Wind Turbine Yaw Bearing Exchange with On-Site Leveling Support
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Solution Overview
Problem
Current methods for servicing or replacing yaw bearings in wind turbines are impractical due to the weight of the machine head, requiring oversized load transportation and complex operations, especially when upgrading or replacing existing machine heads with different models.
Innovation Solution
A yaw bearing servicing and exchange system that includes a support stand with levelers and a leveling-lifting assembly, allowing the machine head to be lifted and leveled without inverting it, enabling the yaw bearing to be serviced or replaced at the wind turbine site without removing internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the machine head is inverted and lowered into place during manufacturing, then the yaw bearing can be installed, but the process becomes impractical in the field due to the 70+ ton weight
Solution Approach 1:
Instead of inverting the machine head to access the yaw bearing (conventional method), the patent inverts the approach by providing support from below through a support stand with posts positioned under the machine head. This allows the yaw bearing to be serviced while the machine head remains in its normal upright orientation, making field operations practical and safe.
Solution Approach 2:
The patent introduces a support stand with multiple posts as an intermediary structure between the ground and the machine head. This intermediary provides the necessary support and access to the yaw bearing without requiring direct manipulation of the entire 70+ ton machine head, thereby enabling field servicing.
2Ease of repair
If oversized load transportation is used to transport the machine head to a facility, then the yaw bearing can be serviced, but the complexity and cost significantly increase
Solution Approach 1:
The patent enables self-service by providing all necessary support structures (support stand with posts) that can be deployed directly at the wind turbine site. This eliminates the need to transport the machine head to specialized facilities, allowing the yaw bearing to be serviced in situ with reduced complexity and cost.
3Ease of operation
If the machine head is supported from below with posts, then the yaw bearing becomes accessible, but the posts must be positioned precisely to avoid interfering with yaw rotation
Solution Approach 1:
The support structure is segmented into multiple discrete posts rather than a single continuous support. This segmentation allows the posts to be positioned at specific locations that provide support while clear of the yaw rotation path. The posts can be independently positioned and adjusted to achieve the necessary precision without interfering with machine head rotation.
Data Source
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AI summary
The present disclosure is directed to a system and methods for the service and exchange of a yaw bearing for a machine head of a wind turbine. The yaw bearing servicing and exchange system has a support stand. The support stand includes a base assembly and at least one support post extending perpendicularly from the base assembly. The support stand also includes at least one first post cap removably coupled to the support post and at least one leveler operably coupled to the at least one first post cap for establishing a level orientation of a support surface with respect to a horizontal plane.