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Gearbox Support Assembly Of A Wind Turbine, Wind Turbine And Method For Adjusting A Gear Box Assembly

Abstract: GEARBOX SUPPORT ASSEMBLY OF A WIND TURBINE, WIND TURBINE AND METHOD FOR ADJUSTING A GEAR BOX ASSEMBLY The invention relates to a gearbox support assembly (1) of a wind turbine, comprising at least one adjustment means (13, 17, 18, 26, 27) coupling a gearbox (10) with at least one external part (11, 12, 102) of the gearbox (10) in an adjustable spatial position relative to each other with at least one fixation force (F) and at least one friction connection (19, 20) and / or at least one formlocking connection between the gearbox (10) and the at least one external part (11, 12, 102) of the gearbox (10). The invention further relates to a wind turbine and a method of adjusting a gearbox (10). Figure 3

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Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
06 June 2017
Publication Number
28/2019
Publication Type
INA
Invention Field
MECHANICAL ENGINEERING
Status
Email
nandan.pendsey@azbpartners.com
Parent Application

Applicants

SUZLON ENERGY LIMITED
Shrimali Society, Near Shri Krishna Complex, Navrangpura, Ahmedabad 380 009, Gujarat, India

Inventors

1. Christian Reimer
Margaretenstrasse 59a 18057 Rostock, Germany
2. Jorg Meyer-Bothling
Zur Muhle 16b 18184 Neu Thulendorf

Specification

DESC:FIELD OF THE INVENTION
The present invention relates to a gearbox support assembly according to claim 1, a wind turbine according to claim 15 and a method for adjusting a gearbox of a wind turbine according to claim 16.

BACKGROUND
A modern wind turbine typically includes a tower, generator, nacelle, rotor blades and gearbox. The nacelle of a wind turbine according houses a rotor assembly coupled to a gearbox and a generator. The rotor blades capture kinetic energy of wind and the same is converted into energy with the aid and assistance of generator. Many wind turbines have an essentially horizontally orientated rotor shaft which is mounted on top of the wind turbine tower within a nacelle. Within the nacelle, units like a gearbox and a generator coupled to shafts are mounted e.g. on a main frame. Generally, it is also possible to position the gearbox and / or the generator in the tower. To efficiently generate electrical power through the generator, the rotational speed of the low speed shaft connected to the rotor (for machines rated between 300 kW and 2000 kW the upper rotational speeds are between 48 and 17 rpm) has to be increased through the gearbox to e.g. more than 1500 rpm. Since wind turbines are subjected to highly dynamic mechanical loads, efficient support mechanisms, in particular for the gearbox, are required. The gearbox support assemblies have to absorb not only mechanical loads but also facilitate a sound decoupling and an accurate and easy adjustment, which is generally lacking in the technologies available till date. In an embodiment, the present invention attempts to overcome this limitation.
To overcome the limitations discussed above and several others, the present invention discloses a roller bearing with modified geometry to optimize the stress level thereby increasing its durability and efficiency.

OBJECT OF THE INVENTION
It is therefore, the object of the present invention to provide an effective gearbox support assembly according to claim 1.
Another object of the present invention is to provide a wind turbine according to claim 15.
Yet another object of the present invention is to provide a method for adjusting a gearbox of a wind turbine according to claim 16.

SUMMARY OF THE INVENTION
The gearbox support assembly of a wind turbine comprises at least one adjustment means coupling a gearbox with at least one external part of the gearbox. The coupling between the gearbox and the external part of the gearbox is made in an adjustable spatial position relative to each other with at least one fixation force and at least one friction connection and / or at least one formlocking connection between the gearbox and the at least one external part of the gearbox.
With the at least one adjustable gearbox support assembly the gearbox position can be changed, i.e. adjusted in more than one direction and then it can be securely fixed. When e.g. coaxially positioned (e.g. gearbox relative to a low speed shaft of the wind turbine), there are no or very little additional loads on the shafts, in the gearbox, in couplings or other units in the drive train. Since the gearbox support assembly allows for flexible adjustment, connecting elements in the drive train can be manufactured with less stringent tolerances resulting in reduced manufacturing costs.
In one embodiment, the external parts of the gearbox support assembly comprise at least one torque support coupled with the housing of the gearbox, at least one support body coupled to a mainframe of the wind turbine and / or a low speed shaft drive ably connecting a hub of the wind turbine with the gearbox. These parts allow considerable flexibility in spatially adjusting the gearbox within the drive train.
In one particular embodiment, the external parts of the gearbox comprise a torque support on the outside of the housing of the gearbox and a support body coupled to a mainframe of the wind turbine. The at least one adjustment means for this embodiment comprise at least one bolt engaging a hole in the at least one torque support, the at least one bolt also extending through the at least one support body. The bolt is fastened with nuts fixing the position relative to the at least one torque support. Depending on the dimensions of the hole and the bolt in particular the spatial orientation of the gearbox can be adjusted before it is fixed. With the nuts and bolt connection the fixation force can be effectively directed towards the friction connection and / or the formlocking connections.
In one embodiment, at least one bolt is surrounded at least partially by at least one sleeve forming a support for the nuts. The sleeve can give stability to the nut and bolt connection. For an improved adjustability the at least one bolt has at least one section with a diameter which is smaller than a diameter in a threaded section of the bolt, the section with the smaller diameter allowing for an adjustment gap, in particular an increased adjustment gap.
In another embodiment, the at least one torque support of the gearbox is coupled with at least one bracket of the support body with the at least one bolt extending through the at least one bracket and a hole in the at least one torque support.
In another embodiment, the at least one torque support is coupled to the housing of a gearbox through at least one adjustment means in form of a screw connection exerting the fixation force between the housing of the gearbox and the at least one torque support.
In a further embodiment, the at least one elastic element is surrounding at least partially the at least one bolt in the support body and / or at least one elastic element is positioned between the gearbox and the at least one torque support. It is also possible that the elastic elements comprise at least partially flat elements, in particular in contact with at least one sleeve with polygonal cross-section.
Another adjustment possibility is enabled by an embodiment with the low speed shaft being connected through a shrinking joint, a screw connection and / or a formlocking connection with the gearbox.
Yet a further embodiment of the gearbox support assembly comprises at least one adjustment element, in particular the form of shim plates for adjusting the space and / or the shape of surfaces in the friction connection and / or the formlocking connection, in particular between the main frame and the torque support, between the main frame and the support body, between the support body and at least one elastic element and / or between a bolt and at least one elastic element. The adjustment element might provide an additional degree of freedom to fix the connection between the gearbox and the main frame. At least one friction connection can, in one embodiment, be formed by at least one surface of the at least one torque support and at least one surface of the at least one support body and / or the housing of the gearbox, the surfaces being in particular perpendicular to the fixation force.
In a further embodiment, the at least one adjustment means allows for an adjustment gap in a not fully fixed connection of the external parts of the gearbox. This allows the assembly of the drive train e.g. with an intermediate tightening of the connection during the assembly before the final connection is made. The adjustment means can also comprises a hydraulic means which can be used in addition or as an alternative to other adjustment means. The issue is also addressed by a wind turbine with a rotor, a low speed rotor shaft connecting the rotor and a gearbox comprising at least one gearbox support assembly according to at least one of the claims 1 to 14, preferably two gearbox support assemblies according to at least one of the claims 1 to 14. The issue is also addressed by a method for adjusting a gearbox, comprising the steps
a) positioning a gearbox on or above a main frame of a wind turbine,
b) coupling at least one external part of the gearbox with the gearbox;
c) exerting a fixation force by at least one adjustment means for connecting the external part in an adjustable position relative the gearbox through at least one friction connection and / or at least one formlocking connection.
After step a) it is possible that the low speed shaft and the gearbox are coaxially adjusted. In this way the assembly of the low speed shaft and the gearbox together are subjected to the coupling with the at least one external part. In case the connection is made with at least one torque support and at least one support an embodiment of the method can further comprise the following steps:
a) The at least one torque support of the gearbox is coupled with at least one bracket of a support body with a bolt extending through the at least one bracket and a hole in the at least one torque support.
b) Then nuts are fastened for generating a pre-assembly of the gearbox support assembly and subsequently.
c) the nuts are fastened according to the final specification with the friction connections, keeping the position of the gearbox within the drive train.
Different exemplary embodiments are shown in connection with the enclosed figures.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE INVENTION
Figure 1 showing a schematic side view of a wind turbine with a drive train comprising a gearbox;
Figure 1A showing a schematic perspective view of a wind turbine with a drive train comprising a gear train;
Figure 1B showing a perspective view of an embodiment of a gearbox;
Figure 2 showing a perspective view of an embodiment of a gearbox support assembly;
Figure 3 showing a sectional view of the embodiment of a gearbox support assembly shown in Fig. 2;
Figure 4 showing a schematic frontal view of another embodiment of a gearbox support assembly;
Figure 4A showing the connection between the support body and the torque support of the embodiment shown in Fig. 4;
Figure 4B showing perspective view of the embodiment shown in Fig. 4;
Figure 5 showing a perspective view of an embodiment with a gearbox with a screw connected torque support;
Figure 6 showing a perspective view of an embodiment with a gearbox with molded torque support;
Figure 7 showing a perspective view of an embodiment of the gearbox support assembly with a support body with one bracket;
Figure 8 showing a perspective view of an embodiment of the gearbox support assembly with a support body with one bracket and a sleeve;
Figure 8A showing a perspective view of an embodiment of the sleeve shown in Fig. 8;
Figure 9 showing a perspective view of an embodiment of an elastic element;
Figure 9A-C showing different views of an embodiment of the gearbox support assembly with an elastic element shown in Fig. 9;
Figure 10 showing a cross-section of an embodiment of the gearbox support assembly with a coupling of an input shaft to the gearbox comprising shrinking joint;
Figure 10A showing a variation of the embodiment shown in Fig. 10;
Figure 10B showing a further variation of the embodiment shown in Fig. 10;
Figure 10C showing a perspective view of an embodiment of the gearbox support assembly with a coupling of an input shaft to the gearbox comprising a screw connection;
Figure 11A showing an axial adjustment of a gearbox in a first step during the assembly of the drive train;
Figure 11B showing the coupling of the torque support with the support body in the adjustment of the gearbox as a second step during the assembly of the drive train;
Figure 11C showing the engagement of the torque support with the support body through a nuts and bolt connection as a third step in the assembly of the drive train;
Figure 11D showing the final positioning of the gearbox as a fourth step in the assembly of the drive train;
Figure 12 showing a variation of the embodiment shown in Fig. 4;
Figure 12A showing the torque support of the embodiment shown in Fig. 12;
Figure 13A showing an embodiment with flat adjustment element;
Figure 13B showing an embodiment with a semi-cylindrical adjustment element in first position;
Figure 13C shows an embodiment with a semi-cylindrical adjustment element in second position.
Figure 14 shows a flow process of an embodiment of the present invention depicting the method for adjusting the gearbox.

DETAILED DESCRIPTION OF THE INVENTION
Reference is made to Figure 1, Figure 1A and Figure 1B, which typically discloses the construction and arrangement of a drive train.
Figure 1 of the present invention discloses an embodiment wherein the principal parts of a drive train (100) for a wind turbine are shown mounted on a main frame (108) without the nacelle. A hub (101) connects the blades of the rotor (not shown here) to the drive train (100). The hub (101) is coupled to a low speed shaft (102) which is supported in a rotor main bearing (103). Yaw drives (104), (105) allow a controlled orientation of the rotor relative to the wind. The low speed shaft (102) enters a gearbox (10) via a rigid coupling as input shaft (see e.g. Fig. 10, 10A, 10B, 10C). A high speed shaft (106) leaves the output side of the gearbox (10) and is coupled to a generator (107) which generates the electricity.
The modular embodiment of the drive train shown in Fig. 1 is only exemplary. Other embodiments have a different drive train (100) configuration, such as an integrated drive train where the different units are fixed directly together or a partially integrated drive train in which the rotor shaft support and the gearbox support are combined. Also the relative position of the units and / or the position of the shafts (102), (106) can be different in other embodiments. In any case, the gearbox (10) needs to be supported effectively to take e.g. the mechanical loads and to absorb noise. Furthermore, a gearbox supporting assembly (1) should enable an effective spatial adjustment of the different parts in the drive train (100).
In Fig. 1 the gearbox supporting assembly (1) with a torque support (11) and a support body(12) (e.g. comprising an elastomer bearing) is shown. Both, the torque support (11) and the support body (12) can be considered as external parts of the gearbox (10). The spatial positioning of the gearbox (10) relative to at least one of those external parts (11), (12) of the gearbox is an objective of the embodiments described in the following. The torque support (11) in this embodiment is a part of the housing of the gearbox (10) and is coupled to the support body (12) through a bolt (13) and through the fastening of the nuts (17), (18).
In Fig.1A a perspective view of a drive train of a wind turbine (100) similar to the one shown in Fig. 1 is depicted. In particular, the attachment of the torque support (11) on one side of the gearbox (10) is visible.
In Fig. 1B a perspective view of an embodiment of a gearbox (10 is shown),which can be used in connection with a drive train of the wind turbine (100) as e.g. shown in Fig. 1 and 1A. Fig. 1B shows a view from the front, i.e. from the direction of the hub (101) to the gearbox (10). The torque supports (11) with the respective holes (16) are positioned to the left and right of the gearbox (10) housing.
Reference is made to Figure 2 and Figure 3, which typically shows a perspective and a sectional view of an embodiment of a gearbox support assembly, is shown in more detail. In the embodiment shown in Fig. 2 and 3, the torque support (11) is attached to the gearbox (10). The relative position between the torque support (11) and hence the gearbox (10) to the support body (12) attached to the main frame (108) can be adjusted so that the gearbox (10) becomes coupled to the external part of the gearbox i.e. the support body (12). The rotor bearing (103) is shown axially in front of the gearbox (10).
The support body (12) comprises two brackets (14), (15) and an opening as coupling means (25).
The torque support (11) is placed between two brackets (14), (15) into the opening (25) of the support body 12. Here, the opening (25) is an essentially U-shaped space between the brackets (14), (15). In other embodiments the opening (25) can be closed off e.g. on the top and / or on the outside, covering more of the opening (25).In further embodiments, described e.g. in Fig. 7or 8, the support body (12 comprises only one bracket (14).
In this particular embodiment the length of the support body (12) in axial direction is about 30 cm, the height is about 20 cm, however, the same should not be construed as limitations, since the length is limited for the embodiment as discussed and strictly for illustration purposes. The dimensions of gearbox support assemblies (1) in other embodiments will be different and will be adapted to the respective support task. Fig. 2 and 3 show only one side of the gearbox (10) so that only one gearbox support assembly (1) is visible. On the far side of the gearbox (10) an analogue gearbox support assembly (1) is located in a symmetrical arrangement.
In Fig. 3a sectional view of an embodiment of the gearbox support assembly (1) is shown. The torque support (11) has a circular hole (16) to fit the bolt (13) in axial direction. For the embodiment shown, a threaded M72 bolt (13) is used. The bolt (13) extends through the brackets (14), (15) and hole (16) and is secured at both ends with nuts (17), (18). This nut (17), (18) and bolt (13) connection is one example of an adjustment means, i.e. means to allow the controlled adjustment and eventually fixation of the torque support (11) relative to the support body (12) and to the rest of the drive train (100). Through the nut-bolt connection an axial fixation force F can operate on the brackets (14), (15) clamping the torque support (11) between the brackets (14),(15).
The shown embodiment of the gearbox support assembly (1) comprises two friction connections (19), (20) between the respective inside surfaces of the brackets (14), (15) and the surfaces of the torque support (11). Here, the friction connections (19), (20) are both positioned perpendicular to the longitudinal axis of the bolt (13). The friction connections (19), (20) comprise surfaces such as without limitation untreated metal surface, sandblasted metal surface, structured surfaces on the torque support (11) and / or the inside of the brackets (14), (15).
The two nuts (17), (18) abut the outside of two cylindrical sleeves (21), (22) surrounding the bolt (13) at least partially. The sleeves (21), (22) have approximately the same axial length as the brackets (14), (15) in which they are positioned. The wall diameter (e.g. 20 to 50 mm) of the sleeves (21), (22) is sufficient large to provide a seat for the nuts (17), (18). The two sleeves (21), (22) are surrounded respectively by cylindrical elastic elements (23), (24 (e.g.in the form of a bushing), e.g. made from an elastomer, such as rubber or from a sandwiched plastic material. The elastic elements (23), (24) can compensate or dampen vertical and / or horizontal loads and vibrations. The axial dimension of the elastic elements (23), (24) is the same as of the sleeves (21), (22), i.e. the axial sides are flush. The elastic elements (23), (24) in this embodiment can be in one cylindrical part or in two half-shells. The diameter D1 of the bolt (13) in the section of the torque support (11) is smaller than the diameter D2 in the threaded part of the bolt (13). This results in an adjustment gap A around the bolt (13) in the middle. This gives room to maneuver the gearbox (10) in the adjustment process. The gap A can extend into the sleeves (21), (22).The adjustment gap A allows a better adjustment of the gearbox (10) in the gearbox support assembly (1) during assembling the drive train (100) of the wind turbine. The adjustment might be required due to e.g. manufacturing tolerances. Typically in an embodiment, such an adjustment would take place in the following steps:
a) A gearbox (10) is positioned on or above the main frame (108) of the wind turbine. Generally it is possible in one embodiment to adjust the low speed shaft (102) and the gearbox (10) after this positioning.
b) An external part of the gearbox (10), such as the support body (12), is coupled with the gearbox (10). In the embodiment of Fig. 2 and 3 the torque support (11) is inserted into the opening (25) of the support body (12).
c) Subsequently, the fixation force F is exerted by adjustment means (13), (17), (18) (here the nut and bolt connection) for connecting the external part of the gearbox (10) (here the support body 12) in an adjustable position relative to the gearbox (10) through at least one friction connection (19), (20) and / or at least one form locking connection.

More specifically, referring to the embodiment shown in Fig. 3 the steps would be:
a) The gearbox (10) is positioned on or above the main frame 108 of the wind turbine.
b) The gearbox (10) is spatially adjusted (e.g. by hydraulic means) so that the shafts (102), (106) and the gearbox (10) are properly, in particular coaxially, aligned.
c) The support body (12), i.e. the brackets (14), (15) are positioned around the torque support (11) and the bolt (13) is extended through the sleeves (21),(22) held in the in the brackets (14),(15), by elastic elements (23),(24) and through the hole (16). The nuts(17),(18) are fastened for generating during the pre-assembly in the gearbox support assembly (1). The pre-assembly might introduce some preliminary fixation of the support body (12).
d) The nuts(17), (18) are fastened according to the final specification. The friction connections(19),(20) keep the position of the gearbox (10) relative to the drive train (100).
A further embodiment of the method comprises further step before, during and between those four steps:
1. Inserting studs for connecting input shaft (102) (main shaft) to gearbox (10) and (5), threes guide pins in the input (102) shaft (guide pin diameter is larger than stud diameter).
2. Positioning of the gearbox (10) above the mainframe (108) with crane (for following steps gearbox (10) will hanging from the crane).
3. Ensuring parallelism between input shaft flange and gearbox flange.
4. Mating the input shaft (102) flange and the gearbox (10) flange, so that gearbox (10) will be aligned coaxial with guide pins; guide pins will protect other studs threads.
5. Tightening of all studs to connect input shaft flange to gearbox (10) flange.
6. Removal of the three guide pins.
7. Inserting standard studs in previous guide pin positions and tighten as well.
8. Pre-assembling all four gearbox (10)mounts, i.e. the support bodies (12) including the lower block, upper block of brackets (14), (15), elastic elements (b), (24), bushes (i.e. sleeves 21, 22), (could be done at any time in parallel).
9. Inserting gearbox mount studs in main frame (108).
10. Positioning the gearbox mounts (i.e. the support bodies 12) on mainframe 108 (do not tighten the bolts to final specification).
11. Tolerance in bolt holes of gearbox mounts (i.e. support bodies 12) will allow certain movement of gearbox mounts.
12. Bringing gearbox arms in horizontal position, i.e. the gearbox is to be levelled.
13. Moving gearbox mounts (i.e. support bodies 12) in a way that the bush and the torque arm faces mate.
14. Tightening of the gearbox mount studs.
15. Inserting M72 bolt through bushes (i.e. sleeves 21, 22) and gearbox torque arm.
16. Tightening the M72 bolt while gearbox (10) is still hanging on the crane (gearbox mount assemblies are automatically positioned by tightening M72 Bolt).
17. Releasing crane.
The nut (17), (18) and bolt (13) connection with two friction connections (19), (20) in the gearbox support assembly (1), depicted in Fig. 2 and 3, is just one example of a detachable connection between the torque support (11) of the gearbox and – through the support body (12) – with the main frame (108).
In another embodiment, as an alternative to the nut (17), (18) and bolt (13) connection, a hydraulic means such as a known hydraulic clamp or a hydraulic nut (e.g. manufactured by Schaaf) could be used to exercise axial pressure on the friction surfaces (19), (20). Therefore, the adjustment means can comprise such a hydraulic means instead or in combination with e.g. the nut and bold connection.
In other embodiments the friction connection (19), (20) can be replaced with a formlocking connection, e.g. a gasket – groove connection. The linear groves would allow the movement of the gearbox (10) in one direction during adjustment.
In the embodiment of Fig. 2 and 3 further adjustment elements(26) (shim plates) could be inserted, e.g. vertically in the second friction connection (20). This adjustment element (26) could e.g. be used to level some manufacturing tolerances. Further applications of the adjustment elements (26) are described in connection with Fig. 13A, 13B, 13C.
In Figure. 4, a further embodiment of a gearbox support assembly (1) of a wind turbine is shown. Here, the gearbox (10) is coupled with the support body (12) via a torque support (11). Whereas the torque support (11) shown in the embodiments of Fig. 2 and 3 is molded with the housing of the gearbox (10), here the connection between the torque support (11) and the gearbox (11) is made through an adjustable screw connection (27) exerting the fixation force F at the friction connection (19). Hence, unlike the embodiment shown in Fig. 2 and 3, the torque support (11) and the support body (12) are both external parts to the gearbox (10). The spatial position of the gearbox (10) relative to the torque support (12) can be adjusted through the screw connection (27).Elastic elements (23), (24) can be positioned at the interface between the gearbox (10) and the torque support(11). In other embodiments the elastic elements can also be positioned within the support body (12), as e.g. shown in Fig. 4A. Fig. 4A shows an embodiment of a support body (12) which can be used with the embodiment shown in Fig. 4. Here only a bolt (13) (i.e. a solid pin) is used to connect the torque support (11) and the support body (12). The support body (12) in this embodiment comprises sleeves (21), (22) and elastic elements (23), (24) as the embodiment shown in Fig. 2. Here, the connection between the support body (12) and the torque support (11) is made through a solid pin. It could alternatively be made through a nut and bolt connection. The torque support (11) and the support body (12) together form a suspension assembly for the gear box (10).
Figure 5 shows a perspective drawing of a gearbox (10) with one torque support (11) attached to the gearbox (10) e.g. through a screw connection. This is similar to the embodiment shown in Fig. 4.
Figure 6 shows - from the same perspective - a gearbox (10) with a torque support (10) molded with the housing of the gearbox (10) which is similar to the embodiment shown in Fig. 2 and 3.
In Figure 7 a detail of a gearbox support assembly (1), i.e. one of the torque supports (11) of the gear box (10) is shown. Unlike the embodiment shown in Fig. 2 and 3, the torque support (11) is coupled to the support body (12) having only one bracket (14). The torque support (11) acts as a cavity through which the bolt (13) extends. The bolt (13) and the nut (17) are shown in non-fastened position, i.e. during an adjustment.
In Figure. 8 a variation of the embodiment shown in Fig. 7 is shown so that reference can be made to the respective description. As in the embodiment shown in Fig. 2 and 3 the bolt (13) is guided by a sleeve (21) with a circular cross-section. In Fig. 8A the sleeve is shown in detail. The circular cross-section is not mandatory. The hatched line (21A) in Fig. 8A indicates that the sleeve (21) can also have a quadratic cross-section. Such sleeves (21)could then be paired with flat elastic elements, and not with circular elastic elements (not shown here). The bolt (13) and the nut (17) are shown in Fig. 8 in non-fastened position, i.e. during an adjustment.
Figure 9 shows an embodiment of an elastic element (23) which can e.g. be used in connection with the embodiment shown in Fig. 2, 3, 7 and 8. The elastic element (23)comprises two shells (23A), (23B), each with a semi-circular cross-section. In Fig. 9 the hard shells (23C) of the elastic element (23) are depicted. The elastic rubber material is positioned between the hard shells (23C), i.e. a laminated device. In an alternative embodiment, the elastic device (23) comprises flat elements, e.g. to be connected with a sleeve with a quadratic cross-section.
In Figure 9A, an application of the elastic element (23) shown in Fig. 9 is shown in connection with a support body (12) with two brackets (14), (15) (only one bracket (14) shown in Fig. 9A). In Fig. 9A the elastic element (23) envelops the bolt (13). The elastic element (23) is embedded in the first bracket (14). In Figure 9B the lower part of the second bracket (15) is shown supporting the elastic element (23). In Fig. 9C the full support body (12) with both assembled brackets (14), (15) and respective fully enclosed elastic elements (23) is shown. So far, the adjustment of the gearbox (10) relative to other parts of the wind turbine has been described in connection to a torque support (11) which is attached to the gearbox (10) and / or a support body (12) which is attached to the main frame (108).
In further embodiments of the gearbox support assembly (1) the gearbox (10) is coupled with the low speed shaft (102) using e.g. a shrinking joint (28).In Fig. (10)the connection of the hub (101) with the gearbox (10) via the low speed shaft (102) is shown in a cross-sectional view. At the end of the gearbox (10) the low speed shaft (102) is positioned in a retainer (29) which is cup-shaped with a circular cross-section. The connection between the shaft (102) and the retainer is effected by the shrinking joint (28) exerting a circumferential fixation force F on the low speed shaft (102).
In Figure 10A and 10B details of variations of the shaft connection are shown. In the embodiment in Fig. 10A the low speed shaft has a central cavity (30) into which the retainer (29) is inserted, i.e. unlike the embodiment shown in Fig. 10, the low speed shaft (102) is positioned at the outside of the retainer (29). The fixation force F is exerted by the shrinking joint (28). To prevent an unwanted deformation of the low speed shaft, a support ring (31) is positioned within the retainer (29).
In Figure 10B the low speed shaft (102) also has a cavity (30) but no support ring (31) is used. In Fig. 10C a screw connection between the low speed shaft (102) and the gearbox (10) is shown. This can be used in addition or alternatively to the shrinking joint (28).
In Figure 11A to 11D different steps of the assembly and adjustment of a drive train for a wind turbine (100) are shown. As mentioned above, the axial adjustment of the low speed shaft (102) and the gearbox is important.
In Figure 11A the gearbox (10) is shown as hanging from a crane which itself is not shown. In this situation the gearbox (10) has in particular axial and lateral degrees of freedom. The axial fixation of the low speed shaft (102) and the gearbox can e.g. be made through the shrinking joint (28) as described in connection with Fig. 10, 10A or 10B. In alternative embodiments, the adjustment can also be made through screw connections.
In Fig. 11B it is shown that the external parts of the gearbox 10, here the torque support (11), is inserted into the support body (12) with two brackets (14), (15).The fixation of the torque support (11) is described e.g. in connection with Fig. 2 and 3. Figure11B shows the connection without the inserted bolt (13). An intermediate stage of the fixation is shown in Fig. 11C. The gearbox (10) is still suspended from the crane, i.e. it is movable relative to the support body (12). Once the adjustment is made, the bolt (13) is inserted and the nuts (17), (18) are tightened to create the friction connection (19),(20) (see Fig. 2 and 3). Eventually the connection to the crane is removed (Fig. 11D) so that the fully assembled drive train rests on the support bodies (12).
In Fig. 4, 4A, 4B an embodiment with a screw connection (27) between the gearbox (10) and the torque support (11) was described. Figure12and 12A show a variation of this embodiment. In Figure 12 a perspective view of the gearbox (10)is shown. The torque (25) support (11) comprises a ring segment (see Fig. 12A) with holes (32). Screws (only shown in Fig. 12) of the screw connection (27) can engage those holes (32). Given the appropriate tolerance of the holes (32) the relative position of the torque support (11) and the gearbox (10) can be adjusted. Fig. 12A shows a part of the one-piece torque support with one hole (16) for taking a bolt (13) (not shown here) for connecting with the support body (12) as e.g. shown in Fig. 2, 3 or 4.
In Fig. 13A, 13B, 13C further embodiments with adjustment elements (26) are shown in perspective sectional views, all within support bodies (12), as described e.g. in Fig. 2, 3 or4. In Fig. 13A a flat, horizontal adjustment element (26) in the form of a plate is used between the support body (12) and the main frame (108) (not shown here). This adjustment element (26)can be used to level rough surfaces or large tolerances.
In Fig. 13Ba semi-cylindrical shell (seen individually to the right) is used as an adjustment element (26). This is placed to surround the elastic elements (23), (24) to level height differences. In Fig. 13C a semi-cylindrical shell is used as an adjustment element (26) but it is placed to (5) surround the bolt (13).
In Figure 14a flowsheet for an embodiment of the method for adjusting the gearbox (10 is shown.). In the first step 201, the gearbox (10) is positioned on or above a main frame (108) of a wind turbine. Then in a second step 202, at least one external part (11), (12), (102) of the gearbox (10) is coupled with the gearbox (10).In a third step 203,at least one adjustment means (13), (17), (18), (26), (27) exerts a fixation force F for connecting the external part (11), (12), (102) of the gearbox (10) in an adjustable position relative to the gearbox (10) through at least one friction connection (19), (20) and / or at least one formlocking connection.

Reference Numbers
1 gearbox support assembly
10 gearbox
11 torque support
12 support body (bearing)
13 bolt (adjustment means)
14 first bracket of support body
15 second bracket of support body
16 hole for bolt
17 first nut (adjustment means)
18 second nut (adjustment means)
19 first friction connection
20 second friction connection
21 first sleeve
21A cross-section of sleeve
22 second sleeve
23 first elastic element
23A first shell
23B second shell
23C hard shell
24 second elastic element
25 coupling means (opening in support body)
26 adjustment element (adjustment means)
27 screw connection (adjustment means)
28 shrinking joint
29 retainer for low speed shaft
30 central cavity of the low speed shaft
31 support ring for retainer
32 hole for screw connection

100 drive train of wind turbine
101 hub for blades
102 input shaft (low speed shaft)
103 rotor main bearing
104 first yaw drive
105 second yaw drive
106 output shaft
107 generator
108 main frame

201 first step of an embodiment of the method
202 second step of an embodiment of the method
203 third step of an embodiment of the method
A adjustment gap around bolt
D1 diameter of bolt
D2 diameter of bolt in threaded part
F fixation force

The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present invention is accordingly not limited.
,CLAIMS:We claim:

1. Gearbox support assembly (1) of a wind turbine, comprising at least one adjustment means (13, 17, 18, 26, 27) coupling a gearbox (10) with at least one external part (11, 12, 102) of the gearbox (10) in an adjustable spatial position relative to each other with at least one fixation force (F) and at least one friction connection (19, 20) and / or at least one formlocking connection between the gearbox (10) and the at least one external part (11, 12, 102) of the gearbox (10).

2. Gearbox support assembly (1) according to claim 1, wherein the external parts of the gearbox (10) comprise at least one torque support (11) coupled with the housing of the a gearbox (10) and / or at least one support body (12) coupled to a mainframe (108) of the wind turbine of the gearbox (10).

3. Gearbox support assembly (1) according to claim 2, wherein the external parts (11, 12) of the gearbox (10) comprise a torque support (11) on the outside of the housing of the gearbox (10) and a support body (12) coupled to the mainframe (108) of the wind turbine, the a least one adjustment means (13, 17, 18) comprise at least one bolt (13) engaging a hole (16) in the at least one torque support (11), the at least one bolt (13) also extending through the at least one support body (12)and nuts (17, 18) for fixing the position relative to the at least one torque support (11).

4. Gearbox support assembly (1) according to claim 3, wherein at least one bolt (13) is surrounded at least partially by at least one sleeve (21, 22) forming a support for the nuts (17,18).

5. Gearbox support assembly 1) according to at least one of the claims 3 to 5, wherein the at least one bolt (13) has at least one section with a diameter (D1) which is smaller than a diameter (D2) in a threaded section of the bolt (13), the section with the smaller diameter (D1) allowing for an adjustment gap (A).

6. Gearbox support assembly (1) according to at least one of the claim 3 to 5, wherein the at least one torque support (11) of the gearbox (10) is coupled with at least one bracket (14,15) of the support body (12) with the at least one bolt (13) extending through the at least one bracket (14,15) and a hole (16) in the at least one torque support (11).

7. Gearbox support assembly (1) according to at least one of the preceding claims, wherein the at least one torque support (11) is coupled to the housing of a gearbox (10) through at least one adjustment means in form of a screw connection (27)exerting the fixation force (F) between the housing of the gearbox (10) and the at least one torque support (11).

8. Gearbox support assembly (1) according to at least one of the preceding claims, wherein at least one elastic element (23, 24) is surrounding at least partially the at least one bolt (13) in a support body (12) and / or at least one elastic element (23) is positioned between the gearbox (10) and the at least one torque support (11)..

9. Gearbox support assembly (1) according to claim 8, wherein the at least one elastic element (23, 24) comprise at least partially flat elements, in particular in contact with at least one sleeve (21, 22) with polygonal cross-section.

10. Gearbox support assembly (1) according to at least one of the preceding claims, wherein the low speed shaft (102) is connected through a shrinking joint (28), a screw connection and / or a formlocking connection with the gearbox (10).

11. Gearbox support assembly (1) according to at least one of the preceding claims, comprising at least one adjustment element (26), in particular shim plates for adjusting the space and / or the shape of surfaces in the friction connection (19, 20) and / or the formlocking connection, in particular between the main frame (108) and the torque support (11), between the main frame (108) and the support body (12), between the support body (12) and at least one elastic element (23, 24) and / or between a bolt (13) and at least one elastic element.

12. Gearbox support assembly (1) according to at least one of the preceding claims, wherein the at least one friction connection (19, 20) is formed by at least one surface of the at least one torque support (11) and at least one surface of the at least one support body (12) and / or the housing of the gearbox (10), the surfaces being in particular perpendicular to the fixation force (F).

13. Gearbox support assembly (1) according to at least one of the preceding claims, wherein the at least one adjustment means (13, 17,18, 27, 26) allows for an adjustment gap (A) in a not fully fixed connection of the external parts (11, 12, 102) of the gearbox (10).

14. Gearbox support assembly (1) according to at least one of the preceding claims, wherein the adjustment means (13, 17, 18, 26, 27, 28) comprises a hydraulic means.

15. Wind turbine with a rotor, a low speed rotor shaft (102) connecting the rotor and a gearbox (10) comprising at least one gearbox support assembly (1) according to at least one of the claims 1 to 14, preferably two gearbox support assemblies (1) according to at least one of the claims 1 to 14.

16. Method for adjusting a gearbox (10), comprising the steps
a) positioning a gearbox (10) on or above a main frame (108) of a wind turbine;
b) coupling at least one external part (11, 12, 102) of the gearbox (10) with the gearbox (10);
c) exerting a fixation force (F) by at least one adjustment means (13, 17, 18, 26, 27) for connecting the external part (11, 12, 102) of the gearbox (10) in an adjustable position relative to the gearbox (10) through at least one friction connection (19, 20) and / or at least one formlocking connection.

17. Method for adjusting a gearbox (10) according to claim 16, comprising the step of coaxially adjusting the low speed shaft (102) with the gearbox (10) after positioning the gearbox (10) on or above the main frame (108) of the wind turbine.

18. Method according to claim 15 or 17, wherein,
a) at least one torque support (11) of the gearbox (10) is coupled with at least one bracket (14, 15) of a support body (12)with a bolt (13) extending through the at least one bracket (14, 15) and a hole (16) in the at least one torque support (11),
b) the nuts (17,18)are fastened for generating a pre-assembly of the gearbox support assembly (1) and subsequently;
c) the nuts (17, 18)are fastened according to the final specification with the friction connections (19, 20) keeping the position of the gearbox (10) within the drive train (100).

Documents

Application Documents

# Name Date
1 Power of Attorney [06-06-2017(online)].pdf 2017-06-06
2 Form 5 [06-06-2017(online)].pdf 2017-06-06
3 Form 3 [06-06-2017(online)].pdf 2017-06-06
4 Form 1 [06-06-2017(online)].pdf 2017-06-06
5 Drawing [06-06-2017(online)].pdf 2017-06-06
6 Description(Provisional) [06-06-2017(online)].pdf 2017-06-06
7 201721019775-COMPLETE SPECIFICATION [04-06-2018(online)].pdf 2018-06-04
8 201721019775-ORIGINAL UNDER RULE 6 (1A)-040917.pdf 2018-08-11
9 201721019775-FORM 18 [16-08-2018(online)].pdf 2018-08-16
10 Abstract1.jpg 2019-05-11
11 201721019775-FORM 18 [13-08-2019(online)].pdf 2019-08-13
12 201721019775-FER.pdf 2020-07-20

Search Strategy

1 2020-07-1620-54-34E_17-07-2020.pdf