Wind Turbine Rotor Support Frame for Internal Generator Access
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Solution Overview
Problem
Existing wind turbine generators face challenges in maintainability due to limited interior access, making it difficult for maintenance engineers to service internal components without disassembly.
Innovation Solution
A powertrain assembly with a generator rotor assembly featuring a cylindrical field structure and a rotor support frame that includes stepping regions and access apertures, allowing for improved internal access and servicing without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a conventional generator rotor assembly is used, then the generator can be compact and efficient, but maintenance personnel cannot access internal components for servicing
Solution Approach 1:
The rotor support frame is segmented into multiple components including a first support component, a second support component, and a bridging component. This segmentation allows the structure to be divided into accessible sections while maintaining overall structural integrity, enabling maintenance personnel to access internal components through openings in the segmented structure.
Solution Approach 2:
The rotor support frame components are designed to be nested together, with the bridging component connecting the first and second support components. This nested arrangement allows the structure to collapse or open up to create access pathways while maintaining a compact form when assembled, enabling both space efficiency and maintainability.
2Ease of operation
If the rotor assembly is designed with a central hollow portion, then maintenance access is improved, but structural strength may be compromised
Solution Approach 1:
The rotor support frame exhibits local quality variations where different regions serve different functions. The first and second support components provide structural strength and support the cylindrical field structure, while the bridging component and intentional openings provide access pathways. This localized differentiation of properties allows the structure to simultaneously achieve strength and accessibility.
Solution Approach 2:
The design transitions from a solid two-dimensional cross-section to a three-dimensional structure with intentional voids and openings. By adding the dimension of accessibility through the rotor support frame openings, the design creates pathways for maintenance personnel to reach internal components without compromising the overall structural integrity of the rotor assembly.
3Ease of repair
If the rotor support frame includes openings for access, then servicing becomes possible, but the enclosed protective environment is reduced
Solution Approach 1:
The rotor support frame is designed with pre-positioned openings and access points that allow maintenance personnel to reach internal components without requiring complete disassembly of the generator. This preliminary design of access pathways enables servicing while maintaining the enclosed structure, reducing contamination risk compared to fully open designs.
Solution Approach 2:
The rotor support frame acts as an intermediary structure that mediates between the need for maintenance access and the need for protection. The framed openings and access points serve as controlled interfaces that allow personnel to reach internal components while the surrounding frame structure maintains the enclosed environment and protects against contamination.
Data Source
AI summary
A wind turbine powertrain assembly including a gearbox coupled to an electrical power generator for a wind turbine. The power generator comprises a stator at a radially outward position and a rotor in a radially inward position, wherein the rotor comprises a cylindrical field structure that is configured to rotate about a generator rotor axis, and wherein the rotor is configured to define a central hollow portion. The rotor further comprises a rotor support frame connected to and structurally supporting the cylindrical field structure, wherein the rotor support frame comprises: a rotor connection flange attaching the rotor support frame to the cylindrical field structure, a gearbox connecting flange connecting the rotor support frame to an output drive shaft of the gearbox, and a transition section extending between the rotor connection flange and the gearbox connection flange, the transition section defined at least in part by one or more stepping regions, the or each stepping region shaped to define a surface that is inclined at an angle of less than 30 degrees to the rotor axis. Advantageously, the stepping regions provide an integrated platform inside the hollow portion on which service personnel can stand to work inside the generator.