Wind Turbine Generator Cleaning by Rotor-Driven Grease Removal

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Generators in wind turbines face grease leakage issues due to limited access, causing grease to accumulate in non-reachable areas and clog critical components, leading to thermal and electrical problems.

Innovation Solution

A method involving locking the rotor, filling a cleaning agent, idling the rotor to distribute the agent, removing contaminants, and analyzing the agent's contamination level to ensure thorough cleaning without damaging the generator.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the generator is cleaned using traditional cleaning apparatuses, then the accessible areas can be cleaned, but the non-accessible areas (space between segments and generator housing) cannot be cleaned due to limited space

Engineering Contradiction:

Improvecleaning accessibilityVSAvoidcleaning apparatus design

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent uses a liquid cleaning agent introduced into the generator to clean internal surfaces. The cleaning agent is distributed throughout the generator interior, allowing it to reach non-accessible areas that mechanical cleaning apparatuses cannot access, thereby resolving the contradiction between cleaning accessibility and device complexity

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The generator itself is used as the cleaning apparatus by idling the rotor to generate centrifugal force. The rotor's rotation distributes the cleaning agent throughout the generator interior and creates mechanical stress that removes grease, eliminating the need for external cleaning devices and simplifying the overall system

Inventive Principle:

Principle #25Self-service

2Reliability

If the rotor is idled for an extended period to ensure thorough cleaning, then cleaning effectiveness improves, but the cleaning time and operational downtime increase

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidcleaning duration

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent optimizes the idle rotation parameters (speed and duration) to achieve effective cleaning within a reasonable time frame. By controlling the rotor to idle at specific rotational speeds for determined periods, the method balances cleaning thoroughness with time efficiency, preventing both insufficient cleaning and excessive downtime

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a strong cleaning agent is used to effectively remove grease, then cleaning effectiveness improves, but the risk of damaging the generator increases

Engineering Contradiction:

Improvegrease removal efficiencyVSAvoidgenerator damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent carefully selects and controls the properties of the cleaning agent (chemical composition, viscosity, temperature) to ensure effective grease removal while maintaining safety for generator components. The cleaning agent is chosen to have sufficient cleaning power without being corrosive or damaging to electrical insulation and mechanical parts

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The cleaning process includes monitoring and evaluation steps to assess cleaning effectiveness and generator condition. Based on feedback from the cleaning results, the process can be adjusted or repeated if necessary, ensuring thorough cleaning while preventing damage through controlled application and monitoring

Inventive Principle:

Principle #23Feedback

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

Effectively removes grease from hard-to-reach areas within the generator, preventing damage and ensuring reliable operation by using a non-damaging cleaning agent and controlled process steps.

Implementation Method 1

This movement causes mechanical stress between the cleaning agent and the generator, which causes rubbing off grease from the generator

Methodology Applied

Scientific EffectMechanical stress: Mechanical Force

Implementation Method 2

This movement causes mechanical stress between the cleaning agent and the generator, which causes rubbing off grease from the generator. In particular, this circulates the cleaning agent to non-accessible areas of the generator and dilutes grease in order for the grease to run off to more accessible areas

Methodology Applied

Scientific EffectDilution:

Implementation Method 3

idling the rotor moves the generator together with the cleaning agent inside the generator. This movement causes mechanical stress between the cleaning agent and the generator, which causes rubbing off grease from the generator. In particular, this circulates the cleaning agent to non-accessible areas of the generator

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentEP4488514B1Method for cleaning a generator in a wind turbine

Publication Date: 2025.12.31 SIEMENS GAMESA RENEWABLE ENERGY AS

Figure 1
Figure 2~3
Figure 4

AI summary

The present invention relates to a Method (100) for cleaning a generator (200) in a wind turbine, the method (100) comprising: locking (101) a rotor (217) of the wind turbine, shutting (103) off the generator (200), filling fresh (105) cleaning agent into the generator (200), releasing (107) the rotor (217), idling (109) the rotor (217) for at least a given cleaning time, locking (111) the rotor (217) again, removing (113) the contaminated cleaning agent from the generator (200), releasing (115) the rotor (217) again, and starting (117) the generator (200).