Split Main Bearing Housing for Wind Turbine Shaft Replacement
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Solution Overview
Problem
The existing methods for replacing large bearings in wind turbines, such as the main bearing, require dismantling the rotor shaft and gearbox, which is costly, complex, and risky, especially in offshore applications, due to the scaling issues and unfavorable load distribution leading to premature damage.
Innovation Solution
A method and bearing arrangement that allows for the replacement of the bearing without dismantling the rotor shaft, using a split bearing design with segmented housing that can be assembled around the rotor shaft, and innovative connection technologies to reduce installation space and enhance load distribution, enabling safer and faster assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the rotor shaft and gearbox are dismantled to replace the bearing, then the bearing can be replaced, but the complexity and cost of the repair process increases significantly
Solution Approach 1:
The bearing housing is divided into multiple segments that can be separated and reassembled without dismantling the rotor shaft. The housing includes a first housing segment and a second housing segment that can be detached, allowing bearing replacement while keeping the rotor shaft and gearbox intact.
2Ease of repair
If the rotor shaft is dismantled for bearing replacement, then the bearing can be accessed, but the time and financial expenditure increases
Solution Approach 1:
The bearing housing is segmented into removable parts that provide direct access to the bearing without requiring rotor shaft dismantling. This allows maintenance personnel to replace the bearing quickly by simply removing and reassembling the housing segments.
3Stability of the object's composition
If the bearing housing is made as a single piece for structural strength, then the housing is stable, but the bearing cannot be replaced without destroying the housing
Solution Approach 1:
The bearing housing is designed with multiple segments that can be separated for bearing replacement and then reassembled. The segments include connection elements that ensure stable and precise reconnection, maintaining housing stability while enabling bearing replacement without destruction.
Solution Approach 2:
The connection elements between housing segments include positioning features such as定位 pins or keyed connections that ensure accurate alignment when reassembling. These features guarantee that the housing segments connect precisely, maintaining the original structural stability.
4Ease of repair
If a split bearing housing is used to enable bearing replacement, then the housing can be disassembled, but the structural integrity may be compromised
Solution Approach 1:
The bearing housing is divided into segments connected by specially designed connection elements that maintain structural integrity. The connection elements include positioning features and fastening mechanisms that ensure the segmented housing remains as strong as a single-piece housing while allowing disassembly for bearing replacement.
Data Source
Figure 1~2
Figure 3A~4B
Figure 5A~10
AI summary
In the process for replacing a used bearing, in particular the main bearing of a wind turbine, with a new bearing (8), the used bearing and a used bearing housing are first removed. The new bearing (8) is designed as a split bearing and a split bearing housing (10) is provided. The assembly of the new bearing (8) and the bearing housing (10) takes place without dismantling a rotor shaft (4). Housing segments (10A, 10B) of the bearing housing (10) are suitably designed for this purpose. In particular, these are rotated around the rotor shaft (4) during assembly or guided past it.