Wye Ring Centering System for Wind Turbine Generator Repair
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Solution Overview
Problem
The existing methods for repairing a cracked wye ring in wind turbine generators require replacing the entire generator, which is costly and time-consuming, as cranes capable of lifting heavy loads to great heights are needed, causing the turbine to be out of service until a new generator is installed.
Innovation Solution
A wye ring centering system with rollers and mounting fasteners is used to center and replace the wye ring in-situ, allowing for mechanical and electrical connection to the rotor windings, enabling the repair of the generator without replacing the entire unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire generator is replaced to repair a cracked wye ring, then the generator reliability is restored, but the repair cost and time increase significantly due to requiring heavy-duty cranes and generator removal
Solution Approach 1:
The invention divides the generator into separable components, allowing the wye ring to be replaced independently from the rest of the generator assembly. The wye ring is removed from the rotor core, and a new wye ring is installed through the stator bore without requiring generator disassembly or removal from the turbine, thus restoring reliability while minimizing downtime.
Solution Approach 2:
The wye ring is extracted from the generator assembly for replacement. The method involves removing the old wye ring from the rotor core and installing a new wye ring through the stator bore, separating the repair operation from the entire generator replacement process. This extraction approach eliminates the need for heavy-duty cranes and reduces turbine downtime significantly.
2Reliability
If the entire generator is replaced to repair a cracked wye ring, then the generator reliability is restored, but the repair cost increases due to requiring expensive heavy-duty cranes
Solution Approach 1:
The invention segments the repair operation to replace only the wye ring component rather than the entire generator. This segmentation allows the use of smaller, less expensive equipment for installation through the stator bore, eliminating the need for expensive heavy-duty cranes while restoring generator reliability.
Solution Approach 2:
The wye ring is extracted and replaced independently through the stator bore using minimal equipment. This extraction method removes the requirement for expensive heavy-duty cranes, significantly reducing repair costs while achieving the same reliability restoration as full generator replacement.
3Reliability
If the entire generator is replaced to repair a cracked wye ring, then the generator reliability is restored, but the complexity of the repair operation increases due to requiring crane operations at great heights
Solution Approach 1:
The repair operation is segmented to replace only the wye ring component through the stator bore rather than replacing the entire generator. This segmentation simplifies the repair operation by eliminating complex crane operations at great heights, reducing safety risks, and making the procedure more manageable while restoring generator reliability.
Solution Approach 2:
The wye ring replacement is extracted as a separate, simplified operation that can be performed through the stator bore without requiring heavy-duty cranes or complex assembly/disassembly procedures. This extraction approach reduces repair operation complexity and eliminates the need for dangerous high-altitude crane operations.
4Reliability
If the entire generator is replaced to repair a cracked wye ring, then the generator reliability is restored, but the loss of operational status increases as the turbine must be shut down
Solution Approach 1:
The invention segments the repair to replace only the wye ring component in place rather than replacing the entire generator. This allows the turbine to remain operational or require minimal shutdown time, maintaining productivity while restoring generator reliability through a quick component swap procedure.
Solution Approach 2:
The wye ring is extracted and replaced through the stator bore without removing the generator from the turbine. This extraction-based repair method minimizes turbine shutdown time, maintaining operational status and productivity while restoring generator reliability through a rapid component replacement procedure.
Data Source
AI summary
A wye ring centering system and method are provided. The system includes a plurality of rollers configured for contacting a wye ring, and a plurality of mounting fasteners configured for supporting the plurality of rollers. Each of the mounting fasteners is configured to pass through a fan hub. The plurality of rollers and the plurality of mounting fasteners are distributed at substantially equal intervals around the fan hub. The wye ring is placed over the plurality of rollers to center the wye ring around a shaft.