Wind Turbine Yaw Assembly Anti-Rotation Collar Design
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Solution Overview
Problem
Wind turbine yaw bearing systems face significant challenges due to yaw pad wear, leading to performance degradation, noise, and increased maintenance costs, particularly in accessing and servicing the yaw assemblies, which are time-consuming and costly, resulting in production shutdowns and technician fatigue.
Innovation Solution
The implementation of a threaded yaw piston bushing with multiple force adjustment screws and an anti-rotation collar to distribute spring pre-loading force, reducing torque requirements and stabilizing the thrust stem, along with a lubrication system that facilitates easier maintenance and extended pad life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional single-point torque adjustment is used for yaw piston assembly, then the structure is simple, but the torque requirement is excessively high and difficult to service
Solution Approach 1:
The single-point torque adjustment mechanism is segmented into multiple force adjustment screws distributed around the yaw piston assembly. This divides the total force requirement into smaller incremental components, reducing the torque needed for each individual adjustment while maintaining the overall preloading force on the yaw pads.
Solution Approach 2:
The adjustment mechanism transitions from a single-point (one-dimensional) torque application to a multi-point distributed arrangement (two-dimensional spatial distribution). The force adjustment screws are positioned at different angular locations around the yaw piston, creating a distributed force system that reduces the mechanical advantage requirement and lowers peak torque demands.
2Force
If multiple force adjustment screws are used to distribute spring pre-loading force, then the torque requirement is reduced, but the device complexity increases
Solution Approach 1:
The force adjustment screws serve multiple functions simultaneously: they apply preloading force to the yaw pads, provide adjustment capability for optimal contact pressure, and act as positioning elements for the yaw piston assembly. This multi-functionality reduces the need for separate adjustment mechanisms, thereby limiting the increase in overall device complexity despite adding multiple screws.
3Duration of action of stationary object
If yaw pads are serviced frequently to maintain performance, then the pad life is extended, but the maintenance cost and downtime increase
Solution Approach 1:
The yaw pad assembly incorporates self-lubricating features and is designed to maintain optimal performance through its inherent mechanical properties. The gliding surface geometry and material selection enable the pads to self-regulate friction and wear characteristics, reducing the frequency of maintenance interventions required while extending service life.
4Ease of repair
If technicians service yaw assemblies high in the air inside the nacelle, then the maintenance can be performed, but the technician fatigue and safety risks increase
Solution Approach 1:
The force adjustment screws and key components are designed with standardized, easily identifiable features including prominent heads and uniform spacing. This visual standardization allows technicians to quickly locate and identify adjustment points without excessive searching or complex procedures, reducing mental fatigue and the time spent in difficult-to-reach positions within the nacelle.
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
This solution reduces maintenance complexity, lowers costs, extends yaw pad life, and improves operational stability by distributing force more evenly, reducing wear and noise, and allowing for more efficient servicing with smaller tools, thereby minimizing technician fatigue and downtime.
Implementation Method 1
A spring resides inside the yaw piston and applies spring pressure to the yaw piston through a plurality of force adjustment screws
Implementation Method 2
Lubrication and proper pressure on the yaw pads can be used to reduce the possibility of fog-horning and extend the life of the yaw pads
Data Source
AI summary
A yaw assembly for a wind turbine may include a bushing configured for securement within a yaw cylinder containing a yaw piston and a yaw pad having a first side configured for engagement with a slew ring of the wind turbine and a second side configured for engagement with the yaw piston, a thrust stem engaged with the bushing and configured to apply force to the yaw pad against the slew ring, the thrust stem biased away from the yaw pad by one or more springs residing within the yaw piston, and an anti-rotation collar disposed at an interface between the thrust stem and the yaw piston, the anti-rotation collar including a flange extending from a bottom-center portion thereof, the flange disposed between the one or more springs and a bottom end of the yaw piston.