Placement and replacement system and method for placing and replacing the electrical components of electromagnetic rotary machine

Abstract

A placement and replacement system and method for placing and replacing the electrical components of electromagnetic rotary machine, wherein the system comprises a frame, multiple of system fixing means to attach the system to the electromagnetic rotary machine, moving means for inserting electrical components to the electromagnetic rotary machine and extracting the electrical components from the electromagnetic rotary machine to place or replace the electrical components.

Claims

1. A placement and replacement system for placing and replacing electrical components of electromagnetic rotary machine, comprising a frame, multiple system fixing means to attach the system to the electromagnetic rotary machine, moving means for inserting electrical components to the electromagnetic rotary machine and extracting the electrical components from the electromagnetic rotary machine to place or replace the electrical components, wherein the frame of the system comprises a movable carriage and main body comprising guiding means; the system fixing means comprises a first mounting bracket and a second mounting bracket, multiple nut block fixing means, at least one adjustment mean, at least one bracket mounting element; the moving means comprises a screw mechanism including a locking mean, a nut block, a crank block assembly, a first bearing assembly and a second bearing assembly connecting the main body and the movable carriage, a turning head, a support bearing, multiple support bearing fixing means, and an attachment profile, wherein the screw mechanism is attached to the movable carriage via the nut block, which is fixed to the movable carriage by the nut block fixing means, the movable carriage is translated along the rotational axis of the screw mechanism while the mechanism is being turned, the movable carriage is guided on surface of the main body by a first bearing assembly and a second bearing assembly, the crank block assembly is supported by the support bearing, the support bearing is attached to the main body by the support bearing fixing means and the electrical components to be replaced are engaged with the movable carriage.

2. The placement and replacement system according to claim 1, wherein the electrical component is a stator coil module or a rotor magnet module.

3. The placement and replacement system according to claim 1, wherein the first mounting bracket is adjustable and the second mounting bracket is fixed.

4. The placement and replacement system according to claim 1, wherein the guiding mean of main body is pair of linear ball bearing rails, sliding bearings, multiple of attached roller bearings or full block anti friction materials.

5. The placement and replacement system according to claim 1, wherein by the carriage, the main body and the first bearing assembly and the second bearing assembly the system exhibiting stiffness properties is formed.

6. The placement and replacement system according to claim 1, wherein the screw mechanism comprises a locking mean, which is trapezoidal thread profile, square thread profiles, braking system, usage of high ratio gearing or application of bearings, with high friction.

7. The placement and replacement system according to claim 1, wherein the turning head can be engaged with a hexagonal wrench, a hand-crank, a pneumatic, electric or hydraulic mechanism or another tool capable of generating rotational force to move the movable carriage.

8. The placement and replacement system according to claim 1, wherein the first mounting bracket and the second mounting bracket are attached to the main body.

9. The placement and replacement system according to claim 1, wherein the first mounting bracket is fixed to the main body via at least one adjustment mean.

10. The placement and replacement system according to claim 1, wherein the bearing assemblies are linear ball bearing, screwed on blocks of antifriction material or screwed on roller bearings.

11. The placement and replacement system according to claim 1, wherein the movable carriage comprises inner mounting surfaces, vertical mounting surfaces and outer mounting surfaces, forming an enclosed space in a manner that once the movable carriage has been inserted into the cavity, only translational movement along the screw mechanism's length wise axis remains possible and the geometrical locking between the movable carriage and attachment profile is achieved.

12. The placement and replacement system according to claim 11, wherein the inner mounting surfaces and the outer mounting surfaces in the profile are horizontal and the vertical supporting surfaces are vertical.

13. The placement and replacement system according to claim 11, wherein the inner mounting surfaces, the outer mounting surfaces are non-horizontal.

14. The placement and replacement system according to claim 11, wherein the geometrical locking between the movable carriage and the attachment profile is achieved in contact of the inner mounting surfaces, the supporting surfaces, the outer mounting surfaces with the movable carriage.

15. The placement and replacement system according to claim 11, wherein the geometrical locking between the movable carriage and the attachment profile is achieved by fishtail like elements.

16. A method for placing and replacing electrical components of an electromagnetic rotary machine with a system comprising a frame, multiple et system fixing means to attach the system to the electromagnetic rotary machine, moving means for inserting electrical components to the electromagnetic rotary machine and extracting the electrical components from the electromagnetic rotary machine to place or replace the electrical components, wherein the method comprises: attaching the system to the electromagnetic rotary machine to place and/or replace the electrical components, removing the electrical component to replace the electrical component, and inserting the electrical component to the electromagnetic rotary machine, wherein Attaching the system to the electromagnetic rotary machine comprises following steps: Sliding the system through a cavity in electrical component attachment profile; Clamping initially the system to extending edges of stator sector rails by a first mounting bracket and a second mounting bracket; Once initial clamping is achieved, moving the first mounting bracket forward towards the extending edge of the stator rail and fixing to it by at least one bracket mounting element; Removing the electrical component from the electromagnetic rotary machine comprises following steps: Positioning and placing of the system; Translating movable carriage into attachment profile by a crank block assembly and geometrically locking the attachment profile and the system; Locking the mounting elements into place and removing module mounting elements and engaging the electrical component with the placement and replacement system and transporting out of the electromagnetic rotary machine air-gap by using the crank block assembly; Transporting the electrical component out of the electromagnetic rotary machine air-gap to the end position and removing the mounting elements; Finalizing the removing procedure by sliding the electrical component off the placement and replacement system; Removing the placement and replacement system by unclamping the first mounting bracket and second mounting bracket from the rails or inserting the electrical component to the electromagnetic rotary machine, wherein inserting the electrical component comprises following steps: Inserting new electrical component by sliding the electrical component onto the movable carriage and locking into place by the mounting elements; Translating the electrical component into end position of the placement and replacement system via the crank block assembly; Fixing the electrical component onto the rails by the module mounting elements; Releasing the placement and replacement system by removing the mounting elements from the attachment profile and the main body; Translating the movable carriage into the start position via the crank block assembly; Loosening the adjustment elements and removing the bracket mounting elements; Moving the first mounting bracket away from the rail and sliding the placement and replacement system out of the attachment profile.

17. The method according to claim 16, wherein the electrical component is a stator coil module or a rotor magnet module.

18. The method according to claim 16, wherein to generate translational movement the screw mechanism is driven by a drive mechanism via the crank block assembly by applying force or a tool, capable of generating such force, to the turning head.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0026] The present invention is explained more precisely with references to figures added, where:

[0027] FIG. 1 shows a preferred embodiment of a placement and replacement system according to present invention;

[0028] FIG. 2 shows an example of electromagnetic rotary machine with replaceable coil and magnet modules;

[0029] FIG. 3 illustrates a front view of the present placement and replacement system shown on FIG. 2 with magnet module;

[0030] FIG. 4 illustrates a front view of the present placement and replacement system shown on FIG. 2 with coil module;

[0031] FIG. 5 illustrates a cross-sectional view of the placement and replacement system and attachment profile, bearing assemblies and main body in the preferred embodiment;

[0032] FIG. 6 shows an alternative embodiment of attachment profile, bearing assemblies and main body;

[0033] FIG. 7 shows second alternative embodiment of attachment profile, bearing assemblies and main body;

[0034] FIG. 8 to FIG. 10 show an example of a procedure concerning electrical component removal and replacing with the placement and replacement system according to present invention.

DESCRIPTION OF EMBODIMENTS

[0035] The placement and replacement system according to present invention for placing and replacing the electrical components of electromagnetic rotary machine, comprising frame, multiple of system fixing means to attach the system to the electromagnetic rotary machine, moving means for inserting electrical components to the electromagnetic rotary machine and extracting the electrical components from the electromagnetic rotary machine to place or replace the electrical components.

[0036] The frame of the system comprises a movable carriage 1 and main body 2 comprising guiding means. The system fixing means comprises first mounting bracket 3 and second mounting bracket 4, multiple of nut block fixing means 5, at least one adjustment mean 6, at least one bracket mounting element 7. The moving means comprises movable carriage 1, screw mechanism 8 including locking mean, nut block, preferably threaded nut block 9, crank block assembly 10, first bearing assembly 11 and second bearing assembly 12 connecting the main body 2 and movable carriage 1, turning head 13, support bearing 14, multiple of support bearing fixing means 15, and attachment profile 16.

[0037] The placement and replacement system according to present invention comprises a movable carriage 1, screw mechanism 8, threaded nut block 9, crank block assembly 10, main body 2, first bearing assembly 11 and second bearing assembly 12 connecting the main body 2 and movable carriage 1, turning head 13, support bearing 14, adjustable mounting bracket 3, at least one adjustment mean 6 (for example bolts), fixed mounting bracket 4, multiple of nut block fixing means 5, multiple of support bearing fixing means 15.

[0038] FIG. 2 shows an example of electromagnetic rotary machine for which the present placement and replacement system is used having a stator 27 and rotor 28. Both of which are supported by main shaft and king-pin assembly 29. To use the present placement and replacement system, the rotor 28 of electromagnetic rotary machine is preferably located radially inward from the stator 27 however, in the alternative embodiments the placement and replacement system is used in configuration where stator 27 is located radially inward from the rotor 28. Both stator 27 and rotor 28 are made up from plurality of stator structure segments 30 and rotor structure segments 31 which functionally complete the stator 27 and rotor 28 carrier structures. These carrier structures feature generator fixing rails 22, having the same cross-sectional geometry.

[0039] The present placement and replacement system in the preferred embodiment is applicable, wherein the rails feature preferably H-shaped geometry, however in alternative embodiments the placement and replacement system is applicable for various other geometrical shapes that feature at least one extending edge like L, Z or T-bars; the stator and rotor fixing rails 22 feature the same cross-sectional geometry; the electrical component, coil and magnet, modules 17 feature a similar geometry in terms of features relevant for achieving fixing and the electrical component, coil and magnet, modules 17 can be handled with a crew of maximum two persons.

[0040] The stator rails 22 are used to carry the stator coil modules 17 and rotor rails 22 are used to carry the rotor magnet modules 17. Modularity of stator 27 is achieved by using concentrated air-gap windings which do not specifically require that the stator active parts form a circumferentially tight structure in order to achieve reasonable electromagnetic efficiency figures for the rotary machine. Furthermore, the utilization of air-gap winding concept has a number of advantages, for example the possibility to design and build the modules relatively light and fully independent of each other, which makes it possible to replace them in case of dielectric break down. This is of significant importance when considering electromagnetic rotary machines placed in wind power units. There the maintenance and repair works can be very difficult and expensive especially when large cranes and crews are needed. Therefore, the present placing and replacement system which can be handled by a crew of maximum 2 persons without additional lifting equipment or jigs helps to achieve large economic impact.

[0041] FIG. 1 shows a preferred embodiment of the present placement and replacement system for placing and replacing the electrical component modules 17, wherein the component modules are coil and magnet modules, which are to be engaged with the movable carriage 1. In order to facilitate translational movement a screw mechanism 8 is attached to the movable carriage 1 via threaded nut block 9. As the threads of the screw mechanism 8 and nut block 9 become engaged, the movable carriage 1 will be translated along the rotational axis of the screw mechanism 8 while the mechanism is being turned. The threaded nut block 9 is fixed to the movable carriage 1 by nut block fixing means 4.

[0042] To combat the acting forces and block the rotational movement of the movable carriage 1, it is guided on the surface of the main body 2 by a first bearing assembly 11 and second bearing assembly 12. In the present embodiment, preferably pair of linear ball bearing rails are positioned on the main body 2, in alternative embodiments various other guiding means to facilitate the needed manner of guiding, like sliding bearings, multiple of attached roller bearings or full block anti friction materials, are possible. By the movable carriage 1, main body 2 and first bearing assembly 11 and second bearing assembly 12 is formed a system exhibiting stiffness properties that allow the system to withstand the magnetic and gravity forces without compromising the system's ability to facilitate translational movement for example due to the blockage of the first bearing assembly 11 and second bearing assembly 12 by deformations.

[0043] During the operation of the present placement and replacement system, it experiences a number of forces varying in strength and direction. In the preferred embodiment, to avoid involuntary movement of the carriage 1 while under the influence of these forces, the screw mechanism 8 comprises locking mean, for example trapezoidal or square thread profiles. In alternative embodiments the involuntary movement is avoided by application of braking systems, usage of high ratio gearing or application of bearings, with high friction, to support the screw mechanism 8.

[0044] To generate translational movement the screw mechanism 8 can be driven by a suitable drive mechanism via the crank block assembly 10 by applying force or a tool, capable of generating such force, to the turning head 13 (for example hexagonal wrench, hand-crank, pneumatic or electric or hydraulic mechanism or another tool capable of generating rotational force to move the movable carriage 1). The crank block assembly 10 is supported by a support bearing 14, which enables the crank block to turn around its rotational axis while blocking all other movements. The support bearing 14 is attached to the main body 2 by support bearing fixing screws 5.

[0045] Adjustable mounting bracket 3 and fixed mounting bracket 4 are attached to the main body 2 in order to make it possible for the system to become engaged with stator rails and rotor rails 22 (FIG. 2). The fixed mounting bracket 4 is attached to the main body 2 by means of welding or utilization of screws and bolts. The adjustable mounting bracket 3 is fixed to the main body via at least one adjustment mean 6 in order to allow necessary adjustment movements described in following paragraphs.

[0046] FIG. 3 illustrates a front view of the placement and replacement system's engagement with the electrical component module 17, for example magnet module, comprising attachment profile 16, base plate 32 and permanent magnet blocks 33, wherein the attachment profile 16 is magnet attachment profile, having a cavity 21 in the middle of the profile with inner mounting surfaces 18, vertical mounting surfaces 19 and outer mounting surfaces 20.

[0047] FIG. 4 illustrates the system's engagement with the electrical component module, for example coil module 17, comprising attachment profile 16 and embedded winding module 34, wherein the attachment profile 16 is coil attachment profile, having a cavity 21 in the middle of the profile with inner mounting surfaces 18, vertical mounting surfaces 19 and outer mounting surfaces 20.

[0048] Due to that, the magnet module and coil module comprise attachment profile 16 with the exactly same inner geometry, the system's engagement with the module is therefore only illustrated based on the example of the magnet module 17.

[0049] In addition to the placement and replacement action the attachment profile 16 serves also as a passive heat exchanger by dissipating heat generated during energy production of the electromagnetic rotary machine. The heat exchanger for the modules is required from the operational side of the machine, while only the inner geometry of it is shaped in a form suitable for placement and replacement action. Therefore, the attachment profile 16 is utilized for two functions, bringing savings in material and production costs.

[0050] Referring to FIG. 3 and FIG. 4, to facilitate the placement or replacement action, the system is slid through the cavity 21 in the attachment profile 16. This features inner mounting surfaces 18, vertical mounting surfaces 19 and outer mounting surfaces 20, which form an enclosed space in a manner that once the movable carriage 1 has been inserted into the cavity 21, only translational movement along the screw mechanism's 8 length wise axis remains possible. This degree of freedom is removed by placing at least two mounting elements 23 (for example screws, bolts, etc.) through the apertures 35 of attachment profile 32 into the apertures 36 of movable carriage 1.

[0051] Geometrical locking between placement and replacement system and attachment profile 16 is facilitated in such a manner that the movable carriage 1 fully supports the attachment profile 16 despite the particular direction of gravity or magnetic forces acting in the view plane. For example, if the major force component is acting in the vertical direction of the view plane, the module is supported by inner mounting surfaces 18 or outer mounting surfaces 20. When the major force component is acting in the horizontal direction of the view plane, the module is supported by vertical mounting surfaces 19. The particular feature makes it possible to use the placement and replacement system at any position of the electromagnetic rotary machine if proper mounting of the system to the rails 17 can be facilitated.

[0052] The ability to use the system at any position of the electromagnetic rotary machine with same effectiveness allows performing the needed replacement action without having to employ complicated positioning systems to achieve correct position between rotor and stator.

[0053] Handling and initial positioning of the system under the influence of magnetic forces is complicated and labour intensive work. In general, the influence of magnetic forces can be avoided for the placement of coil modules 17 but must be taken into account for magnet modules 17. Therefore, to use one system for both of the electrical component modules 17 the elements of the present placement and replacement system are composed of non-ferromagnetic materials, such as austenitic stainless steel, ceramics, plastic, fiberglass or other composite materials. This allows using the same system for both electrical component, coil and magnet, modules 17 with same effectiveness.

[0054] FIG. 5 illustrates cross-sectional view of the placement and replacement system with the attachment profile 16. In this alternative embodiment the inner mounting surfaces 18 and outer mounting surfaces 20 in the profile are horizontal while the vertical supporting surfaces 19 are vertical. All these surfaces come in contact with the movable carriage 1 and facilitate the geometrical locking between elements. The movement of the carriage 1 relative to the main body 2 is facilitated by the first bearing assembly 11 and second bearing assembly 12, wherein the first and second bearing assembly are linear ball bearing.

[0055] FIGS. 6 and 7 show both alternative embodiments of attachment profile 16 and first bearing assembly 11 and second bearing assembly 12 designs. On FIG. 6 the movement of the carriage 1 relative to the main body 2 is facilitated by bearing assemblies 11 and 12 consisting of screwed on blocks of antifriction material (for example polyamide).

[0056] On FIG. 7 the bearing assemblies 11 and 12 consist of numerous screwed on roller bearings while the inner mounting surfaces 18 and outer mounting surfaces 19 are non-horizontal and the geometrical locking between the movable carriage 1 and attachment profile 16 is achieved by fishtail like elements.

[0057] The method, according to the present invention, for placing and replacing the electrical components of electromagnetic rotary machine with the system comprising frame, multiple of system fixing means to attach the system to the electromagnetic rotary machine, moving means for inserting electrical components to the electromagnetic rotary machine and extracting the electrical components from the electromagnetic rotary machine to place or replace the electrical components. The method comprises attaching the system to the electromagnetic rotary machine to place and/or replace the electrical components, removing the electrical component to replace the electrical component and inserting the electrical component to the electromagnetic rotary machine.

[0058] Attaching the system to the electromagnetic rotary machine comprises following steps: sliding the system through the cavity 21 in the electrical component 17 attachment profile 16; clamping initially the system to the extending edges of stator sector rails 22 by first mounting bracket 3 and second mounting bracket 4; once initial clamping is achieved, moving the first adjustable mounting bracket 3 forward towards the extending edge of the stator rail 17 and fixing to it by at least one bracket mounting element 7 and by securing at least one adjustment element 6 to the main body 2.

[0059] Removing the electrical component from the electromagnetic rotary machine comprises following steps: positioning and placing of the system; translating the movable carriage 1 into the attachment profile 16 by crank block assembly 10 and geometrically locking the attachment profile 16 and the system; locking the mounting elements 23 into place and removing module mounting elements 24 and engaging the electrical component 17 with the placement and replacement system and transporting out of the electromagnetic rotary machine air-gap 25 by using the crank block assembly 10; transporting the electrical component 17 out of the electromagnetic rotary machine air-gap 25 to the end position and removing the mounting elements 23; finalizing the removing procedure by sliding the electrical component 17 off the placement and replacement system.

[0060] Removing the placement and replacement system by unclamping the first mounting bracket 3 and second mounting bracket 4 from the rails 22 or inserting the electrical component to the electromagnetic rotary machine, wherein inserting the electrical component comprises following steps: inserting new electrical component 17 by sliding the electrical component 17 onto the movable carriage 1 and locking into place by mounting elements 23; translating the electrical component 17 into end position of the placement and replacement system via crank block assembly 10; fixing the electrical component 17 onto the rails 22 by module mounting elements 24; releasing the placement and replacement system by removing the mounting elements 23 from the attachment profile 16 and main body 2; translating the movable carriage 1 into the start position via crank block assembly 10; loosening the adjustment elements 6 and removing the bracket mounting elements 7; moving the first mounting bracket 3 away from the rail 22 and sliding the placement and replacement system out of the attachment profile 16.

[0061] As follows the present method is described in more detailed. FIG. 8, FIG. 9 and FIG. 10 show an example of a procedure concerning electrical component, for example coil module, 17 removal with the placement and replacement system. In the preferred embodiment referring to FIG. 8, the system has been slid through the cavity 21 in the electrical component, for example coil module, 17 attachment profile 16. Adjustable mounting bracket 3 and fixed mounting bracket 4 are used to achieve the initial clamping between the system and the extending edges of stator sector rails 22. The possibility to use the attachment profile 16 in order to slide the system into correct position for fixing is crucial, when considering the effort required to manipulate the system. Although, it can be handled by one person, less effort is required to position the system correctly, when it can be initially supported by the coil profile.

[0062] Once initial clamping has been achieved, the adjustable mounting bracket 3 is moved forward towards the extending edge of the stator rail 22 and fixed to it by at least one bracket mounting element 7. Final position and placement of the system is achieved by securing at least one adjustment element 6 to the main body 2.

[0063] FIG. 9 describes a situation where the movable carriage 1 has been translated into the attachment profile 16 by the use of crank block assembly 10. By this action the initial geometrical locking between the attachment profile 16 and placement and replacement system is achieved. Once the mounting elements 23 are locked into place and module mounting elements 24 have been removed, the electrical component, for example coil module, 17 is fully engaged only with the placement and replacement system and can be transported out of the electromagnetic rotary machine air-gap 25 by the use of the crank block assembly 10.

[0064] FIG. 10 illustrates the phase where the electrical component, for example coil module, 17 has been transported out of the electromagnetic rotary machine air-gap 25 to the end position and the mounting elements 23 (FIG. 9) have been removed. At this position the coil module 17 does not experience any magnetic forces and therefore is safe to handle without use of extra equipment. Now the module can be slid off the placement and replacement system and thus the removal procedure can be considered finalized. In the final position of the coil module 17, the support offered by the movable carriage 1 reduces the amount of manual labour required to handle the module, which makes it possible to handle it with a crew of maximum two persons.

[0065] After removal of coil the module 17 either the placement and replacement system can be removed by unclamping the adjustable mounting bracket 3 and fixed mounting bracket 4 from the stator rails 22 or a new coil module 17 can be inserted by reversing the previously described steps. New module is slid onto the movable carriage 1 and locked into place by mounting elements 23. After locking, the module will be translated into end position of the placement and replacement system via crank block assembly 10. There the plurality of module mounting elements 24 are utilized to fix the coil module 17 onto the stator rails 22. In order to remove the placement and replacement system the mounting elements 23 are removed from the attachment profile 16 and main body 2. The movable carriage 1 is translated into the starting position via crank block assembly 10. Adjustment elements 6 are loosened and bracket mounting elements 7 are removed. The adjustable mounting bracket 3 is moved away from the stator rail 22 and the placement and replacement system is slid out of the attachment profile 16.

[0066] In an alternative embodiment initial positioning of the placement and replacement system is attached to the stator rails 22 without having an electrical component, for example coil module, 17 on the site of placement. In that particular situation the system is clamped to the stator structure segment 30 in similar manner, however the initial positioning of the system is achieved via bracket mounting elements 7. The correctness of the positioning is confirmed by insertion and alignment of module mounting elements 24. In case of erroneous or undesired positioning, the whole coil module 17 and placement and replacement system assembly can be relocated by slightly loosening the bracket mounting elements 7 without compromising any of safety related requirements.

[0067] Low weight of the system, simple and fast operation principles make it possible and also technically reasonable to utilize the system for both coil and magnet placement and replacement up tower, in the factory and on the wind power unit erection site.

[0068] Furthermore, due to the fact that for example only rotor rails 22 are required to achieve system placement, neither the existence of stator or even full rotor structure is necessary. As outer diameters of directly driven electromagnetic rotary machines in wind power units are growing as capacities grow, ultimately mechanical segmentation of the carrier structures for such machines is necessary in order to avoid transportation issues. In such cases, the final assembly of machines would take place on the wind power unit erection site. As it is dangerous and economically unjustified to transport highly magnetized segments of electromagnetic rotary machines, the permanent magnet modules would ultimately have to be assembled also on that erection site. Therefore, a device and method which could be used to assemble coil and magnet modules at wind power unit erection site with needed efficiency and without demands for infrastructure can be regarded as highly beneficial.