Wind Turbine Gearbox Housing Support for Uptower Repair

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Solution Overview

Problem

The existing methods for repairing wind turbine gearboxes uptower require large ground cranes, which are costly and complex to schedule due to the weight and size of the gearbox housing components, often exceeding the available space, necessitating a more efficient maintenance solution.

Innovation Solution

A repair system comprising a lifting apparatus and gearbox housing support members that allow for the removal and support of gearbox housing portions uptower, utilizing an uptower crane and safety supports to facilitate safe and efficient maintenance without the need for large ground cranes, enabling the gearbox to be offset and secured during repair.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a large ground crane is used to remove the gearbox housing portion, then the heavy component can be lifted and removed, but the cost and scheduling complexity increase significantly

Engineering Contradiction:

Improvegearbox housing portion weightVSAvoidcrane system complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The gearbox housing is divided into multiple portions (first portion and second portion), allowing the heavy first portion to be removed and supported separately. This segmentation enables the use of smaller, more manageable lifting equipment rather than requiring a single large ground crane to handle the entire housing at once.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A support member is introduced as an intermediary component between the first portion of the gearbox housing and the second portion. This support member temporarily bears the weight of the removed first portion, eliminating the need for continuous crane support and simplifying the overall lifting operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Force

If a large ground crane is used to support the removed gearbox housing portion, then the component can be held in position, but the available space uptower is insufficient

Engineering Contradiction:

Improvesupport force for gearbox housingVSAvoidnacelle internal space

Core Design Contradiction:

ForceVSArea of stationary object

Solution Approach 1:

Instead of lowering the heavy first portion of the gearbox housing to the ground for support, the invention inverts the approach by providing support from above. The support member is lowered through the access hatch and positioned within the nacelle to support the first portion from the top, utilizing the vertical space rather than requiring horizontal ground space.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The support arrangement transitions from a horizontal ground-based crane system to a vertical support configuration. The support member extends vertically from the second portion of the housing to support the first portion, utilizing the vertical dimension within the nacelle rather than requiring horizontal space on the ground.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of repair

If maintenance operations are performed uptower with the current system, then the gearbox can be accessed, but the process becomes costly and time-consuming

Engineering Contradiction:

Improvegearbox maintenance accessibilityVSAvoidmaintenance operation duration

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The support member is pre-positioned and secured to the second portion of the gearbox housing before the first portion is removed. This preliminary setup ensures that when the first portion is lifted out for maintenance, the support structure is already in place, eliminating the need for time-consuming adjustments during the maintenance operation and streamlining the overall process.

Inventive Principle:

Principle #10Preliminary action

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 solution reduces the reliance on large ground cranes, simplifies maintenance operations, and provides a safer, more efficient method for repairing wind turbine gearboxes uptower by allowing for the support and offset positioning of heavy components within the turbine's structure.

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

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

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 of the gearbox that is offset from the second portion

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS10982655B2System and method for repairing a gearbox of a wind turbine uptower

Publication Date: 2021.04.20 GE INFRASTRUCTURE TECH LLC

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.