Segmented Wind Turbine Generator Assembly With Small-Crane Mounting
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Solution Overview
Problem
The mounting of wind turbine generators requires large and expensive cranes that are often unavailable and inefficient, leading to limited flexibility and increased costs.
Innovation Solution
A segmented generator design with stator and rotor segments that can be assembled using smaller cranes, featuring connection interfaces with flanges, centering bolts, and screw connections to align and fasten the segments without extensive crane use, allowing for pre-fixing and minimal screw connections during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a segmented generator design with connection interfaces is used, then the ease of manufacture and mounting is improved, but the device complexity increases due to multiple segments and connection components
Solution Approach 1:
The generator is divided into multiple segments (stator segments and rotor segments) that can be manufactured separately and assembled on-site. Each segment has standardized connection interfaces with flanges, centering bolts, and screw connections, enabling modular assembly without requiring the entire generator to be manufactured as a single complex unit.
2Adaptability or versatility
If smaller cranes are used for mounting generator segments, then the cost and availability of mounting equipment is improved, but the productivity decreases due to increased assembly time and steps
Solution Approach 1:
Connection interfaces including flanges, centering bolts, and screw connections are pre-configured on each generator segment during manufacturing. This preliminary preparation enables rapid on-site assembly using smaller cranes, as the segments are ready for immediate connection without requiring complex alignment or additional mounting components during installation.
Solution Approach 2:
Standardized connection interfaces act as intermediaries between generator segments, providing a universal connection mechanism that works across all segments. The flanges, centering bolts, and screw connections serve as intermediary components that facilitate easy coupling and decoupling of segments, enabling efficient assembly and disassembly with smaller cranes.
3Manufacturing precision
If centering bolts and centering pins are used in connection interfaces, then the manufacturing precision of air gap alignment is improved, but the device complexity increases due to additional alignment components
Solution Approach 1:
Centering bolts and centering pins are integrated into the connection interfaces of generator segments, enabling the segments to self-align during assembly. The centering components automatically guide the relative positioning of adjacent segments, ensuring precise air gap alignment without requiring external alignment tools or complex adjustment procedures during installation.
Data Source
AI summary
Aspects of the present disclosure are directed to methods for mounting a segmented generator of a wind turbine, wherein the segmented generator for the operation of the wind turbine is formed from two or more generator segments, wherein the generator segments each have a stator segment and a rotor segment, wherein the stator segment for fastening the stator segment to a machine carrier flange of a machine carrier has a stator flange and the rotor segment for fastening to a rotor carrier of a main bearing has a rotor flange, wherein the two or more generator segments in the circumferential direction (U) each extend between two connection interfaces (V1, V2) which are formed for connection with connection interfaces (V1, V2) of generator segments arranged adjacent in the circumferential direction (U).