Segmented Wind Turbine Generator Assembly Without Large Cranes
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Solution Overview
Problem
The assembly of wind turbine generators requires large cranes, which are expensive and often in limited supply, leading to complex and time-consuming assembly processes.
Innovation Solution
A method for assembling a segmented generator using smaller cranes by connecting generator segments with force-fit and positive-locking interfaces, allowing alignment without complex air gap adjustments, and pre-fixing components for assembly, enabling assembly at difficult-to-access sites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If large cranes are used for assembling the generator, then the assembly can be completed, but the cost increases and availability is limited
Solution Approach 1:
The generator is divided into multiple generator segments (first generator segment, second generator segment, etc.), each comprising a stator segment and a rotor segment that can be assembled and transported separately. This segmentation allows smaller, more available cranes to be used instead of requiring a single large crane, thereby improving crane availability while maintaining assembly capability.
2Ease of manufacture
If large cranes are used for assembling the generator, then the assembly can be completed, but the cost increases
Solution Approach 1:
The generator is divided into multiple generator segments that can be assembled separately using smaller, more cost-effective cranes. This eliminates the need to rent or deploy expensive large cranes, thereby reducing the quantity of substance (crane cost) while maintaining assembly capability.
Solution Approach 2:
Multiple generator segments are merged together through connecting interfaces (flanges with screw connections) to form the complete generator. This merging process can be performed using smaller cranes for each segment, reducing overall crane costs compared to using a single large crane for the entire assembly.
3Ease of manufacture
If traditional assembly methods are used, then the generator can be assembled, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The generator is segmented into modular units with standardized connecting interfaces, simplifying the assembly process. Each segment can be prepared independently and then quickly connected to others, reducing overall assembly complexity while ensuring complete generator assembly.
Solution Approach 2:
The stator segment and rotor segment are preliminarily connected within each generator segment before final assembly. The connecting interfaces (flanges with screw connections) are pre-prepared, allowing for quicker and less complex final assembly of multiple segments into the complete generator.
4Ease of manufacture
If traditional assembly methods are used, then the generator can be assembled, but the assembly time increases
Solution Approach 1:
The generator is divided into multiple segments that can be assembled in parallel or sequence using smaller cranes, significantly reducing assembly time compared to assembling a single large generator unit. This improves productivity while maintaining complete generator assembly.
Solution Approach 2:
Multiple generator segments with pre-prepared connecting interfaces are quickly merged together to form the complete generator. This merging process is more efficient than traditional assembly methods, thereby increasing assembly speed and productivity.
Data Source
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AI summary
Method (1000) for assembling a segmented generator (1) of a wind turbine (100), wherein the segmented generator (1) for operating the wind turbine (100) is formed from two or more generator segments (2), wherein the generator segments (2) each have a stator segment (3) and a rotor segment (4), wherein the stator segment (3) has a stator flange (3a) for fastening the stator segment (3) to a machine support flange (5a) of a machine support (5), and the rotor segment (4) has a rotor flange (4a) for fastening to a rotor support (6a) of a main bearing (6), wherein the two or more generator segments (2) each extend in the circumferential direction (U) between two connection interfaces (V1, V2) which are designed for connection to connection interfaces (V1, V2) of generator segments arranged adjacent in the circumferential direction (U),the method (1000) comprising the steps of: providing (1010) a tower (102) of the wind turbine (100) in an installed state, providing (1020) the machine support (5); and lifting and positioning (1030) the machine support (5) at an upper end of the tower (102) so that the machine support (5) can be rotatably coupled to the tower (102) via a tower bearing (103), pre-fixing (1040) the machine support to the tower (102) for assembly purposes so that the machine support (5) is rotatably mounted relative to the tower (102) by means of the tower bearing (103), providing (1050) two or more generator segments (2) in a transport position, wherein the stator segment (3) and the rotor segment (4) of the respective generator segment (2) are connected to one another, lifting and positioning (1060) one of the two or more provided generator segments (2) from the transport position into an assembly position,in which the stator flange (3a) is arranged on the machine support flange (5a), pre-fixing (1070) the generator segment (2) for assembly purposes by means of the stator flange (3a) on the machine support flange (5a) in the assembly position, lifting and positioning (1080) at least one further of the two or more generator segments (2) from the transport position into a further assembly position on the machine support flange (5a) of the machine support (5), so that the already pre-fixed generator segment (2) can be connected to the generator segment positioned in the further assembly position via the connection interfaces of the respective generator segments, pre-fixing (1090) the further generator segment (2) for assembly purposes in the further assembly position by means of the stator flange (3a) on the machine support flange (5a) and/or on the already pre-fixed generator segment via the connection interfaces of the respective generator segments,wherein the steps of lifting, positioning and pre-fixing are repeated with further of the two or more generator segments (2) until the lifted, positioned and fixed generator segments (2) can form the segmented generator (1), providing (1100) the main bearing (6) and a hub (7) fastened to the main bearing (6) in the transport position, wherein preferably three rotor blade bearings (7a) are provided on the hub, wherein the main bearing (6) comprises the rotor carrier (6a) and a journal (6b), wherein the rotor carrier (6a) is rotatably mounted relative to the journal (6b) for the operation of the segmented generator (1), lifting and positioning (1110) the main bearing (6) so that the stator flange (3a) of the stator segment (3) is arranged between the machine carrier flange (5a) and the journal (6b), and fastening (1120) the Axle flange (6b) on the machine support flange (5a) for the operation of the wind turbine,wherein the stator flange (3a) of the stator segment (3) is arranged between the machine support flange (5a) and the axle journal (6b), wherein the rotor support (6a) for the assembly of rotor blades (108) on the hub (7) is not yet or will not be connected to the respective rotor segments (4) of the generator segments (2).