Wind Turbine Gearbox Dismantling via Hydraulic Shaft Separation
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Solution Overview
Problem
The challenge of dismantling a wind turbine gearbox from a main shaft in the nacelle is complicated by the strong connection required to transfer massive torque, making existing methods complex and expensive.
Innovation Solution
A method involving the use of a hydraulic connection plug secured in the gearbox shaft, connected to a hydraulic pump that pumps liquid into the connection cavity to force the main shaft out, while securing the gearbox shaft against axial displacement to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a strong connection between the main shaft and gearbox is used to transfer massive torque, then the torque transfer capability is improved, but the difficulty of dismantling increases
Solution Approach 1:
A hydraulic connection plug is introduced as an intermediary component in the center channel of the gearbox shaft. This plug provides a controlled interface for introducing hydraulic pressure to dismantle the connection, allowing the strong torque transfer connection to be easily separated when needed through the intermediary hydraulic access point.
Solution Approach 2:
Hydraulic pressure is applied through the hydraulic connection plug to generate a separation force that overcomes the strong connection between the main shaft and gearbox. The incompressible hydraulic fluid transmits force efficiently to push the main shaft out of the connection cavity, enabling easy dismantling despite the strong operational connection.
2Ease of operation
If jacking devices are used to dismantle the main shaft from the gearbox, then the dismantling capability is improved, but the system complexity and cost increase
Solution Approach 1:
The hydraulic connection plug extracts only the essential function needed for dismantling - a controlled access point for hydraulic pressure - from the complex jacking device system. This eliminates the need for external jacking equipment while maintaining the ability to generate sufficient separation force through the existing center channel of the gearbox shaft.
Solution Approach 2:
The gearbox shaft's own center channel is utilized as the hydraulic access path, allowing the system to dismantle itself without external equipment. The existing structural feature (center channel) is repurposed to provide the dismantling function, eliminating the need for additional complex external devices.
3Force
If hydraulic pressure is applied to the connection cavity to force separation, then the separation force is improved, but the risk of damaging the gearbox shaft increases
Solution Approach 1:
The hydraulic connection plug is pre-installed and secured in the center channel before hydraulic pressure is applied. This preliminary positioning ensures that the pressure is directed through a controlled path and that the plug itself is protected from damage, preventing the pressure from directly affecting the gearbox shaft structure.
Solution Approach 2:
The hydraulic connection plug acts as a mediator that absorbs and directs the hydraulic pressure forces. It protects the gearbox shaft from direct exposure to high pressure by providing a dedicated pressure reception surface and controlled discharge path, eliminating the harmful effect of uncontrolled pressure on the shaft structure.
4Ease of manufacture
If the hydraulic connection plug is not secured against axial displacement, then the dismantling process is simpler, but liquid leakage occurs reducing effectiveness
Solution Approach 1:
The securing function is extracted as a separate, simple feature of the hydraulic connection plug design. The plug includes integrated securing elements (such as threads or engagement features) that provide axial retention, separating the securing function from the main body design and allowing for simple installation while ensuring reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method generates a significant separation force in a simple and cost-effective way, reducing friction through lubrication and allowing for controlled dismantling of the gearbox from the main shaft.
Implementation Method 1
pumping liquid into the connection cavity by means of the hydraulic pump to force the main shaft out of the connection cavity
Implementation Method 2
a massive separation force hereby can be generated in a simple and inexpensive way
Implementation Method 3
the liquid being pumped into the connection cavity may lubricate the connection between the wind turbine gearbox and the main shaft in the connection cavity to thereby reduce friction
Data Source
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AI summary
Disclosed is a method for dismantling a wind turbine gearbox (15) from a main shaft (7) in the nacelle (3) of a wind turbine (1), wherein a first end (11) of the main shaft (7) is connected to the gearbox (15) in a connection cavity (22) of the gearbox (15) and a second end (12) of the main shaft (7) is connected to a rotor (4) of the wind turbine (1). The method comprises the steps of: - arranging a hydraulic connection plug (13) in a centre channel (14) of a second end (37) of a gearbox shaft (21) of the gearbox (15), wherein a first end (20) of the gearbox shaft (21) is arranged at the connection cavity (22) on a first side (23) of the gearbox (15) and wherein the second end (37) of the gearbox shaft (21) is arranged at a second side (24) of the gearbox (15) opposite the first side (23), - securing the hydraulic connection plug (13) and the gearbox shaft (21) against axial displacement in a direction towards the second side (24) of the gearbox (15), - connecting a hydraulic pump (25) to the hydraulic connection plug (13), and - pumping liquid into the connection cavity (22) by means of the hydraulic pump (25) to force the main shaft (7) out of the connection cavity (22). Furthermore, use of the method is disclosed.