Self-Lifting Exchange Device for Wind Turbine Stator Segment Maintenance
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Solution Overview
Problem
Current methods for maintaining wind turbines are costly and time-consuming, particularly when exchanging stator segments of generators, as they require dismounting the generator and using external equipment like cranes, leading to prolonged downtime.
Innovation Solution
A method and exchange device that self-lifts to the wind turbine hub, aligns with the stator segment, and handles the segment without external assistance, using lifting ropes and fork elements to facilitate removal or installation without dismounting the generator, thus reducing maintenance time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the generator is dismounted and stator segments are exchanged in a workshop, then the exchange can be performed with standard equipment, but the maintenance time and downtime are prolonged
Solution Approach 1:
The exchange device is equipped with a self-lifting mechanism that enables it to lift itself to the hub using lifting ropes and winches without requiring external cranes or heavy equipment. This self-service capability eliminates the need for external assistance, allowing the device to perform stator segment exchanges independently directly at the wind turbine, thereby reducing maintenance downtime while maintaining ease of operation
Solution Approach 2:
The exchange device acts as an intermediary between the stator segments and the handling equipment. It couples to the stator segments via fork elements, lifts itself to the hub, and facilitates the exchange process directly at the turbine location. This intermediary function enables stator segment replacement without requiring the generator to be dismounted and transported to a workshop, significantly reducing maintenance time
2Force
If external equipment like cranes is used for stator segment exchange, then the lifting capability is sufficient, but the maintenance costs and operational expenses increase
Solution Approach 1:
The exchange device incorporates a self-lifting mechanism with winches and lifting ropes that enable it to lift itself to the hub without requiring external cranes. This eliminates the need for expensive external equipment and the associated operational costs, while the winches provide sufficient lifting force to handle the stator segments directly at the turbine location, thereby reducing maintenance expenses
Solution Approach 2:
The lifting mechanism is extracted from external equipment and integrated directly into the exchange device. The winches and lifting ropes are built into the device itself, allowing it to perform lifting operations independently without relying on external cranes or heavy equipment, thus eliminating the costs associated with renting or operating such external machinery
3Adaptability or versatility
If the exchange device is equipped with a self-lifting mechanism, then external equipment is eliminated, but the device complexity increases
Solution Approach 1:
The exchange device is designed as a multi-functional unit that combines stator segment handling, self-lifting capability, and hub access functions in a single device. The lifting mechanism, fork elements, and winches serve multiple purposes: the lifting ropes both support the device during ascent and assist in positioning, the fork elements both grasp the stator segments and guide them during exchange. This multi-functionality reduces the need for separate specialized equipment while maintaining independence from external assistance
Solution Approach 2:
The exchange device is designed with modular components including fork elements, lifting mechanism, and handling tools that can be independently positioned and operated. The fork elements can be extended or retracted as needed, and the lifting mechanism can be deployed or stowed. This segmented design allows the device to perform multiple functions with relatively simple individual components, managing overall device complexity while maintaining versatility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and cost-effective exchange of stator segments by eliminating the need for external equipment and minimizing downtime, allowing for quicker maintenance and reduced operational expenses.
Implementation Method 1
coupling a lifting mechanism of an exchange device to a plurality of lifting ropes, wherein the plurality of lifting ropes is fixed to a hub of the wind turbine, self-lifting the exchange device to the hub by the lifting mechanism
Data Source
Figure 1~2
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AI summary
The present invention describes a method for removing or installing a stator segment (981) of a generator being installed in a nacelle of a wind turbine, and an exchange device (100) for removing or installing a stator segment (981) of a generator being installed in a nacelle of a wind turbine. The method comprises coupling a lifting mechanism (110) of an exchange device (100) to a plurality of lifting ropes (512), wherein the plurality of lifting ropes (512) is fixed to a hub (471) of the wind turbine, self-lifting the exchange device (100) to the hub (471) by the lifting mechanism (110), fastening the exchange device (100) to the hub (471), rotating the hub (471) such that the exchange device (100) is aligned with the stator segment (981) to be removed, and handling the stator segment (981) between a stator of the generator and the exchange device (100) for removing or installing the stator segment (981).