Rotor Shaft Installation Tool for Wind Turbine Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of large and heavy main rotor shafts in wind turbines is hazardous and time-consuming, requiring two cranes and multiple workers, which increases the risk of damage and prolongs the assembly process due to the need for precise guidance and stabilization during rotation and placement.
Innovation Solution
A single-worker installation tool with a rotating support frame allows the rotor shaft to be rotated and positioned safely, eliminating the need for two cranes by using a rotatable support plate and actuator, reducing assembly time and enhancing worker safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If two cranes are used to rotate and position the rotor shaft, then the rotor shaft can be handled and rotated, but the assembly process becomes time-consuming and requires multiple workers
Solution Approach 1:
A support frame with support elements acts as an intermediary device between the rotor shaft and the floor/ground. The support frame enables single-worker operation by providing a stable platform for rotation and positioning, eliminating the need for two cranes while reducing assembly time
Solution Approach 2:
The support frame is designed to be self-stabilizing with a wide base and support elements that distribute the rotor shaft weight. The system allows one worker to operate independently without requiring coordination between multiple crane operators, making the process more efficient
2Ease of operation
If the rotor shaft is rotated using two cranes, then the shaft can be positioned, but the process creates dangerous situations and increases damage risk
Solution Approach 1:
The support frame serves as a stable intermediary platform that supports the rotor shaft during positioning operations. It provides a controlled environment for rotation and placement, eliminating the hazardous swinging and uncontrolled movement that occurs when using two cranes
Solution Approach 2:
The support frame is designed with a wide base and multiple support elements that stabilize the rotor shaft before placement. This pre-stabilization prevents uncontrolled swinging and tipping that could cause damage or injury during the positioning process
3Ease of manufacture
If wooden support elements are used to lower the shaft, then the shaft can be positioned, but the support elements can be accidentally pushed out causing uncontrolled movement
Solution Approach 1:
The support frame uses removable support elements that can be easily installed and removed. These elements provide temporary stabilization during the critical positioning phase, then can be quickly removed once the rotor shaft is securely in place, allowing for efficient reconfiguration
Solution Approach 2:
The support frame is divided into multiple independent support elements that can be individually positioned and secured. This segmentation allows for flexible configuration and easy removal without compromising the overall stability during the critical positioning phase
Data Source
AI summary
The present invention relates to an installation tool for assembling a main rotor shaft unit and an assembly method thereof. The installation tool comprises a first element for supporting the generator end of the rotor shaft and a rotatable support plate is coupled to a second element of the installation tool via engaging coupling elements. The rotor shaft is rotated by a single crane unit via lifting elements mounted to the generator end, and then lifted out of the installation tool and placed on a floor. The bearing units are then mounted to the outer surface of the rotor shaft. The rotor shaft is afterwards lifted onto the installation tool so that the coupling element is brought into engagement and the rotor shaft is rotated on to the first element. This provides an installation tool that eliminates the need for two crane units to rotate the rotor shaft and reduces the amount of man-hours needed to assemble the rotor shaft unit by up to six hours. The installation tool also provides a stable tool for the workers since the center of gravity is located between the first element and the rotation point.