Wind Turbine Component Alignment via Adjustable Support Elements
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Solution Overview
Problem
Modern wind turbines face challenges in achieving and maintaining proper alignment of components like the gearbox and generator with the rotor hub, leading to increased vibrations, material stresses, and reduced lifespan due to misalignment during installation and operation, which is labor-intensive and costly to correct.
Innovation Solution
A method and system utilizing adjustable supports with elements that can adjust in stiffness, thickness, or position to align wind turbine components, allowing for initial approximate placement and subsequent precise alignment without disrupting operation, using proximity sensors to monitor and correct misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are installed using cranes or hoisting apparatus, then installation is feasible for heavy components, but alignment precision deteriorates due to inherent imprecision during installation
Solution Approach 1:
The support structure is pre-installed on the rotor hub before the heavy component is hoisted into position. This preliminary action creates a reference framework that guides the component into approximate alignment, reducing the precision demands on the hoisting apparatus while ensuring final alignment capability through the adjustable support elements.
2Manufacturing precision
If components are repositioned to correct misalignment, then alignment precision is improved, but operation interruption and service costs increase
Solution Approach 1:
The support structure incorporates adjustable elements that can be modified while the turbine is operating. This dynamic capability allows operators to correct misalignment by adjusting the support elements without disassembling or repositioning heavy components, thereby maintaining continuous operation and avoiding costly shutdowns.
Solution Approach 2:
The adjustable support structure acts as an intermediary between the rotor hub and the heavy component. Instead of directly repositioning the heavy component, the support elements are adjusted to correct misalignment, serving as a mediator that enables precision alignment without moving the component itself.
3Manufacturing precision
If adjustable elements are added to the support structure, then alignment capability is improved, but device complexity increases
Solution Approach 1:
Rather than making the entire support structure adjustable and complex, only specific local elements within the support are made adjustable. These localized adjustable elements provide the necessary alignment capability while the rest of the support structure remains simple and robust, minimizing overall complexity.
Solution Approach 2:
The adjustable elements modify specific parameters of the support structure (such as position, angle, or dimensional parameters) to achieve alignment. By changing only the necessary parameters locally rather than redesigning the entire support structure, the invention achieves alignment capability with minimal increase in overall device complexity.
Data Source
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AI summary
The invention relates to a method of aligning a wind turbine component with a wind turbine rotor hub (3), characterised in that it comprises the steps of providing the component with a support comprising at least one adjustable element (20) and adjusting said at least one element to align the wind turbine component. The invention further relates to a system for aligning a wind turbine component with a wind turbine rotor hub comprising a support with at least one adjustable element (20) supporting said wind turbine component, such that said wind turbine component can be aligned by adjusting said at least one element (20).