Vertical Wind Turbine Generator Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of large wind turbine generators is time-consuming and cost-intensive due to the need for precise alignment and stabilization of heavy components, which are prone to deformation and misalignment during the horizontal marriage process, requiring cumbersome and expensive support structures and precise adjustment mechanisms.
Innovation Solution
A method and assembly arrangement that allows for vertical assembly of wind turbine generators using a horizontal assembly support with vertical columns and an access opening, eliminating the need for additional stabilization rings and enabling precise alignment and assembly with reduced weight and complexity, utilizing a crane for component handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If horizontal marriage assembly method is used with support structures, then alignment precision is improved, but assembly time and cost increase significantly
Solution Approach 1:
The patent inverts the conventional horizontal assembly approach by implementing vertical assembly. The rotor and stator are assembled in a vertical orientation with the rotor positioned above the stator, allowing gravity to assist in alignment and reducing the need for complex horizontal support structures. This inversion of the assembly orientation fundamentally changes the approach while maintaining precision requirements.
Solution Approach 2:
The patent extracts and eliminates the cumbersome support structures and adjustment mechanisms that are necessary in horizontal assembly. By transitioning to vertical assembly, the complex horizontal support systems, rails, and precision adjustment actuators are removed, simplifying the overall assembly system while maintaining alignment precision through gravitational assistance.
2Stability of the object's composition
If heavy support structures are used for horizontal assembly, then component stability is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies the self-service principle by allowing gravity to automatically provide the stabilizing force needed for vertical assembly. Instead of using external heavy support structures to counteract gravity, the assembly process itself utilizes gravitational force to maintain component stability and alignment, eliminating the need for complex active stabilization systems.
Solution Approach 2:
By inverting the assembly orientation from horizontal to vertical, the patent changes which forces are dominant. In vertical assembly, gravity acts along the assembly axis rather than perpendicular to it, naturally providing stability in the horizontal plane and reducing the need for complex support structures to prevent lateral movement or deformation.
3Manufacturing precision
If precise adjustment mechanisms are used for alignment, then manufacturing precision is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent employs self-service by using gravity as the primary alignment mechanism in vertical assembly. The gravitational force naturally guides the rotor and stator into proper alignment along the vertical axis, eliminating the need for complex active adjustment mechanisms, sensors, and control systems that would be required in horizontal assembly to achieve the same precision.
Solution Approach 2:
The patent substitutes complex mechanical adjustment systems with a simpler gravitational field-based alignment approach. Instead of using motors, sensors, and active control mechanisms to achieve precision alignment, the vertical assembly process relies on the natural gravitational field to provide the necessary alignment forces, significantly reducing mechanical complexity.
4Stability of the object's composition
If horizontal assembly with multiple support structures is used, then component stability is improved, but weight of handling equipment increases
Solution Approach 1:
The patent extracts and removes the heavy horizontal support structures from the assembly system. By transitioning to vertical assembly, the numerous heavy-duty horizontal supports, rails, and stabilization mechanisms are eliminated, significantly reducing the weight of handling equipment needed while maintaining component stability through gravitational assistance.
Solution Approach 2:
The assembly system becomes self-service by using gravity to provide the stabilizing force that previously required heavy external support structures. The vertical orientation allows gravity to naturally stabilize components during assembly, eliminating the need for heavy counterbalancing equipment and reducing overall handling equipment weight.
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
This approach simplifies the assembly process, reduces costs, and allows for accurate and efficient assembly of wind turbine generators by leveraging gravity for component stability, reducing the need for extensive support structures and enabling faster assembly with a more economical and reliable crane system.
Implementation Method 1
leveraging gravity for component stability
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention describes a method of vertically assembling a generator of a wind turbine, which method comprises the steps of providing a horizontal assembly support (10, 10') for supporting components (2, 3, 4, 5) of the generator such that a rotational axis (R) of a component (2, 4, 5) is essentially vertical during assembly, and wherein the assembly support (10, 10') is realised to allow access to an interior of a generator component (2, 3) during the assembly procedure; arranging a rotor part (2) on the horizontal assembly support (10, 10'); arranging a stator part (3) in the rotor part (2); and joining the stator part (3) to the rotor part (2). The invention further describes an assembly arrangement (1, 1') for use in the vertical assembly of a generator of a wind turbine, which assembly arrangement (1, 1') comprises a horizontal assembly support (10) for supporting components (2, 3, 4, 5) of the generator such that a rotational axis (R) of a component (2, 4, 5) is essentially vertical during assembly, and wherein the assembly support (10) is realised to allow access to an interior of a generator component (2, 3) during the assembly procedure. The invention further describes the use of such an assembly arrangement (1, 1') in the assembly of a wind turbine generator.