DESC:TECHNICAL FIELD
[0001] The present invention relates to the field of geared wind turbines located in various zonal locations and more particularly, to the three-pole column steel structure constructed in nacelle for removing and replacing the failed generators as per the need for the nacelle orientation, wherein the different shapes of the structure are proposed to large corrective actions in a wind turbine generator.
BACKGROUND
[0002] The background information herein below relates to the present disclosure but is not necessarily prior art.
[0003] The field of the invention is generally related to wind turbines and more specifically, to manage the downtime of wind turbine generator failures.
[0004] Recently, with the increasing cost of fossil fuels and other presently widely used energy sources, interest is again being directed to the use of wind as a competitive source of energy. Generally, a wind turbine includes a rotor having multiple blades. The rotor is mounted within a housing of a nacelle which is positioned on top of a truss or tubular or hybrid tower in horizontal axis. When the wind passes over the blades, it exerts a turning force. The rotating blades make a shaft turn inside the nacelle, which goes into a gearbox. Next, the gearbox speeds up the rotation to an appropriate level for the generator, which uses magnetic fields to convert the rotational energy into electricity, which is fed into a utility grid.The majority of the wind turbines have been operated at constant speed. Subsequently, the number of variable-speed wind turbines installed in wind farms has increased. Based on the fixed speed and variable speed wind turbine, suitable generators are used in the wind turbine capacity.
[0005] There are many technical challenges to face, especially for the long life, and low maintenance of wind turbine systems. The half of the failures were electrical in nature and most of those were due to mechanical failures of the insulation support structure. Many of the failures appear to be of a serial nature due to the inadequate original design of the machine and/or the insulation system. These generators are exposed, at least in some part, to the typical voltage irregularities and mechanical stresses of any machine that operates 100 meters in the atmosphere in a wide variety of weathers. However, they are also sometimes affected by poor power quality from the IGBT-based converters used in most turbines. These failures could result from voltage stresses created by the convertor in the turbine or from neighbouring turbines.
[0006] An overview of different wind turbine generators including DC, synchronous, and asynchronous wind turbine generators have some relative merits and disadvantages with the criteria based on the speed range, cost, complexity, size, and power quality at the grid connection. During operation, inefficient maintenance of the over-speeding sensor and adoption of low-quality sensors lead to malfunctioning which in turn, affects the operation of wind. Other failures include rotor speed reading errors, encoder failure, software failure, frequent grid stoppage errors, lightning strikes, wind loading, weather extremes, etc. However, the components of the generator are expensive and have been known to fail prematurely, thereby resulting in down time for the wind turbine as the generator is replaced or repaired. Hence, there is an urgent need for cost-effective operation and maintenance (O&M) strategies, especially unplanned downtime represents one of the main cost drivers of a modern wind farm. Here, the failure prediction models can enable operators to apply preventive O&M strategies rather than corrective actions. But, in order to reduce the downtimes of wind turbine (WT) component failures have to be understood profoundly.
[0007] Now, wind turbine owners and manufacturers are practicing the unplanned failure of components to be replaced by heavy-duty cranes. For that purpose, wind turbines are getting bigger and higher–reaching physical limits as they become higher than conventional cranes can reach. Commonly heavy-duty cranes are used for the lifting of major components on turbine erection. These have the drawback of needing to be significantly taller than the tower and require significant time to erect and dismantle, needing a large amount of transport equipment, and may suffer problems of access in difficult-to-reach remote places, with the result that they are an expensive, more fuel-consuming and somewhat inflexible solution. The turbine typically also has an internal crane within the nacelle which is suitable for the lifting of relatively small components. Such cranes are, however,not of sufficient capacity, dimension, or positioning to be able to handle major components including turbine components of generators to be repaired or replaced.
[0008] The above said available failure and the lack of execution on existing practices to overcome the aforementioned drawbacks. Based on wind turbine operational maintenance technologies are evaluated in terms of complexity, size, and other factors. Hence there is a need to overcome for cost-effective operational maintenance (O&M) strategies has been developed in order to minimize the downtime. For this, a newly developed column steel structure is introduced based on various wind turbine construction. The system and method are an assembly of column steel structure placed in nacelle chassis uses to replace the generator from the machine head.
OBJECTS
[0009] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
[0010] It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
[0011] The object of the present system of the invention is too simplified column steel structure having multiple segments that are adapted for different types of the nacelle and are used as a replacement for failure generators in wind turbines.
[0012] Another object of the present disclosure is to provide a column structure and its construction system for replacing the components of the nacelle that facilitate quick and efficient removal and installation of the generator from the nacelle.
[0013] Another object of the present disclosure is to provide an invention that relates to a method for removing a component housed in a nacelle of a wind turbine, referring now in more detail to the drawings in which like numerals indicate like parts throughout the several views of various embodiments.
[0014] Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying FIG.s, which are not intended to limit the scope of the present disclosure.
SUMMARY
[0015] The present disclosure envisages a system for generator replacement in a wind turbine. The system broadly comprises of an electrical winch, an assembly of three-pole column steel structure, and a pulley system.
[0016] The electrical winch is disposed on the ground in the vicinity of the wind turbine. The pulley system including a back pulley, a guide pulley, a fixed pulley on the end of a monorail, and a moving pulley connected to the fixed pulley. The assembly of three-pole column steel structure is placed in nacelle chassis, wherein said structure includes at least one semi-type pivoted arm supports with a main pole connecting at least two support cross pole placed on an upper surface of nacelle frame to lift the generator, a bottom stool, connected with anchorage point or holes provision of the nacelle frame to fasten, a lifting jig to hold the generator for replacing from the machine head in wind turbine, and a wire rope connected with the fixed pulley at rotatable arm and connected perpendicular to the moving pulley attached with the jig in the formation of block and tackle arrangement.
[0017] In an aspect, the lifting line which operates though load bearing mechanism is used to lift the generator with moving pulley through fixed pulley and back pulley which forms obtuse angle when passing through the back pulley.
[0018] In an aspect, the monorail is a fabricated I-beam with its end secured with plates to act as a stopper for a trolley.
[0019] In an aspect, the lifting jig includes a hook, wherein the hook is provided on a stay cross support–2 and wherein the existing hook provisions of the generator is followed by assembling the moving pulley on hooking provisions of the lifting jig.
[0020] In an aspect, the semi-type pivoted arm is used to lift the generator by winch method or traction hoist method.
[0021] In an aspect, the auxiliary hook is provided near to the fixed pulley to provide support to the lifting line.
[0022] In an aspect, the structure further comprises a bottom pipe which is cylindrical shaped component with extension square plates welded on one end and the round shaped plate on other end and wherein a top inner pipe is placed over the bottom pipe by means of matching the holes that are provided on the extension square plates.
[0023] In an aspect, a rotating pipe is a fabricated component which looks similar to the top inner pipe with its cylindrical diameter larger than the top inner pipe’s diameter while its length is shorter than the top inner pipe’s length and the top inner pipe assembly is subset to the rotating pipe.
[0024] In an aspect, a removable link of rotating fixed holder is fastened with another projection circumference plate of the rotating pipe to provide a hooking point to the rotating pipe and reduce the force required to turn the rotating pipe for moving of generator.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0025] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various ‘FIG.s’ may be represented by a like numeral or similar text. A three-pole steel structure of the present system is now described with the help of the accompanying drawings, for purposes of clarity, not every component may be labelled in every drawing, in which like process is represented throughout the drawings, wherein:
[0026] FIG.1 is a side view of a preferred embodiment of a turbine of the present invention showing the three pole column structure assemblies for replacing the component of the wind turbine by winch method and the similar construction used by the traction hoist method in FIG.1B;
[0027] FIG. 1A illustrates a back view of a preferred embodiment of the present invention shown the structure construction of FIG.1;
[0028] FIG.2 illustrates a side cross-sectional view of another embodiment of the second invention showing the three pole column structure assemblies for replacing the component of another type of wind turbine by winch method and the similar construction used by traction hoist method in FIG.2B;
[0029] FIG.2A illustrates a back view of assemblies of the present invention shown the structure fixing in wind turbine of FIG.2;
[0030] FIG.3 illustrates a cross-sectional view of another embodiment of the third invention showing the three pole column structure assemblies’ position for replacing the component of the wind turbine executed by winch method and the same construction operated by traction hoist method in FIG.3B;
[0031] FIG.3A illustrates a three-pole rotatable arm of the handy assembly structure installed in another type of nacelle construction for a wind turbine generator of FIG.3;
[0032] FIG.4 illustrates a cross-sectional view of another invention showing another type of nacelle construction of wind turbine and the invention of cross-section of handy structure assembly placed in accordance with the present schematic plan view managed by winch method and the same structure executed by traction hoist method as shown in FIG.4B;
[0033] FIG.4A illustrates a cross-sectional view of a four-pole structure assembly in wind turbine of FIG.4;
[0034] FIG.5 illustrates a side elevation view of another inventive method of three pole cross-sectional structure assembly positioned in another type of nacelle frame of the machine head executed by winch method and the same development operated by traction hoist method shown in FIG.5B;
[0035] FIG.5A illustrates back elevation view of three pole rotatable arm structure fixed in nacelle of FIG.5;
[0036] FIG.6 illustrates a detailed illustration of a side section view of another type of inventive method of handy structure for lowering the generator placed in the nacelle by winch method and the same structure executed by traction hoist method shown in FIG.6B;
[0037] FIG.6A illustrates a back view of two pole cross section with stay type structure assembly of FIG.6;
[0038] FIG.7 illustrates a schematic view of another invention showing the three-pole structure fixated in the nacelle frame and incorporated with other lifting accessories which is used to lower the generator of a wind turbine by winch method and the same structure is executed by traction hoist method as shown in FIG.7B;
[0039] FIG.7A illustrates a detailed back view of the structure assembly in wind turbine nacelle of FIG.7;
[0040] FIG.8 illustrates a perspective side view of a four-pole steel structure positioned at a lateral surface of a nacelle to lowering the generator from the machine head of the wind turbine by winch method and the same construction used by traction hoist method is shown in illustrates;
[0041] FIG.8A illustrates a back view illustrating the structure assembly in nacelle as illustrated in FIG. 8;
[0042] FIG.9 illustrates another invention of structure assembly positioned in nacelle frame which is used for replacing the generator according to the present invention by winch method and the same structure operated by traction hoist method as shown in FIG.9B;
[0043] FIG. 9A illustrates a back view of three pole structure assembly placed in present invention of FIG. 9;
[0044] FIG. 10 illustrates a side cross-sectional view of connecting the generator by a rotatable arm by traction hoist to swing up the load into outside nacelle;
[0045] FIG.11 illustrates a turn up the component from the nacelle frame in the machine head outside and ready to operating for lowering the generator by traction hoist;
[0046] FIG.12 illustrates the method of lowering the generator from wind turbine through traction hoist;
[0047] FIG.13 illustrates in detail, the system showing the rotating of main pipe with monorail or cantilever swivel plate using a lever hoist or a hydraulic cylinder to shift the generator;
[0048] FIG.14 illustrates a rear view showing the method of lifting or lowering the generator using by chain hoist from bed and transferring the load to a traction hoist or chain hoist;
[0049] FIG.15 illustrates a schematic view of complete system and method of generator lowering from the nacelle by winch connections with the column structure; and
[0050] FIG.16 illustrates one of the embodiments of the present disclosure showing the generator lowering with the system connected with the invented structure.
LIST OF REFERENCE NUMERALS
Reference Number Description
10 Ground
11 Tower
12 Nacelle
13 Nacelle frame
14 Rotor
15 Blade
16 Main shaft
17 Gearbox
18 Gearbox mount
19 Generator
20 Yaw Drive
21 Generator column structure
22 Bottom stool
23 Bottom post
24 Square arch post and beam
25 Bottom pipe
26 Top inner pipe
27 Rotating pipe
28 End cap
29 Monorail/Rotator arm
30 Monorail cross support
31 Monorail mounting support
32 Cantilever swivel plate
33 Artin plate hook
34 Stay stool-1
35 Stay stool-2
36 Stay stool-3
37
38 Stay cross support-1
Stay cross support-2
39 Stay cross support-3
40 Vertical stay support-1
41 Vertical stay support-2
42 Vertical stay support-3
43 Horizontal stay support-1
44 Horizontal stay support-2
45 Horizontal stay support-3
46 X-Support
46-A Front x-support post
46-B Rear support post
47 Diagonal cross support
48 Swivel lifting arm
49 Top lifting arm
50 Lifting arm
51 Lifting arm bottom post
52 Lifting arm middle post
53 Lifting arm top support
54 Cross beam
55 Stay rope/stays
56 Platform
57 Chain hoist
58 Trolley
59 Hydraulic cylinder
60 Bottom pulley
61 Back pulley
62 Guide pulley
63 Fixed pulley
64 Moving pulley
65 Wire Rope
66 Winch
67 Counter weight
68 Work force
69 Hoist mount plate
70 Traction hoist
71 Lifting jig
72 Bottom jig
73 Rotating fixed holder
74 Tagline
75 Fasteners
76 Lever hoist
77 Hook
78 Auxiliary Hook

DETAILED DESCRIPTION
[0051] Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
[0052] Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components and methods to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known apparatus structures, and well-known techniques are not described in detail.
[0053] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an”, and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms, “comprises”, “comprising”, “including” and “having” are open-ended transitional phrases and therefore, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0054] When an element is referred to as being “embodied thereon”, “engaged to”, “coupled to” or “communicatively coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
[0055] The invention relates to a method to construct the three-pole column steel structure in machine head of wind turbine by applying the invention is provided for replacement and servicing of generator 19 in wind turbine. Aspects of the present invention also relate to the positioning of and structure for placing over the nacelle frame within the number of simplified parts assembled together of a nacelle in manners that provide for de-erection and re-erection of the failure generator 19 while also allowing for optimal rotatable lifting arm positioning of a swinging mechanism.
[0056] According to one aspect of the invention, a three-pole steel structure construction of a wind turbine is disclosed that includes a rotatable lifting arm supported by a structure is handy solution. The steel structure has atleast semi-type pivoted arm supports with main pole and connects atleast two support cross pole has placed an upper surface of nacelle frame placing in anywhere position to ends with main pole.The three-pole steel structure includes a suitable bottom stool 22 and connecting about at-least a portion of the nacelle frame is varied from machine to machine construction. The connection of the bottom stool 22 is connected with anchorage point or holes provision of the nacelle frame is used to fasten. A semi-type pivoted arm in main pole is used to lift the generator 19 by winch method or traction hoist 70 method.
[0057] According to another aspect, a three-pole steel structure includes a suitable lifting jig 71 used to holding the generator 19 for replacing from the machine head in wind turbine. This further involves the lifting jig 71 is position in generator top hook. In yet further aspect, the wire rope 65 is connected the fixed pulley at rotatable arm and it relatively connected perpendicular to the moving pulley attached with the jig 71 in the formation of block and tackle arrangement. By operating the ground electrical winch 66 or traction hoist 70, the generator 19 is lowering from the nacelle to the ground 10.The present invention to provide a wind turbine for replacing a generator 19 in a nacelle by three pole structure, whereas the installation can be carried out in relatively quick, cost effective, seamless and simple process which can reduce installation time and downtime in relation to fixing the generator 19.
[0058] According to the invention, all essential components are transported in one standard container for that purpose, such as, truck container transporters, by means of which the containers can also be transported on location and stored for attending the unscheduled breakdown maintenance failure.
[0059] The invention also relates to a method for removing a component housed in a nacelle of a wind turbine, referring now in more detail to the drawings in which like numerals indicate like parts throughout the several views of various embodiments.
[0060] FIG.1 illustrates, the exemplary embodiments of an integrated structure which may be comprising of bottom stool 22 which is a single component profile that is fabricated as a welded frame of I-beams with rectangular plates at both flange sides with the square plates at both ends to match the holes projection and provide support to the nacelle side. The bottom stool 22 is placed on the left side of the nacelle frame 13 between the mid of the gearbox 17 and the generator 19. Simultaneously, assemble the stay stool–2 35, on the same side just in front of the gearbox 17 mount by using nacelle frame holes provision or hook. Concurrently, another bottom stool 22 is placed as similar to the position of the existing bottom stool 22 but in the right-hand side of the nacelle frame between the mid of the gearbox-generator. The assembly of the stay stool–2 35, bottom stool 22 and another bottom stool 22 seems look like as 3’o clock position.
[0061] In one embodiment, the bottom pipe 25 which is a cylindrical shaped component with extension square plates welded on one end and the round shaped plate on other end wherein both these extension plates have holes in order to match the other components during the assembly. In addition to that, this bottom pipe 25 has at least one projection on its cylindrical circumference to hold the support to the top lifting arm 49. The bottom pipe 25 is attached over the bottom stool 22 with its projection on the cylinder circumference. Using fasteners 75, the assembly of the bottom stool 22 is connected by means of matching both the square plate holes of the bottom stool 22 and the bottom pipe 25.
[0062] Followed by assembling the top inner pipe 26 over the bottom pipe 25 while the top inner pipe 26 is a fabricated component which comprises of cylindrical pipe with round extension plates welded on its bottom end while the upper end is set to be free. Also, another extension plate is provided with some interval from the bottom side to provide the support and substructure to the rotating pipe 27 during its rotary motion. In addition to that, at least one rib is placed along the circumference of the top inner pipe 26 in between the base and its extension plates. In some of the top inner pipe constructs, two projections have to made on its pipe’s circumference at acute angle with each other and within these extension plates through which they match the stay horizontal post-1 43 to the stay vertical post-1 40 in another bottom stool 22 and stay horizontal post-2 44 ends with stay cross supports-2 38 mounted in stay stool–2 35. Both these extension projections in top inner pipe 26 ribs are placed over on cylinder surface to gives more support.
[0063] In one embodiment, the stay vertical post-1 40 is assembled with another bottom stool 22 followed by assembling the stay cross support-1 37 connected to the top inner pipe 26 with the projection over it. Followed by assembling the top lifting arm 49 through the projection provided on the bottom pipe 25 fastened firmly. Then, the top lifting arm 49 is used to lift the rotating pipe 27 and place it on its desired position with the help of the manual lifting mechanism (lever hoist 76). The rotating pipe 27 is a fabricated component which looks similar to the top inner pipe 26 with its cylindrical diameter larger than the top inner pipe’s diameter while its length is shorter than the top inner pipe’s length and the top inner pipe 26 assembly is subset to the rotating pipe 27. Also, this rotating pipe 27 has at least one projection near the bottom extension plates for monorail cross support assembly and at least one projection on top of its circumference for monorail 29 assembly. These projections have been supported with at least one set of ribs to ensure the stress concentration factor within the threshold value. In addition to that, a removable link of rotating fixed holder 73 is fastened with another projection circumference plate of the rotating pipe 27 by means of matching the holes in it. The main purpose of this link is to provide a hooking point to the rotating pipe 27 as well as it reduces the force required to turn the rotating pipe 27 for moving of generator 19. After placing the rotating pipe 27, the end cap pipe 28 is used to place over the rotating pipe 27 at the same time its inner surface should cover the extend length of the top inner pipe 26. This end cap pipe 28 is one which has two projection as same as the top inner pipe 26 to provide the stay cross supports to the entire set of columns.
[0064] In another view of FIG.1A, embodiments say the additional support of two stay supports for the column of the structure. It’s described as the stay cross support–2 38 is introduced in between the stay stool-2 35 and the end cap pipe 28. As the length of this stay cross support–2 37 is too large, hence provides the additional support of horizontal stay post-2 44 is placed in between the stay cross support–2 38 and the projection over the top inner pipe 26. The stay cross support-2 38 is a fabricated component with at least one extension plates attached on it to make the cross-support assembly as feasible and also it contains one hooking point to attach the manual lifting mechanism like the lever hoist 76 or hydraulic cylinder 59 which is used to turn the rotating pipe 27. Like as the stay cross support–1 37 is ends may connected with the flanges in horizontal stay post-1 43 by fasteners 75 then the further end of stay cross supports-1 37 is connected with the end cap pipe 28 and also have one hooking points projected in side face which was welded.
[0065] In a set of embodiments, the monorail 29 and the monorail cross support 30 has to be assembled by means of matching the projection over the rotating pipe 27. At the monorail 29 is in the form of a cantilever beam and it carries the maximum load, it will tend to bend. In order to prevail over this, the monorail 29 is fabricated in the form of I-beams with attachment plates at either side of the flanges. Also, an extension plate is welded on its bottom to provide support to the monorail 29. Thereby, the length of the monorail 29 is reduced as well as the cross section is developed which both results to overcome the bending defect while loading the desired component 19. The monorail cross support 30 is also a fabricated component of two channels welded together to form a square face with at least one projection to turn the rotating pipe 27 and at least one projection provided to hold the back pulley 61 which is a single sheave. Then, the fixed pulley 63 is assembled on the end of the monorail 29 which has at least double sheaves and at least one projection on top of the side plates to provide the hooking point to attach the chain hoist 57, same hook projection is provided on the side plates of moving pulley 64 to assemble the hook of the chain hoist 57. Both, this fixed pulley 63 and back pulley 61 have no relative displacement in between them and with respect to the monorail 29. The lifting line 65 which operates though load bearing mechanism is used to lift the generator 19 with moving pulley 64 through fixed pulley 63 and back pulley 61 which forms obtuse angle when passing through the back pulley 61.
[0066] The FIG.2 illustrates in one embodiment, the bottom stool 22 placed over the nacelle frame 13 on left side placed in between the gearbox-generator where it gets assembled with the fastening units 75 over the hooking points or it may be assembled at both flange sides to match the holes projections. This bottom stool 22 comprises of two plates which are welded with each side of the section in the form of a rectangle which has at least one rib provided to ensure the stress concentration factor in safe. Thus, the fabricated component has an inclination in between its upper and lower plates, is to match the nacelle inclination angle and make the upper portion in level with the horizontal. Similarly, the stay stool-2 35 which is identical in construction to the bottom stool 22 and placed over the hooking point or holes projection that provided on the right side between the generator 19 and gearbox 17 in order to secure the connection in safe condition fasten it with the bolts 75. This construction of the column structure 21 is also framed as two stay supports.
[0067] In another embodiment, the stay stool–1 34 is placed in front of the left-hand side of the gearbox mount 18 and the connection is secured with the bolted joints 75 through the provisions made on the nacelle frame mounts. This stay stool–1 34 is comprising of at-least one bottom and top plate which are joined with rectangular sections while the lower plate is to match the hole provision on the nacelle bed nearer to the gearbox mount 18 and the top plate should have at least provision to provide the support to its corresponding vertical stay support-1 40 with the help of fastening units 75. After assembling the stay stool–1 34, bottom stool 22 and the stay stool-2 35, which are all in the form of a right-angle position.
[0068] Over the bottom stool 22, introduce the bottom pipe 25 which has cylindrical in construction with square plate welded at one of its ends while the circular extension plate with some holes provision is welded on the other end. Both these extension plates are used to weld with the cylindrical pipe with at least one rib provided on each. Fasten the bottom pipe 25 over the bottom stool 22 by means of matching both the holes on the square plates.
[0069] In a further set of embodiments, the assembly has the top inner pipe 26 mounted over the bottom pipe 25 and this top inner pipe 26 is a fabricated component of cylindrical pipe with extension plate attached at its bottom while the top end is set to be free with at least one-hole provision throughout its radial direction. Also, another extension plate of similar geometry is made to weld on the exterior surface of the pipe with some interval from the bottom extension plate. Both this extension plates are used to be weld jointed together with at least one rib along the axial direction of the cylindrical pipe without disturbing the holes that provided on the bottom extension plate. The segment of the assembly, two projection plates are weld joined on the circumference in between the two extension plates at the bottom. Also, these projection plates are at right angle to each other which will provide the additional supports to the load carrying column and its extending for further cross support assembly.
[0070] In one embodiment, the vertical stay support-1 40 is assembled over the stay stool–1 34 which is kept on the right side between the generator 19 and the gearbox 17. This vertical stay support-1 40 comprises of square section with one end being attached to the stay stool–1 34 while the other end is set to be free. The free end has plate projections to provide at least one support to the load carrying column. Then, introduce the stay cross support–2 38, in between the projections of the stay stool-2 35 and the end cap pipe 28 followed by fastening the joints with proper connections. The segment of the assembly may be constructed as placing the rotating pipe 27 over the top inner pipe 26. This rotating pipe 27 is comprising of cylindrical pipe with extension plate being welded at bottom end while the top end is kept free and its inner diameter is greater than the outer diameter of the top inner pipe 26 but shorter in length, by this the rotating pipe 27 set to place over the top inner pipe 26 by means of contacting the outer surface area of the top inner pipe 26 along with inner surface area of the rotating pipe 27. In addition to that, the rotating pipe 27 has at least one projection near to the bottom and top end to secure the supports to the rotator arm 29 which carries the generator 19 and at least one hook provision in between these two projections to support the lever hoist 76 which used to turn the rotating pipe 27.
[0071] Then, the end cap pipe 28 is placed over the top inner pipe 26 consisting of two projections on its longitudinal circumference placed adjacent to each other by which these projections are at right angle to each other. And also, this end cap pipe 28 has a hole provision throughout its radial direction just to match with the holes provision that provided on the top inner pipe 26. A mechanically followed by, assemble this end cap pipe 28 with the top inner pipe 26 with fastening joints 75 to arrest the vertical motion of the rotating pipe 27. Then, the assemblies include the stay cross support–2 38 have at least one hook provision on its longitudinal face to support the lever hoist 76 and is connected in between the projections of the stay stool–2 35 and end cap pipe 28. In similar of as shown in FIG.2A an assembly says the stay cross support–1 37 in between the projections of the stay vertical post-1 40 and the hook in end cap pipe 28. Hence, it means the additional support to the load carrying column, introduce the stay horizontal support–1 43 in between the projections of the top inner pipe 26 and the projections of the stay vertical post–1 40 which forms right angle to top inner pipe 26 and acute angle to stay cross support–1 37. According to the FIG., the stay horizontal support–2 44 is assembled with fastening units 75 in between the provisions of the top inner pipe 26 and stay cross support–2 38 by forming acute angle with stay cross support–2 38.
[0072] In another embodiment, assemble the rotator cross support 30 with the projections provided on the top of the rotating pipe 27. Then it followed the assembly of the rotator arm 29 on the projections provided on the bottom of the rotating pipe 27. This rotator arm 29 consists of two extrusions from the first link and two projections; first projection is attached to the first extrusion with some extent from the first link; while second projection is attached at the end of the second projections. This first projection carries the back pulley 61 and the second projection carries the fixed pulley 63 with at least one hook provision on pulley’s side plate to attach the chain hoist 57 with top hook connected with fixed pulley 63 while bottom hook being connected with moving pulley 64 through the lifting line 65 which can be operated by load bearing mechanism 66 to lift the generator 19. The rotator arm 29 has also one more projection as in opposite face of the first projection. This third projection is used to provide hook point for the rotator cross support 30 to assemble in between the rotating pipe 27 and the rotator arm 29. The rotator arm 29 have two degrees of freedom, first is the rotation of the rotation pipe 27 in which the rotator arm 29 is being attached; while the second one is the turning of the rotator arm 29 by means of rotator cross support 30.
[0073] From all the above mentioned embodiments shown in Fig.2&2A, the Fig.3&3A describes the same assembly and process maybe proceeded with small interchange in components dimension without altering the profile by assembling the stay stool–2 35 over the gearbox rear left mount and both the stay stool-1 34 and the bottom stool 22 are assembled over the hook provision that made on the nacelle bed instead of assembling on the nacelle bed with locking plate. These alterations in generator column structure 21 may be suitable for higher versions of the wind turbine generators and change in nacelle 12 and interior construction.
[0074] As shown in FIG. 4, the bottom stool 22 is a component which is cuboidal in shape with two of its adjacent side opening and also having a hole’s projection to match it with the provision that extended on the gearbox 17. Similarly, the bottom stool 22 in left hand side is a replica of component bottom stool 22 placed on the right-hand side of the gearbox 17. Both these bottom stools 22 have provision of holes on top of their faces, which is to match the hole provision of the corresponding bottom post 23 and placed rear to the gearbox 17.
[0075] In rear side of the gearbox, each bottom post 23 may be placed over the bottom stool 22. The bottom post 23 is a fabricated component of cylinder-shaped structure with square plates welded on both sides of its longitudinal ends. The square plates have holes on its corners that should match with the square plate of the bottom stool 22. The rear side of the bottom post 23 in left-hand side and right-hand side is needed to be placed over the bottom stool 22 in both sides by means of matching the extension plates that are provided on its end and the plates are assembled with the fastening units 75.
[0076] In one embodiment, the back side of the cross beam support is introduced 54 in between the left hand side bottom pipe 25 and right hand side bottom pipe 25 and then, the components with the extension plates provided on both ends of the back side are assembled, wherein the cross beam 54 support is a fabricated component of cross beam with rectangular square plates on both of its flange sides. In addition to that, at least one extension plates provided near the end of the cross beam 54 along its lateral direction. This extension plates have same holes provision as like the extension plates on the top of the bottom pipes 25 in both sides.
[0077] In another embodiment, the square arch post and beam 24 are assembled over the projection that is made on the gearbox. This square arch post and beam 24 are similar in construction like the back cross-beam 54 instead of the square extension plate on both lateral sides only one side is provided with the square extension plates while the other end is fabricated with an extended channel to match the provision and the height as in level. This extended channel is fabricated with arch plates in order to make adequate contact area over the gearbox frame and to reduce the stress concentration. Thereby, both the rear side cross beam 54 and square arch post and beam 24 are in same flatness level which provides the entire support in stable condition during the loading operation of the generator 19.
[0078] For matching the height to lift the generator 19 from the nacelle frame 13, then the cross beam 54 support is assembled over the front square arch post and beam 24 and back cross-beam 54 on its left side by means of matching the extension square plates and then secures the connection with fastening joints 75. This cross-beam 54 support in left hand side is a fabricated component of I-beam which is welded with rectangular plates on both of its flange sides to close the flange distance. In addition to that, at least one square extension plates are provided on both of its lateral side. As the extension plate carries the maximum load, it is necessary to secure these extension plates with at least one ribs on either side of the cross beam 54. Similarly, the cross beam 54 support in right hand side is assembled on the right side. Further, the bottom pipe 25 followed by the top inner pipe 26 is placed over the rear extension plate of the cross beam 54 in right-hand side by means of matching the holes provision on its extension plates.
[0079] Simultaneously, assemble the front x-support post 46A is placed over the front extension plate of the right and left side cross beam. This front x-support post 46A is constructed with two pipes which are cross-linked with each other through the pipe to make it rigid and both ends of the pipe have been provided with extension plates and holes on it to match with adjacent components. In addition to that, the right portion of the front x-support post 46A is provided with one hook provisions to support the diagonal cross support 47 while the left portion has been provided with two hook provision on its top with acute angle in between these provisions and at least one hook provision is provided near to the bottom extension plate to connect the X-support 46.
[0080] In accordance to one embodiment, the rear support post 46B is assembled over the rear end on the left side of cross beam 54 and fasten it with the holes provision over the square extension plates with the fastening units 75. This rear support post 46B is constructed with cylindrical section and both of its ends are secured with extension plates of square profile. Also, at least one provision is provided near to the extension plates at the bottom side while the upper side is fabricated with two provisions which are right angle to each other; one is to provide support x-support 46 and the second one is to provide and take the support for the load carrying column in which the top rotating pipe 27 and end cap pipe 28 are assembled. Followed by assembling the X-support 46 in between the provisions of the rear support post 46B and left side of the front x-support post 46A with the fastening units 75 to secure the connection. This X-support 46 is a fabricated part which has X-orientation with four of its ends having hook connections to join with the corresponding provisions made on the rear support post 46B and X-support post 46.
[0081] In another embodiment, the top inner pipe 26 is placed over the bottom pipe 25 by means of matching the holes that are provided on the extension plates. This top inner pipe 26 is a fabricated component with cylindrical pipe that is welded with square extension plate on bottom end while the top end is kept free. Followed by, another extension plates with circular shape is used to join its outer surface with some distance from its square extension plates. At least, one rib is provided in between these extension plates to hold the top rotating pipe 27 in secure manner.
[0082] Followed by assembling the top rotating pipe 27, over the top inner pipe 26, while the rotating pipe 27 have inner diameter greater than the outer diameter of the inner pipe 26 in order to match it with tolerance value and also short in length to provide the extension support at the top by considering safe factors. In addition to that, this top rotating pipe 27 has at least two projections on its external circumference in longitudinal direction to hold the monorail 29 and the monorail mounting support 31. After placing the top rotating pipe 27, insert the end cap pipe 28 over the remaining length of the top inner pipe 26. This end cap pipe 28 is a cylindrical shape with inner diameter greater than the top inner pipe’s outer diameter in order to match it with tight fit. Also, this end cap pipe 28 consists of at least three projections on its longitudinal axes by placing one projection at a required acute angle with respect to the adjacent projection. Thereby, these projections will match with the projections of the front x-support 46A and rear support post 46B in right side of the nacelle 12. Then the further assembly to introduce the diagonal cross support-1 47 in between the end cap pipe 28 and the right hand side portion of the front x-support 46A, diagonal cross support-2 47 in between the end cap pipe 28 and the left hand side portion of the front x-support 46A and the diagonal cross support-3 47 in between the end cap pipe 28 and the rear support post 46B in right hand sideof the nacelle 12. Then secure the connections with corresponding joints.
[0083] In accordance to one embodiment, assemble the monorail mounting support 31 with the provisions of the top rotating pipe 27 and secure the connections with the fastening units while the monorail 29 is assembled with the bottom provision of the top rotating pipe 27 and the extension of the monorail 29 is matched with the bottom holes of the monorail mounting support 31. This monorail 29 is a fabricated I-beam with its end secured with plates to act as a stopper for the trolley 58 and monorail mounting support 31 is fabricated with two plates and both are connected with each other through supporting plates in between them also they have holes to match with the extension plates of the top rotating pipe 27 and set of holes on bottom to match with the extension of the monorail 29. Then, assemble the I-beam trolley-1 58 and I-beam trolley-2 58 over the monorail 29 that assembled on the bottom provision of the top rotating pipe 26. These both I-beam trolleys 58 are used to carry the traction hoist 70 through the hoist mount plate 69 along the length of the monorail 29. This hoist mount plate 69 have at least two holes provision to assemble the traction hoist 70 beneath it also have a first provision to hold the wedge socket and the fixed pulleys 63 of two sheaves are attached in the second provision which made after some extent from the first provision.
[0084] In another embodiment, assemble the lifting jig 71 (which not shown in FIG.) over the existing hook provisions of the generator 19 followed by assemble the moving pulley 64 on hooking provisions of the lifting jig 71. Thus the lifting line 65 from the traction hoist 70 is passed through the first sheave of the fixed pulley 63 and then passed through the second sheave of the fixed pulley 63 via the first sheave of the moving pulley 64 and get bind with the wedge socket on the first provision of the hoist mount plate 69 after passing through the second sheave of the moving pulley 64. This assembly of fixed pulley 63 and moving pulley 64 forms double tackle mechanism and can be operated through the traction hoist 70 the same operation may perform with at least gun tackle mechanism.
[0085] With respect to this embodiment, the monorail 29 and the monorail mounting support 31 have only the turning movement i.e.one degree of freedom with respect to the top inner pipe 26 this turning movement may be performed by the lever hoist 76 or hydraulic cylinder 59 through the hook provisions of the right portion of the square arch post and beam 24 with the right hook on the monorail mount support 31 to turnout from the generator. To turn in, the same combination may use in between the left provisions of the square arch post and beam 24 with left hook on the monorail mount support 31. The trolleys 58 that mounted on the monorail 29 has only movement in one direction along the length of the monorail 29 i.e., one degree of freedom for trolley 58 with respect to the monorail 29 and the generator 19 that being lifted through the traction hoist 70 has only vertical up and down motion i.e., the traction hoist 70 will provide one degree of freedom to the object that being lift. From all these combined operations of the rotating pipe 27, trolley 58 and the traction hoist 70, the generator 19 would experience three degrees of freedom.
[0086] FIG.5 In one embodiment, the bottom stool 22 which profiles looks like rectangular prism with holes on its side faces to reduce the weight of the structure part also the top and bottom faces are inclined with each other to match the nacelle angle. This yield the top face of the bottom stool 22 to be in flat to match with the bottom pipe 25. Followed by, assemble the bottom pipe 25 and the lifting arm bottom post 51 over the top face of the bottom stool 22, then the back side of lifting arm followed by bottom pipe 25 and secure the connection with fastening joints 75. While the bottom pipe 25 is cylindrical in shape with extension plates at its both ends with some hole projections to match it with the bottom stool 22 at bottom as well as top inner pipe 26 at the top side of the bottom pipe 25. Similarly, the lifting arm bottom post 51 is also having two extrusion plates one at the top and other at its bottom to match with the bottom post 23.
[0087] In one set of embodiments, the top inner pipe 26 which has cylindrical in shape with one extension plate at its bottom as replicate to match with the bottom pipe 25. Also, this top inner pipe 26 has at least one additional extension plate that placed at some interval from the bottom side with some ribs along the cylinder’s longitudinal surface to provide the additional strength to the top inner pipe 26.
[0088] In another set of embodiments, the lifting arm middle post 52 which has rectangular in profile with projection plate at both of it ends and also have at least projections attached as normal to the lateral side of the middle post 52 and is mounted over the bottom post 51. Followed by, the lifting arm top post 53 is mounted over the middle post 52 with the necessary fastening units 75. This lifting arm top post 53 is similar is construction with the middle post 52 and its purpose is to lift the other components to make the assembly phase as ease. Also, this top post 53 has at least one projection near to its top to support the lifting support arm. The lifting arm 50 has at least one hooks provided on its bottom side to provide the hooking support to use the lift of rotating pipe 27 or may top inner pipe 26 for easiest assembly. The right side of the hook projection arranged in top and bottom of lifting arm middle post 52 in a structure in such a way that it can used to connect the swivel lifting arm 48 or top lifting arm 49 to lift and assemble the bottom pipe 25 and top inner pipe 26. Similarly, in lifting arm top post 53 hook projection in right side also can used to connect the top lifting arm 49 to lift the rotating pipe 27 and end cap pipe 28 for assembly.
[0089] In relation to one set of embodiments, the top rotating pipe 27 is placed over the top inner pipe 26. This rotating pipe 27 has cylindrical in construction with its inner diameter is greater than the outer diameter of the top inner pipe 26 while its length is shorter than the top inner pipe 26. This is to ensure that the rotating pipe 27 is securely placed over the top inner pipe 26 and its free to turn along the longitudinal axes of the rotating pipe 27.
[0090] In another set of embodiments, the stay stool–1 34 is assembled over the gearbox mount 18 on the right side of the gearbox 17 when viewing gearbox 17 in front followed by rotor 14. Then, the stay cross support–1 37 is introduced in between this stay stool–1 34 and the provision that is made on the lifting arm middle post 52 and the connection with the fastening units is secured 75. Followed by introducing the end cap pipe 28 over the top inner pipe 26 on its existing space and securing the joint with the pin or bolt connection to avoid its turning while loading. This end cap pipe 28 has at least one projection along its longitudinal axes to provide supporting connections with the lifting arm middle post 52 and the stay cross support–2 38.
[0091] Assemble the stay stool-2 35 over the nacelle bed on left side of the gearbox 17 when viewing from gearbox in front and rotor behind it; match the provisions on the nacelle bed and assemble the stay stool–2 35. Insert the stay vertical post-2 41 over the stay stool–2 35 and which has at least one provision on its other end to provide support to the next connections. Concurrently, introduce the structure part of stay horizontal support–2 44 and stay cross support-2 38 with the provision that made on over the stay vertical post-2 41. The stay horizontal support-2 44 is placed in horizontal position in between the stay vertical post-2 41 and the provision on the top inner pipe 26 while the stay horizontal support–2 44 is placed in between the stay vertical post-2 41 and the end cap pipe 28 by matching the provision made on it and fasten 75 the connection securely. This embodiment of invention represents two-stay support in a column structure 21 is a member which helps to resist loads.
[0092] The assemble the rotator arm 29 over the external provisions that provided on the external circumference of the top rotating pipe 27 by using the artin plate hook 33 to lift the rotator arm 29 to its desired position. Followed by assemble the traction hoist 70 on the right portion of the rotator arm 29 so the position of the traction hoist 70 is easily to operating to lift and lower the generator 19. This rotator arm 29 is constructed with two similar plates as shown in FIG. and both are welded along its edges to make the rotator arm 29 as rigid and a back pulley 61 is made to assemble permanently in between the bottom of these plates. In addition to that, the provision for guide pulley 62 of single sheave is provided on the right portion of the rotator arm 29 followed by provision for the fixed pulley 63 of double sheave is constructed at the end with the first sheave in between the plates and second sheave in right side of the rotator arm 29. Then the provisions for the guide plate to make the guidance for the lifting line 65 is provided on the left portion followed by a hook provision to bind the wedge socket on the same side.
[0093] In another embodiment, the lifting jig 71 (which is not shown in FIG.) is assembled over the existing hook provisions of the generator 19 followed by the assembling of the moving pulley 64 of two sheaves on hooking provisions of the lifting jig 71. Then, the lifting line 65 from the load bearing mechanism 66 is passed onto the first sheave of the fixed pulley 63 via the back pulley 61 and further passed through the second sheave of the fixed pulley 63 after passing through the first sheave of the moving pulley 64 and then passed through the second sheave of the moving pulley 64. Later, the free end of the lifting line 65 is guided through the guide pulley 62 using holding mechanism like through the combinations of U-bolts or wedge sockets. This assembly of fixed pulley 63 and moving pulley 64 forms double tackle mechanism and the same operation may be performed with at least gun tackle mechanism and this set of operations may be executed by a load bearing mechanism 66.
[0094] In another process of this embodiment says the same generator 19 lifting operation can be performed with the help of traction hoist 70 by means of the alternatives in the lifting line passage construction. Under such option, the lifting line 65 is set to guide through the guide pulley 62 and pass through the second sheave of the fixed pulley 63 from the traction hoist 70 and then pass through the second sheave of the fixed pulley 63 via the second sheave of the moving pulley 64 and then set to pass through the first sheave of the moving pulley 64. Then, the free end of the lifting line 65 is guided to the hook provision that is made on the left side of the rotator arm 29 through the guide plate and binded with the hook provision by wedge socket or suitable U-bolt assembly.
[0095] With respect to this embodiment, the rotator arm 29 only the turning movement i.e.one degree of freedom with respect to the top inner pipe 26 this turning movement may be performed by the lever hoist 76 or hydraulic cylinder 59 through the hook provisions of the right portion of the stay cross support-1 37 with the right hook on the rotator arm 29 to turnout from the generator position. To turn in, the same combination may use in between the left provisions of the stay cross support-2 38 with left hook on the rotator arm 29. The traction hoist 70 which mounted on rotator arm will provide one degree of freedom to the object that being lift i.e., the up and down movement of the generator 19. From all these combined operations of the rotating pipe 27 and traction hoist 70, the generator 19 would experience two degrees of freedom.
[0096] In one embodiment as shown in FIG.6, the bottom stool 22 is assembled over the nacelle frame 13 by means of matching the holes or provisions that is provided on the frame itself. The bottom stool 22 is constructed in a manner that they will match the nacelle inclination angle and provide flatness to the adjacent structure part while assembling. It consists of at least one extension plate at the bottom which has to be kept on the nacelle frame 13 and match its one projection with the holes of the bottom stool 22 and fasten these units along with the nacelle bolts 75. In order to arrest the slippage during the loading, introduce another support at its bottom and in between the bottom stool 22 and the nacelle frame 13 and secure it with the fastening units 75 followed by securing the connection between this additional support with the nacelle frame 13 through the stud connections 75.
[0097] With respect to the above embodiment, introduce the bottom post 23 over the bottom stool 22 and match the holes of their extension plates and fasten these assembly parts. This bottom post 23 is consist of two extension plates welded normal to the longitudinal axes of the square column while the bottom extension plate is similar to the top extension plate of the bottom stool 22 and on the other side, the top extension plate is large in area and enough to hold two components over the bottom post 23. At least one side ribs are provided in between the square column and the extension plates to secure the buckling of the column or bending of the extension plates while the load acts on it. As mentioned, the top extension plate of the bottom post 23 is somewhat extended and load acts on this area are in the form of cantilever beam so there will be a change for the bending of this extension plates, it is necessary to provide the additional support to that extension to reduce the stress concentration factor at the welding joints in between the extension plates and the square channel.
[0098] In a set of embodiments, first assemble the lifting arm bottom post 51 by means of matching the holes on the extrusion plates and just eccentric to the bottom post 23. Followed by, assemble the swivel lifting arm 48 on its right side. By using this lifting arm as a hooking point, lift the top inner pipe 26 and then shift it to the required position and then assemble it over the bottom post 23 and the top inner pipe 26 should be inline position with the bottom post 23. This top inner pipe 26 is cylindrical extruded component with supporting plates welded at its bottom side to assemble over the top of the bottom post 23. In addition to that, the top inner pipe 26 has one more supporting plate of cylindrical profile that welded on the outer circumference of the top inner pipe 26 with at least one set of ribs provided in between these supporting plates along the circumference of the top inner pipe 26 in longitudinal axes. This circular supporting plate has to provide support to the top rotating pipe 27 which has to be placed over it. So, this circular supporting plate doesn’t have any hole projection in it.
[0099] With respect to one embodiment, place the lifting arm top post 53 over the lifting arm bottom post 51. This lifting arm top post 53 is similar to the bottom post 51 but it has at least one provision on its lateral side and it should face the top inner pipe 26. The ends of the lifting arm top post 53 are welded with supporting plates as like the bottom post while the top portion is attached with the top lifting arm 49 which is immovable from its position. Followed by, assembling the lifting arm–2 49 on the side of the top inner pipe 26. While lifting the generator 19, the entire lifting arm 50 assembly is protected with stay rope 55 to provide additional strength through the hole’s provisions on the gearbox 17 or any other components.
[00100] With the help of the top lifting arm–1 49, raise the top rotating pipe 27 to the nacelle frame 13 and then using the top lifting arm–2 49 raise the rotating pipe 27 to the top of the inner pipe 26 and then assemble the rotating pipe 27 over the top inner pipe 26 by means of mating its inner surface area to the outer surface area of the top inner pipe 26. As the top rotating pipe 27 is shorter in length when compared to the top inner pipe 26, there will be an extension of the top inner pipe’s 26 length after assembling the top rotating pipe 27. By provided the end cap pipe 28 to assemble this extension length of the top inner pipe 26 with the lifting frame top post 53 simultaneously assemble the stay stool–1 34 on left portion of the gearbox 17 over the nacelle frame 13 and its should be in line with the bottom stool 22 position. Then introduce to connect the stay cross support–1 37 in between the stay stool–1 34 and the end cap pipe’s 28 projections. So, there will be no relative motion in between the top inner pipe 26 and the lifting frame top post 53 while the load acts on the top inner pipe 26. This top rotating pipe 27 has at least one projection on its outer circumference along its longitudinal direction to hold the rotator arm 29 and this projection have been secured with the ribs on outer sides to secure the stress concentration factor on the joining points.
[00101] In accordance to the one embodiment, with the help of the swivel lifting arm–1 48, swivel lifting arm–2 48 and the top lifting arm 49, raise the rotator arm 29 to the required position and assemble it in between the projections made on the rotation pipe 27. After the assemblance, the rotator arm 29 has one degree of freedom with respect to the top inner pipe i.e., the rotator arm 29 turning along the axis of the top inner pipe 26. This rotator arm 29 is constructed with two similar plates as shown in FIG. and both are welded along its edges to make the rotator arm 29 as rigid and a back pulley 61 is made to assemble permanently in between the bottom of these plates. Also, these plates have holes provision along its length to reduce the weight without affecting the strength of the rotator arm 29. In addition to that, the provision for traction hoist 70 is attached horizontally on the top of the rotator arm 29 and followed by the provision for guide pulley 62 of single sheave is provided to guide the lifting line 65 from the traction hoist 70 and at the end of rotator arm 29, the provision is provided for the fixed pulley 63 of double sheave and also have holes provisions on either of its sides to provide hooking support to the chain hoist 57 hook in order to lift the generator 19 without operating the load bearing mechanism 66. Then another hook provision is provided on the left portion of the rotator arm 29 to bind the wedge socket.
[00102] In another embodiment, assemble the lifting jig 71 (which not shown in FIG.) over the existing hook provisions of the generator 19 followed by assemble the moving pulley 64 of two sheaves on hooking provisions of the lifting jig 71. This moving pulley have holes provisions on either of its side plates to provide hooking for the chain hoist 57. Then pass the lifting line 65 from the load bearing mechanism 66 to the second sheave of the fixed pulley 63 via the back pulley 61 and pass through the first sheave of the fixed pulley 63 after passing through the second sheave of the moving pulley 64 and then passed through the first sheave of the moving pulley 64. Later the free end of the lifting line 65 is bind with the left side provision using holding mechanism like through combination of U-bolts & wedge sockets. Then this assembly of fixed pulley 63 and moving pulley 64 forms double tackle mechanism and the same operation may perform with at least gun tackle mechanism and this set of operations may executed by load bearing mechanism 66 only when the generator 19 is completely lifted and turned out from its position to out of the nacelle 12 by means of operating the chain hoist 57 and hydraulic cylinder 59 respectively.
[00103] In another process of this embodiment says the same generator 19 lifting operation can be performed with the help of traction hoist 70 by means of the guiding the lifting line 65. Under such modification, the lifting line 65 is set to guide through the guide pulley 62 and pass through the second sheave of the fixed pulley 63 from the traction hoist 70 and then pass through the second sheave of the fixed pulley 63 via the second sheave of the moving pulley 64 and then set to pass through the first sheave of the moving pulley 64. Then the free end of the lifting line 65 is bind to the hook provision that made on the left side of the rotator arm 29 with the combinations of wedge socket & suitable U- bolt assembly.
[00104] With respect to this embodiment, the rotator arm 29 only the turning movement i.e.one degree of freedom with respect to the top inner pipe 26 this turning movement may be performed by hydraulic cylinder 59 through the hook provisions of the left portion of the stay cross support-1 37 with the left hook on the rotator arm 29. The extension of the hydraulic cylinder 59 will turnout the generator position while the retraction of the hydraulic cylinder 59 will turn in. The traction hoist 70 which mounted on rotator arm 29 will provide one degree of freedom to the object that being lift i.e., the up and down movement of the generator 19. From all these combined operations of the rotating pipe 27 and traction hoist 70, the generator 19 would experience two degrees of freedom. This entire structure assembly is suitable for the de-erection and re-erection of the generator 19 of variable speed with asynchronous type and other types too.
[00105] The FIG.7 In one embodiment, match the bottom stool 22 over the hook point that provided over the nacelle 12 bed on the left side of the coupling when viewing from the rotor 14. This bottom stool 22 has two plates that are welded together to form a single component with at least one vertical plates and ribs in between them and also the top plate has to place in an inclination angle to the bottom plate in order to match the nacelle angle. The vertical plates of these bottom stool 22 have placed in separately with a distance equal to the hook width. Similarly, the bottom plate should have notch to match the holes in the centre of the bottom stool 22 while the top plate has holes provision to match the adjacent component during the assembly.
[00106] In another set of embodiments, assemble the stay stool–1 34 as just opposite to the position of the bottom stool 22. This stay stool–1 34 is a component which has square plate welded with at least one provision on its both faces; the bottom provision is to match with the hooking point while the top provision is to provide support to the adjacent component. Meantime, the stay stool–2 is assembled 35 over the hook point on the left side of the nacelle frame 13 which lies in front of the gearbox mount 18 when viewing from the rotor 14. This stay stool–2 35 is a replicate component of stay stool–1 34.
[00107] With respect to one embodiment, the bottom pipe 25 is assembled over the bottom stool 22 by means of matching the holes provisions. This bottom pipe 25 is a component which has cylindrical-shaped profile welded with supporting plates at both of its longitudinal ends. The bottom end is attached with the square profile plate along with ribs while the top end is welded with the circular profile plate with holes through it and ribs attached below it to bear the vertical load acts over the bottom pipe 25. It is necessary that the ribs provided on the bottom pipe has more supports provided throughout the supporting plates. In addition to that, this bottom pipe 25 has at least three provisions along its longitudinal surface. The swivel lifting arm is then assembled 48 through the provisions made on the bottom pipe 25 and the connections are secured with the fastening units 75.
[00108] Followed by, lift the top inner pipe 26 to the nacelle frame 13 with the help of the swivel lifting arm 48 and top lifting arm 49. Then assemble the top inner pipe 26 over the bottom pipe 25 by means of matching their circular profile supporting plates and secure the holes provision with the fastening units 75. This top inner pipe 26 has cylindrical shaped component and a circular profile plate used to weld joint on its bottom face while the top face is set to be free in order to assemble the top rotating pipe 27. In addition to that, one supporting plate is weld joint over the circumference of the top inner pipe 26 with some extend interval from the bottom face and at least one vertical rib is provided in between them to make the supports as rigid. These vertical ribs don’t affect the holes that provided throughout the bottom supporting plate.
[00109] In one embodiment, lift the top rotating pipe 27 with the top lifting arm 49, and place it over the top inner pipe 26 by means of matching the outer surface of the top inner pipe 26 along with the inner surface of the top rotating pipe 27. This top rotating pipe 27 looks similar to the bottom pipe 25 in construction but the bottom face is weld joint with the circular profile supporting plate. The inner diameter of the top rotating pipe 27 is set to larger than the outer diameter of the top inner pipe 26 while the length of the top rotating pipe 27 is shorter in length when compared to the top inner pipe 26. In addition to that, the top rotating pipe 27 has at least one provision along its longitudinal axes on the outer circumference. This provision has supported with ribs on outer sides to reduce the stress concentration factor.
[00110] Followed by, place the end cap pipe 28 over the top rotating pipe 27 by means of matching the extended length of the top inner pipe 26 and secure the connection with the fastening units 75. This end cap pipe 28 has at least two provision provided along its longitudinal axes at right angle to each other. In accordance to one embodiment, assemble the stay cross support–1 37 with the stay stool–1 34. This stay cross support–1 37 is constructed in square tube profile with the free end has at least one provision to support the adjacent column structure part. Then assemble the stay cross support–1 37 in between the provision of the bottom pipe 25 top portion. There by, the stay horizontal support–1 43 has placed in horizontal position to bear the horizonal forces that act during the loading. The stay cross support–1 37 has at least provision on its middle to provide support to the stay vertical support-1 40 in adjacent part of stay horizontal support-1 43. Followed by, assemble the stay cross support–2 38 in between the provisions of the end cap pipe 28 and the stay stool–2 35. This stay cross support–2 38 has at least one provision on its lateral faces to match the stay horizontal support-2 44 in adjacent side. Finally, introduce the stay vertical support–2 41 in between the provision of the stay horizontal support–2 44 and the stay cross support–2 38. This construction of the column structure 21 part is framed with two stay supports mounted in nacelle frame 13.
[00111] With respect to one embodiment, introduce the connecting link in between the provisions of the stay cross support–1 37 and the stay cross support–2 38 and secure the connection with the fastening units 75. Thereby, the connecting link has in horizontal position and it secure the stay supports as rigid while loading the load at the structure. This connection link has at least one provision in its middle to match with the top lifting arm 49 with vertical post which in turn use to lift the required part at the top. Using the swivel lifting arm 48 and the top lifting arm 49 raise the rotator arm 29 to the required position and assemble the rotator arm 29 with the provision provided on the top rotating pipe 27 and secure the connection with the fastening units 75.
[00112] This rotator arm 29 is a fabricated component with two symmetrical plates and having holes provision along its length to match the holes provisions provided on the top rotating pipe 27 with fastening units 75 and also have the holes provision at the bottom for back pulley 61 with single sheave in between these plates (not shown in FIG.). In addition to that, the free end of these plates is provided with holes provisions to hold the fixed pulley 63 with double sheave and external projections are provided to carry the chain hoists 57 on both of its sides near to the free end. These external provisions may be supported with at least one ribs to add strength to the hook provision from which the chain hoist 57 will bind to lift the generator. An auxiliary hook 78 provision is provided near to the fixed pulley 63 to provide support to the lifting line 65.
[00113] In another embodiment, the lifting jig 71 is assembled through the hole provisions on the generator 19 and then the moving pulley 64 is assembled over the lifting jig 71 and these moving pulley 64 is constructed with two side plates a hole’s provisions on it to carry the two sheaves and external provision as same as fixed pulley 63 is provided on both of its sides. Thus, the external provision of the fixed pulley 63 and moving pulley 64 are set to be in line to each other (these assemblies are not shown in FIG.).
[00114] Then pass the lifting line 65 from the load bearing mechanism 66 to the second sheave of the fixed pulley 63 via the back pulley 61 and pass through the first sheave of the fixed pulley 63 after passing through the second sheave of the moving pulley 64 and then passed through the first sheave of the moving pulley 64. Later, the free end of the lifting line 65 is bound with the auxiliary hook 78 using holding mechanism like through combination of U-bolts & wedge sockets. Then, this assembly of fixed pulley 63 and moving pulley 64 forms double tackle mechanism and the same operation may be performed with at least gun tackle mechanism and this set of operations may get executed by load bearing mechanism 66 only when the generator 19 is completely lifted and turned out from its position to out of the nacelle 12 by means of operating the chain hoist 57 and hydraulic cylinder 59 respectively.
[00115] According to the above embodiment, the generator 19 will be raised from its position to the desired height by means of operating at least two chain hoists 57 through the hook provisions of the fixed pulley 63 and moving pulley 64. Then, using the hydraulic cylinder 59 or lever hoist 76, the rotator arm 29 will turn from its position to out of the nacelle 12 which will simultaneously bring the generator 19 out of the nacelle 12.
[00116] With respect to the above one embodiment, the rotator arm 29 only the turning movement i.e.one degree of freedom with respect to the top inner pipe 26 this turning movement may be performed by hydraulic cylinder 59 or lever hoist 76 through the hook provisions of the right portion of the stay cross support-1 37 with the right hook on the rotator arm 29.The retraction of the hydraulic cylinder 59 or operating the lever hoist 76 would provide translational motion to the generator position. The loading bearing mechanism 66 which positioned on ground 10 will provide one degree of freedom to the object that being lift by operating the lifting line 65 i.e., the up and down movement of the generator 19. From all these combined operations of the rotating pipe 27 and lifting line motion, the generator 19 would experience two degrees of freedom.
[00117] These column structure 21 assembly are mainly suitable to de-erect and re-erect the generator type of asynchronous 3-phase induction generator 19 with slip ring operated of rotor circuit inverter system at variable speed.
[00118] The FIG.8 In one embodiment, position the bottom stool 22 by matching the provisions over the nacelle frame 13 on left side of the gearbox 17 when viewing from the rotor 14 side and secure the unit with the fastening connections. This bottom stool 22 has two rectangular plates which are kept in horizontal orientation with some intervals that have support with vertical plates and side ribs. In this bottom stool 22, the top plate has few holes provision to match the adjacent component and have at least one provision inside the bottom stool 22. Simultaneously, the stay stool–1 34 is positioned over the gearbox mount 18 by which the stay stool–1 34 is placed in straight line to the bottom stool 22 on the right side of the gearbox 17. Concurrently, the stay stool–2 35 is assembled in another bottom stool 22 on left hand side and stay stool-3 36 over the rear gearbox mount 18 on its right-hand side in rotor 14, respectively. This stay stool–2 35 and stay stool-3 36 have bottom pattern to match the top face of the gearbox mount 18 and the stay stool-2 35 has at least one provision that placed on top of it as normal to the longitudinal axes while the stay stool-3 36 has same number of provision that placed over it with an acute angle to the longitudinal axes.
[00119] Followed by, assembling the bottom pipe 25 over the top plate of the bottom stool 22 by means of matching the holes that are made on it. This bottom pipe 25 is a hollow cylinder in geometry and it’s both ends are closed with extension plates while the bottom end is square in profile and the top one is circular in profile. In addition to that, the bottom pipe 25 has three projections which are right angled to each other, irrespective of position. The swivel lifting arm is assembled 48 through the provisions that face extreme right which provided on the bottom pipe 25 and the connection is secured with fastening unit 75 without affecting their turning motions.
[00120] In another embodiment, the top of the inner pipe 26 is raised with the help of the swivel lifting arm 48 and top lifting arm 49 to the desired location and the top inner pipe is assembled 26 over the bottom pipe 25 by means of matching the holes provision. This top inner pipe 26 is constructed similarly like the bottom pipe 25 but the top end is set to be free i.e., without any extension plates for supports. Instead of that, an additional supporting plate is provided on the outer circumference of the top inner pipe 26 with some extent from the bottom extension plate and these extensions plates are secured with the ribs that should place on the longitudinal axes of the cylindrical section.
[00121] With reference to an embodiment, using the top lifting arm 49 and swivel lifting arm 48 which mounted on the bottom pipe 25 raising the rotating pipe 27 to the desired location and assembling the top rotating pipe 27 over the top inner pipe 26. This top rotating pipe 27 has inner diameter greater than the outer diameter of the top inner pipe 26 but shorter in length. This top rotating pipe 27 has supporting plates with circular profile at both of its ends. The top supporting plate of the rotating pipe 27 is to support the end cap pipe 28. In addition to that, the top rotating pipe 27 has at least one provision made on its outer surface to support the monorail 29 and monorail cross support 30 and a hook point to turn the rotating pipe 27 whenever required.
[00122] In accordance to one embodiment, assemble the end cap pipe 28 over the top rotating pipe 27 and secure the connection with the pin or bolt connections 75. This end cap pipe 28 has circular profile plate at bottom and at least two projection plates welded over it along the radial direction to provide supports to the stay cross supports-1 37 and stay cross supports-2 38. The purpose of this end cap pipe 28 is to provide the secure connection for the rotating pipe 27 as well as it arrests the shaking of the entire column with respect to its vertical axes. Followed by, assemble the stay cross support–1 37 and stay cross support–2 38 in between the projections of the end cap pipe 28 along with the stay stool–1 34 and stay stool–2 35 respectively and secure the connections with the fastening units. Followed by, introduce the stay cross support-1 37 in between the stay horizontal support-1 43 and the projections made on the bottom pipe 25. Then introduce the stay vertical support-1 40 in between the stay cross support–1 37 and the stay horizontal support–1 43. Similarly, assemble the stay cross support–2 38, stay horizontal support-2 44 and the stay vertical post–2 41 over it in same manner and secure all the connection with the fastening units 75.
[00123] In relation to that embodiment, insert the top lifting arm 49 in between the stay cross support-1 37 and the stay support–2 38 and fasten the joints securely. This top lifting arm 49 consist of three segments which are right angle to each other in at least one plane projections. The first frame consist has rectangular in profile with both ends attached with supporting plates to grip the adjacent stay cross supports-1 37 and stay cross supports-2 38. In addition to that, it has one provision in it middle to provide the support to stay cross support–3 39. The remaining two cross supports of this top lifting arm 49 is used for lifting purpose. Then assemble the stay cross support–3 39 in between the provision on the top lifting arm 49 and the stay stool–3 36.
[00124] Using the swivel lifting arm 48 and the top lifting arm 49, raise the monorail 29 to the desire position and introduce it in between the provision made on the top rotating pipe 27 and secure the connection with fastening units 75. As the monorail 29 is in the position of cantilever beam, it is necessary to provide additional support name as cross support 30 to the monorail 29 to secure the stiffness. Followed by, assemble the fixed pulley 63 on the free end of the monorail 29 and the traction hoist 70 between the provision made on the monorail 29 just near to the rotating pipe 27 and secure the connections with bolting connections 75. This structure is specially designed to de-erect and re-erect the generator 19 of asynchronous water-cooled type with variable speed.
[00125] The FIG.9 In one embodiment, position the bottom stool 22 by matching the hooking point on the left side of the gearbox 17 when viewing from the rotor side and the hooking point should lie in between the side plates of the bottom stool 22 and secure the unit with the fastening connections 75. This bottom stool 22 has two rectangular plates which kept in horizontal orientation with some intervals that have supported with vertical plates, side plates and side ribs and at least one of its side plates have holes on it to match with the hooking point that provided on the nacelle frame 13. In this bottom stool 22, the top plate has few holes provision to match the adjacent component and have at least one provision to near to its holes. Simultaneously, position the stay stool–1 34 and the stay stool–2 35 over the hook points that provided near the front right side of the gearbox 17 and rear left side of the gearbox 17 from the rotor view.
[00126] Followed by, assemble the bottom pipe 25 over the top plate of the bottom stool 22 by means of matching the holes that made on it. This bottom pipe 25 is hollow cylindrical in geometry and it’s both ends are closed with extension plates while the bottom end is square in profile and top one is circular in profile while the top extension plates is supported with at least two ribs to ensure that this circular extension plate is always at right angle to the cylindrical section. In addition to that, the bottom pipe 25 has three projections which are right angle to each other and irrespective in position. Assemble the swivel lifting arm 45 through the provisions that faces extreme right and provided on the bottom pipe 25.
[00127] In another embodiment, raise the top inner pipe 26 with the help of the swivel lifting arm 45 and top lifting arm 46 to the desired location and assemble the top inner pipe 26 over the bottom pipe 25 by means of matching the holes provision. This top inner pipe 26 has similarly constructed as like the bottom pipe 25 but the top end is set to be free i.e., without any extension plates for supports. Instead of that an additional supporting plate is provided on the outer circumference of the top inner pipe 26 with some extent from the bottom extension plate and these extensions plates are secured with the ribs that should place on the longitudinal axes of the cylindrical section.
[00128] In a set of embodiments, assemble the stay horizontal support–1 43 and stay cross support–1 37 on the stay stool–1 34 and the bottom pipe 25 respectively by means of matching the corresponding provisions. The other end of the stay cross support–1 37 is provided with at least one provisions in which the free end of the stay vertical support–1 40 is fasten at obtuse angle. In same set of embodiments, assemble the stay cross support–2 38, stay vertical support-2 41 and stay horizontal support–2 44 as same as before.
[00129] With reference to an embodiment, using the swivel lifting arm 45 which mounted on the bottom pipe 25 to raise the rotating pipe 27 to the desired location and assemble the top rotating pipe 27 over the top inner pipe 26. This top rotating pipe 27 has inner diameter greater than the outer diameter of the top inner pipe 26 but shorter in length. This top rotating pipe 27 has supporting plates at both of its ends while the bottom supporting plate is larger in size and have some holes provision through it to assemble the removable link at any position along its radial direction. This removable link is used to provide grip for the turning point as well as to make the turning as smooth as possible. The top portion of the top rotating pipe 27 is fabricated with a supporting plate of circular profile to support the end cap pipe 28. In addition to that, the top rotating pipe 27 has at least one provision made on its outer surface to support the monorail 29 and monorail cross support 30.
[00130] In accordance to one embodiment, assemble the end cap pipe 28 over the top rotating pipe 27 and secure the connection with the pin or bolt connections 75. This end cap pipe 28 has circular profile plate at bottom and at least two projection plates welded over it to provide supports to the stay cross supports-1 37 and stay cross supports-2 38. The purpose of this end cap pipe 28 is to provide the secure connection for the rotating pipe 27 as well as it arrests the shaking of the entire column with respect to its vertical axes. Thereby, the stay cross support–1 37 and the stay cross support-2 38 are in line with each other similarly, the stay vertical support–1 40 and the stay vertical support–2 41 are in acute angle to each other. As the length of the stay cross support–2 38 is too large, provide the additional support named as stay vertical support–2 41 in between the stay horizontal support–2 44 and the stay cross support–2 38. Concurrently, assemble the stay cross support–1 37 and the stay vertical support–1 40 in the same manner.
[00131] Then introduce the connecting link in between the provision of the stay cross support–1 37 and the stay cross support–2 38 as made near to the end cap pipe 28. Followed by, assemble the top lifting post over the connecting link and introduce the top lifting arm 46 on top of the top lifting post. Using this top lifting post, raise the monorail 29 to the desire position and introduce it in between the provision made on the top rotating pipe 27 and secure the connection with fastening units 75. As the monorail 29 is in the position of cantilever beam, it is necessary to provide additional support name as monorail cross support 30 to the monorail 29 to secure the stiffness. Followed by, assemble the fixed pulley 63 on the free end of the monorail 29 and the traction hoist 70 between the provision made on the monorail 29 just near to the rotating pipe 27 and secure the connections with bolting connections 75. This structure assembly 21 is specially designed to withstand the lifting capabilities of the generator of type synchronous generator with constant type.
[00132] With reference to the embodiments of FIG. 8 & 9, the traction hoist 70 is used to mount beneath the hoist mount plate 69 which assembled with the monorail 29 through fastening units 75 and pass the lifting line 65 thought the traction hoist 70 which pulls the lifting line 65 and provides it to the first sheave of the fixed pulley 63 as it lies in line with the traction hoist 70. After passing the first sheave of the fixed pulley 63, the lifting line 65 is passed through the second sheave of the fixed pulley 63 via the first sheave of the moving pulley 64 and then bind with the auxiliary hook 78 through the combinations of U-bolt and wedge socket assembly after passing through the second sheave of the moving pulley 64. This lifting line 65 passage between the fixed 63 and moving pulley 64 will result in double tackle mechanism and used to lower the generator 19 by means of operating the generator 19. The same lifting operation may be performed with at least gun tackle mechanism based on the weight of the generator 19 or by means of increasing the capacity of either the monorail 29, generator column structure 21, pulley systems or traction hoist 70.
[00133] The above-mentioned lifting operation may also be performed with load bearing mechanism by means of assembling the back pulley 61 instead of the hoist mount plate 69 with necessary fastening units 75 and this back pulley is constructed with side plates along with holes’ provisions to have at least single sheave in between the side plates. Then the lifting line 65 is operated through the load bearing mechanism 66 and made to pass through the back pulley 61 and then pass to the first sheave of the fixed pulley 63 followed by passing through the second sheave of the fixed pulley 63 via the first sheave of the moving pulley 64 and then bind with the auxiliary hook 78 through the combinations of U-bolt and wedge socket assembly after passing through the second sheave of the moving pulley 64. This lifting line 65 passage between the fixed pulley 63 and moving pulley 64 will result in double tackle mechanism and used to lower the generator 19 by means of operating the power control mechanism. The same lifting operation may be performed with at least gun tackle mechanism based on the weight of the generator 19 or by means of increasing the capacity of either the monorail 29, generator column structure 21, pulley systems or traction hoist 70.
[00134] With reference to the above embodiment, at least two chain hoists 57 are used to suspend on either side of the fixed pulley 63 which is provided with hook provision and the load carrying end of the chain hoists 57 is attached to the hook provision provided on the moving pulley 64. Then, the said set of chain hoists 57 is used to operate simultaneously which results in lifting of the generator 19 from its position to the required height and followed by operating the lever hoist 76 or the hydraulic cylinder 59 which is mounted in between the rotating fixed holder 73 and the hook provision of the stay cross support-1 37 will bring the 12 lifted generator 29 away from the nacelle 12 and makes it free to lower while the position of the rotating fixed holder 73 should lie with at least acute angle with the rotator arm 29 and in between the rotator arm 29 and stay cross support-1 37. The same generator 19 may turn in to the nacelle 12 by means of operating the lever hoist 76 or retracting the hydraulic cylinder 59 which is mounted in between the rotating fixed holder 73 and the hook provision of the stay cross support-2 38 while the position of the rotating fixed holder 73 should lie with at least acute angle with the rotator arm 29 and in between the rotator arm 29 and stay cross support – 2 38.
[00135] The FIG.10 In accordance with an embodiment of the present disclosure comprising a control mechanism, the traction hoist 70 device is fixedly disposed within a steel structure at the side of a monorail 29 attached in rotating pipe 27, such that the side of the monorail 29 for extending out of the mid portion and the rope is travelled from the traction hoist 70 to the guide pulley 62, fixed pulley 63, then connected to the moving pulley 64 exerting a downward force and travelled onto the nacelle surface on which the controls of operating the traction hoist 70, the generator 19 may lifted above the nacelle frame 13 from nacelle trunnion at the wind turbine, here there is provided the rotating fixed holder 73 is placed in a flange at the bottom of the rotating post structure and affixed the lever hoist 76 to the rotating fixed holder 73. In one aspect of the rotating fixed holder 73 is a hook type provision which is attached outside of the bottom flange. Further the lever hoist 76 headroom hook is connected to the rotating fixed holder 73 and the tail end of lever hoist 76 lifting hook is connected to the stay cross support-1 37 locking plate placed in horizontal axis to the key plate. Otherwise to say the stay cross support-1 37 is called as located at opposite side of the generator 19. Additionally, herewith the purpose of the tagline 74 is used in guiding from the ground 10 which is tying associated with the generator 19; it moves from one position to another position and also the tagline 74 serves to hold the tendency of the load in required position. The lever hoist operator operates to pull down the hand chain from the inside of the nacelle 12, this turns to rotate the monorail 29, hence operating the lever hoist 76 applied continuously when pulling the hand chain in dozen times using gear ratio, allowing to easily rotate slowly the lifted loads with multiple ton capacity. Once the rotating unit of top rotating post 27 reaches the desired position then it holds the operation to lock in the same position of rotating arm for lowering the generator 19 conveniently from the nacelle 12 to the ground 10.
[00136] In a preferred embodiment, the reverse process of the lowering the generator 19 and its assembly in nacelle frame 13 is functioned alternatively, the lever hoist 76 mechanism is affixed between the key plate in opposite side of the rotating post 27 and adjacent side of the stay cross support-2 38 which mean right hand side of the assembly. The mechanism is retrofitted to rotate the pipe from outside of the nacelle position to inside nacelle 12 of the generator bed.
[00137] FIG.11 In one aspect of the rotating arm system 29 the mechanism comprises a single acting hydraulic cylinder 59. In yet another, preferred aspect the mechanism is a piston. The mechanism is preferably a hydraulic piston or electric piston. In preferred embodiments, the mechanism is integrally placed within the rotating arm 29 lifting plate/beam and stay cross support-2 38 which mean the stay support-2 is placed in right hand side of the turbine. Using traction hoist 70 to lifting the generator 19 in required height position from the nacelle frame 13 trunnion, and temporarily attaches or ties two tagline ropes 74 in both ends of the generator 19 which is guided by ground team 68 while in travelled from the original position. The system of assembly further comprises a single-acting hydraulic piston utilizes hydraulic fluid, such as hydraulic oil, which is typically supplied from a hydraulic hose and in line with a pump. The pump adds pressure to the system by transferring fluid into the hydraulic piston through the hose. As the hydraulic fluid enters the inlet and applies pressure, it forces the piston to move. When resistance (Single post rotating beam) is added to the other side, this resistance causes the fluid pressure to increase. The system further comprises the opening of the rotating post through which the mechanism extends and retracts. Further the operator continuously operates the hand pumps to piston outwards to rotate the top rotating pipe 27 with monorail 29, simultaneously guiding the tagline 74. Since the generator 19 is reaches the desired position in outside of the nacelle 12, further its hold the single acting cylinder operative function and if any further rotations are prevented from the second safety lock using by the lever hoist 76 blocks to holds the rotating pipe 27 movement. Hence, this would result in the operable controls in the traction hoist 70 performed lowering the generator 19 as shown in FIG.12.
[00138] As is illustrated in FIG.13, either the hook of the lever hoist 76 or one end of the hydraulic cylinder 59 is set to assemble with the customized hooks that provided on the support piece which is attached stay cross support-1 37 while the load carrying hook of the lever hoist 76 or the other end of the extended hydraulic cylinder 59 is assembled with the rotating fixed holder 73 which assembled on the right portion of the generator column structure 21. Both these holes in the hook provision of stay cross support-1 37 and rotating fixed holder 73 are lies in line to reduce the turning force. Then by operating the lever hoist 76 or retracting the hydraulic cylinder 59, the rotator arm 29 will relocate from its original position resulted in shifting the generator 19 from its lifted position from the generator bed to out of the nacelle 12 and then the keep the same position of the rotator arm 29 the generator 19 load is used to act entirely on the chain hoists 57 itself which results no load condition in the lifting line 65 and then the generator 19 is used to raise slightly through the load bearing mechanism 66 which results in slackening of the chain hoists 57 and the entire load the generator 19 is now act on the lifting line 65. Simultaneously, the load hooks of the chain hoist 57 are dismantled from the side plate provisions of the moving pulley 64 where it got assembled and the generator 19 is lower down through the lifting line 65 by means of load bearing mechanism 66 and the same process should reversed in terms of returning or replacing the generator 19 back to the nacelle 12.
[00139] Referring briefly to the column structure of FIG.13A, the translational motion of the generator 19, it comes to raising or replacing the generator 19 to its initial position, the same load bearing mechanism 66 is used to operate the lifting line 65 to carry the generator 19 by keeping the position of the rotator arm 29 as unchanged. Once the generator 19 reaching its desired height, the rotating fixed holder 73 is dismantled from the right portion of the column structure 21 and then assembled on the left portion with the fastening units. Even after replacing the position of the rotating fixed holder 73 the hook holes’ provisions between stay cross support–2 38 and rotating fixed holder 73 holds in order to lies horizontal in line. Then, this is followed by assembling the hook 77 of the lever hoist 76 or one end of the hydraulic cylinder 59 with the customized hook provision that is provided on the stay cross support–2 38 while the load carrying hook of the lever hoist 76 or the other end of the extended hydraulic cylinder 59 is connected with the rotating fixed holder 73 and by using to operate either the lever hoist 76 or the hydraulic cylinder 59, then the rotator arm 29 will bring the generator 19 into the nacelle 12 to its desired position and then using the load bearing mechanism 66 the generator 19 is lowered back to its initial position.
[00140] Still referring to the FIG.14, the generator 19 is shifted from its initial position to out of the nacelle 12 and kept in static position, the load bearing mechanism 66 may operate the lifting line 65 with constant velocity which passed through the bottom pulley 60 being mounted with the bottom jig 72 and passed through the back pulley 61 and then sent to the moving pulley 64 via the fixed pulley 63 and then bind to the generator column structure 21 with the combination of holding mechanism includes U-bolts and wedge socket assembly. Thus, operating the lifting line 65 with linear motion from the load bearing mechanism 66 yields a relative motion in between the generator 19 and the lifting line 65 from the back pulley 61 and make the generator 19 to lower or raise. This relative motion may function due to the double tackle mechanism or any other number of part line in between the fixed pulley 63 and the moving pulley 64. Simultaneously. the work force 68 or any other mechanism to engage with at least two taglines 74 which mount on the generator 19 to provide additional stability to the generator 19 and to make sure to prevent the oscillatory motion and pendulum effect of the generator 19 due to gusty winds or high wind speeds. Based on the wind speed parameter, the load bearing mechanism may operate correspondingly and this change of lifting line 65 velocity will result in dynamic load on the pulley systems and generator column structure 21.
[00141] Briefly referring again to the generator 19 lowering method as shown in FIG.15, the lifeline motion in between the moving pulley 64 and fixed pulley 63 will form a double tackle mechanism or choose any other part line to lower or raise the generator 19. This operation may be performed with at least one gun tackle mechanism by increasing the capacity of the systems including load bearing mechanism 66, pulley sets, Rotating fixed holder 73, and generator column structure 21. Under such a double tackle mechanism, the generator’s up and down motion from the lifted position is delayed with respect to the velocity of the lifting line 65 which is controlled from the load-bearing mechanism 66. This delay is referred to as relative velocity between generator 19 and the lifting line 65 from the back pulley and the relative velocity of the generator is 4 times smaller than the velocity of the lifting line from the load-bearing mechanism in the double tackle mechanism of the moving and fixed pulley.
[00142] The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
[00143] The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a column structure and its construction system for replacing the components of nacelle 12, that:
• facilitates quick and efficient removal and installation of the generator from the nacelle 12; and
• easily moves in principles of right-hand rule, the direction away from the column structure is associated with clockwise rotation and the direction towards the column structure with counter-clockwise rotation position while removal and installation of generator 19 therefrom.
[00144] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[00145] The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
[00146] The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
[00147] Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
[00148] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
[00149] While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A system (100) for generator replacement in a wind turbine, the system (100) comprising :
an electrical winch (66) disposed on the ground in the vicinity of the wind turbine;
a pulley system including :
a back pulley (61),
a guide pulley (62),
a fixed pulley (63) on the end of a monorail (29), and
a moving pulley (64) connected to the fixed pulley (63);
an assembly of three-pole column steel structure (21) placed in nacelle chassis, wherein said structure (21) includes :
at least one semi-type pivoted arm (49) supports with a main pole connecting at least two support cross pole placed on an upper surface of nacelle frame (13) to lift the generator 19,
a bottom stool (22), connected with anchorage point or holes provision of the nacelle frame to fasten,
a lifting jig (71) to hold the generator 19 for replacing from the machine head in wind turbine, and
a wire rope (65) connected with the fixed pulley (63) at rotatable arm and connected perpendicular to the moving pulley attached with the jig 71 in the formation of block and tackle arrangement.
2. The system (100) as claimed in claim 1, wherein a lifting line (65) which operates though load bearing mechanism is used to lift the generator (19) with moving pulley (64) through fixed pulley (63) and back pulley (61) which forms obtuse angle when passing through the back pulley (61).
3. The system (100) as claimed in claim 1, wherein the monorail (29) is a fabricated I-beam with its end secured with plates to act as a stopper for a trolley (58).
4. The system (100) as claimed in claim 1, wherein said lifting jig (71) includes a hook (77), wherein the hook (77) is provided on a stay cross support–2 (38) and wherein the existing hook provisions of the generator 19 is followed by assembling the moving pulley (64) on hooking provisions of the lifting jig (71).
5. The system (100) as claimed in claim 1, wherein the rotator arm (29) is used to lift the generator (19) by winch method or traction hoist (70) method.
6. The system (100) as claimed in claim 1, wherein an auxiliary hook (78) is provided near to the fixed pulley (63) to provide support to the lifting line (65).
7. The system (100) as claimed in claim 1, wherein the structure (21) further comprises a bottom pipe (25) which is cylindrical shaped component with extension square plates welded on one end and the round shaped plate on other end and wherein a top inner pipe (26) is placed over the bottom pipe (25) by means of matching the holes that are provided on the extension square plates.
8. The system (100) as claimed in claim 7, wherein a rotating pipe (27) is a fabricated component which looks similar to the top inner pipe (26) with its cylindrical diameter larger than the top inner pipe’s diameter while its length is shorter than the top inner pipe’s length and the top inner pipe (26) assembly is subset to the rotating pipe (27).
9. The system (100) as claimed in claim 8, wherein a removable link of rotating fixed holder (73) is fastened with another projection circumference plate of the rotating pipe (27) to provide a hooking point to the rotating pipe (27) and reduce the force required to turn the rotating pipe (27) for moving of generator (19).

Dated this 01st day of June, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant