Rotor lock system for wind turbine

Abstract

A rotor lock system for locking a rotor of a wind turbine has a bracket that is slidably mountable on a forwardly protruding projection of a nacelle of the wind turbine so that the bracket is slidable on the projection, and a lock arm connected to the bracket so that the lock arm extends radially away from the projection. The bracket has opposed backing plates and opposed connecting shafts that connect the backing plates together so that at least one of the backing plates is slidable on the connecting shafts when the bracket is mounted on the projection. The lock arm has a protrusion that engages an aperture in a rotor plate when the bracket slides forward on the projection to lock rotation of the rotor plate and disengages from the aperture when the bracket slides rearward on the projection to unlock the rotation of the rotor plate.

Description

[0001] ROTOR LOCK SYSTEM FOR WIND TURBINE

[0002] Cross-reference to Related

[0003] This application claims the benefit of U.S. application USSN 63 / 635,048 filed April 17, 2024, the entire contents of which is herein incorporated by reference.

[0004] Field

[0005] This application relates to wind turbines, in particular to a locking system for preventing rotation of a rotor during maintenance of the wind turbine.

[0006] Background

[0007] Replacement or repair of wind turbine components, in particular wind turbine components connected to a rotor of the wind turbine, is difficult because the rotor may continue to rotate in the wind while attempts are made to effect replacement or repair of the component. Components connected to a rotor include, for example, the main shaft, the gearbox, the generator and the like. To prevent the rotor from rotating during replacement or repair of such components, the rotor may be locked down to prevent rotation. However, different kinds of lock mechanisms have been used depending on the particular component to be replaced or repaired because there are limited locations at which to effectively mount a lock and existing locks are often mounted on the very component that is desired to be replaced or repaired. Further, many existing locks are cumbersome or difficult to install and / or use, often involving the necessity to rotate the rotor before locking the rotor in order to properly align the rotor with the rotor lock for locking the rotor.

[0008] There remains a need for a rotor locking system that is easier to install and use and that can be used to lock a rotor irrespective of the component to be removed and without needing to rotate the rotor before locking the rotor.

[0009] A rotor lock system for locking a rotor plate of a wind turbine comprises: a bracket that is slidably mountable on a forwardly protruding projection of a nacelle of the wind turbine so that the bracket is slidable forward and backward on the projection when mounted on the projection, the bracket comprising first and second opposed backing plates and first and second opposed connecting shafts that connect the backing plates together so that at least one of the backing plates is slidable on the connecting shafts when the bracket is mounted on the projection; and, a lock arm connected to the bracket so that the lock arm extends radially away from the projection when the bracket is mounted on the projection, the lock arm comprising a protrusion that engages an aperture in a rotor plate when the bracket slides forward on the projection to lock rotation of the rotor plate and disengages from the aperture when the bracket slides rearward on the projection to unlock the rotation of the rotor plate.

[0010] A kit comprises the system and instructions for using the system to lock the rotation of the rotor plate.

[0011] The rotor lock system is simple, easy to use and adaptable to lock rotation of the rotor plate without needing to rotate the rotor plate to align the rotor plate with the rotor lock system and without needing to remove studs and nuts that secure a hub of the wind turbine to the rotor plate. Wind turbines comprise a brake to initially stop rotation of the rotor plate, which results in the rotor plate initially stopping in a random radial position. Therefore, it is advantageous to have a rotor locking system that can be applied without the need to release the brake to permit rotation of the rotor plate to align the rotor plate with the rotor lock.

[0012] The rotor lock system comprises a lock arm and a bracket. The bracket permits mounting the rotor lock system on the wind turbine, for example on the nacelle of the wind turbine. The lock arm interacts with the rotor plate to lock the rotor plate from rotating thereby preventing rotation of the rotor.

[0013] In some embodiments, the bracket is mounted at a front of the nacelle behind the rotor plate on a forwardly protruding projection of the nacelle. In some embodiments, the bracket is mountable around the projection and is configured to be slidable forward and rearward on the projection to lock and unlock rotation of the rotor plate. In some embodiments, sliding of the bracket on the projection may be accomplished manually by an operator. In some embodiments, an actuator (e.g., a piston-cylinder device, a mechanical spring or the like) is used to slide the bracket on the projection to move the rotor lock system between engaged and disengaged configurations with the rotor plate.

[0014] In some embodiments, the bracket comprises a first backing plate and a second backing plate opposing the first backing plate. In some embodiments, the second backing plate is rigidly attached to, for example integrally formed with or releasably connected to, a proximal end of the lock arm. In some embodiments, the first backing plate and the second backing plate are adjustably connected by at least one connecting shaft. In some embodiments, the at least one connecting shaft comprises a first connecting shaft and a second connecting shaft that connect the backing plates together. In some embodiments, the at least one connecting shaft extends through holes in the backing plates. In some embodiments, the holes in the first and second backing plates are aligned. In some embodiments, the at least one connecting shaft is a threaded pin (e.g., a bolt or screw), an unthreaded rod or a strut. In some embodiments, the at least one connecting shaft is secured with corresponding securement, for example a threaded nut, a clamp or the like, to secure the backing plates on the at least one connecting shaft.

[0015] In some embodiments, the backing plates and the connecting shafts form edges of a receiving aperture in the bracket. In some embodiments, the backing plates form sides of the receiving aperture and the connecting shafts form the bottom and top of the receiving aperture. In some embodiments, a distance between the first backing plate and the second backing plate is adjustable to permit lateral size adjustment of the receiving aperture. In some embodiments, the lateral size adjustment of the receiving aperture is accomplished by sliding the first backing plate on the at least one connecting shaft. In some embodiments, the bracket comprises means for securing the at least one slidable backing plate against the projection so that the bracket is prevented from sliding on the projection when mounted on the projection. In some embodiments, the means for securing comprises the securement described above. In some embodiments, the at least one connecting shaft comprises at least one threaded pin and the means for securing the at least one slidable backing plate against the projection comprises at least one nut on the at least one threaded pin, wherein tightening the at least one nut on the at least one threaded pin secures the at least one slidable backing plate against the projection.

[0016] The lock arm extends radially away from the projection when the bracket is mounted on the projection. In some embodiments, the lock arm comprises an arcuate elongated element having the protrusion. In some embodiments, the protrusion protrudes forwardly from a front face of the lock arm in a direction perpendicular to a longitudinal axis of the lock arm. In some embodiments, the protrusion extends from the front face of the lock arm in a direction perpendicular to a plane in which longitudinal axes of the at least one connecting shaft and the lock arm are co-parallel. In some embodiments, the longitudinal axes of the at least one connecting shaft and the lock arm are co-parallel in a plane parallel to a plane of the rotor plate when the bracket is mounted on the projection. In some embodiments, the lock arm forms an arc of a circle that is concentric with a circular perimeter of the rotor plate. In some embodiments, the protrusion functions as a rotor lock pin and is shaped to mate with an aperture in the rotor plate. In some embodiments, the protrusion extends forwardly from the front face of the lock arm toward the rotor plate when the rotor lock system is mounted on the wind turbine.

[0017] In some embodiments, the lock arm further comprises a stud tie that engages a rotor stud of the rotor plate to help position the lock arm at the rotor plate. In some embodiments, the stud tie is upwardly extending from the lock arm. The stud tie engages the stud without the need to remove the stud and a corresponding stud nut from the rotor plate, which is important because the stud nut can only be torqued once before the stud and stud nut must be replaced.

[0018] In some embodiments, adaptability of the rotor lock system is accomplished by providing a plurality of lock arms of different lengths, by providing a lock arm that is length adjustable (e.g., telescoping), by providing an angle adjustable lock arm, or by any combination thereof.

[0019] In some embodiments, the rotor lock system comprises a plurality of replaceable lock arms with different lengths where any given lock arm is replaceable with another lock arm of different length. In some embodiments, the protrusions of different replaceable lock arms engage the aperture or different apertures in the rotor plate at different radial positions on the rotor plate. In some embodiments, to mount the rotor lock system on the projection, an operator first chooses a lock arm having an appropriate length so that the protrusion on the lock arm is aligned with one of the apertures in the rotor plate. In some embodiments, because the rotor lock system comprises a plurality of replaceable lock arms of different lengths, rotating the rotor plate to align an aperture with a locking pin is not required. Instead, an operator simply chooses a lock arm of appropriate length, eliminating the need to rotate the rotor plate to align the protrusion with one of the apertures in the rotor plate. In some embodiments, once the replaceable lock arm is chosen, the bracket is slid on to the projection so that the projection is bracketed by the at least one connecting shaft and the backing plates and the bracket is secured from falling off the projection by engaging the securement without tightening the backing plates against the projection. The bracket is thereby slidably mounted on the projection so that the bracket is slidable forward and backward on the projection. Once the bracket is mounted on the projection, the bracket with the lock arm connected thereto may slide forward on the projection so that the protrusion engages the aperture in the rotor plate to lock rotation of the rotor plate. The bracket with the lock arm connected thereto may be slid rearward on the projection so that the protrusion disengages from the aperture to unlock rotation of the rotor plate. When rotation of the rotor plate is locked, the backing plates may be tightened against the projection using the securement to prevent the bracket from sliding rearward on the projection thereby preventing inadvertent unlocking of the rotation of the rotor plate.

[0020] In some embodiments, the lock arm comprises a slide on which the protrusion is located, wherein movement of the slide changes a position of the protrusion relative to the bracket. The protrusion is thereby engageable with the aperture or different apertures in the rotor plate at different radial positions on the rotor plate. In some embodiments, the lock arm is provided with arcuate slots though the faces of the lock arm and the slide is provided with sliding pins that engage the slots. The slide slides in the arcuate slots to change the radial position of the protrusion relative to the rotor plate to align the protrusion with one of the apertures in the rotor plate. In this manner, only a single lock arm is required to adapt the rotor lock system to lock the rotor plate irrespective of the radial position at which the rotor plate stops upon braking.

[0021] Further features will be described or will become apparent in the course of the following detailed description. It should be understood that each feature described herein may be utilized in any combination with any one or more of the other described features, and that each feature does not necessarily rely on the presence of another feature except where evident to one of skill in the art.

[0022] Brief Description of the Drawings

[0023] For clearer understanding, preferred embodiments will now be described in detail by way of example, with reference to the accompanying drawings, in which:

[0024] Fig. 1A depicts a front perspective view of a rotor lock system having a lock arm for engagement with a rotor plate of a wind turbine.

[0025] Fig. 1 B depicts a front view of Fig. 1 A.

[0026] Fig. 1C depicts an exploded view of Fig. 1A.

[0027] Fig. 2A depicts the lock arm shown in Fig. 1A. Fig. 2B depicts a lock arm having a longer length than the lock arm of Fig. 2A.

[0028] Fig. 2C depicts a lock arm having a shorter length than the lock arm of Fig. 2A.

[0029] Fig. 3 depicts a right rear perspective view of the rotor lock system of Fig. 1 A mounted on a projection of the wind turbine with the lock arm engaged with the rotor plate to lock the rotor plate.

[0030] Fig. 4 depicts a rear view of Fig. 3.

[0031] Fig. 5A depicts a left rear perspective view of Fig. 3.

[0032] Fig. 5B depicts Fig. 5A except that the lock arm is disengaged from the rotor plate to unlock the rotor plate.

[0033] Fig. 6A depicts a bottom view of Fig. 5A.

[0034] Fig. 6B depicts a bottom view of Fig. 5B.

[0035] Fig. 7A depicts a rear perspective view of the rotor lock system of Fig. 1A in context with more elements of the wind turbine.

[0036] Fig. 7B depicts a bottom front perspective magnified view of Fig. 7A showing the lock arm engaged with the rotor plate to lock the rotor plate,

[0037] Fig. 8A depicts a rear perspective view of a telescoping variation of a lock arm of the rotor lock system in which a locking pin is slidably mounted on the lock arm to be moveable to different positions along the lock arm.

[0038] Fig. 8B depicts a front perspective view of Fig. 8A.

[0039] Fig. 8C depicts the lock arm of Fig. 8A with the locking pin moved to a more distal position on the lock arm.

[0040] Fig. 8D depicts a front perspective view of Fig. 8C.

[0041] Fig. 8E depicts the lock arm of Fig. 8A with the locking pin moved to a more proximal position on the lock arm. Fig. 8F depicts a front perspective view of Fig. 8E.

[0042] Detailed

[0043] Referring to the Figures, a rotor lock system 1 for locking a rotor plate 30 of a wind turbine against rotation comprises a lock arm 3 rigidly connected to a bracket 10. The bracket 10 comprises a first backing plate 11 and a second backing plate 12 opposing the first backing plate 11 . The second backing plate 12 is rigidly attached to, for example integrally formed with or releasably connected to, a proximal end of the lock arm 3. The first backing plate 11 and the second backing plate 12 are adjustably connected together by a first connecting shaft 13 and a second connecting shaft 14 that connect the backing plates 11 , 12 together through holes in the backing plates 11 , 12, the holes in the first backing plate 11 aligning with the holes in the second backing plate 12. The connecting shafts 13, 14 are illustrated as threaded pins (e.g., bolts) secured with corresponding threaded nuts 15 and washers 16. Other types of connecting shafts are suitable, for example unthreaded rods or struts with clamps to secure the backing plates on the connecting shafts. Together, the backing plates 11 , 12 and the connecting shafts 13, 14 form edges of a receiving aperture 17 in the bracket 10. The backing plates 11 , 12 form sides of the receiving aperture 17 and the connecting shafts 13, 14 form the bottom and top of the receiving aperture 17. With the second backing plate 12 rigidly attached to the lock arm 3, a distance between the first backing plate 11 and the second backing plate 12 is adjustable by sliding the first backing plate 11 on the connecting shafts 13, 14 when the bracket 10 is assembled permitting lateral size adjustment of the receiving aperture 17.

[0044] The lock arm 3 comprises an arcuate elongated element having a protrusion 7 that protrudes forwardly from a front face 9 of the lock arm 3 in a direction perpendicular to a longitudinal axis of the lock arm 3. The protrusion 7 extends from the front face 9 of the lock arm 3 in a direction perpendicular to a plane in which longitudinal axes of the connecting shafts 13, 14 and the lock arm 3 are co-parallel. The lock arm 3 forms an arc of a circle that is concentric with a circular perimeter of the rotor plate 30. The protrusion 7 functions as a rotor lock pin and is shaped to mate with one of the apertures 32 (only one labeled) in the rotor plate 30, the protrusion 7 extending forwardly from the front face 9 of the lock arm 3 toward the rotor plate 30 when the rotor lock system 1 is mounted on the wind turbine. The lock arm 3 further comprises an upwardly extending stud tie 8 that engages a rotor stud 34 (only one labeled in Fig. 7A) of the rotor plate 30 to help position the lock arm 3 at the rotor plate 30 when configuring the rotor lock system 1 on the wind turbine. The stud tie 8 engages the stud 34 without the need to remove the stud 34 and its corresponding stud nut 36 from the rotor plate 30. The stud tie 8 slides over a protruding end of the stud 34 that protrudes from the stud nut 36, the protruding end of the stud 34 having sufficient remaining threads to secure the stud tie 8 on the stud 34 with a thin tie-securing nut. Fig. 3 to Fig. 5B illustrate the rotor plate 30 without the studs 34, but Fig. 3 to Fig. 5B illustrate the rotor plate 30 with corresponding stud holes 35. The studs 34 and stud nuts 36 secure a hub of the wind turbine to the rotor plate 30.

[0045] As seen in Fig. 2A to Fig. 2C, the rotor lock system 1 can comprise a plurality of lock arms 3 with different lengths (only three illustrated). Fig. 2A depicts a lock arm 3a having a first length; Fig. 2B depicts a longer lock arm 3b than the lock arm 3a; and Fig. 3C depicts a shorter lock arm 3c than the lock arm 3a. Other than the length, the lock arms of different lengths are similarly designed. Therefore, any given lock arm 3 is replaceable with another lock arm 3 of different length.

[0046] In use, the rotor lock system 1 is mounted on the wind turbine at a front thereof and behind the rotor plate 30. Ideally, a forwardly protruding projection 41 of a nacelle 40 of the wind turbine provides the mount on which the rotor lock system 1 is mounted. To mount the rotor lock system 1 on the projection 41, an operator first chooses a lock arm 3 having an appropriate length so that the protrusion 7 on the lock arm 3 is aligned with one of the apertures 32 in the rotor plate 30. Because the rotor lock system 1 may comprise a plurality of replaceable lock arms 3 of different lengths, rotating the rotor plate 30 to align an aperture 32 with a locking pin is not required. Instead, an operator simply chooses a lock arm 3 of appropriate length, eliminating the need to rotate the rotor plate 30 to align the protrusion 7 with one of the apertures 32 in the rotor plate 30. The protrusions 7 of different replaceable lock arms 3 engage one of the apertures 32 in the rotor plate 30 at different radial positions on the rotor plate 30. When mounted, the lock arm 3 extends radially away from a longitudinal axis of the projection 41 in a direction that is parallel to a plane of the rotor plate 30. Once the lock arm 3 is chosen, the bracket 10 with the connecting shafts 13, 14 inserted through the second backing plate 12 is slid on to the projection 41 so that the projection 41 is between the connecting shafts 13, 14 and then the first backing plate 11 is slid on to the connecting shafts 13, 14 and secured from falling off by engaging the nuts 15 with the connecting shafts 13, 14 without tightening the first backing plate 11 against the projection 41. The bracket 10 is thereby slidably mounted around the projection 41 so that the bracket 10 is slidable forward and backward on the projection 41. The second connecting shaft 14 (i.e. , the top connecting shaft 14) slides on the projection 41 as the bracket 10 slides forward and backward. As most clearly shown in Fig. 6A and Fig. 6B, once the bracket 10 is mounted on the projection 41 , the bracket 10 with the lock arm 3 connected thereto may be slid forward on the projection 41 so that the protrusion 7 engages the aperture 32 to lock rotation of the rotor plate 30 (see Fig. 6A). Further, the bracket 10 with the lock arm 3 connected thereto may be slid rearward on the projection 41 so that the protrusion 7 disengages from the aperture 32 to unlock rotation of the rotor plate 30 (see Fig. 6B). When rotation of the rotor plate 30 is locked, the first backing plate 11 may be tightened against the projection 41 by tightening the nuts 15 to prevent the bracket 10 from sliding rearward on the projection 41 thereby preventing inadvertent unlocking of the rotation of the rotor plate 30. Sliding of the bracket on the protrusion may be accomplished manually by an operator or an actuator (e.g., a piston-cylinder device, a mechanical spring or the like) may be used to slide the bracket to move rotor lock system between engaged and disengaged configurations with the rotor plate.

[0047] Fig. 8A to Fig. 8F illustrate an embodiment of the rotor lock system wherein a lock arm 103 comprises a slide 104 on which a protrusion 107 (functioning as a locking pin) is located. Movement of the slide 104 changes a radial position of the protrusion 107 relative to the bracket 10 so that the protrusion 107 is engageable with one of the apertures 32 in the rotor plate 30 at different radial positions on the rotor plate 30. The lock arm 103 is provided with arcuate slots 106 though the faces of the lock arm 103 and the slide 104 is provided with sliding pins 109 (only one labeled in each of Fig. 8A, Fig. 8C and Fig. 8E) that engage the slots 106. The slide 104 slides in the arcuate slots 106 to change the radial position of the protrusion 107 relative to the rotor plate 30 to align the protrusion 107 with one of the apertures 32 in the rotor plate 30. In this manner, only a single lock arm 103 is required to adapt the rotor lock system to lock the rotor plate irrespective of the radial position at which the rotor plate stops upon braking.

[0048] Similar adaptation of the lock arm of the rotor lock system to the radial position of the apertures in the rotor plate can be achieved by utilizing an angle adjustable lock arm.

[0049] The novel features will become apparent to those of skill in the art upon examination of the description. It should be understood, however, that the scope of the claims should not be limited by the embodiments but should be given the broadest interpretation consistent with the wording of the claims and the specification as a whole.

Claims

Claims:

1. A rotor lock system for locking a rotor plate of a wind turbine, the rotor lock system comprising: a bracket that is slidably mountable on a forwardly protruding projection of a nacelle of the wind turbine so that the bracket is slidable forward and backward on the projection when mounted on the projection, the bracket comprising first and second opposed backing plates and first and second opposed connecting shafts that connect the backing plates together so that at least one of the backing plates is slidable on the connecting shafts when the bracket is mounted on the projection; and, a lock arm connected to the bracket so that the lock arm extends radially away from the projection when the bracket is mounted on the projection, the lock arm comprising a protrusion that engages an aperture in a rotor plate when the bracket slides forward on the projection to lock rotation of the rotor plate and disengages from the aperture when the bracket slides rearward on the projection to unlock the rotation of the rotor plate.

2. The system of claim 1 , wherein the lock arm comprises the second backing plate integrally formed with the lock arm.

3. The system of claim 1 or claim 2, wherein the bracket comprises means for securing the at least one slidable backing plate against the projection so that the bracket is prevented from sliding on the projection when mounted on the projection.

4. The system of claim 3 wherein the connecting shafts comprise threaded pins and the means for securing the at least one slidable backing plate against the projection comprises nuts on the threaded pins, wherein tightening the nuts on the threaded pins secures the at least one slidable backing plate against the projection.

5. The system of any one of claims 1 to 4, wherein longitudinal axes of the connecting shafts and the lock arm are co-parallel in a plane parallel to a plane of the rotor plate when the bracket is mounted on the projection.

6. The system of claim 5, wherein the protrusion protrudes from a face of the lock arm in a direction perpendicular to the plane in which the connecting shafts and the lock arm are coparallel.

7. The system of any one of claims 1 to 6, wherein the protrusion comprises a pin shaped to mate with the aperture, the pin extending forwardly from a front face of the lock arm toward the rotor plate when the bracket is mounted on the projection.

8. The system of any one of claims 1 to 7, wherein the lock arm is arcuate comprising an arc of a circle that is concentric with the rotor plate.

9. The system of any one of claims 1 to 8, wherein the lock arm further comprises a stud tie that engages a stud of the rotor plate to help position the lock arm at the rotor plate.

10. The system of any one of claims 1 to 9, wherein the lock arm is a first replaceable lock arm and the system comprises a plurality of replaceable lock arms having different lengths whereby the protrusions of different replaceable lock arms engage the aperture or different apertures in the rotor plate at different radial positions on the rotor plate.

11. The system of any one of claims 1 to 9, wherein the lock arm comprises a slide on which the protrusion is located, wherein movement of the slide changes a position of the protrusion relative to the bracket so that the protrusion is engageable with the aperture or different apertures in the rotor plate at different radial positions on the rotor plate.

12. A kit comprising the system of any one of claims 1 to 11 and instructions for using the system to lock the rotation of the rotor plate.

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