Counterweight Assembly for Use During Single Blade Installation of a Wind Turbine
20200072187 ยท 2020-03-05
Inventors
Cpc classification
F03D1/0658
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E10/728
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F03D13/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2240/90
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D13/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
A method for installing a plurality of rotor blades to a rotatable hub secured atop a tower of a wind turbine includes providing a counterweight assembly having, at least, a mounting assembly and a counterweight mass secured at a distal end of the mounting assembly. The method also includes securing the mounting assembly at a first position on the hub of the wind turbine such that the counterweight mass biases the hub to rotate about its rotation axis in a first direction. Further, the method includes consecutively installing the plurality of rotor blades onto the hub of the wind turbine. Moreover, the method includes adjusting a position of the counterweight mass between each consecutive installation of the plurality of rotor blades to continuously change a center of gravity of the hub and maintain a balanced rotor of the wind turbine during installation of the plurality of rotor blades.
Claims
1. A method for installing a plurality of rotor blades to a rotatable hub secured atop a tower of a wind turbine, the method comprising: providing a counterweight assembly having, at least, a mounting assembly and a counterweight mass secured at a distal end of the mounting assembly; securing the mounting assembly at a first position on the hub of the wind turbine such that the counterweight mass biases the hub to rotate about its rotation axis in a first direction; consecutively installing the plurality of rotor blades onto the hub of the wind turbine; and, adjusting a position of the counterweight mass between each consecutive installation of the plurality of rotor blades to continuously change a center of gravity of the hub and maintain a balanced rotor of the wind turbine during installation of the plurality of rotor blades.
2. The method of claim 1, wherein a proximal end of the mounting assembly is fixed with respect to the hub.
3. The method of claim 2, wherein securing the mounting assembly of the counterweight assembly at the first position on the hub of the wind turbine such that the counterweight mass biases the hub to rotate about its rotation axis in a first direction further comprises: positioning the hub with a first pitch axis in a twelve o'clock position, a second pitch axis between a three o'clock position and a six o'clock position, and a third pitch axis between the six o'clock position and a nine o'clock position; and, securing the mounting assembly between the first pitch axis and the second pitch axis.
4. The method of claim 1, wherein a proximal end of the mounting assembly is secured to the hub at a hinge point.
5. The method of claim 4, wherein adjusting the position of the counterweight mass between each consecutive installation of the plurality of rotor blades further comprises: securing the mounting assembly to a pitch bearing of a pitch system of the wind turbine, the pitch system having a pitch drive mechanism, the mounting assembly initially being substantially parallel to a pitch axis of the pitch bearing; and, allowing the counterweight mass to rotate about the hinge point of the hub to bias the hub to rotate about its rotation axis in the first direction.
6. The method of claim 5, wherein adjusting the position of the counterweight mass between each consecutive installation of the plurality of rotor blades further comprises rotating the counterweight mass about the pitch axis via the pitch drive mechanism.
7. The method of claim 5, wherein adjusting the position of the counterweight mass between each consecutive installation of the plurality of rotor blades further comprises changing a direction of rotation of the counterweight mass in an opposite direction of the first direction after first and second rotor blades of the plurality of rotor blades are installed.
8. The method of claim 1, wherein the mounting assembly further comprises a set of arm members, the set of arm members comprising a first arm member and a second arm member, the second arm member secured to the first arm member at a controllable hinge point.
9. The method of claim 8, wherein adjusting the position of the counterweight mass between each consecutive installation of the plurality of rotor blades further comprises: initially securing the second arm member to the first arm member at a first angle; and, adjusting the first angle by rotating the second arm member about the controllable hinge point as the hub rotates about its rotation axis and subsequent rotor blades are installed to the hub.
10. The method of claim 9, further comprising limiting rotation of the second arm member with respect to the first arm member via at least one mechanical stop.
11. The method of claim 1, further comprising: affixing an outer race of a slewing ring bearing to a front, exterior location of the hub and allowing an inner race of the slewing ring bearing to rotate with respect to the outer race; mounting the first arm member to the slewing ring bearing, wherein rotation of the inner race of the slewing ring bearing allows for rotation of the arm member and the counterweight mass.
12. The method of claim 11, wherein the inner race of the slewing ring bearing further comprises gear teeth that mesh with a drive mechanism, the drive mechanism configured to drive rotation of the inner race with respect to the outer race.
13. The method of claim 1, further comprising locking the counterweight mass in a predetermined position.
14. A counterweight assembly for maintaining balance of a rotor of a wind turbine during installation of a plurality of rotor blades onto a rotatable hub secured atop a tower of the wind turbine, the counterweight assembly comprising: a counterweight mass configured to be moved to multiple positions between consecutive installations of the plurality of rotor blades to continuously change a center of gravity of the hub and maintain a balanced rotor of the wind turbine during installation of the plurality of rotor blades; and, a mounting assembly comprising a proximal end and a distal end spaced apart from the proximal end to provide a predetermined distance between the counterweight mass and the hub, the proximal end configured for securing the mounting assembly to the hub, such that, when the mounting assembly is secured to the hub, the counterweight mass biases the hub to rotate about its rotation axis.
15. The counterweight assembly of claim 14, further comprising a lifting device for lifting each of the plurality of rotor blades consecutively atop the tower of the wind turbine.
16. The counterweight assembly of claim 14, further comprising a rotor drive mechanism for rotating or braking the rotor during installation of the plurality of rotor blades.
17. The counterweight assembly of claim 14, wherein the counterweight mass moves to the multiple positions between consecutive installations of the plurality of rotor blades via gravity.
18. The counterweight assembly of claim 16, further comprising a rotating mechanism for rotating the counterweight mass, the rotating mechanism comprising at least one of an existing pitch system, the rotor drive mechanism, or an additional bearing drive system secured to a front, exterior location on the hub of the wind turbine.
19. The counterweight assembly of claim 18, wherein the additional bearing drive system further comprises a slewing ring bearing comprising an outer race and an inner race rotatable with respect to the outer race, the outer race affixed to the front, exterior location of the hub, the inner race comprising gear teeth that mesh with a drive mechanism, the drive mechanism configured to drive rotation of the inner race with respect to the outer race.
20. The counterweight assembly of claim 14, wherein the mounting assembly further comprises a set of arm members, wherein the set of arm members comprises a first arm member and a second arm member, the second arm member hinged to the first arm member at a controllable hinge point.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
DETAILED DESCRIPTION
[0029] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0030] Generally, the present subject matter is directed to various methods for consecutively installing a plurality of rotor blades to a rotatable hub secured atop a tower of a wind turbine. Specifically, as will become apparent from the description provided below, the disclosed methods utilize a counterweight that can change the center of gravity of the rotor of the wind turbine in order to drive the rotor forward without putting new demands on components.
[0031] Referring now to the drawings,
[0032] Referring now to
[0033] Each rotor blade 22 may also include a pitch adjustment mechanism 34 configured to rotate each rotor blade 22 about its pitch axis 36. Further, each pitch adjustment mechanism 34 may include a pitch drive motor 38 (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox 40, and a pitch drive pinion 42. In such embodiments, the pitch drive motor 38 may be coupled to the pitch drive gearbox 40 so that the pitch drive motor 38 imparts mechanical force to the pitch drive gearbox 40. Similarly, the pitch drive gearbox 40 may be coupled to the pitch drive pinion 42 for rotation therewith. The pitch drive pinion 42 may, in turn, be in rotational engagement with a pitch bearing 44 coupled between the hub 20 and a corresponding rotor blade 22 such that rotation of the pitch drive pinion 42 causes rotation of the pitch bearing 44. Thus, in such embodiments, rotation of the pitch drive motor 38 drives the pitch drive gearbox 40 and the pitch drive pinion 42, thereby rotating the pitch bearing 44 and the rotor blade 22 about the pitch axis 36. Similarly, the wind turbine 10 may include one or more yaw drive mechanisms 46 configured to change the angle of the nacelle 16 relative to the wind (e.g., by engaging a yaw bearing 48 of the wind turbine 10).
[0034] Referring now to
[0035] Moreover, as shown in
[0036] Referring now to
[0037] As shown at 102, the method 100 includes providing a counterweight assembly 80 having, at least, a mounting assembly 84 and a counterweight mass 83 secured at a distal end of the mounting assembly 84. As shown at 104, the method 100 may include securing the mounting assembly 84 at a first position on the hub 20 of the wind turbine 10 such that the counterweight mass 83 biases the hub 20 to rotate about its rotation axis in a first direction. As shown at 106, the method 100 may include consecutively installing the plurality of rotor blades 22 onto the hub 20 of the wind turbine 10. As shown at 108, the method 100 may include adjusting a position of the counterweight mass 83 between each consecutive installation of the rotor blades 22 to continuously change a center of gravity 82 of the hub 20 and maintain a balanced rotor 18 during installation of the rotor blades 22.
[0038] The method 100 of
[0039] As shown at (B), the counterweight assembly 80 is secured to the hub 20. More specifically, as shown, the counterweight assembly 80 may include at least one beam 85 having a proximal end secured to the hub 20 and a distal end with a counterweight mass 83 secured thereto. Thus, as shown, the mounting assembly 84 may be secured at a first position on the hub 20 such that the counterweight mass 83 biases the hub 20 to rotate about its rotation axis in a first direction (i.e. clockwise). For example, as shown in the illustrated embodiment, the hub 20 may be positioned with a first pitch axis 36 in a twelve o'clock position, a second pitch axis 36 between a three o'clock position and a six o'clock position, and a third pitch axis 36 between the six o'clock position and a nine o'clock position. Thus, as shown, the counterweight assembly 80 may be secured between the first and second pitch axes so as to bias the hub 20 to rotate about its rotation axis in the clockwise direction.
[0040] Thus, the counterweight mass 83 described herein may be adjusted to multiple positions via gravity or an active rotating mechanism. For example, in one embodiment, the rotating mechanism may include the existing pitch drive mechanism 34, the rotor drive mechanism 92, and/or an additional bearing drive system 95 secured to a front, exterior location on the hub 20. For example, referring back to
[0041] Referring back to
[0042] Referring still to
[0043] Referring now to
[0044] Thus, as shown at (D), the rotor 18 can easily be rotated to the first mounting position for the first rotor blade 22 to be installed (i.e. the 9 o'clock position). As mentioned, the rotor 18 may be rotated using the counterweight assembly 80, the rotor drive mechanism 92, and/or combinations thereof. As shown at (E), the first rotor blade 22 can then be installed in the horizontal position (e.g. the 9 o'clock position). As shown at (F), the counterweight assembly 80 is adjusted to a different, second position as the rotor 18 is rotated toward the mounting position for the second rotor blade 22 (e.g. the 9 o'clock position). Accordingly, as shown at (G), the rotor 18 is in the mounting position (e.g. the 9 o'clock position) for the second position. Thus, as shown at (H), the second rotor blade may be secured to the hub 20 in the 9 o'clock position. As shown at (I) and (J), the counterweight assembly 80 may be adjusted (e.g. by swinging the mass 83 similar to a pendulum) to an opposing side of the blade axis 36 (i.e. in a counterclockwise direction) so as to shift the center of gravity 82 as shown after first and second rotor blades of the rotor blades 22 are installed. As shown at (K), (L) and (M), the counterweight assembly 80 is continuously adjusted as the rotor 18 is rotated to the mounting position for the third rotor blade (i.e. the 3 o'clock position). As shown at (N), the counterweight assembly 80 can then be removed, e.g. via the lifting device 90. Accordingly, as shown at (0), the third rotor blade 22 is then secured to the hub 20 in the 9 o'clock position.
[0045] Referring now to
[0046] As shown at (C), the rotor 18 is rotated to the first mounting position for the first rotor blade (i.e. a horizontal position) as the counterweight assembly 80 shifts the center of gravity 82 of the rotor 18. As shown at (D), the first rotor blade is installed in the horizontal position (i.e. the 9 o'clock position) and the center of gravity 82 shifts back towards the center of the rotor 16. As shown at (E), the counterweight assembly 80 is adjusted to a different, second position as the rotor 18 is rotated to the mounting position for the second rotor blade. More particularly, as shown, during rotation, the controllable hinge point 88 may be at least partially released. In other words, the initial or first angle may be adjusted by rotating the second arm member 86 about the controllable hinge point 88 as the hub 20 rotates about its rotation axis (or before) and subsequent rotor blades 22 are installed to the hub 22.
[0047] Still referring to
[0048] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.