Yaw braking assembly of a wind turbine
11592003 · 2023-02-28
Assignee
Inventors
Cpc classification
F03D17/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D65/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D66/022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D55/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2260/902
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D65/16
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
F16D65/092
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D2055/0066
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D66/024
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D55/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D7/0204
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B23P6/002
PERFORMING OPERATIONS; TRANSPORTING
F16D2250/0084
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D7/0244
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2230/80
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F03D7/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D66/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D80/50
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D55/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D65/092
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D65/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B23P6/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A yaw braking assembly of a wind turbine is presented. Accordingly, the yaw braking assembly includes a bedplate support frame having an annular flange defining a plurality of recesses formed into a lower-most annular surface of the annular flange and extending at least partially through an axial thickness of the annular flange. Each of the plurality recesses define an open exterior circumferential side. The yaw braking assembly also includes a plurality of brake pads which are positioned within the plurality of recesses and configured to engage at least one race of an adjacent yaw bearing. The yaw braking assembly further includes a plurality of actuators for driving the plurality of brake pads to engage the yaw bearing.
Claims
1. A yaw braking assembly of a wind turbine, the yaw braking assembly comprising: a yaw bearing; a bedplate support frame comprising a flange arranged adjacent to the yaw bearing, the flange defining a plurality of recesses formed into a lower-most arcuate surface of the flange and extending at least partially through an axial thickness of the flange, each of the plurality of recesses defining an open, exterior circumferential side; a plurality of brake pads positioned within the plurality of recesses, each of the plurality of brake pads configured to engage at least one race of the yaw bearing; and a plurality of actuators for driving the plurality of brake pads to engage the at least one race of the yaw bearing so as to resist a yawing of a nacelle of the wind turbine.
2. The yaw braking assembly of claim 1, further comprising: a plurality of arm members positioned within a corresponding plurality of holes through the flange between the plurality of actuators and the plurality of brake pads, the plurality of arm members being oriented to transfer a force from the plurality of actuators to the plurality of brake pads.
3. The yaw braking assembly of claim 1, wherein each of the plurality of brake pads has a non-circular shape.
4. The yaw braking assembly of claim 1, wherein each of the plurality of brake pads has at least one of a polygonal shape, a curvilinear polygonal shape, or rounded-square planform.
5. The yaw braking assembly of claim 1, wherein each of the plurality of brake pads defines a maximal length and a maximal width, the maximal length being greater than the maximal width.
6. The yaw braking assembly of claim 1, wherein each open, exterior circumferential side of the plurality of recesses defines a circumferential length which is greater than a maximal length of the corresponding brake pad.
7. The yaw braking assembly of claim 1, wherein only one of the plurality of brake pads is positioned within each of the plurality of recesses.
8. The yaw braking assembly of claim 7, wherein the plurality of recesses and corresponding plurality of brake pads are distributed circumferentially about the flange in a plurality of adjacent pair sets.
9. The yaw braking assembly of claim 8, wherein a single actuator is operably coupled to each of the plurality of pair sets.
10. The yaw braking assembly of claim 1, wherein the plurality of brake pads are radially aligned with an outer race of the yaw bearing.
11. The yaw braking assembly of claim 1, further comprising: a retention bracket secured to the exterior circumferential side, the retention bracket occluding at least one of the circumferential openings.
12. The yaw braking assembly of claim 1, wherein at least one of the plurality of brake pads further comprises at least one sensor configured to generate an alert relating to a wear level of one or more of the plurality of brake pads.
13. The yaw braking assembly of claim 12, wherein the at least one sensor comprises a continuity sensor.
14. The yaw braking assembly of claim 1, wherein the plurality of brake pads are accessible from outside of the bedplate support frame via the corresponding circumferential openings.
15. The yaw braking assembly of claim 1, wherein each of the plurality of brake pads is formed with at least one extraction feature, the extraction feature being positioned to facilitate the removal of each of the brake pads from the corresponding recesses.
16. A wind turbine, comprising: a tower; a nacelle mounted atop the tower and comprising a bedplate support frame, the bedplate support frame comprising a flange, the flange defining a plurality of recesses formed into a lower-most arcuate surface of the flange and extending at least partially through an axial thickness of the flange, each of the plurality of recesses defining an open, exterior circumferential side, a yaw bearing arranged adjacent to the flange; a rotor mounted to the nacelle, the rotor comprising a rotatable hub having one or more rotor blades secured thereto; and a plurality of brake pads positioned within the plurality of recesses, each of the plurality of brake pads configured to engage at least one race of the yaw bearing; and a plurality of actuators for driving the plurality of brake pads to engage the at least one race of the yaw bearing so as to resist a yawing of a nacelle of the wind turbine.
17. The wind turbine of claim 16, wherein each of the plurality of brake pads comprises at least one of a polygonal shape, a curvilinear polygonal shape, or rounded-square planform.
18. The wind turbine of claim 16, wherein each of the plurality of brake pads defines a maximal length and a maximal width, the maximal length being greater than the maximal width.
19. The wind turbine of claim 18, wherein each circumferential opening defines a circumferential length that is greater than the maximal length of a corresponding brake pad of the plurality of brake pads.
20. A method for servicing a yaw braking assembly of a wind turbine, the method comprising: accessing at least one brake pad of a plurality of brake pads via an open, exterior circumferential side of a recess defined by at least one of a plurality of recesses formed into a lower-most arcuate surface of a flange of a bedplate support frame and extending at least partially through an axial thickness of the flange, wherein the lower-most arcuate surface is disposed adjacent to a yaw bearing of the wind turbine; and passing the at least one brake pad through the open, exterior circumferential side of the recess while retaining a corresponding actuator of a plurality of actuators in an assembled configuration.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) 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:
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(15) Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
DETAILED DESCRIPTION
(16) 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.
(17) As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.
(18) The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein.
(19) Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin.
(20) Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.
(21) Generally, the present disclosure is directed to a yaw braking assembly of a wind turbine. In particular, the yaw braking assembly of the present disclosure may include a bedplate support frame having an annular flange. The annular flange may be formed with a plurality of recesses formed into a lower-most annular surface of the annular flange. The recesses may extend at least partially through an axial thickness of the flange and may define an opening in the exterior circumferential side of the annular flange. In other words, each of the recesses may have two open sides through which a corresponding brake pad may pass. One opening may be in the lower-most annular surface of the annular flange and may facilitate the brake pad's engagement with a braking friction surface, such as a yaw bearing. The second opening may be in the exterior circumferential side of the annular flange and may facilitate access to the brake pad without requiring that the yaw braking assembly be disassembled.
(22) The brake pads inserted into each of the recesses may have a non-circular shape. For example, the brake pads may have a polygonal shape, a curvilinear polygonal shape, or a rounded-square planform. Being formed with a non-circular shape, the brake pads may interface with the recesses so as to transfer loads generated during braking to the bedplate support frame, rather than to the actuator components of the yaw braking assembly. It should be appreciated that because the brake pads interface with the recesses, the brake pads may be prevented from spinning during braking operations. This, in turn, may increase the braking effectiveness of the yaw braking assembly and may facilitate the inclusion of a wear sensor with the brake pads.
(23) Referring now to the drawings,
(24) The wind turbine 100 may also include a turbine controller 114 centralized within the nacelle 106. However, in other embodiments, the turbine controller 114 may be located within any other component of the wind turbine 100 or at a location outside the wind turbine. Further, the turbine controller 114 may be communicatively coupled to any number of the components of the wind turbine 100 in order to control the components. As such, the turbine controller 114 may include a computer or other suitable processing unit. Thus, in several embodiments, the turbine controller 114 may include suitable computer-readable instructions that, when implemented, configure the turbine controller 114 to perform various different functions, such as receiving, transmitting and/or executing wind turbine control signals.
(25) Referring now to
(26) Each rotor blade 112 may also include a pitch control mechanism 120 configured to rotate each rotor blade 112 about its pitch axis 116. The pitch control mechanism 120 may include a pitch controller configured to receive at least one pitch setpoint command from the turbine controller 114. Further, each pitch control mechanism 120 may include a pitch drive motor 128 (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox 130, and a pitch drive pinion 132. In such embodiments, the pitch drive motor 128 may be coupled to the pitch drive gearbox 130 so that the pitch drive motor 128 imparts mechanical force to the pitch drive gearbox 130. Similarly, the pitch drive gearbox 130 may be coupled to the pitch drive pinion 132 for rotation therewith. The pitch drive pinion 132 may, in turn, be in rotational engagement with a pitch bearing 134 coupled between the hub 110 and a corresponding rotor blade 112 such that rotation of the pitch drive pinion 132 causes rotation of the pitch bearing 134. Thus, in such embodiments, rotation of the pitch drive motor 128 drives the pitch drive gearbox 130 and the pitch drive pinion 132, thereby rotating the pitch bearing 134 and the rotor blade(s) 112 about the pitch axis 116.
(27) The wind turbine 100 may also include one or more yaw drive mechanisms 138 communicatively coupled to the controller 114. Each yaw drive mechanism(s) 138 may be configured to change the angle of the nacelle 106 relative to the wind by engaging a yaw bearing 140 of the wind turbine 100. The yaw bearing 140 may couple the tower 102 and nacelle 106 at a yaw bearing interface 146. For example, as shown in
(28) As depicted in
(29) Referring now to
(30) As is particularly depicted in
(31) In an embodiment, the brake pads 312 may include a wear layer 320 coupled to a backer plate 322. The wear layer 320 may be configured to engage the yaw bearing 140 and develop a friction therewith. As such, the wear layer 320 may be any suitable material selected based on wear characteristics and heat tolerance. The backer plate 322 may be a rigid/semi-rigid material, such as steel, configured to increase the ability of the wear layer 320 to resist structural loading.
(32) In at least one embodiment, such as depicted in
(33) It should also be appreciated that forming the plurality of recesses 304 coincide to the non-circular shape of the plurality of brake pads 312 may facilitate the transfer of braking loads from the of brake pads 312 to the bedplate support frame 136 by precluding the spin or rotation of the brake pads 312. As such, only one of the plurality of brake pads 312 may be positioned within each of the plurality of recesses 304. In other words, in at least one embodiment, the number of recesses 304 may equal the number of brake pads 312.
(34) In at least one embodiment, such as depicted in
(35) In an embodiment, each of the plurality of brake pads 312 may define a maximal length (M.sub.L) and a maximal width (M.sub.W). In at least one embodiment, such as depicted in
(36) In an embodiment, each open, exterior circumferential side 308 of the plurality of recesses 304 may define a circumferential length (C.sub.L) which is sufficient to permit the passage of the corresponding brake pad 312. The passage of the corresponding brake pad 312 may be accomplished without requiring that the brake pad 312 be rotated or disassembled. For example, in at least one embodiment, the circumferential length (C.sub.L) of the opening in the exterior circumferential side 310 of the annular flange 302 may be greater than the maximal length (M.sub.L) of the corresponding brake pad 312. It should be appreciated that the ability to pass the brake pad 312 through the open, exterior circumferential side 308 of the recess 304 may facilitate the utilization of brake pads 312 having a pad surface area which may be larger than an actuator piston area. In other words, the brake pads 312 may be larger than the holes 318. It should further be appreciated that the utilization of brake pads 312 having a larger area may facilitate more controlled pad pressure, and thus may result in more desirable reliability and wear characteristics.
(37) As depicted in
(38) In an embodiment, such as depicted in
(39) In a further embodiment, each of the plurality of brake pads 312 may be formed with at least one extraction feature 330. The extraction feature 330 may be positioned to facilitate the removal of each of the brake pads 312 from the corresponding recesses 304. For example, as shown in
(40) Referring now to
(41) As shown at (402), the method 400 may include accessing at least one brake pad of a plurality of brake pads via an open, exterior circumferential side of a recess defined by at least one of a plurality of recesses formed into a lower-most annular surface of an annular flange of a bedplate support frame and extending at least partially through an axial thickness of the annular flange. The lower-most annular surface may be disposed adjacent to a yaw bearing of the wind turbine. As shown at (404), the method 400 may also include passing the at least one brake pad through the open, exterior circumferential side of the recess while retaining a corresponding actuator of a plurality of actuators in an assembled configuration.
(42) Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents for each such methods and feature, can be mixed and matched by one of ordinary skill in this art to construct additional systems and techniques in accordance with principles of this disclosure. Of course, it is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
(43) 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.
(44) Further aspects of the invention are provided by the subject matter of the following clauses:
(45) Clause 1. A yaw braking assembly of a wind turbine, the yaw braking assembly comprising: a yaw bearing; a bedplate support frame comprising an annular flange arranged adjacent to the yaw bearing, the annular flange defining a plurality of recesses formed into a lower-most annular surface of the annular flange and extending at least partially through an axial thickness of the annular flange, each of the plurality of recesses defining an open, exterior circumferential side; a plurality of brake pads positioned within the plurality of recesses, each of the plurality of brake pads configured to engage at least one race of the yaw bearing; and a plurality of actuators for driving the plurality of brake pads to engage the at least one race of the yaw bearing so as to resist a yawing of a nacelle of the wind turbine.
(46) Clause 2. The yaw braking assembly of any preceding clause, further comprising: a plurality of arm members positioned within a corresponding plurality of holes through the annular flange between the plurality of actuators and the plurality of brake pads, the plurality of arm members being oriented to transfer a force from the plurality of actuators to the plurality of brake pads.
(47) Clause 3. The yaw braking assembly of any preceding clause, wherein each of the plurality of brake pads has a non-circular shape.
(48) Clause 4. The yaw braking assembly of any preceding clause, wherein each of the plurality of brake pads has at least one of a polygonal shape, a curvilinear polygonal shape, or rounded-square planform.
(49) Clause 5. The yaw braking assembly of any preceding clause, wherein each of the plurality of brake pads defines a maximal length and a maximal width, the maximal length being greater than the maximal width.
(50) Clause 6. The yaw braking assembly of any preceding clause, wherein each open, exterior circumferential side of the plurality of recesses defines a circumferential length which is greater than the maximal length of the corresponding brake pad.
(51) Clause 7. The yaw braking assembly of any preceding clause, wherein only one of the plurality of brake pads is positioned within each of the plurality of recesses.
(52) Clause 8. The yaw braking assembly of any preceding clause, wherein the plurality of recesses and corresponding plurality of brake pads are distributed circumferentially about the annular flange in a plurality of adjacent pair sets.
(53) Clause 9. The yaw braking assembly of any preceding clause, wherein a single actuator is operably coupled to each of the plurality of pair sets.
(54) Clause 10. The yaw braking assembly of any preceding clause, wherein the plurality of brake pads are radially aligned with an outer race of the yaw bearing.
(55) Clause 11. The yaw braking assembly of any preceding clause, further comprising a retention bracket secured to the exterior circumferential side, the retention bracket occluding at least one of the circumferential openings.
(56) Clause 12. The yaw braking assembly of any preceding clause, wherein at least one of the plurality of brake pads further comprises at least one sensor configured to generate an alert relating to a wear level of one or more of the plurality of brake pads.
(57) Clause 13. The yaw braking assembly of any preceding clause, wherein the at least one sensor comprises a continuity sensor.
(58) Clause 14. The yaw braking assembly of any preceding clause, wherein the plurality of brake pads are accessible from outside of the bedplate support frame via the corresponding circumferential openings.
(59) Clause 15. The yaw braking assembly of any preceding clause, wherein each of the plurality of brake pads is formed with at least one extraction feature, the extraction feature being positioned to facilitate the removal of each of the brake pads from the corresponding recesses.
(60) Clause 16. A wind turbine, comprising: a tower; a nacelle mounted atop the tower and comprising a bedplate support frame, the bedplate support frame comprising an annular flange arranged adjacent to the yaw bearing, the annular flange defining a plurality of recesses formed into a lower-most annular surface of the annular flange and extending at least partially through an axial thickness of the annular flange, each of the plurality of recesses defining an open, exterior circumferential side, a yaw bearing arranged adjacent to the annular flange; a rotor mounted to the nacelle, the rotor comprising a rotatable hub having one or more rotor blades secured thereto; and a plurality of brake pads positioned within the plurality of recesses, each of the plurality of brake pads configured to engage at least one race of the yaw bearing; and a plurality of actuators for driving the plurality of brake pads to engage the at least one race of the yaw bearing so as to resist a yawing of a nacelle of the wind turbine.
(61) Clause 17. The wind turbine of any preceding clause, wherein each of the plurality of brake pads comprises at least one of a polygonal shape, a curvilinear polygonal shape, or rounded-square planform.
(62) Clause 18. The wind turbine of any preceding clause, wherein each of the plurality of brake pads defines a maximal length and a maximal width, the maximal length being greater than the maximal width.
(63) Clause 19. The wind turbine of any preceding clause, wherein each circumferential opening defines a circumferential length that is greater than the maximal length of a corresponding brake pad of the plurality of brake pads.
(64) Clause 20. A method for servicing a yaw braking assembly of a wind turbine, the method comprising: accessing at least one brake pad of a plurality of brake pads via an open, exterior circumferential side of a recess defined by at least one of a plurality of recesses formed into a lower-most annular surface of an annular flange of a bedplate support frame and extending at least partially through an axial thickness of the annular flange, wherein the lower-most annular surface is disposed adjacent to a yaw bearing of the wind turbine; and passing the at least one brake pad through the open, exterior circumferential side of the recess while retaining a corresponding actuator of a plurality of actuators in an assembled configuration.