Wind Turbine Pitch Bearing Segmentation for Maintenance

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Solution Overview

Problem

Existing wind turbine pitch drive systems require the removal of the entire hub and rotor blade to replace worn pitch bearing teeth, leading to costly and time-consuming maintenance, and resulting in rotor imbalances and increased loads on components.

Innovation Solution

A method and system that allows the pitch drive system to be selectively positioned within the pitch bearing to contact a predetermined set of pitch bearing teeth without removing the hub or rotor blade, using a plurality of pitch gearbox brackets to facilitate this relocation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If the entire hub is removed to replace worn pitch bearing teeth, then the pitch bearing teeth can be replaced, but the maintenance cost and time increase significantly

Engineering Contradiction:

Improvepitch bearing teeth replacementVSAvoidmaintenance time

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The pitch bearing is segmented into multiple sets of teeth (first set, second set, third set) arranged at different positions. The pitch drive system can be selectively coupled to different sets of teeth, allowing replacement of worn teeth without removing the entire hub. This segmentation enables localized maintenance while preserving the overall hub structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pitch drive system is designed with selective coupling capability to different sets of pitch bearing teeth. This dynamic reconfigurability allows the system to transition between different tooth sets during operation or maintenance, enabling teeth replacement without hub removal and reducing maintenance time.

Inventive Principle:

Principle #15Dynamics

2Ease of repair

If the entire hub is removed to replace worn pitch bearing teeth, then the pitch bearing teeth can be replaced, but the maintenance cost increases

Engineering Contradiction:

Improvepitch bearing teeth replacementVSAvoidmaintenance cost

Core Design Contradiction:

Ease of repairVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple sets of pitch bearing teeth are pre-installed and positioned within the hub during manufacturing. This preliminary preparation allows maintenance personnel to simply switch between pre-positioned tooth sets during operation or maintenance, eliminating the need for expensive hub removal and reducing maintenance costs.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If pitch bearing teeth are worn, then the pitch assembly becomes less effective, but replacing them requires hub removal

Engineering Contradiction:

Improvepitch assembly effectivenessVSAvoidmaintenance procedure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pitch gearbox brackets serve as intermediary components that facilitate the selective coupling of the pitch drive system to different sets of teeth. These brackets provide a manageable interface for maintenance operations, simplifying the complexity of working with the pitch bearing tooth sets without requiring hub removal.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Device complexity

If worn pitch bearing teeth are not replaced, then the hub remains assembled, but the rotor becomes imbalanced and loads increase

Engineering Contradiction:

Improvehub assembly integrityVSAvoidrotor imbalance and increased loads

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The wind turbine can continue operating with the hub assembled by switching to different sets of pitch bearing teeth that are less worn or newly replaced. This continuity allows the turbine to maintain operational capability while managing the effects of wear without requiring hub disassembly.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS8092171B2Systems and methods for assembling a pitch assembly for use in a wind turbine

Publication Date: 2012.01.10 GE INFRASTRUCTURE TECH LLC

AI summary

A method of assembling a wind turbine. The method includes coupling a pitch bearing to a hub that includes a wall. The pitch bearing includes a plurality of sets of pitch bearing teeth. At least one blade is coupled to the pitch bearing such that the blade is rotatable about a pitch axis. A plurality of pitch gearbox brackets are coupled to the hub wall. A pitch drive system is selectively coupled to one of the plurality of pitch gearbox brackets, wherein a predetermined set of pitch bearing teeth are in contact with the pitch drive system.