• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The present invention relates to an installation tool for assembling a main rotor shaft unit and an assembly method thereof. The installation tool comprises a first element for supporting the generator end of the rotor shaft and a rotatable support plate is coupled to a second element of the installation tool via engaging coupling elements. The rotor shaft is rotated by a single crane unit via lifting elements mounted to the generator end, and then lifted out of the installation tool and placed on a floor. The bearing units are then mounted to the outer surface of the rotor shaft. The rotor shaft is after wards lifted onto the installation tool so that the coupling element is brought into engagement and the rotor shaft is rotated on to the first element. This provides an installation tool that eliminates the need for two crane units to rotate the rotor shaft and reduces the amount of man-hours needed to assemble the rotor shaft unit by up to six hours. The installation tool also provides a stable tool for the workers since the center of gravity is located between the first element and the rotation point.
    公开号:DK201370334A1
    申请号:DK201370334
    申请日:2013-06-19
    公开日:2015-01-12
    发明作者:Jan Westergaard
    申请人:Envision Energy Denmark Aps；
    IPC主号:
    专利说明:

    Assembly method for a main rotor shaft and an installation tool thereto Field of the Invention
    The present invention relates to an installation tool for assembling a rotor shaft unit for a wind turbine comprising: - a support frame comprising at least a first element and a second element which are configured to receive and hold a main rotor shaft of a wind turbine, Where the rotor shaft has a generator end and a rotor end, - the first element is positioned towards the generator end of the rotor shaft when the rotor shaft is placed in the installation tool, and a first contact surface is arranged on the first element for contacting at least part of a first outer surface of the rotor shaft.
    The present invention also relates to a method for assembling a main rotor shaft unit of a wind turbine blade, the method comprising the steps of: - placing a main rotor shaft having a generator end and a rotor end on a first element and on a second element of an installation tool according to any one of claims 1 to 6 using lifting means, eg a crane unit; - coupling the generator end to the lifting means for rotating the rotor shaft relative to the rotor end, e.g. via lifting elements mounted to the generator end.
    Background of the Invention
    The size and weight of wind turbines and the blades thereof have increased which means that the size and structural strength of the rotor hub have increased, and the main rotor shaft and other components of the nacelle have to be sized according to the increased loads on the wind turbine. Today, the main rotor shaft forms a large and heavy structure as it has to transfer the rotational torque generated by the wind loads to the drivetrain in the nacelle, e.g. via a gearbox. This makes the rotor shaft difficult to handle during the assembly process and often requires the use of two cranes.
    The two main shaft bearings are normally mounted when the main rotor shaft is placed in a vertical position. The rotor shaft is normally rotated by attaching at least one strap to the generator end of the main shaft and at least one other strap to the rotor end when the shaft is resting on its support frame in a horizontal position. The straps are then coupled to guide wires in the cranes so that one crane guides the generator end while the other crane guides the rotor end. The main rotor shaft is then lifted and rotated into a substantially vertical position before being placed on the floor or on a platform. The main rotor bearings are then mounted by guiding them onto the shaft from the generator end. The use of two cranes means that the main rotor shaft cannot be rotated at a right angle relative to the floor, thereby creating a dangerous situation for the workers as the weight of the main rotor shaft will cause the shaft to sway as the rotor is end brought into contact with the surface of the floor. This also increases the risk of damaging the main rotor shaft as the end of the rotor is placed on its edge before the end surface is brought into contact with the floor. The use of two cranes presents a time consuming process which requires at least two workers to operate the cranes.
    This can be avoided by first lowering the shaft onto a set of support elements of wood. The straps on the rotor end are then removed and the shaft is lifted off the support elements which are then removed and the shaft is lowered onto the floor. However, these support elements can be accidentally pushed out or removed thereby causing the main rotor shaft to sway uncontrollably, or even tip over. The main rotor shaft may be placed in an area of loose gravel or the like. The small rocks may block the mounting holes in the rotor end and then have to be removed after assembly which in turn increases the assembly time.
    The main rotor bearings may also be installed when the main rotor shaft is positioned in a horizontal position. However, this is a much more complicated process which requires a more accurate guidance of the bearings, especially the main shaft bearing, when they are moved along the length of the shaft. This assembly method presents a significant problem as the main shaft bearing has to be guided past at least one of the contact surfaces of the support frame in order to be brought into position on the shaft.
    Object of the Invention
    An object of this invention is to provide an installation tool for a main rotor shaft which allows the rotor shaft to be rotated when inserted into the tool.
    An object of the invention is to provide an installation tool that increases the safety of the workers during assembly.
    An object of the invention is to provide an assembly method for a main rotor shaft unit which reduces the amount of man-hours needed in order to assemble the rotor shaft unit.
    Description of the Invention
    An object of the invention is achieved by an installation tool characterized in that: - the support frame comprises means for rotating the rotor shaft around at least one rotation point located on the second element from a first position to a second position in which the center axis of the rotor shaft extends in a perpendicular direction relative to the longitudinal direction of the support frame.
    This allows the main rotor shaft to be rotated when it is still inserted in the installation tool, thereby increasing the safety of the workers located around the main rotor shaft. The installation tool allows the main rotor shaft to be rotated by one worker operating the rotating means, thereby eliminating the need for two cranes and two workers in order to rotate the shaft. This in turn reduces the total assembly time of the rotor shaft unit, i.e. mounting the bearings and housings thereof onto the outer surface of the shaft.
    The support frame may in a simple structure comprise a base unit configured to be placed on a floor or another planar surface. The first element is coupled to the base unit and may be configured as an arm, e.g. a Y-shaped arm, extending outwards from the base unit. The free end of the arm may be configured as a recess having a contact surface shaped to follow at least a portion of the outer surface of the rotor shaft. The first element may instead be configured as a plate or another support structure where the recess is arranged at the free end facing the rotor shaft. The contact surface may be covered with a soft deformable material, such as plastic, a weaved fabric, or another padding, to protect the rotor shaft. The height and distance between the two elements may be adapted to the size and configuration of the rotor shaft.
    In one embodiment, a support plate configured to be mounted to the rotor end of the rotor shaft is rotatably coupled to the second element at the rotation point, while the support plate comprises a contact surface for contacting a third contact surface on the rotor end when the support plate is mounted to the rotor shaft.
    The support plate allows the main rotor shaft to be mounted or fixed to the installation tool so that it does not slide or turn relative to the support frame during rotation. This allows the rotor shaft to be rotated using a single lifting unit, such as an external crane unit or a lifting unit coupled to the support frame. The use of a rotatable support plate allows the rotor shaft to be rotated faster and safer than when using two cranes. This allows the assembly time to be reduced by up to six man-hours.
    The support plate may comprise one or more mounting holes for mounting the support plate to one or more mounting holes in the rotor end. Fastening means, such as bolts, nuts or screws, may be used to mount the support plate to the rotor end. The mounting holes on the support plate may be aligned with the primary mounting holes in the rotor end used to mount the rotor shaft to the rotor hub or may be aligned with one or more secondary mounting holes arranged in the rotor end. The size and configuration of the mounting surface may be adapted to the desired configuration of the rotor end of the rotor shaft.
    In one embodiment, the center of gravity of the support frame is located between the point of rotation and the first element when the rotor shaft is placed in the installation tool.
    This allows the installation tool to use its own weight to prevent it from tipping over since the center of gravity is located between the two support elements which hold the rotor shaft. This increases the safety of the workers and provides a stable tool for the workers since the rotor shaft does not have to be placed on a set of wooden support elements before being lifted onto the floor.
    In a special embodiment, the support plate is removably coupled to the second element via at least one first coupling element configured to engage at least a second coupling element located on the second element, while the first coupling element is configured to rotate relative to the second coupling element when the support plate is coupled to the second element.
    This allows the support plate to be mounted to the rotor at the start of the assembly process before the rotor shaft is lifted into position on the installation tool using a crane unit. The support plate may comprise at least one lifting element in the form of a hook or ring for lifting the support plate out of the support frame and into position relative to the rotor end of the rotor shaft. The lifting element may be arranged on one of the sides of the support plate. The lifting element is preferably located at a balance point on the support plate, e.g. a point above the center of gravity, so that the support plate hangs downwards from the crane wire in a more or less vertical position. This allows a quick and easy alignment of the support frame relative to the rotor end since the mounting holes in the support frame only have to be rotated to the nearest mating mounting holes if needed.
    In one embodiment, the second element comprises means for locking the rotor shaft relative to the second element when the rotor shaft is rotated around the rotation point.
    This allows the support plate to be secured to the second element so that the coupling elements do not accidentally disengage during rotation causing a dangerous situation for the workers. The locking means may be disengaged or removed when the support plate is lifted out of the second element and engaged or put in place when the support plate is lowered onto the second element again. The locking means may be configured as an electrically activated unit in which a sensor or detector senses / detects when the support plate is lifted out of the second element. The signal from the sensor / detector is then used to activate a mechanical moveable element, e.g. a pin, which prevents the two coupling elements from disengaging. In a simple embodiment, the locking means may be a removable pin or locking latch, e.g. comprising a through hole at the free end for receiving a locking split.
    The first element may comprise a movable sub-element, such as a clamping element, configured to be moved or rotated over the rotor shaft to lock the generator end to the first element. The sub-element may be locked to the arm by fastening means such as a bolt, nut, screw, clamp, or another suitable fastening means.
    The second element may be configured as two outwards extending support arms or plates where the support plate is arranged in between the two support arms. The coupling element may be located at the free end of the arms and may be configured as a recess, e.g. Y-shaped recess, or a through-hole for at least partially receiving a mating coupling element on the support plate. The coupling element may be arranged on at least one of the sides of the support plate and may be configured as an axis extending outwards from the side of the support plate. In one embodiment, the support element comprises two axes aligned with each other so that they form a rotation axis around which the rotor shaft is able to rotate.
    In one embodiment, at least one actuator is coupled to the support frame and comprises at least one movable element having a fourth contact surface for contacting at least a fifth contact surface of the rotor shaft, wherein the actuator is driven by a hydraulic, electrical or pneumatic drive unit.
    The rotor shaft may be rotated using one or more actuators in the form of movable pistons arranged on the support frame where the free end of the pistons may be configured to clamp or at least partially receive the rotor shaft. The piston may be coupled to an internal or external drive unit which uses an electrical current, a hydraulic fluid or compressed air to drive the piston. In one embodiment, a crane unit is used to rotate the rotor shaft where one or more lifting elements may be mounted to the generator end which is then coupled to the crane wire.
    An object of the invention is also achieved by an assembly method characterized in that: - the rotor end is coupled to a rotation point in the second element, and - the generator end is rotated around the rotation point from a first position to a second position in which the center axis of the rotor shaft extends in a direction perpendicular to the longitudinal direction of the support frame.
    This provides an assembly process which requires the use of two crane units to rotate the main rotor shaft during assembly. The installation tool allows a single worker to rotate the rotor shaft when it is placed in the tool which reduces the amount of manhours needed to assemble the rotor shaft unit with up to six hours. This also increases the safety of the worker since the center of gravity of the installation tool with the rotor shaft is located between the rotation point and the position of the first element. This provides a more stable tool during the rotation of the rotor shaft.
    When the rotor shaft is placed in the installation tool, one or more lifting elements are mounted to a corresponding number of mounting holes in the generator end. The crane unit is then coupled to a crane unit and the worker uses the crane unit to rotate the rotor shaft. The worker may instead couple the rotor shaft to an actuator in the installation tool and rotate the rotor shaft by extending the piston of the actuator.
    In one embodiment, a support plate is mounted to the rotor end of the rotor shaft, and the support plate is rotated around the rotation point.
    The rotor shaft may be mounted to a support plate in the installation tool so that it does not slide or turn relative to the installation tool during rotation. This increases the safety of the worker and allows for faster and easier rotation of the rotor shaft than if two crane units were used. The rotor shaft may be lifted into position on the installation tool by using two or more slings or wires coupled to the crane unit. The rotor end is then aligned with the mounting holes on the contact surface of the support element and mounted to the support element. The support plate is rotated relative to the second element via one or more engaging coupling elements on the support element and the second plate respectively.
    In a special embodiment, the support plate is removed from the installation tool and mounted to the rotor end before the rotor shaft is placed in the installation tool.
    The support plate may be mounted to the rotor end before the rotor shaft is placed in the installation tool. This may be done when the rotor shaft is still placed in the lathe or on a temporary support frame. The support frame may be lifted out of engagement with the second element using at least one lifting element located on the side of the support plate. The support plate is lifted into a balanced position which allows for a quicker mounting to the rotor than since the mounting holes of the support plate only have to be rotated to the nearest mounting hole on the rotor than if needed.
    The rotor shaft may then be lifted into position on the installation tool again by coupling the crane wire to one or more holes in the generator and rotor ends, e.g. via one or more hooks or carbine hooks. Alternatively, one or more slings or wires may be arranged around the rotor shaft and coupled to the crane wire.
    The rotor shaft is then placed in the installation tool so that the rotor shaft contacts the first element near the generator end and the coupling elements of the support plate are brought into engagement with the coupling elements on the second element. Locking means on the second element may be used to prevent the coupling elements from disengaging during rotation.
    In one embodiment, the rotor shaft is lifted out of the installation tool after being rotated and then placed on a surface, e.g. a floor, where the rotor shaft rests on top of the support plate.
    The installation tool allows the rotor shaft to be rotated and lifted onto the floor using the same crane unit. The rotor shaft is simply lifted out of the installation tool and placed on the floor. This significantly reduces the risk of damaging the rotor end when the rotor shaft is brought into contact with the floor since the crane unit may be aligned with the center axis of the rotor shaft. Furthermore, the support plate acts as a platform for the shaft during mounting of the bearing units and is able to absorb any impacts with the floor as the rotor shaft is lowered into position.
    This also eliminates the need for placing the rotor shaft on a set of wooden support element before lowering onto the floor since the support plate is mounted to the rotor end and is used as a platform for the rotor shaft.
    In one embodiment, one or more bearing units are guided into position on the rotor shaft from the generator end and mounted to the rotor shaft, after which the rotor shaft is placed in the installation tool again using the lifting means.
    Placing the rotor shaft in a vertical position allows a much easier assembly of the bearing units on the rotor shaft. The bearing units may be guided into position from the generator end by using their own weight to guide them into position. One or more sealing elements, e.g. a seal ring, may be mounted to the outer surface of the rotor shaft at a location near the rotor end. One or more bearings are then expanded by heating them and then guided into position on the sealing elements. The cooling of the bearings means that they will form a tight fit around the outer surface of the rotor shaft. The housing is then guided into position on the bearings and the housing may be sealed off. A second bearing unit may be mounted to the outer surface of the rotor shaft at a location near the generator end in a similar manner. The second bearing unit may instead be a rotor braking unit, e.g. a mechanical or electrical braking unit.
    After the bearing units have been mounted, the rotor shaft may then be placed in the installation tool again by coupling the crane unit to the lifting elements. The coupling elements of the support plate are brought into engagement with the mating coupling element on the second element. The rotor shaft is then rotated around the rotation point until the rotor shaft is brought into contact with the first element again. The crane unit and lifting element are then removed and the remaining components, such as one or more service platforms, service latters and other components are finally mounted to the rotor shaft unit.
    The installation tool may also be used to transport the rotor shaft unit to the installation site which eliminates the need for a transport frame. The rotor shaft may be secured to the first element also during transportation, e.g. by a clamping element or one or more transport straps. The rotor shaft may then be lifted up to the nacelle by coupling two or more slings or wires to the rotor shaft which in turn is coupled to a crane unit at the site. The crane wire may instead be coupled to both ends of the rotor shaft by coupling the crane wire to one or more holes in both ends of the rotor shaft, e.g. via one or more hooks or carbine hooks. One or more mounting flanges of the bearing housings of the rotor shaft unit are then positioned and mounted to mating mounting flanges in the nacelle, after which the support plate may be removed and lifted down onto the installation tool again.
    Description of the Drawing
    The invention is described by example only and with reference to the drawings, wherein:
    FIG. 1 shows an exemplary embodiment of a wind turbine;
    FIG. 2 shows an exemplary embodiment of an installation tool according to the invention;
    FIG. 3 shows an enlarged image of the rotating coupling between the second element and the support plate;
    FIG. 4 shows an exemplary embodiment of a lifting element of the support plate;
    FIG. 5 shows a first step of an assembly method according to the invention;
    FIG. 6 shows a second step of an assembly method according to the invention;
    FIG. 7 shows a third step of an assembly method according to the invention;
    FIG. 8 shows a fourth step of an assembly method according to the invention; spirit
    FIG. 9 shows a fourth step of an assembly method according to the invention.
    In the following text, the figures will be described one by one and the different parts and positions seen in the figures will be numbered with the same numbers in the different figures. Not all parts and positions indicated in a specific figure will necessarily be discussed together with that figure.
    Detailed Description of the Invention Reference list 1 Wind turbine 2 Wind turbine tower 3 Nacelle 4, 5 Tower sections 6 Rotor hub 7 Wind turbine blade 8 Foundation 9 Ground level 10 Blade root 11 Tip end 12 Installation tool 13 Support frame 14 Main rotor shaft 15 Base unit 16 First element 17 Contact surface on first element 18 Contact surface on rotor shaft 19 Second element 20, 21 Support arms 22 Support plate 23 Rotating coupling 23a, 23b Coupling elements 24 First contact surface on support plate 25 Contact surface on rotor shaft 26 Mounting holes on support plate 27 Mounting holes on rotor shaft 28 Second contact surface on support plate 29 Free end of support arm 30, 31 Side surfaces on support plate 32 Contact surface on first coupling element 33 Contact surface on second coupling element 34 Flange 35 Removable pin 36 Through-hole 37 Through-hole 38 Lifting element 39 Side surface on support plate 40 Crane unit 41 Crane wire 42 Generator end 43 Rotor end 44 Outer surface of ro tor shaft 45 Contact surface on rotor shaft 46 First bearing unit 47 Contact surface on rotor shaft 48 Second bearing unit 49 Primary mounting holes 50, 51 Holes 52 Lifting element 53 Straps, slings 54 Service laughter 55 Service platform 56 Mounting flanges
    FIG. 1 shows an exemplary embodiment of a wind turbine 1 with a wind turbine tower 2 and a nacelle 3 mounted on top of the wind turbine tower 2. The wind turbine tower 2 may comprise two or more tower sections 4, 5 mounted on top of each other. A rotatable rotor hub 6 may be mounted to the nacelle 3 via a rotor shaft (not shown). Two or more wind turbine blades 7 may be mounted to the rotor hub 6 extending outwards from the center of the rotor hub 6. The wind turbine blades 7 may be coupled to the rotor hub 6 via at least one pitch system (not shown) configured to pitch the blade 7 or a section thereof into a pitch angle relative to the length of the blade 7. The wind turbine tower 2 may be mounted onto a foundation 8 extending above a ground level 9.
    The wind turbine blade 7 may comprise a blade root 10 configured to be mounted to the rotor hub 6 and a tip end 11 arranged at the free end of the blade 7. The wind turbine blade 7 may have an aerodynamic profile along the length of the blade 7.
    FIG. 2 shows an exemplary embodiment of an installation tool 12 according to the invention. The installation tool 12 may comprise a support frame 13 configured to receive and hold a main rotor shaft 14 which is designed and configured to be installed in the wind turbine 1. The support frame 13 may comprise a base unit 15 configured to be placed on a floor or another planar surface such as a platform. The base unit 15 may comprise a contact surface for contacting a contact surface on the floor.
    At least one first element 16 may be coupled to the base unit 15 and extend outwards from the base unit 15, e.g. in a direction perpendicular to the longitudinal direction of the base unit 15. The first element 16 may be configured as an arm having a free end facing away from the base unit 15. The first element 16 may comprise a contact surface 17 located at the free end for contacting at last part of a contact surface 18 on the rotor shaft 14. The free end of the arm 16 may form a recess in which the rotor shaft 14 may be placed.
    At least one second element 19 may be coupled to the base unit 15 and extend outwards from the base unit 15, e.g. in a direction perpendicular to the longitudinal direction of the base unit 15. The second element 19 may be arranged on the base unit 15 at the opposite end of the first element 16, as shown in fig. 2. The second element 19 may be configured as two support arms 20, 21 extending outwards from the base unit 15, e.g. in a direction perpendicular to the longitudinal direction of the base unit 15. The support arms 20, 21 may at their free end be configured to form a rotation point around which a rotatable support plate 22 may rotate. The height of each element 16, 19 and the distance between the two elements 16, 19 may be adapted to the size and configuration of the rotor shaft 14.
    The support plate 22 may be arranged between the support arms 20, 21 and may be coupled to each of the arms 20, 21 via a rotating coupling 23. The support plate 22 may be configured as a mounting plate for mounting to the rotor shaft 14 The support plate 22 may comprise a first contact surface 24 for contacting a contact surface 25 on the rotor shaft 14. The contact surface 25 may comprise one or more mounting holes 26 for mounting the support plate 22 to one or more mating mounting holes 27 on the rotor shaft 14 via fastening means, such as bolts, nuts, or screws. In one embodiment, at least three mounting holes 26 are arranged in the contact surface 25, eight holes are shown in fig. 2. A second contact surface 28 may be arranged on the opposite side of the support plate 22 for contacting the surface of the floor. The size and configuration of the support plate 22 and the contact surface 25 may be adapted to the desired configuration of the rotor shaft 14.
    FIG. 3 shows an enlarged image of the rotating coupling 23 shown in fig. 2. The support plate 22 may be removably coupled to each of the two second elements 19 via a first coupling element 23a configured to engage a second coupling element 23b. The first coupling element 23a may be located at the free end 29 of the support arm 20, 21 and a second coupling element 23b may be located on a side surface 30, 31 on the support plate 22. The first coupling element 23a may be configured configured to receive and hold the second coupling element 23b as a recess. The second coupling element 23b may be configured as an axis extending outwards from the side surface 30, 31. The first coupling element 23a may comprise a contact surface 32 shaped to follow at least a portion of a contact surface 33 on the second coupling element 23b . The coupling elements 23a, 23b may be aligned with each other so that they form a common rotation axis around which the support plate 22 may rotate.
    The first coupling element 23a may comprise at least one outward extending flange 34, two flanges are shown in FIG. 3, for guiding the second coupling element 23b into position. The flanges 34 may be placed at an angle, e.g. an acute angle relative to the rotation point or to each other. The flanges 34 may be placed at an angle between 0 degrees and 90 degrees relative to each other, as shown in fig. 3. This allows the support plate 22 to be guided into position on the second support element 19.
    Locking means in the form of a removable pin 35, e.g. a locking pin, may be arranged at the free ends of the flanges 34. Both flanges 33 may comprise a through-hole 36 for receiving the pin 35. The pin 35 may comprise a through-hole 37 for receiving a removable locking split (not shown). The locking split may be coupled to or form part of pin 35. This allows the support plate 22 to be secured to the second element 19 during rotation.
    FIG. 4 shows an exemplary embodiment of a lifting element 38 coupled to the support plate 22. The lifting element 38 may be arranged on a third side surface 39, e.g. on a flange 39a, on the support plate 22. The lifting element 38 may be configured as a ring for lifting the support plate 22 in and out of engagement with the second element 19 via a crane unit 40. The lifting element 38 may be located at a balance point of the support plate 22, eg a point above the center of gravity, so that it hangs downwards from a crane wire 41 in a more or less vertical position.
    FIG. 5 shows a first step of an assembly method for assembling a rotor shaft unit according to the invention. The rotor shaft 14 may comprise a generator end 42 connected to a rotor end 43 via at least one outer surface 44. The rotor shaft 14 may comprise a first contact surface 45 for contacting a first bearing unit 46 and a second contact surface 47 for contacting. a second bearing unit 48.
    Before the rotor shaft 14 may be placed in the support frame 13 of the installation tool 12, the crane wire 41 may be coupled to the lifting element 38 and the support plate 22 may be lifted out of engagement with the second element 19. The support plate 22 may then be positioned relative to the rotor shaft 14 so that the contact surface 24 on the support plate 22 may be aligned with the contact surface 25 of the rotor end 43. The support plate 22 may then be mounted to the rotor end 43 via the mounting holes 26, 27. The mounting holes 27 may be arranged between the primary mounting holes 49 of the rotor end 43 or offset relative to the primary mounting holes 49, as shown in FIG. 5th
    The rotor shaft 14 may then be lifted into position on the installation tool 12 by coupling the crane wire 41 to one or more holes 50, 51 in the generator and rotor ends 42, 43, e.g. via one or more hooks or carbine hooks. The contact surface 18 may be located towards the generator end 42, as shown in fig. 5, e.g. between the generator end 42 and the second contact surface 47. The rotor shaft 14 may be lowered into position so that the rotor shaft 14 contacts the first element 16 and the coupling elements 23b of the support plate 22 is brought into engagement with the coupling elements 23a on the second element 19.
    FIG. 6 shows a second step of the assembly method where the rotor shaft 14 is rotated into a second position relative to the support frame 13.
    Before rotating the rotor shaft 14, one or more removable lifting elements 52 may be mounted to one or more of the holes 51, e.g. mounting holes, in the generator end 42. Three lifting elements 52 may be mounted to the generator end 42, as shown in fig. 6. The lifting elements 52 may comprise an eye to which the crane wire 41 may be coupled, e.g. via one or more straps or slings 53. The support plate 22 may be secured to the second element 19 by locking the pin 35 in place on the flanges 33. The crane unit 40 may then be used to rotate the rotor shaft 14 and the support plate 22 around the rotation point from a first position, as shown in fig. 5, to the second position, as shown in fig. 6, in which the center axis of the rotor shaft 14 may extend in a direction perpendicular to the longitudinal direction of the support frame 13.
    The installation tool 12 may be configured such that the center of gravity of the support frame 13 and the rotor shaft 14 during rotation may be continuously located between the rotation point defined by the coupling 23 and the contact surface 17 of the first element 16, as indicated in fig. 6. This provides a sable installation tool 12 and increases the safety of the worker rotating the rotor shaft 14 via the crane unit 40.
    FIG. 7 shows a third step of the assembly method where the rotor shaft 14 is placed on a floor or another planar surface (not shown).
    After the rotor shaft 14 has been rotated, the rotor shaft 14 may be lifted so that the coupling elements 23b on the support plate 22 are brought out of engagement with the coupling elements 23a on the second element 19. The locking pin 35 may be removed from the flanges 33 before lifting the rotor shaft 14. The rotor shaft 14 may then be placed on the floor so that the contact surface 28 is brought into contact with the surface of the floor. The crane unit 40 may then be decoupled from the lifting elements 52. This allows the rotor shaft 14 to rest on the support plate 22.
    Then, a first bearing unit 46 may be mounted to the contact surface 45 located near the rotor end 43 of the rotor shaft 14. The bearing unit 46 may comprise a housing in which one or more different components may be arranged, such as one or two inner sealing elements, one or two bearings (SRBs, TRBs or CRBs), one or two outer sealing elements, or other relevant components. The bearings and / or sealing elements may be heated to a predetermined temperature before being lowered onto the rotor shaft 14 through the generator end 42 and into position using the crane unit 40. The components of the bearing unit 46 and the mounting of these are known and will not be described in further details.
    FIG. 8 shows a fourth step of the assembly method where a second bearing unit 48 is mounted on the rotor shaft 14.
    Then, a second bearing unit 48 may be mounted to the contact surface 47 located near the generator end 42 of the rotor shaft 14. The bearing unit 48 may comprise a housing in which one or more different components may be arranged, such as one or two inner sealing elements, one or two bearings (SRBs, TRBs or CRBs), one or two outer sealing elements, or other relevant components. The bearings and / or sealing elements may be heated to a predetermined temperature before being lowered onto the rotor shaft 14 through the generator end 42 and into position using the crane unit 40. The components of the bearing unit 48 and the mounting of these are known and will not be described in further details.
    FIG. 9 shows a fourth step of the assembly method where the rotor shaft unit is placed on the support frame 13 of the installation tool 12.
    After the bearing units 46, 48 have been mounted, the rotor shaft unit may then be lifted onto the installation tool 12 for final assembly. The crane unit 40 may be coupled to the lifting elements 52 again, e.g. via one or more straps or slings. The rotor shaft unit may then be lifted and positioned relative to the second element 19 using the crane unit 40. The rotor shaft unit may be lowered into position so that the coupling elements 23a, 23b are brought into engagement again. The locking pin 35 may then be mounted to the flanges 34 and the rotor shaft unit may be rotated in a reverse direction relative to the rotation point. Finally, the crane unit 40 may be decoupled from the lifting element 52 after the rotor shaft 14 is brought into contact with the first element 16. The lifting element 52 may also be dismounted.
    The remaining components of the rotor shaft unit may then be mounted to the rotor shaft 14 and the bearing units 46, 48. One or more service latters 54, service platforms 55 and other items may be mounted to complete the rotor shaft assembly.
    In one embodiment, the rotor shaft 14 may be firmly coupled to the first element 16 for transporting the assembled rotor shaft unit. At the installation site, the fastening means at the first element 16 and the locking pin 35 may be removed and the rotor shaft unit may then be lifted into position in the nacelle 3 using another crane unit. The generator and rotor ends 42, 43 may be coupled to the nacelle by bringing the mounting flanges 56 into contact with mating mounting flanges located inside the nacelle 3. The support plate 22 may then be dismounted and lowered into position on the installation tool 12 again .
    权利要求:
    Claims (11)
    [1] 1. An installation tool for assembling a rotor shaft unit for a wind turbine comprising: - a support frame (13) comprising at least a first element (16) and a second element (19) which are configured to receive and hold a main rotor shaft (14) of a wind turbine (1), wherein the rotor shaft (14) has a generator end (42) and a rotor end (43), - wherein the first element (16) is positioned towards the generator end (42) of the rotor shaft (14) when the rotor shaft (14) is placed in the installation tool (12), and a first contact surface (17) is arranged on the first element (16) for contacting at least a part of a first outer surface (18) on the rotor shaft, characterised in that - the support frame (13) comprises means for rotating the rotor shaft (14) around at least one rotation point located on the second element (19) from a first position to a second position in which the centre axis of the rotor shaft (14) extends in a perpendicular direction relative to the longitudinal direction of the support frame (13).
    [2] 2. An installation tool according to claim 1, wherein a support plate (22) configured to be mounted to the rotor end (43) of the rotor shaft (43) is rotatable coupled to the second element (19) at the rotation point, wherein the support plate (22) comprises a contact surface (24) for contacting a third contact surface (25) on the rotor end (43) when the support plate (22) is mounted to the rotor shaft (14).
    [3] 3. An installation tool according to claim 1 or 2, wherein the centre of gravity of the support frame (13) is located between the rotation point and the first element (16) when the rotor shaft (14) is placed in the installation tool (12).
    [4] 4. An installation tool according to claim 2 or 3, wherein the support plate (22) is removable coupled to the second element (19) via at least a first coupling element (23b) located on the support plate (22) configured to engage at least a second coupling element (23a) located on the second element (19), wherein the first coupling element (23b) is configured to rotate relative to the second coupling element (23a) when the support plate (22) is coupled to the second element (19).
    [5] 5. An installation tool according to any one of claims 1 to 4, wherein the second element (19) comprises means (35) for locking the rotor shaft (14) relative to the second element (19) when the rotor shaft (14) is rotated around the rotation point.
    [6] 6. An installation tool according to any one of claims 1 to 5, wherein at least one actuator is coupled to the support frame (13) and comprises at least one moveable element having a fourth contact surface for contacting at least partly a fifth contact surface of the rotor shaft (14), wherein the actuator is driven by a hydraulic, electrical or pneumatic drive unit.
    [7] 7. A method for assembling a main rotor shaft unit of a wind turbine blade, wherein the method comprising the steps of: - placing a main rotor shaft (14) having a generator end (42) and a rotor end (43) on a first element (16) and on a second element (19) of an installation tool (12) according to any one of claims 1 to 6 using lifting means (40), e.g. a crane unit; - coupling the generator end (42) to the lifting means (40) for rotating the rotor shaft (14) relative to the rotor end (43), e.g. via lifting elements (52) mounted to the generator end (42) characterised in that - the rotor end (43) is coupled to a rotation point in the second element (19), and - the generator end (42) is rotated around the rotation point from a first position to a second position in which the centre axis of the rotor shaft (14) extends in a direction perpendicular to the longitudinal direction of the support frame (13).
    [8] 8. A method according to claim 7, wherein a support plate (22) is mounted to the rotor end (43) of the rotor shaft (14), and wherein the support plate (22) is rotated around the rotation point.
    [9] 9. A method according to claim 8, wherein the support plate (22) is removed from the installation tool (12) and mounted to the rotor end (43) before the rotor shaft (14) is placed in the installation tool (12).
    [10] 10. A method according to any one of claims 7 to 9, wherein the rotor shaft (14) is lifted out on the installation tool (12) after being rotated, and then placed on a surface, e.g. a floor, where the rotor shaft (14) rests on top of the support plate (22).
    [11] 11. A method according to any one of claims 7 to 10, wherein one or more bearing units (46, 48) are guided into position on the rotor shaft (14) from the generator end (42) and mounted to the rotor shaft (14), after which the rotor shaft (14) is placed in the installation tool (12) again using the lifting means (40).
    类似技术:
    公开号 | 公开日 | 专利标题
    US9624902B2|2017-04-18|Assembly method for a main rotor shaft and an installation tool thereto
    EP2370692B1|2014-01-29|Method for installing a wind turbine, a nacelle for a wind turbine, and method for transporting elements of a wind turbine
    US8764082B2|2014-07-01|Arrangement for lifting a tower wall portion of a wind turbine and method for lifting a tower wall portion of a wind turbine
    EP2604850B1|2015-09-16|Lifting bracket
    US10161388B2|2018-12-25|Wind turbine blade lifting device and a method for lifting a wind turbine blade
    US9546573B2|2017-01-17|Method and equipment for turning a blade or a blade part for a wind turbine during production or installation
    CN102187090A|2011-09-14|A service crane for a wind turbine
    US20170067447A1|2017-03-09|Wind Turbine Blade Removal and Installation System and Method
    WO2011095167A2|2011-08-11|A method for lifting and lowering of a wind turbine blade
    US20190271298A1|2019-09-05|Rotor blade assembly
    US20140034418A1|2014-02-06|Repair/cleaning scaffolding tower for wind turbines
    DK178949B1|2017-06-26|Moment bearing test device for testing a moment bearing of a wind turbine and a method thereof
    CN106812670B|2018-12-14|The construction method for hanging of large-scale wind electricity equipment under Mountain Conditions
    US10968893B2|2021-04-06|Wind turbine comprising a parking structure for carrying the rotor during removal of the nacelle
    US11125214B2|2021-09-21|Method for anchoring a holding means in a wind turbine and adapter
    EP3034860A1|2016-06-22|Tool assembly and method for lifting wind turbine parts
    US11231017B2|2022-01-25|System and method for the service and exchange of a yaw bearing for a machine head of a wind turbine
    JP2021143599A|2021-09-24|Tower member building-up method and lifting-up tool used for tower member building-up method
    US20210299820A1|2021-09-30|Clamping of components, particularly wind turbine blade tips
    DK201070309A|2011-07-01|A wind turbine
    WO2010083837A2|2010-07-29|A gripping apparatus for handling and/or servicing components of a wind turbine, and a method and a wind turbine tower therefore
    同族专利:
    公开号 | 公开日
    EP2816224B1|2015-12-23|
    ES2565160T3|2016-03-31|
    US9624902B2|2017-04-18|
    EP2816224A1|2014-12-24|
    US20140373353A1|2014-12-25|
    DK177934B9|2015-01-19|
    CN104234931B|2017-01-11|
    DK177934B1|2015-01-12|
    CN104234931A|2014-12-24|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    EP1617075A1|2004-07-13|2006-01-18|Eickhoff Machinenfabrik GmbH|Method and apparatus for changing a gearbox of a wind turbine|
    EP2495433A1|2011-03-02|2012-09-05|Alstom Wind, S.L.U.|Wind turbine, lifting tool and method for lifting a gearbox torque arm|
    DE102011013844A1|2011-03-14|2012-09-20|Repower Systems Ag|Caddy for the drive train of a wind turbine|
    US20010038207A1|2000-05-02|2001-11-08|Willis Jeffrey O.|Method and means for mounting a wind turbine on a tower|
    JP3784668B2|2001-07-13|2006-06-14|株式会社日立ビルシステム|Fitting method and assembling method of heavy machine object and assembling work apparatus used in the assembling method|
    CN101903651B|2007-12-21|2012-11-21|维斯塔斯风力系统有限公司|A drive train for a wind turbine|
    DE102010009050B4|2010-02-23|2012-03-08|Emb Systems Ag|Positioning device for a wind turbine and wind turbine|
    DE102010016840A1|2010-05-06|2011-11-10|Eickhoff Antriebstechnik Gmbh|Assembly device for wind power plant, has section unit coupled with linear guide, where section unit is composed of set of individual sections, where one individual section is guided along linear guide relative to another individual section|
    DK2434141T3|2010-09-24|2016-02-01|Siemens Ag|A device for handling a wind turbine component|
    CN102011712A|2010-12-07|2011-04-13|沈阳远大机电装备有限公司|Flexible connection transmission mechanism of wind generating set|
    WO2014002297A1|2012-06-29|2014-01-03|三菱重工業株式会社|Method for assembling shafting of regenerated energy power generation device, and tool for assembling shafting|
    US9097237B2|2013-03-14|2015-08-04|Broadwind Energy, Inc.|Tools and methods for uptower maintenance|US9228451B2|2011-05-03|2016-01-05|Pratt & Whitney Canada Corp.|Gas turbine engine module adapter to a carrier|
    CN105705452B|2013-09-03|2017-07-25|维斯塔斯风力系统有限公司|Method for the swinging mounting and rotation rotor hub of the rotor hub of wind turbine|
    DK179522B1|2017-02-20|2019-02-06|Envision EnergyAps|Method and tool for blade replacement and installation|
    US10352305B2|2017-04-27|2019-07-16|General Electric Company|System and method for removing or installing a main shaft of a wind turbine with a push/pull system configured at an end of the main shaft|
    US10436180B2|2017-04-27|2019-10-08|General Electric Company|Apparatus and method for removing or installing a bearing unit in a wind turbine bedplate with an adjustable bearing support|
    US10422322B2|2017-04-27|2019-09-24|General Electric Company|System and method for removing or installing a main shaft of a wind turbine with main shaft support elements|
    US10337503B2|2017-04-27|2019-07-02|General Electric Company|System and method for removing or installing a main shaft of a wind turbine with rigging|
    CN107855807A|2017-11-30|2018-03-30|中信戴卡股份有限公司|A kind of stationary fixture for aluminum-alloy wheel processing|
    CN108087204B|2017-12-08|2020-05-12|北京金风科创风电设备有限公司|Hoisting alignment system and method for wind generating set|
    CN112810527A|2020-12-30|2021-05-18|三一重能股份有限公司|Wind generating set wheel hub carrying frock and carrying system|
    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    DK201370334A|DK177934B9|2013-06-19|2013-06-19|Assembly method for a main rotor shaft and an installation tool thereto|
    DK201370334|2013-06-19|DK201370334A| DK177934B9|2013-06-19|2013-06-19|Assembly method for a main rotor shaft and an installation tool thereto|
    CN201410149250.1A| CN104234931B|2013-06-19|2014-04-14|Assembly method for a main rotor shaft and an installation tool thereto|
    EP14164864.2A| EP2816224B1|2013-06-19|2014-04-16|Assembly method for a main rotor shaft and an installation tool thereto|
    ES14164864.2T| ES2565160T3|2013-06-19|2014-04-16|Mounting method for a main rotor shaft and corresponding installation tool|
    US14/305,678| US9624902B2|2013-06-19|2014-06-16|Assembly method for a main rotor shaft and an installation tool thereto|
    [返回顶部]