Wind Turbine Shaft Alignment Tool
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Solution Overview
Problem
As wind turbine generators increase in size, misalignment between the gearbox shaft and the generator main shaft leads to premature and costly failures, and reduced energy generation, necessitating improved maintenance methods to ensure alignment and reliability.
Innovation Solution
A method and apparatus using a wind turbine alignment tool with a push plate and indexing means applied to selected support flanges, guided by misalignment data from a measurement device, to align the input shaft with the output shaft, and recheck for further alignment adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If wind turbine generators increase in size to increase output, then power generation capacity is improved, but misalignment between shafts occurs more frequently leading to premature failures
Solution Approach 1:
The patent applies preliminary action by performing alignment measurement and adjustment before the wind turbine generator is put into operation. The alignment tool is installed on the generator, measurement devices are attached to measure shaft positions, and misalignment is corrected before operation begins, preventing premature failures caused by misalignment in larger turbines
Solution Approach 2:
The patent implements feedback by using measurement devices to continuously monitor shaft alignment and providing real-time data about misalignment conditions. This feedback loop allows operators to detect and correct misalignment issues, maintaining reliability as turbine size and power generation capacity increase
2Manufacturing precision
If misalignment measurement and adjustment is performed, then shaft alignment is improved, but maintenance time and complexity increase
Solution Approach 1:
The patent applies self-service by designing an alignment tool that can be easily installed and operated by maintenance personnel without requiring specialized external equipment or extensive expertise. The tool performs self-measurement and provides clear indication of misalignment, enabling maintenance staff to quickly correct alignment issues without prolonged downtime
Solution Approach 2:
The patent replaces complex mechanical alignment methods with a simplified measurement and adjustment system. Instead of using traditional mechanical gauges and manual measurement techniques, the invention uses a specialized alignment tool with integrated measurement devices that automatically detect shaft positions and guide correction, reducing maintenance time and complexity while improving alignment precision
Data Source
AI summary
A method and apparatus for aligning an input shaft of a wind turbine generator with an output shaft of a wind turbine are disclosed. Preferably, the method includes placing a push plate of a wind turbine alignment tool into pressing contact with a selected support flange of a wind turbine generator identified by a misalignment measurement device. With the push plate positioned, an indexing means of the wind turbine alignment tool is advanced along an adjustment link member of the wind turbine alignment tool to impart an alignment force onto the selected support flange to align the input shaft of the wind turbine generator with the output shaft of the wind turbine. The method preferably concludes by rechecking the alignment of the input shaft of the wind turbine generator with the output shaft of the wind turbine.