Wind Turbine Gearbox Housing Lifting for Crane-Free Uptower Repair
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Solution Overview
Problem
The existing methods for maintaining wind turbine gearboxes require large, ground cranes for removing heavy gearbox housing portions, leading to increased costs and scheduling complexities due to inadequate space uptower for supporting the removed parts.
Innovation Solution
A repair system that includes a lifting apparatus and gearbox housing support members to lift and support the first portion of the gearbox housing relative to the second portion, allowing for safe and efficient maintenance uptower without the need for a large ground crane, utilizing an uptower crane and safety supports to divert and secure the gearbox during descent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a large ground crane is used to remove the heavy gearbox housing portion, then the housing can be removed, but the cost and scheduling complexity increase
Solution Approach 1:
The gearbox housing is divided into a first portion and a second portion, allowing the heavy first portion to be separately removed and supported. This segmentation enables maintenance operations without requiring a single large ground crane to handle the entire housing at once.
Solution Approach 2:
A support member is introduced as an intermediary component between the first and second portions of the gearbox housing. This support member provides a support surface for the removed first portion, enabling safe maintenance operations without requiring external ground crane support.
2Ease of repair
If the first portion of the gearbox housing is removed with a ground crane, then the housing can be accessed, but inadequate space uptower prevents support of the removed portion
Solution Approach 1:
The support function is moved from the horizontal ground plane to the vertical uptower space. By positioning the support member within the nacelle assembly, the system utilizes the vertical dimension and available internal space rather than requiring external ground space for crane operations.
3Weight of moving object
If a large ground crane is used for maintenance operations, then heavy components can be handled, but the cost increases
Solution Approach 1:
The wind turbine nacelle assembly becomes self-sufficient for handling heavy components during maintenance. The lifting apparatus and support member enable the system to support and manipulate the gearbox housing portions using only its own internal resources, eliminating the need for external ground crane services and associated costs.
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
Enables safe and cost-effective gearbox maintenance uptower by providing a support system for the gearbox housing, reducing the reliance on large ground cranes and simplifying the maintenance process while ensuring safety during the repair procedure.
Implementation Method 1
a lifting apparatus for removably coupling to the first portion of the gearbox housing of the gearbox. The lifting apparatus may be adapted for lifting the first portion of the gearbox housing relative to the second portion of the gearbox housing
Implementation Method 2
at least one gearbox housing support member adapted for mounting to the second portion of the gearbox housing so as to provide a support surface for the first portion of the gearbox housing during a repair procedure
Implementation Method 3
The force arm may be adapted so as to impart a moment on the first portion of the gearbox housing during an unplanned descent of the first portion of the gearbox housing
Data Source
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AI summary
A repair system for a gearbox of a wind turbine includes for removably coupling to the first portion of the gearbox housing of the gearbox. The lifting apparatus is adapted for lifting the first portion of the gearbox housing relative to the second portion gearbox housing. The repair system also includes at least one gearbox housing support member for mounting to the second portion of the gearbox housing. The at least one gearbox housing support member provides a support surface for the first portion of the gearbox housing during a repair procedure of the gearbox. The support surface is offset from the second portion of the gearbox housing.