Wind Turbine Main Bearing Replacement With Uptower Rotor Lock
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Solution Overview
Problem
Current wind turbine maintenance methods require the removal of the entire drive train assembly for replacing the main bearing, which is costly and time-consuming due to the need for large cranes and off-site repairs, especially for larger turbines.
Innovation Solution
A method involving a rotor lock to prevent main shaft rotation, a lifting device to elevate the main shaft, and the installation of a split main bearing, allowing for in-situ maintenance without disassembling the gear train, using a sectionable crane to facilitate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire drive train assembly is removed for main bearing replacement, then the bearing can be serviced, but large cranes are required and off-site transport is needed, increasing cost and time
Solution Approach 1:
The main bearing is extracted from the drive train assembly for replacement, while the assembly remains in place. The bearing is removed through thenacelle access point, allowing servicing without complete disassembly or removal of the drive train.
Solution Approach 2:
A bearing removal tool acts as an intermediary device, inserted through the nacelle to extract the main bearing from the drive train assembly. This tool enables bearing replacement without requiring crane removal of the entire assembly.
2Ease of repair
If a large crane is used to remove the drive train assembly, then the main bearing can be replaced, but the crane itself is difficult and costly to install
Solution Approach 1:
The bearing removal function is extracted from the crane system. Instead of using a crane to remove the entire drive train, a specialized bearing removal tool is used to extract only the bearing through the nacelle, eliminating the need for large crane installation.
Solution Approach 2:
The bearing removal tool is self-contained and can be manually operated or powered through the nacelle, making the bearing replacement process self-sufficient without requiring external crane assistance for the actual bearing extraction.
3Ease of repair
If the entire drive train assembly is removed for bearing maintenance, then the bearing can be serviced, but additional time and expense are incurred by transporting the assembly off-site
Solution Approach 1:
The main bearing is extracted from the drive train assembly through the nacelle access point, allowing direct removal and replacement at the turbine site. This eliminates the need to transport the entire drive train assembly off-site for bearing servicing.
Solution Approach 2:
The bearing removal tool is inserted and positioned through the nacelle before bearing extraction begins. This preliminary positioning enables direct bearing removal at the site, preventing the need for subsequent off-site transport of the drive train assembly.
Data Source
AI summary
A method for performing uptower maintenance of a wind turbine in order to replace the main bearing on the turbine shaft is disclosed. Embodiments of this method to perform maintenance may include installing a rotor lock to resist rotation of the main shaft during maintenance, providing a lifting device in order to elevate the main shaft, removing the main bearing from its main bearing housing, and installing a replacement split main bearing. A crane may also be installed uptower to assist in the maintenance.