In-situ Wye Ring Replacement 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, leading to extended downtime for wind turbines.

Innovation Solution

A replacement Wye ring system is positioned radially inside the existing Wye ring and co-axially with the rotor, mechanically and electrically connected to connection lugs, allowing for in-situ repair without replacing the entire generator, using a fastening system that includes bolts, anti-rotation nuts, and shims, and ensuring electrical conductivity through plated surfaces.

Engineering Contradictions & Design Principles

VSEngineering 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

Engineering Contradiction:

Improvegenerator reliabilityVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention divides the generator into separable components, specifically isolating the Wye ring as a replaceable module. The replacement Wye ring system includes a new Wye ring, fastening system, and insulation system that can be installed independently without replacing the entire generator, thus reducing downtime while restoring reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The replacement Wye ring is positioned radially inside the existing Wye ring structure. The fastening system components (bolts, anti-rotation nuts, shims) are nested within the Wye ring assembly, allowing compact installation within the existing generator space without requiring complete disassembly

Inventive Principle:

Principle #7Nested doll (Nesting)

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 crane requirements

Engineering Contradiction:

Improvegenerator reliabilityVSAvoidrepair cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By segmenting the repair scope to only the Wye ring component rather than the entire generator, the invention eliminates the need for heavy-duty cranes capable of lifting multi-ton generators. The replacement Wye ring system weighs significantly less, reducing equipment requirements and associated costs

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention treats the Wye ring as a replaceable consumable component rather than a permanent part of the generator. The replacement Wye ring system is designed as a cost-effective, shorter-lived component that can be easily replaced without investing in expensive generator-level repairs or replacements

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If a replacement Wye ring is installed radially inside the existing Wye ring, then the electrical connection is restored, but the rotor balance may be affected

Engineering Contradiction:

Improveelectrical connectionVSAvoidrotor balance

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The fastening system includes shims that act as counterweights to compensate for the mass imbalance introduced by installing the replacement Wye ring inside the existing structure. These shims are strategically positioned to maintain the rotor's dynamic balance while enabling the electrical connection repair

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Solution Approach 2:

The fastening system incorporates adjustable components (shims, bolts, anti-rotation nuts) that allow for dynamic adjustment of the replacement Wye ring's position and mass distribution. This enables precise balancing of the rotor after installation, ensuring stable operation while maintaining the restored electrical connection

Inventive Principle:

Principle #15Dynamics

4Loss of time

If the Wye ring is replaced in-situ, then the repair time is reduced, but the installation complexity increases

Engineering Contradiction:

Improverepair timeVSAvoidinstallation complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The replacement Wye ring system is pre-assembled with the fastening system components (bolts, anti-rotation nuts, shims) and insulation materials before installation. This preliminary preparation reduces the complexity and time of the actual installation process, as components are ready-to-install rather than requiring assembly during the repair

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fastening system acts as an intermediary mechanism that simplifies the connection between the replacement Wye ring and the rotor structure. The standardized bolts, anti-rotation nuts, and shims provide a mediating interface that makes the complex task of securing the replacement Wye ring straightforward and repeatable

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9143022B2System and method for rebalancing generator rotor in-situ

Publication Date: 2015.09.22 GE INFRASTRUCTURE TECH LLC

AI summary

A Wye ring system for a rotor of a generator includes a replacement Wye ring configured to replace an existing Wye ring serving as a floating neutral connection in the rotor. The replacement Wye ring is positioned radially inside the existing Wye ring and co-axial with the rotor. A fastening system is configured for mechanically and electrically connecting the replacement Wye ring to a plurality of connection lugs. The plurality of connection lugs are electrically connected to the rotor windings. The replacement Wye ring replaces the floating neutral connection of the existing Wye ring.