Wind Turbine Generator Cleaning for Grease-Contaminated Windings
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Solution Overview
Problem
Generators in wind turbines face grease leakage issues from the main bearing seals, which accumulate inside the generator and cannot be effectively cleaned due to limited space, posing a challenge in maintaining the stator windings.
Innovation Solution
A method involving a specific cleaning agent with unique properties (non-water-soluble, fluid liquid with defined density and viscosity) is introduced, allowing it to be inserted into the generator to remove grease by contacting and dissolving it, using a combination of rotational movement and gravitational forces, and then removed without damaging the generator components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the generator housing is sealed and space-limited, then the generator structure is compact and protected, but grease leakage cannot be effectively cleaned
Solution Approach 1:
The generator housing is divided into separable sections with a removable cover, allowing the interior to be accessed for cleaning while maintaining structural integrity during operation. This segmentation enables maintenance without compromising the overall protective enclosure.
Solution Approach 2:
A drainage system with collection container is pre-installed in the generator housing to capture grease before it accumulates. This preliminary action prevents grease buildup that would otherwise require disassembly for cleaning, maintaining both protection and ease of maintenance.
2Strength
If cleaning apparatuses are used from outside the generator, then the generator structure remains intact, but the limited space prevents effective cleaning of internal components
Solution Approach 1:
The generator housing is segmented with a removable cover that provides direct access to internal components. This allows cleaning agents and tools to be applied directly to windings and internal surfaces, achieving effective cleaning while the remaining housing structure remains intact and protective.
Solution Approach 2:
A drainage system acts as an intermediary between the generator interior and exterior, collecting and removing grease through a dedicated channel. This intermediary structure enables effective removal of contaminants without requiring direct access to all internal surfaces for cleaning.
3Reliability
If grease is allowed to accumulate in the generator, then the housing remains sealed and protected, but the grease leakage issue worsens
Solution Approach 1:
A drainage system with collection container is integrated into the generator housing to actively extract and remove grease before it can accumulate on internal components. This extraction mechanism maintains the sealed protective housing while eliminating the harmful effect of grease buildup through continuous removal.
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
The method effectively cleans the generator surfaces, including stator windings, by ensuring thorough contact and removal of grease without structural harm, maintaining generator functionality.
Implementation Method 1
a specific cleaning agent having a unique composition is indeed suitable... the cleaning agent is or comprises a grease remover, and wherein the grease remover is a non-waters-soluble and is a fluid liquid such that the generator of the wind turbine can be partially flushed with the grease remover
Implementation Method 2
using a combination of rotational movement and gravitational forces
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention relates to a method (100) for cleaning a generator (200) of a wind turbine (1), wherein the wind turbine (1) comprises a tower (12), a nacelle (207) rotatably mounted to the tower (12), a wind turbine rotor (217) with at least one rotor blade, the wind turbine rotor (217) being rotatably mounted to the nacelle (207) around an essentially horizontal rotational axis (218), and an electric generator (200) drivable by the rotor (217), wherein the generator (200) comprises a fixed housing (203) and a rotating housing (215), a generator rotor (213) having magnetic elements (214), a stator (201) having windings (202), and a cooling device (211) attached to an opening (204) of the fixed housing (203). The method comprises the steps: locking (101) the wind turbine rotor (217), shutting off (103) the generator (200); removing the cooling device (211) such that the opening (204) is accessible for maintenance purposes; inserting (105) a cleaning agent into the opening (204) such that the cleaning agent gets at least partially in effective contact with a winding (202) and/or with a magnetic element (214); at least partially removing (107) the cleaning agent from the generator (200); mounting the cooling device (211) to the opening (204); and releasing (109) the wind turbine rotor (217), wherein the cleaning agent is or comprises a grease remover, and wherein the grease remover is a non-waters-soluble and is a fluid liquid such that the generator (200) of the wind turbine can be partially flushed with the grease remover, has a density larger than 0.6 g/cm3 and lower than 0.85 g/cm3, has kinematic viscosity larger than 1.3 mm2/s and lower than 2.5 mm2/s, and comprises N-Paraffins and hydrocarbons.