Uptower Gearbox Component Removal Tools

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Solution Overview

Problem

Current methods for maintaining and rebuilding gearbox components in wind turbines require large cranes to remove entire assemblies, which is costly and inefficient, especially for components located in difficult-to-access positions.

Innovation Solution

The development of specialized tools and systems, including lifting tools and adaptors, that allow for the disassembly and removal of separate gearbox components without displacing the entire assembly, enabling the use of smaller cranes and reducing maintenance costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If large cranes are used to remove entire gearbox assemblies, then components can be accessed and maintained, but operational expenses increase and efficiency decreases

Engineering Contradiction:

Improvemaintenance accessibilityVSAvoidoperational expenses

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The gearbox assembly is divided into separable components (housing, gears, bearings) that can be independently removed and maintained. Adaptors are designed to attach to specific components rather than requiring removal of the entire assembly, enabling targeted maintenance operations with smaller equipment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Specialized adaptors serve as intermediary devices between the lifting tool and gearbox components. These adaptors enable connection to individual components (planetary carrier, ring gear, etc.) and facilitate their removal using smaller cranes, bridging the gap between component size and lifting capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If large cranes are deployed for maintenance operations, then components can be removed, but maintenance efficiency decreases

Engineering Contradiction:

Improvecomponent removal capabilityVSAvoidmaintenance efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The maintenance process is segmented into discrete component removal operations rather than requiring complete assembly removal. Each component can be addressed independently, reducing overall maintenance time and improving efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Adaptors are pre-configured and attached to specific gearbox components before lifting operations begin. This preliminary preparation enables faster component removal and reduces on-site maintenance time, thereby improving overall productivity.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If adaptors are designed for specific gearbox components, then targeted maintenance is enabled, but device complexity increases

Engineering Contradiction:

Improvecomponent-specific attachmentVSAvoidadaptor variety

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adaptors are designed with universal features that allow a single adaptor design to work with multiple component types. The lifting tool can be configured with different adaptors for planetary carriers, ring gears, and other components, reducing the need for completely different lifting equipment for each component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9784246B2Tools and methods for uptower maintenance

Publication Date: 2017.10.10 RENEW ENERGY MAINTENANCE LLC

AI summary

Tools, systems, and methods for use in conjunction with maintenance, assembly, rebuilding, or other procedures which involve displacing components of an assembly are disclosed. These tools, systems, and methods may be used in conjunction with a crane or other lifting device and may be configured to assemble, disassemble, or otherwise maintain components of an uptower gearbox.