Wye Ring Patch Repair for Wind Turbine Generators

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Solution Overview

Problem

The existing methods for repairing a cracked wye ring in a wind turbine generator require replacing the entire generator, which is costly and time-consuming, as cranes and logistics are needed to transport heavy equipment to remote locations, leading to extended downtime.

Innovation Solution

A method and system for repairing a wye ring by dismantling the generator, determining the fault location, and attaching a patch to create an electrical path around the fault, allowing in-situ repair, using a patch with various shapes and attachment methods, including soldering, brazing, and mechanical fasteners, and insulating cuffs for high-voltage protection.

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 reliabilityVSAvoidrepair time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The repair process is segmented into discrete steps: removing the old wye ring, preparing the mounting surface, and installing the new wye ring separately from the entire generator replacement. This allows only the faulty component to be replaced rather than the entire generator system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The faulty wye ring is extracted and removed from the generator, and a new wye ring is installed in its place. This extraction approach allows repair of the specific faulty component without replacing the entire generator assembly.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If the entire generator is replaced to repair a cracked wye ring, then the generator reliability is restored, but the logistical complexity and cost increase

Engineering Contradiction:

Improvegenerator reliabilityVSAvoidlogistical complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The replacement operation is segmented to involve only the wye ring component rather than the entire generator. This reduces the logistical complexity from transporting and handling multi-ton generator equipment to installing a much smaller wye ring component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wye ring is extracted as a separate replaceable component from the generator system. This allows the repair to focus on a small, manageable part rather than requiring complete generator removal, storage, and reinstallation.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of repair

If a crane is used to lift the generator for replacement, then the generator can be replaced, but the equipment cost and operational disruption increase

Engineering Contradiction:

Improvegenerator replaceabilityVSAvoidrepair operation cost

Core Design Contradiction:

Ease of repairVSEase of manufacture

Solution Approach 1:

The repair is segmented to replace only the wye ring component using smaller, more affordable lifting equipment rather than requiring heavy-duty cranes capable of lifting entire generators. This reduces equipment costs and operational complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wye ring is extracted as a separate component that can be handled with minimal lifting equipment. This extraction approach eliminates the need for expensive heavy-lift cranes and complex generator replacement operations.

Inventive Principle:

Principle #2Taking out (Extraction)

4Productivity

If the generator is kept in service with a cracked wye ring, then operational continuity is maintained, but the risk of complete failure increases

Engineering Contradiction:

Improveoperational continuityVSAvoidgenerator reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The wye ring is replaced proactively during scheduled maintenance before complete failure occurs. This preliminary replacement action maintains both operational continuity and reliability by preventing catastrophic failure while minimizing downtime.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A temporary or interim wye ring replacement process serves as an intermediary solution that maintains operational continuity while restoring full reliability. The repair process acts as a mediator between maintaining operation and ensuring complete system reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 rapid and cost-effective repair of wye rings in wind turbines, reducing downtime and logistical challenges by allowing on-site maintenance, thus extending the generator's operational life without the need for full replacement.

Implementation Method 1

The patch provides an electrical path around the fault location so that the generator is repaired

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

Due to operational stresses which fatigue the brazed connection between the wye ring and its rotor connection points

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS10038357B2Method for repairing or servicing a wye ring

Publication Date: 2018.07.31 GE INFRASTRUCTURE TECH LLC

AI summary

A method for repairing or servicing a wye ring of a generator includes the steps of, dismantling the generator to gain access to the wye ring, determining a fault location in the wye ring; and attaching a patch to the wye ring in an area of the fault location. The patch provides an electrical path around the fault location so that the generator is repaired.