Generator Bell-Mount Fixture for In-Situ Wind Turbine Repair
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Solution Overview
Problem
The existing methods for repairing and maintaining wind turbine generators are time-consuming and costly, requiring the removal of the generator and high speed shaft from the turbine for substantial repairs, which is dangerous and inefficient.
Innovation Solution
A bell-mount fixture and associated accessory fixtures that allow for in-situ repair and maintenance of the generator shaft by mounting to the generator housing, providing a platform for securing tools and machinery, enabling axial and rotational movement of the high speed shaft for machining operations without the need to remove the generator from the turbine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the generator and high speed shaft are removed from the turbine for repair, then repair accessibility is improved, but maintenance time and cost increase significantly
Solution Approach 1:
The bell-mount fixture serves as an intermediary device that provides a stable mounting platform within the bell housing, enabling repair operations to be performed in-situ without removing the generator. This intermediary structure bridges the gap between the confined space constraints and the need for repair accessibility.
Solution Approach 2:
The fixture enables the generator system to service itself by providing all necessary mounting and positioning capabilities within the existing bell housing structure, eliminating the need for external removal and transport to separate repair facilities.
2Ease of operation
If the generator and high speed shaft are removed from the turbine for repair, then repair accessibility is improved, but operational disruption increases
Solution Approach 1:
The bell-mount fixture acts as an intermediary that enables repair operations within the confined bell housing space, eliminating the need to disconnect the generator from the drivetrain and avoid operational disruptions associated with full removal.
Solution Approach 2:
The fixture is installed and configured before repair operations begin, establishing a stable working platform that enables all necessary repair activities to be completed in-situ, preventing the need for subsequent removal operations that would cause operational disruption.
3Adaptability or versatility
If the generator and high speed shaft are removed from the turbine for repair, then comprehensive inspection capability is improved, but safety risks increase
Solution Approach 1:
The bell-mount fixture serves as a stable intermediary platform that provides secure mounting for inspection and repair equipment within the bell housing, enabling comprehensive inspections without the safety risks associated with removing and handling heavy generator components.
Solution Approach 2:
The fixture creates a simplified working environment within the bell housing that replicates the accessibility and stability needed for comprehensive inspections, allowing detailed examination of the high speed shaft and generator components without removing them from their operational context.
Data Source
AI summary
A fixture and methods of using the fixture that can be used in situ to perform repair and maintenance work on a generator shaft and associated components of a wind turbine generator is described. The fixture is typically mounted to a plurality of the threaded bores provided in the generator housing used to attach the generator's end bell or the gearbox/transmission to the generator, and provides a platform for attaching accessory fixtures to support the shaft of the generator, as well as, provide for the mounting of tools used to maintain and repair the generator shaft.