Segmented Yaw Bearing Calliper for Easier Pad Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional yaw bearing systems for wind turbines are heavy, costly, difficult to handle, and require complex and time-consuming maintenance, with issues such as radial pads being squeezed out and high service costs due to complex machining and large, heavy calliper structures.
Innovation Solution
A yaw bearing system with individual calliper structures divided into upper and lower portions, allowing for separate manufacturing and servicing, featuring a radial pad that extends along the entire length of the radial surface to reduce pressure and wear, and an adjusting mechanism for pre-tension force adjustment, enabling quick pad replacement without dismounting the entire calliper structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single large and heavy calliper structure is used, then the radial pad can be supported along the entire length, but the system becomes difficult to handle and service
Solution Approach 1:
The calliper structure is divided into multiple segments (first calliper structure and second calliper structure) that can be independently removed and serviced. This segmentation maintains the radial pad support stability while enabling easier handling and maintenance of individual components without requiring removal of the entire calliper assembly.
2Strength
If the calliper structure is made as one single piece, then structural strength is improved, but maintenance becomes time-consuming and costly
Solution Approach 1:
The calliper structure is divided into separable segments that maintain overall structural strength through proper connection design. Individual segments can be removed and serviced independently, significantly reducing maintenance time and costs compared to a monolithic structure where the entire assembly must be dismantled for pad replacement.
Solution Approach 2:
The radial pad and its support structure are extracted as a separate serviceable component. The radial pad can be removed and replaced by simply removing the specific calliper segment, without affecting the integrity or requiring disassembly of the entire calliper structure, thus enabling quick maintenance while preserving overall strength.
3Reliability
If separate fixing elements are arranged between adjacent bearing units, then individual pad support is improved, but device complexity and costs increase
Solution Approach 1:
The fixing element functionality is merged into the calliper structure itself rather than being separate components. The calliper segments incorporate integrated fixing features that provide stable pad positioning without requiring additional separate fixing elements between adjacent bearing units, thus reducing overall device complexity while maintaining reliability.
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
The system reduces the risk of radial pad squeeze-out, lowers maintenance costs, and simplifies servicing by allowing individual pad replacement, resulting in a lighter, easier-to-handle, and more cost-effective yaw bearing system with improved fatigue and extreme strength.
Implementation Method 1
a radial pad and a lower pad project from the calliper structure and contact the flange
Implementation Method 2
at least one radial pad is arranged between the radial surface of flange and the radial surface of upper portion, wherein said at least one radial pad has a lower edge contacting the upper surface of lower portion and extends along the entire length of the radial surface of upper portion
Implementation Method 3
an adjusting mechanism for pre-tension force adjustment
Implementation Method 4
The bearing system is an adjustable pre-tensioning system continuously applying a brake torque on the flange by means of friction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a wind turbine comprising a plurality of individual yaw bearing units and a method of replacing a pad of such a yaw bearing unit. The yaw bearing unit comprises a calliper structure divided into an upper portion and a lower portion, wherein the lower portion can be dismounted without also dismounting the upper portion. An upper pad is provided between a flange providing support for a nacelle and a mainframe of the nacelle. A radial pad is arranged on a radial surface of the upper portion and contacts a stop element located at either ends of the upper portion. An adjustable lower pad is arranged in a through hole in the lower portion and can be replaced via a lower opening in the lower portion. The radial pad can be replaced in a sideward direction by removing one of the stop elements or replacing it in an axial direction by removing the lower portion.