System for assembling and/or disassembling a wind turbine electric generator

Abstract

A method of assembling and/or disassembling a rotating electric machine of a wind turbine having a vertical structure; a main frame fitted to the top of the vertical structure; a blade assembly fitted to the main frame to rotate about a rotation axis; and a tubular rotating electric machine having a plurality of axial active segments; the method including inserting and/or extracting the active segments axially on the blade assembly side.

Claims

1. A wind turbine rotating electric machine assembly device comprising: an insertion and extraction device configured to facilitate an insertion of at least one active segment axially from a blade assembly side of a wind turbine including a vertical structure, a main frame fitted to a top of the vertical structure, a blade assembly fitted to the main frame and configured to rotate about a rotation axis, and a tubular rotating electric machine including a plurality of active segments distinct from the at least one active segment; and a cylindrical safety cell configured to: fit to the blade assembly, and accommodate an operator, wherein said insertion and extraction device is housed inside the cylindrical safety cell.

2. The wind turbine rotating electric machine assembly device of claim 1, which includes a connecting device configured to: connect the insertion and extraction device to the blade assembly, and rotate the blade assembly to selectively position the insertion and extraction device a designated distance away from one of the plurality of active segments.

3. The wind turbine rotating electric machine assembly device of claim 2, which includes a hoisting device configured to hoist the insertion and extraction device to the blade assembly.

4. The wind turbine rotating electric machine assembly device of claim 3, wherein the hoisting device is mounted on the wind turbine and extends inside the wind turbine.

5. The wind turbine rotating electric machine assembly device of claim 4, wherein the hoisting device includes: a winch fixed to the wind turbine, and a cable extending through the tubular rotating electric machine and the blade assembly.

6. The wind turbine rotating electric machine assembly device of claim 1, wherein the cylindrical safety cell includes at least one circular guide.

7. The wind turbine rotating electric machine assembly device of claim 6, which includes a store configured to house the at least one active segment, said store being selectively movable along the circular guide.

8. The wind turbine rotating electric machine assembly device of claim 6, which includes a service winch selectively movable along the circular guide.

9. The wind turbine rotating electric machine assembly device of claim 6, which includes a manipulator configured to manipulate the at least one active segment, said manipulator being selectively movable along the circular guide.

10. A wind turbine rotating electric machine disassembly device comprising: an insertion and extraction device configured to facilitate an extraction of at least one active segment axially from a blade assembly side of a wind turbine including a vertical structure, a main frame fitted to a top of the vertical structure, a blade assembly fitted to the main frame and configured to rotate about a rotation axis, and a tubular rotating electric machine including a plurality of active segments distinct from the at least one active segment; and a cylindrical safety cell configured to: fit to the blade assembly, and accommodate an operator, wherein said insertion and extraction device is housed inside the cylindrical safety cell.

11. The wind turbine rotating electric machine disassembly device of claim 10, which includes a connecting device configured to: connect the insertion and extraction device to the blade assembly, and rotate the blade assembly to selectively position the insertion and extraction device a designated distance away from one of the plurality of active segments.

12. The wind turbine rotating electric machine disassembly device of claim 11, which includes a hoisting device configured to hoist the insertion and extraction device up to the blade assembly.

13. The wind turbine rotating electric machine disassembly device of claim 12, wherein the hoisting device is mounted on the wind turbine and extends inside the wind turbine.

14. The wind turbine rotating electric machine disassembly device of claim 13, wherein the hoisting device includes: a winch fixed to the wind turbine, and a cable extending through the tubular rotating electric machine and the blade assembly.

15. The wind turbine rotating electric machine disassembly device of claim 10, wherein the cylindrical safety cell includes at least one circular guide.

16. The wind turbine rotating electric machine disassembly device of claim 15, which includes a store configured to house the at least one active segment, said store being selectively movable along the circular guide.

17. The wind turbine rotating electric machine disassembly device of claim 15, which includes a service winch selectively movable along the circular guide.

18. The wind turbine rotating electric machine disassembly device of claim 15, which includes a manipulator configured to manipulate the at least one active segment, said manipulator being selectively movable along the circular guide.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A non-limiting embodiment of the present disclosure will be described by way of example with reference to the attached drawings, in which:

(2) FIG. 1 shows a longitudinal section, with parts removed for clarity, of a system configured to assemble and/or disassemble a wind turbine rotating electric machine in accordance with the present disclosure;

(3) FIG. 2 shows a larger-scale elevation, with parts removed for clarity, of the FIG. 1 system;

(4) FIG. 3 shows a larger-scale view in perspective, with parts removed for clarity, of one operating stage of the FIG. 1 system; and

(5) FIGS. 4 and 5 show larger-scale elevations, with parts removed for clarity, of further operating stages of the FIG. 1 system.

DETAILED DESCRIPTION

(6) Referring now to the example embodiments of the present disclosure illustrated in FIGS. 1 to 5, number 1 in FIG. 1 indicates as a whole a wind turbine configured to generate electric power. Wind turbine 1 is a direct-drive type and, in the example shown, comprises a vertical support 2; a main frame 3; a rotating electric machine 4; and a blade assembly 5 which rotates about a rotation axis A. Rotating electric machine 4 is located between main frame 3 and blade assembly 5, and, in addition to producing electric power, provides for supporting blade assembly 5, and for transmitting forces and moments induced by blade assembly 5 and rotating electric machine 4 to main frame 3.

(7) In the example shown, main frame 3 is defined by a curved, tubular nacelle 6, which comprises a circular end flange 7 for connection to rotating electric machine 4; an end flange 8 configured to house a pivot 9 for connection to vertical support 2; and an opening 10 such as an opening substantially aligned with end flange 8.

(8) Blade assembly 5 comprises a hub 11 connected to rotating electric machine 4; and a plurality of blades 12 (FIG. 2). Hub 11 comprises a hollow member 13 configured to support blades 12 (FIG. 2); and a flange 14 for connection to rotating electric machine 4.

(9) Rotating electric machine 4 extends about rotation axis A, and is substantially tubular, so as to form a passage between the hollow main frame 3 and the hollow hub 11.

(10) Rotating electric machine 4 comprises a stator 15; a rotor 16, which is located inside stator 15 and rotates about rotation axis A with respect to stator 15; and a frame 17 configured to connect rotating electric machine 4 to main frame 3, and configured to support blade assembly 5, stator 15, and rotor 16.

(11) Frame 17 extends about rotation axis A, and comprises a tubular structure 18 having a cylindrical face 19 and configured to support a tubular active part 20 along cylindrical face 19; an annular flange 21 configured to connect rotating electric machine 4 to main frame 3 of wind turbine 1; and a ring 22 having an annular seat 23 configured to at least partly house a bearing 24. In the example shown, one bearing 24 supports both blade assembly 5 and rotor 16 integral with blade assembly 5. In other words, because tubular structure 18 forms part of tubular stator 15, frame 17 also defines part of tubular stator 15, which comprises tubular structure 18 and active part 20.

(12) Tubular active part 20 is divided into a plurality of axial active segments 25, each of which, in the example shown, has electric windings supported of a substantially prismatic ferromagnetic core extending predominantly parallel to axis of rotation A.

(13) In certain embodiments, active segments 25 are fitted to the structure by respective prismatic joints, so as to slide axially.

(14) In certain embodiments, frame 17 and main frame 3 are connected by a bolted connection (not shown in the drawings) between annular flange 21 and end flange 8, and by which the forces and moments induced by rotating electric machine 4 and blade assembly 5 are transmitted to main frame 3.

(15) In certain embodiments, rotating electric machine 4, (i.e., wind turbine 1), only has bearing 24 to support the radial and axial loads transmitted from tubular rotor 16 and blade assembly 5 to main frame 3.

(16) Tubular rotor 16 comprises a tubular structure 26 having a cylindrical face 27; a tubular active part 28; and a radial structure 29 located inside tubular structure 26 and connected to bearing 24. In other words, radial structure 29 is fixed to bearing 24 on one side, and to hub 11more specifically, to flange 14 of hub 11on the opposite side.

(17) Like active part 20, active part 28 comprises axial active segments 30, each of which, in the example shown, has permanent magnets fitted to respective magnetic guides, is prismatic in shape, and extends predominantly parallel to rotation axis A. In other words, rotating electric machine 4 is tubular, and communicates directly with hollow hub 11.

(18) Dimensionally, active parts 20 and 28 have a minimum diameter larger than the maximum diameter of hub 11. And wind turbine 1 has a front casing 31, which, as shown in FIG. 1, has openings 32 by which to insert and remove active segments 25 and 30 on the hub 11 side. Alternatively, the casing may be removed completely or partly.

(19) Generally speaking, wind turbine 1 as a whole is configured to permit insertion and removal of active segments 25 and 30 on the hub 11 side.

(20) In FIG. 1, wind turbine 1 is connected to a system 33 by which to insert and/or extract active segments 25 and 30 of rotating electric machine 4 on the hub 11 side.

(21) System 33 comprises a hoisting device 34; an insertion and extraction device 35 configured to insert and/or extract active segments 25 and/or 30 axially into/from rotating electric machine 4; and a connecting device 36 configured to connect insertion and extraction device 35 to blade assembly 5more specifically, to hub 11.

(22) In certain embodiments, connecting device 36 comprises a safety cell 37 configured to house at least one operator and a plurality of active segments 25 and/or 30, as shown more clearly in FIG. 2.

(23) As shown in FIG. 1, safety cell 37 is cylindrical, and, in certain embodiments, comprises two circular guides 38 connected by a supporting structure 39. Safety cell 37 comprises two grille type curtain walls 40, one of which is configured to face rotating electric machine 4, and has an opening 41 by which to insert and/or extract active segments 25 and/or 30 (FIG. 1).

(24) Safety cell 37 is configured to fix rigidly to blade assembly 5. More specifically, safety cell 37 is configured to fix to hub 11, and, in certain embodiments, comprises a connecting member 42 located along supporting structure 39, and which cooperates with a connecting member 43 located along hub 11, between two adjacent blades 12.

(25) In certain embodiments, hub 11 and connecting member 42 have respective openings 44 and 45 to permit direct communication between hollow hub 11 and safety cell 37.

(26) In the case of a relatively very large hub 11, openings 44 and 45 may even be formed to enable passage of the operator from hub 11 to safety cell 37 and vice versa.

(27) As shown in FIG. 2, insertion and extraction device 35 is fixed to safety cell 37 with only relatively small radial adjustments enabled.

(28) Safety cell 37 also supports a store 46 for active segments 25 and/or 30; a service winch 47; and a manipulator 48 configured to handle active segments 25 and/or 30 between insertion and extraction device 35 and store 46.

(29) As shown in FIGS. 2 to 5, in certain embodiments, store 46, service winch 47, and manipulator 48 are mounted to run along at least one of guides 38 into different operating positions, depending on the position of, and the work to be carried out in, safety cell 37.

(30) As shown in FIG. 1, hoisting device 34 comprises a winch 49 fitted to main frame 3; a cable 50 of winch 49, connectable to safety cell 37; and guide pulleys 51 configured to route cable 50 through rotating electric machine 4, hub 11, and opening 44.

(31) In actual use, and as shown in FIG. 3, safety cell 37 and insertion and extraction device 35 are hoisted off the ground by hoisting device 34, and, once the assembly and/or disassembly work on wind turbine 1 is completed, are lowered back down to the ground and stowed.

(32) On reaching hub 11, insertion and extraction device 35 is fixed to blade assembly 5in the example shown, to hub 11as shown in FIG. 2, in which the insertion and extraction device is set to the six o'clock position. By rotating blade assembly 5 about rotation axis A, insertion and extraction device 35 can be aligned with any one of active segments 25. FIGS. 4 and 5 show insertion and extraction device 35 in the four o'clock and twelve o'clock positions respectively.

(33) With reference to FIG. 1, the operator assigned to insert and/or extract active segments 25 travels to the work station at hub 11 inside safety cell 37, or, if openings 44 and 45 are large enough, accesses the safety cell from wind turbine 1.

(34) The cylindrical shape of safety cell 37 enables the operator an optimal working position, regardless of the angular position of safety cell 37 about rotation axis A.

(35) Clearly, changes may be made to the method and system according to the present disclosure without, however, departing from the protective scope of the accompanying Claims. That is, various changes and modifications to the presently disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.