantially horizontal orientation. In some examples, the fixing means of the bearing holding portion of the bearing cradle may comprise one or more locating pins configured for insertion into one or more corresponding bores in the inner and / or outer bearing rings. For example, the or each bore in the inner and / or outer bearing ring may be a bore configured to receive a fastening bolt for bolting the wind turbine bearing to another wind turbine component in use. Accordingly, the turnover support apparatus may utilise existing features of the wind turbine bearing to accurately align the bearing cradle with the bearing. The locating pins may help to both align and fix the bearing cradle relative to the wind turbine bearing in use.

[0034] In some examples, the turnover support apparatus may further comprise a lifting fixture comprising a plurality of fasteners for attaching the lifting fixture to at least one of the inner or outer bearing ring. The lifting fixture may additionally define an aperture for coupling lifting apparatus to the lifting fixture. In some examples, the aperture may be defined by a shackle. The aperture may be configured for receiving a sling or a hook associated with lifting apparatus for lifting the lifting fixture and attached wind turbine bearing. In some preferred examples the lifting fixture may be configured for arrangement with a portion of the wind turbine bearing in opposed relation to a portion received in the aperture of the bearing cradle. As such, the lifting fixture may be configured to facilitate the application of a lifting force to an upper portion of the wind turbine bearing whilst a lower portion of the wind turbine bearing is received in the bearing cradle such that the lifting force causes the bearing and bearing cradle to pivot about the turnover axis defined at the contact point between the curved rocking surface and the underlying floor surface.

[0035] As previously described, in some preferred examples the turnover support apparatus may be entirely mechanical. For example, the bearing cradle, optional separate support stands and optional lifting fixture may not comprise any mechanical or electrical components to support the wind turbine bearing during a bearing turnover method. The bearing cradle may therefore provide a simple and cost-effective means for supporting a wind turbine bearing when turning the bearing in an assembly process.

[0036] In another aspect of the present invention there is provided a method of turning over a wind turbine bearing. The method comprises providing a wind turbine bearing comprising an inner bearing ring configured for attachment to a first wind turbine component and an outer bearing ring configured for attachment to a second wind turbine component. The inner and outer bearing rings are rotatable relative to one another about a bearing axis and in a bearing plane orthogonal to the bearing axis. The method further comprises providing turnover support apparatus. The turnover support apparatus comprises a bearing cradle comprising a bearing holding portion on a first side of the cradle and a curved rocking surface on a second side of the bearing cradle opposite to the first side of the cradle. The method comprises arranging at least a portion of the outer bearing ring in an aperture of the bearing holding portion, where the wind turbine bearing is oriented relative to the bearing cradle such that the curved rocking surface extends out of the bearing plane. The method further comprises releasably fixing at least one of the inner and / or outer bearing ring to the bearing cradle. Additionally, the method includes attaching lifting apparatus to a portion of the wind turbine bearing opposite to the portion of the bearing attached to the bearing cradle. The method comprises applying, via the lifting apparatus, a lifting force to the wind turbine bearing such that the bearing is supported by the lifting apparatus and by the bearing cradle on an underlying floor surface via the curved rocking surface. The method further comprises pivoting the bearing cradle and attached wind turbine bearing about a turnover axis that is orthogonal to the bearing axis and is defined at a point of contact between the curved rocking surface and the underlying floor surface, whereby the wind turbine bearing is supported on the floor surface by the bearing cradle throughout the pivoting motion.

[0037] Brief description of the drawings

[0038] Examples of the present invention will now be described by way of non-limiting example only, with reference to the accompanying figures, in which:

[0039] Figure 1 is a schematic perspective view of a wind turbine bearing;

[0040] Figure 2 is a schematic perspective view of a bearing cradle of a turnover support apparatus for supporting the wind turbine bearing in an assembly process;

[0041] Figure 3 is a schematic perspective view of the bearing cradle in an example where the cradle comprises a plurality of cradle sections;

[0042] Figure 4 is a schematic perspective view of the bearing attached to the bearing cradle;

[0043] Figure 5a shows a schematic view of the bearing supported by the bearing cradle in a first horizontal orientation;

[0044] Figure 5b shows schematic view of the bearing supported by the bearing cradle in an upright orientation; Figure 5a shows a schematic view of the bearing supported by the bearing cradle in a transitioning orientation between the upright and the horizontal orientation; and

[0045] Figure 5d shows a schematic view of the bearing supported by the bearing cradle in a second horizontal orientation.

[0046] Detailed description

[0047] Figure 1 shows a schematic perspective view of a wind turbine bearing 10. The wind turbine bearing 10 may be a pitch bearing or a yaw bearing, in some examples. The bearing 10 is configured to facilitate relative rotational movement between two components of a wind turbine. As such, the bearing 10 comprises an inner bearing ring 12 configured for attachment to a first wind turbine component and an outer bearing ring 14 configured for attachment to a second wind turbine component. The inner and outer bearing rings 12, 14 are rotatable relative to one another about a bearing axis A. Further, the bearing rings 12, 14 are rotatable relative to one another in a bearing plane Pwhich is orthogonal to the bearing axis A.

[0048] A first bearing surface 16 may be defined on a first side 18 of the bearing 10 by at least one of the inner and / or outer bearing rings 12, 14. Similarly, a second bearing surface 20 may be defined on a second side 22 of the bearing 10 by at least one of the inner and / or outer bearing rings 12, 14. The first and second bearing surfaces 16, 20 may be configured for engaging the respective first and second wind turbine components between which the bearing 10 is configured to facilitate rotational movement. In some examples, the wind turbine bearing 10 may comprise a plurality of bores 24 in at least one of the first and / or second bearing rings 12, 14 to facilitate a bolted connection attaching the respective bearing ring 12, 14 to a respective wind turbine component in use. As shown in Figure 1 , the bearing 10 may include a bearing plate 25 extending across an internal diameter of the inner bearing ring 12. The bearing plate 25 may provide a floor surface or work platform inside the turbine, for example inside a hub of the turbine, in use. In some examples, an assembly process may involve assembling pitch drive components (not shown) to each side of the bearing plate 25.

[0049] The wind turbine bearing 10 may have a large diameter, such as at least 2 m in some examples. As described by way of background, moving and turning the bearing 10 during an assembly process may therefore be challenging. Apparatus for supporting the wind turbine bearing 10 when turning the bearing 10 in an assembly process will now be described, alongside an example of a method of turning over the wind turbine bearing 10, with reference to the remaining figures.

[0050] Figure 2 shows a schematic perspective view of turnover support apparatus comprising a bearing cradle 26. The bearing cradle 26 is configured for attachment to the wind turbine bearing 10 to assist turning the bearing 10 in an assembly process. Accordingly, the bearing cradle 26 includes a bearing holding portion 28 on a first side 30 of the cradle 26. The bearing holding portion 28 features an aperture 32 for receiving at least a portion of the outer bearing ring 14. Additionally, the bearing holding portion 28 comprises fixing means 34 for releasably fixing at least one of the inner and / or outer bearing ring 12, 14 to the cradle 26. For example, the fixing means 34 may include one or more locating pins which are configured for insertion into one or more corresponding bores 24 in the inner and / or outer bearing rings 12, 14.

[0051] The aperture 32 of the bearing holding portion 28 may be partially defined by a first engagement surface 36 which is configured to abut the first bearing surface 16 when the outer bearing ring 14 is received in the aperture 32. It follows that in some examples, the aperture 32 may also be partially defined by a second engagement surface 38 which is configured to abut the second bearing surface 20 in use. For example, the aperture 32 may therefore be defined between the first and second engagement surfaces 36, 38 in some examples.

[0052] Referring still to Figure 2, the bearing cradle 26 further comprises a curved rocking surface 40 on a second side 42 of the bearing cradle 26 opposite to the first side 30 of the cradle 26. As described later in more detail with reference to Figures 5a to 5d, the bearing cradle 26 is configured such that the bearing 10 may be supported by the bearing cradle 26 on an underlying floor surface F via the curved rocking surface 40 in use. As shown in particular in Figures 4 to 5d, the curved rocking surface 40 is configured to define a turnover axis T at a point of contact between the curved rocking surface 40 and the floor surface F. It follows that the cradle 26 and attached bearing 10 are pivotable about the turnover axis T in use.

[0053] The bearing cradle 26 may be configured to support the wind turbine bearing 10 in a horizontal orientation, as described in more detail later with reference to Figures 5a and 5d. Accordingly, the bearing cradle 26 may comprise a substantially planar surface 44 at an end of the rocking surface 40 for supporting the wind turbine bearing 10 in the horizontal orientation. As shown in Figure 4, the bearing cradle 26 is preferably configured such that the substantially planar surface 44 is parallel to the bearing plane P when the bearing cradle 26 is attached to the wind turbine bearing 10 in use. In some examples, shown more clearly in Figures 5a to 5d, the cradle 26 includes a substantially planar surface 44 at each end of the rocking surface 40. Accordingly the bearing cradle 26 may be configured to supporting the wind turbine bearing 10 in both a first horizontal orientation and in a second horizontal orientation in which the wind turbine bearing 10 is turned over in comparison to the first horizontal orientation.

[0054] Figure 3 shows a schematic perspective view of the bearing cradle 26 in an example wherein the cradle 26 comprises a plurality of cradle sections 46a, 46b. In such an example, the curved rocking surface 40 may be defined at least in part by each of the cradle sections 46a, 46b. Similarly, in some examples the aperture 32 may be partly defined by each cradle section 46a, 46b. For example, the first engagement surface 36 may be defined by a first cradle section 46a, and the second engagement surface 38 may be defined by a second cradle section 46b.

[0055] The cradle sections 46a, 46b may be entirely separable from one another in some examples. Accordingly, the cradle sections 46a, 46b can be arranged around the wind turbine bearing 10, for example with the first and second engagement surfaces 36, 38 sandwiching a portion of the outer bearing ring 14, to thereby position the bearing 10 in the aperture 32. In some examples the bearing cradle 26 may include releasable fixing means 48 for releasably connecting the cradle sections 46a, 46b together.

[0056] Reference is now made to Figure 4, which shows the bearing cradle 26 attached to the wind turbine bearing 10 for supporting the bearing 10 during an assembly process. As shown in Figure 4, in use, a portion of the outer bearing ring 14 is arranged in the aperture 32 of the bearing holding portion 28. Whilst not shown explicitly in Figure 4, at least one of the inner and / or outer bearing ring 12, 14 is releasably fixed to the bearing cradle 26. With the cradle 26 attached to the bearing 10, the curved rocking surface 40 extends out of the bearing plane P. Further, the turnover axis T defined at the point of contact between the curved rocking surface 40 and the underlying floor surface F is orthogonal to the bearing axis A.

[0057] To assist with moving and turning over the bearing 10 during an assembly operation, a turnover method may comprise attaching lifting apparatus (not shown) to the bearing cradle 26. The lifting apparatus may comprise a crane or pulley system in some examples. Preferably the lifting apparatus may be attached to a portion of the wind turbine bearing 10 opposite to the portion attached to the bearing cradle 26. The lifting apparatus may be attached to the bearing 10 via a lifting fixture 50, shown in Figures 5a to 5d, attached to the bearing 10 as shown in Figure 4.

[0058] The lifting fixture 50 may therefore comprise a plurality of fasteners (not shown) for attaching the lifting fixture 50 to at least one of the inner or outer bearing ring 12, 14. Additionally, the lifting fixture 50 may define an aperture 52 for coupling the lifting apparatus to the fixture 50. Attaching the lifting apparatus, via the lifting fixture 50, to a portion of the wind turbine bearing 10 opposite to the portion attached to the bearing cradle 26 facilitates manipulation of the bearing 10 to pivot about the turnover axis T when supported in the bearing cradle 26 as will now be described in more detail with reference to Figures 5a to 5d.

[0059] Figures 5a to 5d show examples of the bearing cradle 26 in use supporting the wind turbine bearing 10 in a plurality of orientations. For example, Figure 5a shows the cradle 26 attached to the bearing 10 and supporting the bearing 10 in a horizontal orientation, which may be a first horizontal orientation. In the horizontal orientation, the bearing plane P is preferably substantially horizontal and the bearing axis A is substantially vertical. As shown in Figure 5a, in the horizontal orientation, the bearing 10 may be supported on the underlying floor surface F via the planar end surface 44 of the bearing cradle 26.

[0060] Figure 5b shows schematic view of the wind turbine bearing 10 supported in the bearing cradle 26 in an upright orientation. In the upright orientation the bearing plane P is substantially vertical and the bearing axis A is substantially horizontal. As shown, the bearing cradle 26 is configured to support the wind turbine bearing 10 on the underlying floor surface F via the curved rocking surface 40 in the upright orientation. In some examples, as shown most clearly in the side view in Figure 5b, the bearing cradle 26 may comprise a plurality of retractable support legs 54 which are configured to stabilise the bearing cradle 26 and the attached wind turbine bearing 10 in the upright orientation.

[0061] The bearing cradle 26 is preferably configured to facilitate moving the wind turbine bearing 10 between the horizontal and upright orientations, for example by rocking or pivoting the bearing 10 and attached bearing cradle 26 about the turnover axis T, which extends into the plane of the page in Figures 5a to 5d. Accordingly, as shown in Figure 5c, the bearing cradle 26 may also be configured to support the wind turbine bearing 10 in transitioning orientations between the upright and horizontal orientations. To move the bearing 10 between the horizontal and upright orientations, a lifting force may be applied to the bearing 10. For example, the lifting force may be applied to the bearing 10 by the lifting apparatus (not shown), via the lifting fixture 50. In a transitioning orientation, the bearing 10 may therefore be supported by the lifting apparatus and by the bearing cradle 26 on the underlying floor surface F via the curved rocking surface 40. Application of the lifting force, and in some examples variation of the direction of the lifting force, may cause the bearing cradle 26 and attached wind turbine bearing 10 to pivot about the turnover axis T. Advantageously, the configuration of the bearing cradle 26 ensures that the wind turbine bearing 10 can be supported on the floor surface F by the bearing cradle 26 throughout the pivoting motion.

[0062] Figure 5d shows an example where the bearing 10 has been turned over by pivoting the bearing cradle 26 and attached wind turbine bearing 10 about the turnover axis T. Accordingly, Figure 5d shows a second horizontal orientation in which the wind turbine bearing 10 is turned over in comparison to the first horizontal orientation shown in Figure 5a, for example. Again in the second horizontal orientation, the bearing 10 is preferably oriented such that the bearing plane P is substantially horizontal and the bearing axis A is substantially vertical.

[0063] As shown in Figure 5d, the bearing 10 may be supported on a substantially planar surface 44 at an end of the curved rocking surface 40 in the second horizontal orientation. In some examples, the turnover support apparatus may additionally comprise a plurality of separate support stands 56 for supporting the wind turbine bearing 10 in the horizontal orientation. For example, the support stands 56 may be arranged relative to the bearing 10 and the bearing cradle 26 such that the cradle 26 and support stands 56 together provide a three- point support for stabilising the bearing 10.

[0064] Each separate support stand 56 may comprise a contact portion 58 for arrangement with the inner bearing ring 12 or the outer being ring 14 of the wind turbine bearing 10. The contact portion 58 may include one or more locating pins (not shown), in some example. Such locating pins may be configured for insertion into a corresponding bore 24 in the inner or outer bearing ring 12, 14 for aligning and temporarily connecting the respective support stand 56 to the wind turbine bearing 10.

[0065] It should be appreciated that, whilst not shown in Figure 5a, the separate support stands 56 shown in Figure 5d may also support the wind turbine bearing 10 in the first horizontal orientation in an equivalent manner. It should also be appreciated that whilst lifting and moving the wind turbine bearing 10 between horizontal and upright orientations has been described previously with reference to a lifting fixture 50, it should be understood that in some examples a specific lifting fixture 50 may not be required. For example, the bearing 10 and attached bearing cradle 26 may be pivoted about the turnover axis Tby applying a lifting force to the bearing 10 in another way, for example via a lifting hook or a sling attached to a portion of the wind turbine bearing 10 opposite to the portion of the bearing 10 attached to the bearing cradle 26.

[0066] The description provided herein serves to demonstrate a plurality of possible examples of the present invention. It will be appreciated that features described in relation to any of the examples above may be readily combined with any other features described with reference to other examples without departing from the scope of the invention as defined in the appended claims.

Claims

CLAIMS:

1. Turnover support apparatus for supporting a wind turbine bearing (10) when turning the bearing in an assembly process, the wind turbine bearing comprising an inner bearing ring (12) configured for attachment to a first wind turbine component and an outer bearing ring (14) configured for attachment to a second wind turbine component, the inner and outer bearing rings being rotatable relative to one another about a bearing axis (A) and in a bearing plane (P) orthogonal to the bearing axis, and the turnover support apparatus comprising a bearing cradle (26) configured for attachment to the wind turbine bearing to assist turning the bearing about an axis orthogonal to the bearing axis; wherein the bearing cradle comprises a bearing holding portion (28) on a first side (30) of the cradle, the bearing holding portion comprising an aperture (32) for receiving at least a portion of the outer bearing ring and fixing means (34) for releasably fixing at least one of the inner and / or outer bearing ring to the cradle; wherein the bearing cradle comprises a curved rocking surface (40) on a second side (42) of the bearing cradle opposite to the first side of the cradle such that, in use, the wind turbine bearing may be supported by the bearing cradle on an underlying floor surface (F) via the curved rocking surface, the curved rocking surface being configured to define a turnover axis (7) at a point of contact between the curved rocking surface and the floor surface about which the cradle and attached bearing are pivotable in use, wherein the curved rocking surface extends out of the bearing plane when the bearing cradle is attached to the wind turbine bearing in use such that the turnover axis is orthogonal to the bearing axis.

2. The turnover support apparatus of claim 1, wherein the bearing cradle (26) is configured to support the wind turbine bearing (10) in a plurality of orientations including: a) an upright orientation in which the bearing plane (P) is substantially vertical and the bearing axis (A) is substantially horizontal; b) a horizontal orientation in which the bearing plane is substantially horizontal and the bearing axis is substantially vertical; and c) transitioning orientations in which the bearing is moving between the upright orientation and the horizontal orientation.

3. The turnover support apparatus of claim 2, wherein the bearing cradle (26) is configured to support the wind turbine bearing (10) on the underlying floor surface ( / =) via the curved rocking surface (40) in the upright and transitioning orientations, and whereinthe cradle comprises a substantially planar surface (44) at an end of the rocking surface for supporting the wind turbine bearing in the horizontal orientation.

4. The turnover support apparatus of claim 3, wherein the substantially planar surface (44) is substantially parallel to the bearing plane (P) when the bearing cradle (26) is attached to the wind turbine bearing (10) in use.

5. The turnover support apparatus of claim 3 or claim 4, wherein the cradle (26) comprises a substantially planar surface (44) at each end of the rocking surface (40) for supporting the wind turbine bearing (10) in both a first horizontal orientation and in a second horizontal orientation in which the wind turbine bearing is turned over in comparison to the first horizontal orientation.

6. The turnover support apparatus of any of claims 2 to 5, wherein the bearing cradle (26) comprises a plurality of retractable support legs (54) configured to stabilise the bearing cradle and the attached wind turbine bearing (10) in the upright orientation.

7. The turnover support apparatus of any of claims 2 to 6, further comprising a plurality of separate support stands (56) in addition to the bearing cradle (26) for supporting the wind turbine bearing (10) in the horizontal orientation.

8. The turnover support apparatus of claim 7, wherein each separate support stand (56) comprises a contact portion (58) for arrangement with the inner bearing ring (12) or the outer being ring (14), the contact portion (58) comprising one or more locating pins for insertion into a corresponding bore (24) in the inner or outer bearing ring for aligning and temporarily connecting the support stand to the wind turbine bearing (10).

9. The turnover support apparatus of any preceding claim, wherein the aperture (32) of the bearing holding portion (28) is defined at least in part by a first engagement surface (36) configured to abut a first bearing surface (16) on a first side (18) of the wind turbine bearing (10) when the outer bearing ring (14) is received in the aperture.

10. The turnover support apparatus of any preceding claim, wherein the bearing cradle (26) comprises a plurality of cradle sections (46a, 46b), and wherein each cradle section defines at least part of the curved rocking surface (40).

11. The turnover support apparatus of claim 10, wherein the aperture (32) of the bearing cradle (26) is defined at least in part by each of a first cradle section (46a) and a second cradle section (46b).

12. The turnover support apparatus of claim 11 , wherein the first cradle section (46a) defines a first engagement surface (36) configured to abut a first bearing surface (16) on a first side (18) of the wind turbine bearing (10), and the second cradle section (46b) defines a second engagement surface (38) configured to abut a second bearing surface (20) on a second side (22) of the wind turbine bearing.

13. The turnover support apparatus of any of claims 10 to 12, wherein the cradle sections (46a, 46b) are entirely separable from one another, and wherein the bearing cradle (26) comprises releasable fixing means (48) for releasably connecting the cradle sections together.

14. The turnover support apparatus of any preceding claim, wherein the fixing means (34) of the bearing holding portion (28) of the bearing cradle (26) comprise one or more locating pins configured for insertion into one or more corresponding bores (24) in the inner and / or outer bearing rings (12, 14).

15. The turnover support apparatus of any preceding claim, further comprising a lifting fixture (50) comprising a plurality of fasteners for attaching the lifting fixture to at least one of the inner or outer bearing ring (12, 14), the lifting fixture further defining an aperture (52) for coupling lifting apparatus to the lifting fixture.

16. A method of turning over a wind turbine bearing (10) comprising: providing a wind turbine bearing comprising an inner bearing ring (12) configured for attachment to a first wind turbine component and an outer bearing ring (14) configured for attachment to a second wind turbine component, the inner and outer bearing rings being rotatable relative to one another about a bearing axis (A) and in a bearing plane (P) orthogonal to the bearing axis; providing turnover support apparatus comprising a bearing cradle (26) comprising a bearing holding portion (28) on a first side (30) of the cradle and a curved rocking surface (40) on a second side (42) of the bearing cradle opposite to the first side of the cradle;arranging at least a portion of the outer bearing ring in an aperture (32) of the bearing holding portion, the wind turbine bearing being oriented relative to the bearing cradle such that the curved rocking surface extends out of the bearing plane; releasably fixing at least one of the inner and / or outer bearing ring to the bearing cradle; attaching lifting apparatus to a portion of the wind turbine bearing opposite to the portion attached to the bearing cradle; applying, via the lifting apparatus, a lifting force to the wind turbine bearing such that the bearing is supported by the lifting apparatus and by the bearing cradle on an underlying floor surface ( / =) via the curved rocking surface; and pivoting the bearing cradle and attached wind turbine bearing about a turnover axis (7) that is orthogonal to the bearing axis and is defined at a point of contact between the curved rocking surface and the underlying floor surface, whereby the wind turbine bearing is supported on the floor surface by the bearing cradle throughout the pivoting motion.

Images