Wind Turbine Refurbishment Using Adapter Hole Patterns
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Solution Overview
Problem
Existing wind turbines often face challenges in refurbishment due to differences in mounting apparatus between new and old components, such as machine heads and towers, which can hinder the integration of newer, more efficient technology without requiring significant capital expenses.
Innovation Solution
The use of adapters with different hole patterns allows for the connection of new machine heads and yaw drive mechanisms to existing towers, facilitating the refurbishment of wind turbines by aligning fastener holes and patterns, enabling the extension of fasteners to secure the new components in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If new machine heads with different mounting apparatus are installed on existing towers, then power generation efficiency is improved, but compatibility with existing components deteriorates
Solution Approach 1:
An adapter is introduced as an intermediary component between the new machine head and the existing tower. The adapter includes a first flange with fastener holes configured to mate with the new machine head's mounting apparatus, and a second flange with fastener holes configured to mate with the existing tower's mounting apparatus. This intermediary component resolves the incompatibility between different mounting apparatus designs, allowing new high-efficiency machine heads to be installed on existing towers without requiring modification to either component.
2Duration of action of stationary object
If existing wind turbines are refurbished with new components, then additional life and efficiency are extended, but capital expenses are reduced only partially
Solution Approach 1:
The refurbishment solution is segmented into modular components: the existing tower is retained, the new machine head is supplied separately, and the adapter is provided as a distinct connecting component. This segmentation allows each component to be optimized independently while maintaining compatibility through standardized interfaces. The adapter serves as a bridge that enables the combination of legacy infrastructure with modern components, maximizing the value of existing assets while achieving technical upgrades.
3Adaptability or versatility
If adapters with different hole patterns are used to connect new components to existing towers, then adaptability is improved, but device complexity increases
Solution Approach 1:
The adapter is designed with universal functionality to accommodate different mounting apparatus configurations. The first flange is configured to mate with various new machine head mounting patterns, while the second flange interfaces with existing tower mounting patterns. This multi-functional design allows a single adapter component to bridge multiple interface standards, reducing the need for multiple specialized adapters and simplifying the overall refurbishment process despite the variety of component interfaces.
Data Source
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AI summary
A method for refurbishing a wind turbine 10 includes removing an existing machine head 120 from the wind turbine 10, and providing a new machine head 220 and an adapter 250. The new machine head 220 includes a base frame 222, and further includes a plurality of fastener holes 224 defined in the base frame 222. The adapter 250 includes an outer sidewall 252 and defines a first plurality of fastener holes 254 and a second plurality of fastener holes 256, the first plurality of fastener holes 254 disposed in a first hole pattern 255, the second plurality of fastener holes 256 disposed in a second hole pattern 257 different from the first hole pattern 255. The method further includes connecting the new machine head 220 and the adapter 250 such that the adapter 250 is connected to and between a yaw bearing 134, 234 and one of the base frame 222 or a top flange 112 of a tower 110 of the wind turbine 10.