Yaw Piston Extraction Using Core Boring and Hydraulic Pulling
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Solution Overview
Problem
Conventional tools are ineffective in removing seized yaw pistons from wind turbine housings due to damage, dirt, or deformation, which are critical for optimal wind capture and turbine performance, often requiring complex and risky manual interventions.
Innovation Solution
A modular system comprising a boring motor, rotary motor, and hydraulic puller tool, along with specialized components, performs sequential operations to safely and efficiently extract seized yaw pistons by removing the center core, creating a separating cut, and using a puller tool to extract the piston barrel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tools are used to remove seized yaw pistons, then the removal process becomes complex and risky, but the pistons cannot be effectively removed due to binding and deformation
Solution Approach 1:
The removal process is divided into three distinct operations using three specialized portable power tools: (1) a boring motor with boring plug and cutter to remove the center core, (2) a rotary motor with cutting wheel to create separating cuts, and (3) a hydraulic tubular actuator with puller tool to extract the piston barrel. This segmentation allows each tool to perform its specific function effectively without requiring complex manual interventions.
Solution Approach 2:
The patent introduces specialized intermediary components such as the boring plug that fits into the housing, the puller tool with wedge plates that engage the piston barrel, and the hydraulic actuator that provides controlled extraction force. These intermediaries enable the removal process while protecting the housing and surrounding components from damage.
2Ease of operation
If manual interventions are used to remove seized pistons, then the process becomes risky, but conventional tools cannot access the confined space inside the turbine
Solution Approach 1:
The three specialized portable power tools are designed to be self-contained and adaptable to the confined space within the turbine housing. Each tool integrates its power source, actuation mechanism, and extraction function into a compact unit that can operate in limited spaces while maintaining safety and effectiveness.
3Productivity
If the piston is removed as a whole, then the deformed mushroomed shape makes extraction difficult, but breaking it apart requires specialized sequential operations
Solution Approach 1:
The piston removal is segmented into three sequential operations: first removing the center core with the boring motor, then creating separating cuts with the rotary motor, and finally extracting the piston barrel with the hydraulic puller tool. This segmentation transforms a single complex extraction task into manageable steps, improving efficiency while controlling overall process complexity.
Solution Approach 2:
Before attempting to extract the seized piston, the patent performs preliminary actions: (1) removing the center core to access the piston cavity, (2) creating separating cuts to divide the mushroomed piston ring from the barrel, and (3) using the puller tool to gradually extract the barrel. These preliminary actions prepare the piston for successful extraction by reducing its structural integrity in a controlled manner.
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 ensures safe and efficient extraction of seized yaw pistons, minimizing damage to the turbine components and facilitating easy assembly and maintenance across various turbine systems.
Implementation Method 1
A third portable power tool, a hydraulic tubular actuator, moves a puller tool to extract the piston barrel from the housing
Data Source
AI summary
A device and method for removing a seized yaw piston from a wind turbine housing is disclosed. The device features a boring plug with retention screws to secure the piston during operation and mounting plates for attaching the boring motor. The boring motor operates a cutter to remove the piston's core. The rotary motor is manually rotated allowing the cutting wheel to create a separating cut designed to sever a mushroomed ring from the barrel of the yaw piston. A puller tool, equipped with expandable wedge plates and a puller screw, grips the piston barrel through the separating cut. A hydraulic actuator, connected to the puller screw, applies force to extract the piston barrel. A tube spacer ensures proper alignment, and manual tools assist in breaking the mushroomed ring for easy removal.