Wind Turbine Gearbox Torque Arm Lifting Tool

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Solution Overview

Problem

Existing wind turbine gearbox maintenance methods require lifting the entire gearbox, which is expensive and unreliable, especially due to space constraints and tilting angles, making it difficult to safely install and use hydraulic pistons for lifting.

Innovation Solution

A method and tool for lifting a gearbox torque arm using a rod with threaded ends and nuts, fitted through aligned holes in the torque arm and support structure, allowing for inspection, repair, or replacement of damping elements without lifting the entire gearbox, using existing support structures and potentially with stabilizing tools to prevent horizontal displacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If hydraulic pistons are used to lift the gearbox torque arm, then lifting capability is improved, but installation reliability deteriorates due to space constraints and tilting angles causing slippage

Engineering Contradiction:

Improvelifting capabilityVSAvoidinstallation reliability

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The patent introduces an intermediary lifting mechanism consisting of a lifting rod with threaded ends and nuts that fits through aligned holes in the torque arm and support structure. This intermediary device transfers lifting force reliably without requiring direct attachment to the torque arm surface, eliminating the slippage problem associated with hydraulic pistons on inclined surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the hydraulic piston system with a mechanical lifting system using a rod with threads and nuts. This substitution eliminates the need for hydraulic components and their associated installation challenges, providing a simpler, more reliable lifting mechanism that works effectively in the constrained nacelle environment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If the entire gearbox is lifted for maintenance, then accessibility to damping elements is improved, but cost and complexity increase due to crane requirements

Engineering Contradiction:

Improveaccessibility to damping elementsVSAvoidmaintenance system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent applies segmentation by separating the lifting operation from the entire gearbox and applying it only to the torque arm assembly. This allows maintenance personnel to access and replace damping elements on the torque arm without removing or lifting the complete gearbox, significantly reducing the complexity and cost of maintenance operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent extracts the lifting function from the overall gearbox maintenance process and applies it specifically to the torque arm. This extraction allows the damping elements to be accessed and replaced independently, eliminating the need for expensive crane operations and full gearbox removal.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If hydraulic pistons are installed underneath the torque arm, then lifting function is achieved, but installation difficulty increases due to space constraints and surface inclination

Engineering Contradiction:

Improveinstallation easeVSAvoidlifting reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Instead of pushing up from underneath the torque arm with hydraulic pistons, the patent inverts the approach by pulling down through aligned holes using a rod with threaded nuts. This inverted lifting mechanism eliminates the need to install components on difficult-to-reach inclined surfaces, making installation straightforward while maintaining lifting reliability.

Inventive Principle:

Principle #13The other way round (Inversion)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables efficient, cost-effective, and safe maintenance of gearbox support elements by allowing for the lifting of torque arms independently, reducing the need for cranes and improving accessibility and reliability of repairs.

Implementation Method 1

A lifting tool suitable for use in such a method is also disclosed. comprising a longitudinal rod having a first end and a second end, wherein portions of the rod near the first and second ends comprise threads, the lifting tool further comprising a first nut adapted to cooperate with the threads at the first end and a second nut adapted to cooperate with the threads at the second end

Methodology Applied

Scientific EffectScrew mechanism: Screw

Implementation Method 2

turning at least one of the nuts such as to reduce the distance between them and thereby raise the gearbox torque arm

Methodology Applied

Scientific EffectMechanical advantage: Mechanical Advantage

Data Source

PatentEP2495433B1Wind turbine and method for lifting a gearbox torque arm

Publication Date: 2016.03.02 ALSTOM RENEWABLE TECH

Figure 1a~1b
Figure 1c~2
Figure 3a~3b

AI summary

The invention relates to a wind turbine comprising a gearbox having a torque arm, an end portion of the torque arm being surrounded by a support structure and being supported by at least one damping element, wherein the support structure and the gearbox torque arm comprise aligned through-holes such that a rod of a lifting tool can be fitted through said through-holes. The invention further relates to a lifting tool and lifting method to be used in such a wind turbine.