Wind Turbine Generator Segment Assembly in Cramped Nacelles

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Solution Overview

Problem

The existing methods for assembling and disassembling wind turbine rotating electric machines face difficulties due to geometric constraints and cramped working conditions, making the process slow and inefficient.

Innovation Solution

A method and system that involves a safety cell and insertion/extraction device housed inside the safety cell, allowing axial insertion and extraction of active segments on the blade assembly side, with the ability to rotate and position the device for alignment with active segments, and utilizing a hoisting device for precise positioning and safe operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If active segments are inserted/extracted on the main frame side, then the process can be performed with existing equipment, but geometric constraints and cramped working conditions slow down the process

Engineering Contradiction:

Improveassembly speedVSAvoidworking conditions

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent inverts the conventional approach by performing active segment insertion/extraction on the blade assembly side instead of the main frame side. This reversal provides better accessibility and working conditions, allowing operators to easily access and manipulate active segments without the geometric constraints that plague main frame side operations.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces a specialized insertion/extraction device as an intermediary tool that facilitates active segment handling on the blade assembly side. This device includes positioning mechanisms, gripping elements, and alignment features that make the operation straightforward and efficient, transforming a difficult task into a simple procedural operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a safety cell is fixed to the blade assembly to house the insertion/extraction device, then operator safety is improved, but the device complexity increases

Engineering Contradiction:

Improveoperator safetyVSAvoidsystem structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The safety cell is designed as a multi-functional platform that simultaneously provides operator protection, houses the insertion/extraction device, enables precise positioning through rotation, and facilitates hoisting operations. By consolidating these functions into a single integrated structure, the patent avoids the complexity that would arise from separate safety and operational systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the safety cell structure with the insertion/extraction device housing and positioning mechanisms. This integration creates a compact, self-contained system where the safety cell serves as both the protective enclosure and the operational platform, eliminating the need for separate safety barriers and control systems.

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If the blade assembly is rotated to align the insertion/extraction device with active segments, then positioning precision is improved, but the time required for alignment increases

Engineering Contradiction:

Improvealignment precisionVSAvoidalignment time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The safety cell is pre-equipped with rotational positioning mechanisms and alignment markers that enable quick, accurate orientation. The insertion/extraction device is pre-configured with indexing features that automatically align with corresponding features on the blade assembly and active segments, eliminating the need for time-consuming manual alignment procedures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates self-aligning features where the insertion/extraction device automatically positions itself relative to the active segments through mechanical indexing or guide features. This self-alignment capability reduces operator intervention and minimizes alignment time while maintaining high precision.

Inventive Principle:

Principle #25Self-service

4Measurement precision

If a hoisting device is used to position the safety cell and insertion/extraction device, then positioning accuracy is improved, but the device complexity and weight increase

Engineering Contradiction:

Improvepositioning accuracyVSAvoidhoisting mechanism

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The hoisting device acts as an intermediary mechanism that uses a winch and cable system to precisely position the safety cell and insertion/extraction device along the blade assembly. This mechanical hoisting system provides accurate positioning through controlled winding and unwinding of the cable, with positioning accuracy determined by the winch mechanism rather than complex electronic controls.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP2961980B1Method and system for assembling and/or disassembling a wind turbine electric generator

Publication Date: 2018.12.12 WINDFIN BV

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AI summary

A method of assembling and/or disassembling a rotating electric machine of a wind turbine (l) having a vertical structure (2); a main frame (3) fitted to the top of the vertical structure ( 2 ); a blade assembly (5) fitted to the main frame (3) to rotate about a rotation axis; and a tubular rotating electric machine (4) having a plurality of axial active segments (25); the method including inserting and/or extracting the active segments (25) axially on the blade assembly (5) side.