Wind turbine with a transportation system for moving drive train components

Abstract

A wind turbine (1) comprising a tower (2) and one or more nacelles (3) mounted on the tower (2) is disclosed, at least one of the nacelle(s) (3) housing one or more drive train components (9,10,11) and a transportation system for moving drive train components (9,10,11) of the wind turbine (1). The transportation system comprises one or more sliding rails (15) configured to carry a drive train component (9, 10,11) during movement, and one or more sledges (19). Each sledge (19) is movably connected to a sliding rail (15), and configured to be attached to a drive train component (9,10,11), thereby allowing the drive train component (9,10,11) to move along the sliding rail(s) (15). Each sliding rail (15) comprises two or more rail modules (6,13,14) being detachably connected to each other along a direction of movement defined by the sliding rail (15).

Claims

1. A wind turbine, comprising: a tower, at least one nacelle mounted on the tower and housing a plurality of drive train components, and a transportation system for moving at least one drive train component of the plurality of drive train components of the wind turbine, the transportation system comprising: at least one sliding rail configured to carry the at least one drive train component during movement, and at least one sledge connected to the at least one sliding rail and being configured to be attached to the at least one drive train component, thereby allowing the at least one drive train component to move along the at least one sliding rail, wherein the at least one sliding rail comprises two or more rail modules being detachably connected to each other along a longitudinal direction of the at least one sliding rail, and wherein one of the two or more rail modules of the at least one sliding rail is attached directly to one of the plurality of drive train components.

2. The wind turbine according to claim 1, further comprising a support structure arranged to support the at least one sliding rail at one end, the support structure being arranged between the at least one sliding rail and a load carrying structure of the nacelle.

3. The wind turbine according to claim 1, further comprising an adjustment mechanism for adjusting an inclination of the at least one sliding rail relative to the nacelle.

4. The wind turbine according to claim 1, wherein the at least one sliding rail extends along a direction which is substantially parallel to a direction defined by a main shaft of the wind turbine.

5. The wind turbine according to claim 1, wherein the at least one sliding rail comprises at least two sliding rails extending below a centre of gravity of the plurality of drive train components.

6. The wind turbine according to claim 1, wherein the at least one sledge comprises: a guiding part comprising a guiding track, the guiding part being configured to be mounted movably on the at least one sliding rail, and a mating part comprising a protruding part being arranged in engagement with the guiding track of the guiding part, the mating part being configured to be attached to the at least one drive train component, wherein relative movement between the guiding part and the mating part of the at least one sledge causes a change in orientation of the at least one drive train component having the at least one sledge attached thereto, relative to the at least one sliding rail, due to the protruding part of the mating part moving along the guiding track of the guiding part.

7. The wind turbine according to claim 1, wherein one of the plurality of drive train components is provided with at least one interface portion configured to have one of the two or more rail modules attached thereto.

8. The wind turbine according to claim 1, wherein the at least one sliding rail is configured to support the at least one drive train component during movement.

9. A transportation system for use in a wind turbine, the wind turbine comprising a tower, and at least one nacelle mounted on the tower and housing a plurality of drive train components, the transportation system for moving at least one drive train component of the plurality of drive train components and comprising: at least one sliding rail configured to carry the at least one drive train component during movement, and at least one sledge connected to the at least one sliding rail and being configured to be attached to the at least one drive train component, thereby allowing the at least one drive train component to move along the at least one sliding rail, wherein the at least one sliding rail comprises two or more rail modules being detachably connected to each other along a longitudinal direction of the at least one sliding rail, and wherein one of the two or more rail modules of the at least one sliding rail is attached directly to one of the plurality of drive train components.

10. A method for unmounting a drive train component of a wind turbine, the wind turbine comprising a tower and at least one nacelle mounted on the tower and housing a plurality of drive train components, the method comprising the steps of: mounting a first rail module of at least one sliding rail on a first drive train component of the plurality of drive train components, attaching at least a second rail module to the first rail module, thereby forming the at least one sliding rail, movably mounting at least one sledge on the at least one sliding rail, attaching the at least one sledge to a second drive train component of the plurality of drive train components to be unmounted, detaching the second drive train component to be unmounted from one of the plurality of drive train components, and moving the second drive train component to be unmounted along the at least one sliding rail by means of the at least one sledge.

11. The method according to claim 10, further comprising the step of adjusting an inclination of the at least one sliding rail, prior to moving the second drive train component to be unmounted.

12. The method according to claim 10, further comprising the step of dismantling the at least one sliding rail when moving of the second drive train component to be unmounted has been completed.

13. A method for mounting a drive train component in a wind turbine, the wind turbine comprising a tower and at least one nacelle mounted on the tower and housing a plurality of drive train components, the method comprising the steps of: mounting a first rail module of at least one sliding rail on a first drive train component of the plurality of drive train components, attaching at least a second rail module to the first rail module, thereby forming the at least one sliding rail, movably mounting at least one sledge on the at least one sliding rail, attaching the at least one sledge to a second drive train component of the plurality of drive train components to be mounted, moving the second drive train component to be mounted along the at least one sliding rail by means of the at least one sledge, and attaching the second drive train component to be mounted to one of the plurality of drive train components.

14. The method according to claim 13, further comprising the step of adjusting an orientation of the second drive train component to be mounted relative to a main shaft of the wind turbine prior to attaching the second drive train component to be mounted to the one of the plurality of drive train components.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be described in further detail with reference to the accompanying drawings in which

(2) FIGS. 1-29 illustrate a wind turbine and a method according to an embodiment of the invention, and

(3) FIGS. 30-32 illustrate a sledge for use in a wind turbine according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

(4) FIG. 1 is a perspective view of a single rotor wind turbine 1 according to an embodiment of the invention. The wind turbine 1 comprises a tower 2 and a nacelle 3 mounted on the tower 2. The wind turbine 1 further comprises a rotor 4 carrying three wind turbine blades 5. In FIG. 1 a rail module 6 is in the process of being hoisted towards the nacelle 3 in order to allow the rail module 6 to pass through a hatch 7 formed in a lower part of the nacelle 3. The rail module 6 may, e.g., be hoisted by means of an onboard crane (not visible) arranged in the nacelle 3.

(5) In FIG. 2 the rail module 6 has been hoisted to the nacelle 3, and is now being handled inside the nacelle 3 by means of an onboard crane 8. In particular, the rail module 6 is being moved along a drive train comprising a number of drive train components in the form of a main bearing housing 9, a gearbox 10 and a generator 11. The main bearing housing 9 houses a main bearing which rotatably supports the main shaft of the wind turbine, and the main shaft. The gearbox 10 houses a gear system.

(6) The main bearing housing 9 is provided with interface portions 12 configured to have a rail module 6 attached thereto. This allows the rail module 6 to be mounted on the main bearing housing 9 accurately at a desired position and with a desired orientation or inclination with respect to the main bearing housing 9. Furthermore, it allows easy attachment of the rail module 6 to the main bearing housing 9.

(7) It should be noted that the gearbox 10 and/or the generator 11 could be provided with similar interface portions, thereby allowing a rail module 6 to be attached to the gearbox 10 or to the generator 11. It is further noted that the interface portions 12 may also be used for attaching a sledge to one of the drive train components 9, 10, 11 in order to move the drive train component 9, 10, 11. This will be described in further detail below. In this case it is only necessary to provide a given drive train component 9, 10, 11 with a single kind of interface portion 12 in order to allow easy attachment of a rail module 6 as well as easy attachment of a sledge to the drive train component 9, 10, 11.

(8) In FIG. 3 the rail module 6 has been bolted to the main bearing housing 9 at the interface portions 12. It can be seen that the orientation or inclination of the rail module 6 is determined by the position and design of the interface portions 12. It can also be seen that the orientation or inclination of the rail module 6 is such that it extends along a direction which is substantially parallel to a longitudinal direction of the drive train, i.e. parallel to a direction defined by the main shaft of the wind turbine.

(9) In FIG. 4 a second rail module 13 has been hoisted into the nacelle 3 and attached to an end part of the first rail module 6, which is illustrated in FIG. 3. Accordingly, the second rail module 13 is arranged in continuation of the first rail module 6, and the rail modules 6, 13 extend along the same direction.

(10) The second rail module 13 is only attached to the first rail module 6, i.e. the second rail module 13 is not attached to the gearbox 10 or the generator 11. Thereby it is possible for the gearbox 10 and the generator 11 to move relative to the rail modules 6, 13. This will be described in further detail below.

(11) In FIG. 5 a third rail module 14 has been hoisted into the nacelle 3 and attached to an end part of the second rail module 13, in a similar manner as the second rail module 13 is attached to the first rail module 6. The three rail modules 6, 13, 14 thereby form a modular sliding rail 15 extending along a direction which is defined by the main shaft of the wind turbine.

(12) It is an advantage that the sliding rail 15 is modular, because this allows the rail modules 6, 13, 14 to be provided and handled separately, and assembled to form the sliding rail 15 inside the nacelle 3. For instance, it is thereby possible to pass the rail modules 6, 13, 14 through the service hatch 7 of the nacelle 3, and the rail modules 6, 13, 14 can be handled by the onboard crane 8. Yet, it is still possible to form long sliding rails 15 capable of handling large and heavy drive train components 9, 10, 11, in a manner which will be described below.

(13) In FIG. 6 it can be seen that a corresponding modular sliding rail 15 has been assembled on the opposite side of the drive train. Thereby the sliding rails 15 extend in parallel on opposite sides of the drive train components 9, 10, 11, and at a level which is below the centre of gravity of the drive train components 9, 10, 11. This allows the drive train components 9, 10, 11 to be supported by the sliding rails 15 from below.

(14) Furthermore, in FIG. 6 a support structure 16 has been arranged between a load carrying structure 17 of the nacelle 3 and end parts of the sliding rails 15 corresponding to free ends of the third rail modules 14. The support structure 16 ensures that the sliding rails 15 are supported on the load carrying structure 17 of the nacelle 3. Accordingly, the sliding rails 15 are each supported at one end by the connection between the first rail module 6 and the interface portion 12 of the main bearing housing 9, and at the opposite end by the support structure 16.

(15) In FIG. 7 the inclination of the sliding rails 15 is adjusted as indicated by arrows 18. This could, e.g., be in order to ensure that the sliding rails 15 are accurately aligned with the direction defined by the main shaft of the wind turbine. The adjustment of the inclination could, e.g., take place manually, such as by rotating a threaded rod engaging a mating inner thread. As an alternative, the adjustment mechanism may comprise hydraulic pistons, and the adjustment may be performed by operating the hydraulic pistons.

(16) In FIG. 8 a part of a sledge 19 has been mounted on one of the sliding rails 15. Arrow 20 indicates that the sledge 19 can move along the length of the sliding rail 15, and that the sledge 19 has been pushed onto the sliding rail 15 at its free end. The sledge 19 is provided with a holding part 57 being configured to hold a relative position between a guiding part and a mating part of the sledge 19.

(17) In FIG. 9 a guiding part 21 has been mounted on the sledge 19, the guiding part 21 being provided with a guiding track 22. The guiding track 22 is inclined with respect to the longitudinal direction of the sliding rail 15. This will be described in further detail below. The guiding part 21 can be moved with respect to the sledge 19 by means of piston 23.

(18) In FIG. 10 an additional sledge 19, including a guiding part 21, has been mounted movably on the sliding rail 15. Furthermore, two interface portions 24 have been attached to the generator 11, and the sledges 19 have been moved along the sliding rail 15 to positions corresponding to the positions of the interface portions 24.

(19) In FIG. 11 a mating part 25 has been mounted on each of the interface portions 24. Each mating part 25 is provided with a protruding part 26 which is arranged in engagement with the guiding track 22 of the guiding part 21 of one of the sledges 19. Since the mating parts 25 are attached to the interface portions 24 they are fixed relative to the generator 11.

(20) When the guiding part 21 of one of the sledges 19 is moved relative to the sledge 19, in particular relative to the holding part 57, by means of the piston 23, the guiding part 21 will also move relative to the corresponding mating part 25. This will cause a corresponding relative movement between the guiding track 22 and the protruding part 26 engaging the guiding track 22. This will cause the protruding part 26 to follow the path defined by the guiding track 22. Since the guiding track 22 is inclined relative to the longitudinal direction of the sliding rail 15, the movement of the protruding part 26 along the guiding track 22 differs from a linear movement along the sliding rail 15. Thereby the orientation of the generator 11 can be adjusted by performing relative movements between the guiding parts 21 and the sledges 19. The holding part 57 ensures that no relative movements between the guiding part 21 and the mating part 25 take place whenever such relative movements are not desired. Thereby it is ensured that a given relative position between the guiding part 21 and the mating part 25, and thereby a given orientation if the generator 11, can be maintained.

(21) If the guiding part 21 of one of the sledges 19 shown in FIG. 11 is moved, while the other one is not moved or is moved in an opposite direction, then the generator 11 will be tilted in such a manner that a rotational axis defined by the generator 11 is tilted relative to the direction defined by the main shaft of the wind turbine.

(22) If the guiding parts 21 of both of the sledges 19 shown in FIG. 11 are moved in the same direction while the guiding part 21 of one or more similar sledges arranged on the opposite sliding rail 15 (not visible in FIG. 11) is not moved or is moved in an opposite direction, then the generator 11 will be rotated about an axis defined by the main shaft of the wind turbine.

(23) If the guiding parts 21 of all of the sledges 19 are moved in the same direction, the generator 11 will be moved in a translational manner in an upwards or downwards direction.

(24) Accordingly, the generator 11, or one of the other drive train components 9, 10, can be adjusted with respect to six degrees of freedom by means of only three sledges 19, two of the sledges 19 being arranged on one side of the drive train component 9, 10, 11, as shown in FIG. 11, and the third being arranged on the opposite side of the drive train components 9, 10, 11. This is obtained in an easy and uncomplicated manner by means of the guiding tracks 22 and the protruding parts 26 arranged in engagement with the guiding tracks 22.

(25) FIG. 12 illustrates part of the floor 17 of the nacelle 3 being removed, as indicated by arrow 27. This is in order to allow drive train components 9, 10, 11 to pass through a lower part of the nacelle 3.

(26) In FIG. 13, two cable guiding structures 29 have been mounted on a load carrying frame 30 of the nacelle 3. Each cable guiding structure 29 is provided with three pulleys 31 arranged for receiving and guiding a cable.

(27) In FIG. 14, cables 32 have been mounted on the pulleys 31 of the cable guiding structures 29, and are lowered through the lower part of the nacelle 3. The cables 32 could, e.g., be in the form of tag lines. Furthermore, one end of each cable 32 may be connected to a hoisting mechanism, such as a winch.

(28) In FIG. 15 one of the cables 32 has been connected to a hoisting mechanism at one end and to an eyelet 33 formed on the cable guiding structure 29 at the other end. This allows the hoisting mechanism to hoist itself towards the nacelle 3. This will be described in further detail below.

(29) FIG. 16 illustrates a situation similar to the situation illustrated in FIG. 11. However, in FIG. 16 the generator 11 has been detached from the gearbox 10, and thereby from the rest of the drive train. Accordingly, the generator 11 is now carried by the sledges 19 and the sliding rail 15, and it is possible to move the generator 11 relative to the main bearing housing 9 and the gearbox 10, by means of the sledges 19.

(30) In FIG. 17 the generator 11 is in the process of being moved away from the main bearing housing 9 and the gearbox 10 as indicated by arrow 34. The generator 11 is moved along the sliding rails 15 due to the sledges 19 sliding along the sliding rails 15. Since the sliding rails 15 are essentially aligned with a direction defined by the main shaft of the wind turbine, the generator 11 is moved essentially along this direction.

(31) In FIG. 18 the movement of the generator 11 along the sliding rails 15 has been completed, and the generator 11 has thereby been moved to a position where it is free of the gearbox 10, i.e. it is no longer connected to the rest of the drive train. Furthermore, the cables 32 have been connected to the generator 11 via connecting parts 35. Thereby the generator 11 is connected to the hoisting mechanism, via the cables 32.

(32) In FIG. 19 the generator 11 has been lifted upwards, as indicated by arrow 36, by means of the hoisting mechanism and the cables 32. Thereby the protruding part 26 of the mating part 25 of each sledge 19 has been moved out of engagement with the guiding track 22 of the guiding part 21. Thus, the generator 11, with the mating parts 25 attached thereto, is now free to move relative to the guiding parts 21. Accordingly, the sledges 19, along with the guiding parts 21, have been moved along the sliding rails 15, away from the mating parts 25, as indicated by arrows 37.

(33) In FIG. 20 the mating parts 25 are in the process of being removed from the interface portions 24, as indicated by arrows 38. This will allow the generator 11 to pass the sliding rails 15 in a downwards direction.

(34) FIG. 21 is a perspective view of the wind turbine 1 which was also illustrated in FIG. 1. A container 39 accommodating a hoisting mechanism (not visible) is arranged on the ground next to the tower 2, i.e. at the base of the wind turbine 1. An anchoring point 40 is also provided on the ground in the vicinity of the wind turbine 1. A tag line 41 interconnects a cable 32, which is attached to the hoisting mechanism inside the container 39, and the anchoring point 40, via a connecting point in the nacelle 3. The tag line 41 could, e.g., have been lowered from the nacelle 3. The connecting point could, e.g., form part of a cable guiding structure as illustrated in FIGS. 13-20 and described above.

(35) Using the tag line 41, the cable 32 is hoisted towards the nacelle 3, as indicated by arrows 42. When the cable 32 has been hoisted to the nacelle 3, it may be attached to a cable guiding structure, as illustrated in FIG. 15 and described above. Thereby the hoisting mechanism accommodated in the container 39 is connected to the cable guiding structure, via the cable 32.

(36) FIG. 22 shows the container 39 where two cables 32 have been hoisted to the nacelle and a third cable 32 is in the process of being hoisted towards the nacelle. When hoisting of the third cable 32 has been completed, the container 39 will be connected to the nacelle via all three cables 32, and the container 39 is thereby ready to be hoisted towards the nacelle by means of the hoisting mechanism accommodated in the container 39.

(37) In FIG. 23 the container 39 is in the process of being hoisted towards the nacelle 3 by means of the hoisting mechanism accommodated in the container 39 and the cables 32. In order to control the movements of the container 39 during the hoisting, two tag lines 41 are provided which connect the container 39 to anchoring points 40 on the ground.

(38) The container 39 is hoisted towards the nacelle 3 in such a manner that mounting interfaces 43 formed on the container 39 are moved into contact with corresponding mounting interfaces 44 formed on the lower part of the nacelle 3. When the interfaces 43, 44 are moved into contact, a locking mechanism will lock the interfaces 43, 44 together, thereby attaching the container 39 to the lower part of the nacelle 3.

(39) In FIG. 24 the interfaces 43, 44 have been moved into engagement, and the container 39 is thereby attached securely to the lower part of the nacelle 3. Furthermore, the tag lines have been removed.

(40) In FIG. 25 a hatch 7 formed in the lower part of the nacelle 3 has been opened, and the generator 11 can be seen through the opening which is thereby formed in the lower part of the nacelle 3. As described above, the generator 11 has been detached from the drive train and is connected to the hoisting mechanism accommodated in the container 39 via the cables 32. Thereby the generator 11 can be lowered towards the ground by means of the hoisting mechanism accommodated in the container 39. When doing so, the container 39 will stem against the lower part of the nacelle 3, and the nacelle 3 thereby performs the function of a counterweight. Accordingly, a separate counterweight is not required in order to lower the generator 11 towards the ground. This is a great advantage, because the costs involved with replacing a heavy drive train component can thereby be reduced considerably.

(41) FIG. 26 illustrates the generator 11 being lowered towards the ground through the opening formed in the lower part of the nacelle 3, as indicated by arrow 45.

(42) FIG. 27 shows the generator 11 being lowered towards the ground by means of the hosting mechanism accommodated in the container 39. The movement of the generator 11 is controlled by means of two tag lines 41, each being connected to an anchoring point 40 on the ground.

(43) FIG. 28 shows the generator 11 being loaded onto a truck 46. The movements of the generator 11 are still controlled by means of the tag lines 41.

(44) FIG. 29 shows an alternative embodiment in which the generator 11 is lowered towards the ground by means of two ground based winches 47 instead of by means of a hoisting mechanism accommodated in a container. The movements of the generator 11 are controlled partly by means of two tag lines 41, and partly by appropriately controlling operation of the two ground based winches 47 in dependence of each other.

(45) FIGS. 30-32 show the sledges 19 described above in further detail. FIG. 30 is a perspective view of two sledges 19 mounted movably on a sliding rail 15. Each sledge 19 comprises a guiding part 21 and a mating part 25 mounted on a drive train component, e.g. in the form of a gearbox 10. The guiding part 21 is provided with a guiding track 22, and the mating part 25 is provided with a protruding part 26 which is arranged in engagement with the guiding track 22 of the guiding part 21. A hydraulic piston 23 is arranged for providing relative movements between the guiding part 21 and the mating part 25 along a direction defined by the sliding rail 15.

(46) When the guiding part 21 and the mating part 25 perform relative movements along the direction defined by the sliding rail 15, the protruding part 26 of the mating part 25 is caused to move along the guiding track 22 of the guiding part 21. Thereby the orientation and/or the position of the gearbox 10 relative to the sliding rail 15 can be adjusted. By performing relative movements of one of the sledges 19 in one direction while keeping the other sledge immovable or performing relative movements in an opposite direction, a rotational axis of the gearbox 10 is tilted relative to the direction defined by the sliding rail 15. If relative movements are performed by both sledges 19 in the same direction while sledges 19 arranged on an opposite side of the gearbox 10 are kept immovable or perform relative movements in an opposite direction, then the gearbox 10 will rotate about its rotational axis. If all of the sledges 19 perform relative movements in the same direction, then the gearbox 10 is moved in a translational manner in an upwards or downwards direction.

(47) FIG. 31 is a side view of the sledges 19 of FIG. 31. Arrows 48 illustrate the relative movement between the protruding part 26 and the guiding track 22 of one of the sledges 19 as a consequence of operation of the hydraulic piston 23.

(48) One of the sledges 19 is provided with two hydraulic pistons 49 which are used for moving the sledge 19 along the sliding rail 15. This takes place in the following manner. The hydraulic pistons 49 are each arranged in engagement with one of a number of recesses 50 formed in the sliding rail 15. One of the hydraulic pistons 49 is then operated in order to move the sledge 19 as indicated by arrows 51. Then one of the hydraulic pistons 49 is moved into engagement with another one of the recesses 50 while the other hydraulic piston 49 remains engaged with the recess 50, before one of the hydraulic pistons 49 is once again operated in order to move the sledge 19 further along the sliding rail 15. Thereby it is ensured that the sledge 19 does not accidentally slide along the sliding rail 15 when the hydraulic pistons 49 are moved in and out of engagement with the recesses 50. This is in particular relevant when the sliding rail 15 is inclined with respect to a horizontal direction.

(49) The other sledge 19 is provided with an alternative moving mechanism comprising a toothed gear wheel 52 arranged the sledge 19 and a toothed rack 53 arranged on the sliding rail 15. Thereby the sledge 19 can be moved along the sliding rail 15 as indicated by arrows 51 by rotating the gear wheel 52 while it engages the toothed rack 53.

(50) FIG. 32 is a top view of one of the sledges 19 of FIGS. 30 and 31. It can be seen from FIG. 32 that the sledge 19 is provided with an additional hydraulic piston 54 which causes relative movements of the guiding part 21 and the mating part 25 along the direction indicated by arrows 55, thereby allowing the position and/or the orientation of the gearbox 10 to be adjusted along this direction.

(51) Furthermore, a spherical joint 56 is provided in the protruding part 26 of the mating part 25. This allows the protruding part 26 and the portion of the mating part 25 which is attached to the drive train component to perform relative movements. This, in turn, allows the guiding part 21 and the mating part 25 to move freely relative to each other when the hydraulic pistons 23, 54 are operated. Accordingly, it is possible to adjust the position and/or the orientation of the gearbox 10 with respect to six degrees of freedom.

(52) It should be noted that in addition to the exemplary embodiments of the invention shown in the accompanying drawings, the invention may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the invention to those skilled in the art. The scope of the invention is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced.