Wind Turbine Generator Frame Replacement Without Cable Disconnection
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Solution Overview
Problem
The existing methods for replacing a generator frame in wind turbines are labor-intensive and time-consuming due to the need to disconnect and reconnect hundreds or thousands of wires associated with the control cabinet, which complicates the process and increases downtime.
Innovation Solution
A method that allows the control cabinet to remain electrically connected during the replacement of the generator frame by relocating and securing it to an uptower location within the nacelle, thereby avoiding the disconnection of cables and simplifying the process of removing and installing the existing and new generator frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the control cabinet is removed and reinstalled during generator frame replacement, then the new generator frame can be installed, but the process becomes labor-intensive and time-consuming due to disconnecting and reconnecting hundreds or thousands of wires
Solution Approach 1:
The generator frame is designed as a separable component that can be removed independently from the control cabinet. The control cabinet remains mounted on the nacelle structure while the generator frame is detached, allowing the frame to be replaced without moving the control cabinet or its cable connections.
Solution Approach 2:
The generator is extracted from the generator frame assembly, allowing the frame to be removed and replaced independently. The control cabinet stays in place on the nacelle structure, and its cable connections remain intact throughout the frame replacement process.
2Ease of operation
If the control cabinet remains mounted during generator frame replacement, then cable disconnection is avoided, but the control cabinet must be relocated to an uptower location within the nacelle
Solution Approach 1:
The control cabinet is separated from the generator frame mounting arrangement. Instead of being attached to the frame, the control cabinet is mounted directly to the nacelle structure at an uptower location, allowing independent replacement of the generator frame without affecting the control cabinet position or cable connections.
3Productivity
If the generator frame is replaced by removing and reinstalling the control cabinet, then the new frame can be installed, but downtime increases due to the labor-intensive process
Solution Approach 1:
The generator frame is designed as an independent replaceable component. The control cabinet remains mounted on the nacelle structure while the generator frame is detached, allowing rapid frame replacement without the time-consuming process of disconnecting and reconnecting control cabinet cables.
Solution Approach 2:
The control cabinet is pre-positioned on the nacelle structure at an uptower location with cable connections already established. This preliminary arrangement allows the generator frame to be quickly removed and replaced without interrupting the control cabinet's electrical connections.
Data Source
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AI summary
A method 100 for replacing an existing generator 25 frame 36 that supports a generator 25 of a wind turbine 10 includes removing 102 the generator 25 from atop the existing generator 25 frame 36. The method 100 also includes dismounting 104 a control cabinet 34 of the wind turbine 10 from the existing generator 25 frame 36. More specifically, the control cabinet 34 is electrically connected to one or more wind turbine 10 components via a plurality of cables 48. The method 100 further includes relocating 106 and securing the control cabinet 34 to an uptower location 50 within a nacelle 16 of the wind turbine 10 with the plurality of cables 48 remaining electrically connected. As such, the method 100 includes removing 108 the existing generator 25 frame 36 from within the nacelle 16. Moreover, the method 100 includes installing 110 a new generator 25 frame 36 in place of the removed existing generator 25 frame 36. Thus, the method 100 also includes remounting 112 the control cabinet 34 to the new generator 25 frame 36.