Wind Turbine Gearbox Removal Using Hydraulic Shaft Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of dismantling a wind turbine gearbox from a main shaft in the nacelle is complicated by the strong connection required to transfer massive torque, making existing jacking systems complex and expensive.
Innovation Solution
A method involving a hydraulic connection plug secured against axial displacement, with a hydraulic pump used to force the main shaft out of the connection cavity, utilizing a lubricating liquid to reduce friction and generate a controlled separation force, and employing a blocking device to prevent damage to the gearbox.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a strong connection is used between the main shaft and gearbox to transfer massive torque, then the torque transfer capability is improved, but the dismantling difficulty increases
Solution Approach 1:
A hydraulic connection plug is introduced as an intermediary component between the hydraulic pump and the connection cavity. This plug receives hydraulic pressure and transmits it uniformly to the main shaft, enabling controlled dismantling without directly modifying the strong mechanical connection between the main shaft and gearbox. The intermediary allows the dismantling force to be applied through fluid pressure rather than direct mechanical intervention.
Solution Approach 2:
Hydraulic pressure is used to generate the separation force needed for dismantling. A hydraulic pump delivers pressurized fluid through the connection plug into the connection cavity, creating sufficient force to break the strong torque transfer connection between the main shaft and gearbox. This hydraulic approach replaces complex mechanical jacking systems with a simpler fluid-based solution.
2Device complexity
If a hydraulic pump is used to generate separation force, then the dismantling process becomes simpler and less expensive, but the gearbox shaft may be damaged by axial forces
Solution Approach 1:
Before applying hydraulic pressure to separate the main shaft from the gearbox, a blocking device is installed on the gearbox shaft to prevent axial displacement. This preliminary protective measure ensures that when the hydraulic pump generates separation force, the gearbox shaft cannot move axially and suffer damage. The blocking device is removed only after the dismantling process is complete.
Solution Approach 2:
The blocking device acts as a protective cushion or constraint that prevents excessive axial movement of the gearbox shaft during the hydraulic dismantling process. By providing this protective constraint in advance, the system allows the use of simple and inexpensive hydraulic equipment while preventing potential damage to the gearbox shaft from uncontrolled axial forces.
3Device complexity
If the hydraulic connection plug is not secured against axial displacement, then the dismantling process is simpler, but liquid leakage occurs reducing effectiveness
Solution Approach 1:
The hydraulic connection plug is secured against axial displacement by threading it into the gearbox shaft before the hydraulic dismantling process begins. This preliminary securing action ensures that the plug remains in position and maintains the hydraulic seal throughout the pressure-building process, preventing liquid leakage that would reduce dismantling effectiveness. The plug is removed only after the main shaft is successfully separated.
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 method allows for a simple and cost-effective dismantling of the gearbox by generating a controlled separation force, reducing friction, and preventing damage to the gearbox components, suitable for wind turbines with a nominal output of at least 1 Megawatt.
Implementation Method 1
pumping liquid into the connection cavity by means of the hydraulic pump to force the main shaft out of the connection cavity
Implementation Method 2
Forcing the wind turbine gearbox and the main shaft apart by means of a pressurized liquid
Implementation Method 3
the liquid being pumped into the connection cavity may lubricate the connection between the wind turbine gearbox and the main shaft in the connection cavity to thereby reduce friction
Data Source
AI summary
Disclosed is a method for dismantling a wind turbine gearbox (15) from a main shaft (7) in the nacelle (3) of a wind turbine (1), wherein a first end (11) of the main shaft (7) is connected to the gearbox (15) in a connection cavity (22) of the gearbox (15) and a second end (12) of the main shaft (7) is connected to a rotor (4) of the wind turbine (1). The method comprises the steps of: —arranging a hydraulic connection plug (13) in a centre channel (14) of a second end (37) of a gearbox shaft (21) of the gearbox (15), wherein a first end (20) of the gearbox shaft (21) is arranged at the connection cavity (22) on a first side (23) of the gearbox (15) and wherein the second end (37) of the gearbox shaft (21) is arranged at a second side (24) of the gearbox (15) opposite the first side (23), —securing the hydraulic connection plug (13) and the gearbox shaft (21) against axial displacement in a direction towards the second side (24) of the gearbox (15), —connecting a hydraulic pump (25) to the hydraulic connection plug (13), and —pumping liquid into the connection cavity (22) by means of the hydraulic pump (25) to force the main shaft (7) out of the connection cavity (22). Furthermore, use of the method is disclosed.