Lateral Movement System for Industrial Generator Maintenance
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Solution Overview
Problem
Large industrial machines, such as generators in single shaft STAG combined-cycle systems, face challenges in maintenance due to axial alignment with gas and steam turbines, which restricts the removal of the generator rotor, requiring complex and costly lifting equipment or movable foundations for lateral movement during maintenance.
Innovation Solution
A system comprising rail elements and linear actuators allows lateral movement of industrial machines by positioning segmented support rails on machine foundations and using synchronized linear actuators to slide skids along these rails, enabling the machine to be moved from an operational position to a maintenance position without the need for extensive lifting or gantries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the generator is axially aligned with gas and steam turbines in a single shaft configuration, then the system achieves compact operation and mechanical coupling for power generation, but the generator rotor cannot be removed for maintenance due to lack of clearance
Solution Approach 1:
The patent introduces lateral movement capability to the generator, allowing it to be displaced perpendicular to its axial alignment with the turbines. This dimensional change enables the generator to be moved sideways off the foundation while maintaining its operational axial alignment, thus resolving the conflict between compact operation and maintenance accessibility
2Ease of repair
If direct lifting is used to remove the generator from the foundation, then the generator can be moved to a laydown area, but specialized heavy-duty lifting equipment is required which is costly and requires adequate on-site lift capability
Solution Approach 1:
The patent introduces skids as intermediary elements between the generator and the foundation. These skids allow the generator to be laterally displaced along guide rails rather than requiring direct vertical lifting. This intermediary mechanism converts a complex heavy-lifting problem into a simpler lateral movement operation that can be performed with less sophisticated equipment
Solution Approach 2:
Instead of moving the generator vertically (lifting), the system enables lateral movement in the horizontal plane. This dimensional change allows the generator to be relocated to a maintenance position without requiring heavy-duty vertical lifting capability, thereby reducing equipment complexity and cost
3Ease of repair
If a movable slab foundation is used to displace the generator laterally, then the generator can be moved from between the turbines, but the foundation configuration becomes complex and requires specialized design
Solution Approach 1:
The foundation system is segmented into fixed portions and movable components. The skids and guide rails are separable elements that can be installed and removed independently from the main foundation structure. This segmentation allows lateral movement capability to be added without redesigning the entire foundation, thus reducing overall system complexity
4Ease of repair
If the generator is mounted on special foundations with removable portions and guides, then rotation about a vertical axis is enabled for field removal, but the foundation configuration becomes complex
Solution Approach 1:
Instead of enabling rotation about a vertical axis (complex 3D movement), the patent achieves field removal capability through lateral translation in the horizontal plane. This dimensional simplification allows the generator to be moved sideways to clear the turbines, eliminating the need for complex rotational mechanisms while still enabling maintenance access
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 method facilitates efficient and cost-effective lateral movement of industrial machines for maintenance, reducing setup time and space requirements, and is more economical and quicker to assemble than conventional systems, while ensuring safety certifications can be performed during downtime.
Implementation Method 1
a pair of linear actuators configured to laterally move the industrial machine as from the first, operative position to the second, maintenance position
Implementation Method 2
each skid slides along a respective segmented support rail
Data Source
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AI summary
A method for laterally moving an industrial machine (10) is provided. The method may include: supporting the industrial machine (10) on a pair of rail elements (104, 106) configured to be positioned laterally below and support the industrial machine (10), the rail elements (104, 106) allowing the industrial machine (10) to be moved laterally from a first operative position to a second, maintenance position. A pair of linear actuators (130, 132) configured to laterally move the industrial machine (10) from the first, operative position to the second, maintenance position.