Wind Turbine Main Bearing Replacement Without Shaft Disassembly

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Solution Overview

Problem

The existing methods for replacing large bearings in wind turbines, such as the main bearing, are costly and time-consuming, often requiring disassembly of the rotor shaft and rotor star, especially in offshore applications, due to unfavorable load distribution and geometric conditions leading to premature damage and complex disassembly processes.

Innovation Solution

A method and device that allow for the replacement of a used bearing with a new one without disassembling the rotor shaft, by retaining and reusing the used bearing housing, axially displacing it to remove the old bearing, and fitting the new bearing in circumferential segments within the same housing, supported by a holding device that temporarily supports the rotor unit during the process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If the rotor shaft and rotor star are disassembled to replace the bearing, then the bearing can be replaced, but the replacement process becomes very costly and time-consuming

Engineering Contradiction:

Improvebearing replacementVSAvoidreplacement time

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The bearing housing is divided into two separable parts: a stationary lower housing part that remains on the machine carrier, and a movable upper housing part that can be removed. This segmentation allows the bearing to be accessed and replaced without disassembling the rotor shaft and rotor star, thereby reducing replacement time and cost while maintaining bearing accessibility.

Inventive Principle:

Principle #1Segmentation

2Ease of repair

If the rotor shaft and rotor star are disassembled to replace the bearing, then the bearing can be replaced, but the financial expenditure increases significantly

Engineering Contradiction:

Improvebearing replacementVSAvoidreplacement cost

Core Design Contradiction:

Ease of repairVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If the bearing housing is retained and reused, then costs are reduced, but the bearing housing must be axially displaced to remove the old bearing

Engineering Contradiction:

Improvehousing reuseVSAvoiddisplacement process

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The upper housing part is extracted or removed from the assembly, allowing the bearing to be accessed and replaced. After replacement, the upper housing part can be reattached to complete the assembly. This extraction approach simplifies the process of bearing replacement while retaining the housing for reuse.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of operation

If the bearing is divided in circumferential direction, then the new bearing can be fitted around the rotor shaft, but the bearing assembly becomes more complex

Engineering Contradiction:

Improvebearing installationVSAvoidbearing structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The bearing is divided into circumferential segments that can be assembled around the rotor shaft. These segmented bearing components can be installed separately and then joined together, facilitating easier installation in confined spaces while maintaining the structural integrity and load-bearing capacity of the complete bearing assembly.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11933362B2Method and device for replacing a used bearing, in particular for replacing a main bearing of a wind turbine, and bearing arrangement in particular of a wind turbine

Publication Date: 2024.03.19 EOLOTEC

AI summary

For replacing in particular a used main bearing of a wind turbine, a bearing housing is first pulled axially off the main bearing along a rotor shaft, then the used main bearing is divided and disassembled. A new main bearing is assembled around the rotor shaft and the original bearing housing is pushed axially back onto the main bearing. During the replacement of the main bearing, the rotor shaft is supported on a machine carrier by means of a holding device, wherein the holding device is arranged at least partially in the region between a bearing seat and a hub-side end region of the rotor shaft.