SYSTEM AND METHOD FOR LOCKING OF A ROTOR OF A WIND TURBINE
DURING EXTENDED MAINTENANCE
FIELD
[0001] The present disclosure relates in general to wind turbines, and more
particularly to systems and methods for locking a rotor of a wind turbine during
extended maintenance operations.
BACKGROUND
[0002] Wind power is considered one of the cleanest, most environmentally
friendly energy sources presently available, and wind turbines have gained increased
attention in this regard. A modern wind turbine typically includes a tower, a
generator, a gearbox, a nacelle, and one or more rotor blades. The nacelle includes a
rotor assembly coupled to the gearbox and to the generator. The rotor assembly and
the gearbox are mounted on a bedplate support frame located within the nacelle.
More specifically, in many wind turbines, the gearbox is mounted to the bedplate via
one or more torque arms or arms. The one or more rotor blades capture kinetic
energy of wind using known airfoil principles. The rotor blades transmit the kinetic
energy in the form of rotational energy so as to turn a shaft coupling the rotor blades
to a gearbox, or if a gearbox is not used, directly to the generator. The generator then
converts the mechanical energy to electrical energy that may be deployed to a utility
grid.
[0003] More specifically, the majority of commercially available wind turbines
utilize multi-stage geared drivetrains to connect the turbine blades to electrical
generators. The wind turns the rotor blades, which spin a low speed shaft, i.e. the
main shaft. The main shaft is coupled to an input shaft of the gearbox, which has a
higher speed output shaft connected to the generator. Thus, the geared drivetrain aims
to increase the velocity of the mechanical motion. Further, the gearbox and the
generator are typically supported by one or more bearings and mounted to a bedplate
member via one or more torque arms or supports.
[0004] During the lifecycle of the wind turbine, it may, from time to time, be
necessary to perform maintenance operations on the various components of the wind
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turbine. Typically, such maintenance cannot be performed on a wind turbine if the
rotor is able to rotate in response to a wind load. As such, maintenance operations
will often require the securing of the rotor in a fixed position. Typically, the rotation
of the rotor may initially be stopped by a combination of brakes applied to the rotor
shaft and pitching of the rotor blades. The rotor may be secured in place through the
use of a low-speed rotor lock, which is typically an integral component of the wind
turbine.
[0005] Generally, the low-speed rotor lock is designed to withstand an anticipated
load of the rotor in response to winds up to a certain threshold. As such, the lowspeed rotor lock may, generally, only be employed for such a length of time as it is
possible to predict, with a reasonable degree of certainty, that the winds will not
exceed the threshold. Such a time period is usually limited to a few hours. However,
certain maintenance procedures cannot be accomplished within this time frame.
[0006] In view of the aforementioned, the art is continuously seeking new and
improved systems and methods for securing the rotor in a fixed position at the greater
wind speeds that may be encountered during an extended maintenance window.
BRIEF DESCRIPTION
[0007] Aspects and advantages of the invention will be set forth in part in the
following description, or may be obvious from the description, or may be learned
through practice of the invention.
[0008] In one aspect, the present disclosure is directed to a rotor lock assembly for
locking a rotor of a wind turbine. The rotor lock assembly may include at least one
removable rotor lock. The removable rotor lock(s) may include a housing including
an opening and a mounting portion. The opening may extend from a first end to a
second end thereof. The mounting portion may be adapted for mounting to a bearing
housing adjacent to a rotor lock plate of the rotor. The removable rotor(s) may
include a pin shaft positioned within the opening. The pin shaft may include a
proximal end and a distal end. The pin shaft may be movable within the opening such
that the distal end moves toward and engages the rotor lock plate of the rotor. The
removable rotor lock(s) may also include a locking mechanism for locking the pin
shaft in place.
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[0009] In an embodiment, the rotor lock assembly may also include a plurality of
fasteners for securing the mounting portion of the housing to the bearing housing
through a plurality of fastener openings of the mounting portion. Additionally, in an
embodiment, the pin shaft may engage the rotor lock plate via a through hole
configured therethrough. The through hole may define an axis parallel to and offset
from a main shaft of the rotor. In another embodiment, the rotor lock assembly may
also include an alignment system operably coupled to the pin shaft so as to align the
pin shaft with the through hole of the rotor lock plate.
[0010] In an embodiment, the removable rotor lock(s) may include a first
removable rotor lock and a second removable rotor lock. The first removable rotor
lock may be coupled to a first quadrant of the bearing housing, and the second
removable rotor lock may be coupled to a second, adjacent quadrant of the bearing
housing. In an additional embodiment, the housing may include a bushing element
positioned within the opening and a bushing securing mechanism oriented to engage a
corresponding feature of the bushing element and secure the bushing element within
the opening.
[0011] In an additional embodiment, the pin shaft may be movable within the
bushing element via at least one of an axial movement or a rotational movement. The
pin shaft may be moved by at least one of a direct-manual engagement system, a
hydraulic engagement system, a geared engagement system, or a motorized
engagement system operably coupled to the pin shaft. In an additional embodiment,
the proximal end of the pin shaft engages the locking mechanism.
[0012] In an embodiment, the distal end of the pin shaft may include a tapered
cross-sectional profile. In another embodiment, the housing may also include at least
one attachment location for providing a lifting point for lifting the rotor lock assembly
uptower.
[0013] In another aspect, the present disclosure is directed to a method for
performing a maintenance and/or repair procedure on a rotor component of a wind
turbine. The method may include coupling the removable rotor lock(s) to a main
bearing housing. The method may include preventing rotation of the rotor and
advancing an integral low-speed rotor lock of the wind turbine so as to engage a first
corresponding feature of the rotor lock plate. The method may include advancing a
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pin shaft of the at least one removable rotor lock to an advanced position so as to
engage a second corresponding feature of the rotor lock plate. The method may also
include securing the pin shaft in the advanced position through the engagement of the
locking mechanism.
[0014] In one embodiment, the method for performing a maintenance and/or
repair procedure on a rotor component of a wind turbine may also include aligning the
pin shaft with the corresponding feature of the rotor lock plate via an alignment
system operably coupled to the pin shaft. In an embodiment, advancing the pin shaft
may include advancing the pin shaft via at least one of a direct-manual engagement
system, a hydraulic engagement system, a geared engagement system, or a motorized
engagement system operably coupled to the pin shaft.
[0015] In an embodiment, the method may include coupling first and second rotor
lock(s) to a first quadrant of the bearing housing and an adjacent, second quadrant of
the main bearing housing, respectively. In an embodiment the method may also
include performing the maintenance procedure on an assembled nacelle, uptower. In
a further embodiment, the method may include hoisting the first and second
removable rotor locks through an access hatch located on an underside of the nacelle
up tower.
[0016] In another aspect, the present disclosure is directed to a wind turbine repair
system. The wind turbine repair system may include a rotor lock plate
circumferentially mounted to a rotor shaft of the wind turbine. The rotor lock plate
may define a plurality of openings, which have an axis parallel to and offset from the
rotor shaft. The wind turbine repair system may include a low-speed rotor lock
coupled to a bedplate support frame perpendicular to the rotor lock plate, a bearing
housing, and at least one removable rotor lock mounted to the bearing housing. The
removable rotor lock may include a housing having an opening and a mounting
portion. The opening may extend from a first end to a second end thereof. The
mounting portion may be adapted for mounting to a bearing housing adjacent to a
rotor lock plate of the rotor. The removable rotor lock may also include a pin shaft
positioned within the opening. The pin shaft may include a proximal end and a distal
end. The pin shaft may be movable within the opening such that the distal end moves
toward and engages the rotor lock plate of the rotor. The removable rotor lock may
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also include a locking mechanism for locking the pin shaft in place.
[0017] These and other features, aspects and advantages of the present invention
will become better understood with reference to the following description and
appended claims. The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments of the invention and,
together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A full and enabling disclosure of the present invention, including the best
mode thereof, directed to one of ordinary skill in the art, is set forth in the
specification, which makes reference to the appended figures, in which:
[0019] FIG. 1 illustrates a perspective view of one embodiment of a wind turbine
according to aspects of the present disclosure;
[0020] FIG. 2 illustrates a perspective view of one embodiment of a simplified,
internal view of one embodiment of a nacelle of a wind turbine according to aspects
of the present disclosure;
[0021] FIG. 3 illustrates a simplified side view of a rotor lock assembly according
to aspects of the present disclosure;
[0022] FIG. 4 illustrates a simplified rear view of a rotor lock assembly according
to aspects of the present disclosure;
[0023] FIG. 5A illustrates a perspective view of a rotor lock according to aspects
of the present disclosure;
[0024] FIG. 5B illustrates an exploded perspective view of the embodiment
depicted in FIG. 5A;
[0025] FIG. 6 illustrates a perspective view of a portion of the bearing housing
according to aspects of the present disclosure.
[0026] FIG. 7 illustrates a flow diagram of one embodiment of a method for
performing a maintenance and/or repair procedure on a rotor component of a wind
turbine according to aspects of the present disclosure.
DETAILED DESCRIPTION
[0027] Reference now will be made in detail to embodiments of the invention,
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one or more examples of which are illustrated in the drawings. Each example is
provided by way of explanation of the invention, not limitation of the invention. In
fact, it will be apparent to those skilled in the art that various modifications and
variations can be made in the present invention without departing from the scope or
spirit of the invention. For instance, features illustrated or described as part of one
embodiment can be used with another embodiment to yield a still further
embodiment. Thus, it is intended that the present invention covers such modifications
and variations as come within the scope of the appended claims and their equivalents.
[0028] Generally, the present disclosure is directed to a rotor lock assembly for
locking a rotor of a wind turbine during an extended maintenance operation. The
rotor lock assembly includes a removable rotor lock(s). The removable rotor lock(s)
includes may a housing, a bushing element, a pin shaft, and a locking mechanism.
The housing has an opening extending from a first end to a second end and a
mounting portion. The mounting portion is adapted or formed for mounting to a
corresponding attachment location on the outer surface of the main bearing housing,
which is adjacent to a rotor lock plate of the rotor. The bushing element is positioned
within the opening of the housing and the pin shaft is positioned within the bushing
element. The pin shaft has a proximal end and a distal end. The pin shaft is movable
within the bushing element such that a force applied to the pin shaft may cause the pin
shaft to move towards and engage the rotor lock plate of the rotor. The pin shaft may
be locked in this engaged position by an attached locking mechanism. The removable
rotor lock(s) may be sized so as to share a working load with an integral low-speed
rotor lock which is coupled to a bedplate support frame. The shared working load of
the removable rotor lock(s) and the low-speed rotor lock may be sufficient to
withstand the forces generated by a wind in excess of the forecasted a speed during an
extended maintenance period.
[0029] Generally, a maintenance and/or repair procedure may be performed on a
component of the wind turbine by coupling the removable rotor lock(s) to the main
bearing housing of the wind turbine. The rotation of the rotor, in response to the force
of the wind, may be stopped and a built-in, or integral, low-speed rotor lock of the
wind turbine may be advanced so as to engage a feature, such as a hole or a
depression, of the rotor lock plate. With the rotor in a locked position, the pin shaft of
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the removable rotor lock(s) may be advanced so as to engage a second feature of the
rotor lock plate. The pin shaft may be secured in the advanced position through the
engagement of a locking mechanism. With the rotor so secured, an extended
maintenance operation may be performed on the wind turbine while the wind turbine
is potentially exposed to a broader range of wind speeds.
[0030] Referring now to the drawings, FIG. 1 illustrates a perspective view of one
embodiment of a wind turbine 100 according to the present disclosure. As shown, the
wind turbine 100 generally includes a tower 102 extending from a support surface
104, a nacelle 106, which includes an outer shell 160, mounted on the tower 102, and
a rotor 108 coupled to the nacelle 106. The rotor 108 includes a rotatable hub 110 and
at least one rotor blade 112 coupled to and extending outwardly from the hub 110.
For example, in the illustrated embodiment, the rotor 108 includes three rotor blades
112. However, in an alternative embodiment, the rotor 108 may include more or less
than three rotor blades 112. Each rotor blade 112 may be spaced about the hub 110 to
facilitate rotating the rotor 108 to enable kinetic energy to be transferred from the
wind into usable mechanical energy, and subsequently, electrical energy. For
instance, the hub 110 may be rotatably coupled to an electric generator 118 (FIG. 2)
positioned within the nacelle 106 to permit electrical energy to be produced.
[0031] The wind turbine 100 may also include a wind turbine controller 114
centralized within the nacelle 106. However, in other embodiments, the controller
114 may be located within any other component of the wind turbine 100 or at a
location outside the wind turbine. Further, the controller 114 may be
communicatively coupled to any number of the components of the wind turbine 100
in order to control the components. As such, the controller 114 may include a
computer or other suitable processing unit. Thus, in several embodiments, the
controller 114 may include suitable computer-readable instructions that, when
implemented, configure the controller 114 to perform various different functions, such
as receiving, transmitting and/or executing wind turbine control signals.
[0032] Referring now to FIG. 2, a simplified, internal view of one embodiment of
the nacelle 106 of the wind turbine 100 shown in FIG. 1 is illustrated. As shown, the
generator 118 may be coupled to the rotor 108 for producing electrical power from the
rotational energy generated by the rotor 108. For example, as shown in the illustrated
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embodiment, the rotor 108 may include a rotor shaft 122 coupled to the hub 110 for
rotation therewith. The rotor shaft 122 may be rotatably supported by a main bearing
144. The rotor shaft 122 may, in turn, be rotatably coupled to a generator shaft 124 of
the generator 118 through a gearbox 126 connected to a bedplate support frame 136
by one or more torque arms 142. As is generally understood, the rotor shaft 122 may
provide a low speed, high torque input to the gearbox 126 in response to rotation of
the rotor blades 112 and the hub 110. The gearbox 122 may then be configured to
convert the low speed, high torque input to a high speed, low torque output to drive
the generator shaft 124 and, thus, the generator 118.
[0033] Each rotor blade 112 may also include a pitch adjustment mechanism 120
configured to rotate each rotor blade 112 about its pitch axis 116. Further, each pitch
adjustment mechanism 120 may include a pitch drive motor 128 (e.g., any suitable
electric, hydraulic, or pneumatic motor), a pitch drive gearbox 130, and a pitch drive
pinion 132. In such embodiments, the pitch drive motor 128 may be coupled to the
pitch drive gearbox 130 so that the pitch drive motor 128 imparts mechanical force to
the pitch drive gearbox 130. Similarly, the pitch drive gearbox 130 may be coupled to
the pitch drive pinion 132 for rotation therewith. The pitch drive pinion 132 may, in
turn, be in rotational engagement with a pitch bearing 134 coupled between the hub
110 and a corresponding rotor blade 112 such that rotation of the pitch drive pinion
132 causes rotation of the pitch bearing 134. Thus, in such embodiments, rotation of
the pitch drive motor 128 drives the pitch drive gearbox 130 and the pitch drive
pinion 132, thereby rotating the pitch bearing 134 and the rotor blade 112 about the
pitch axis 116. Similarly, the wind turbine 100 may include one or more yaw drive
mechanisms 138 communicatively coupled to the controller 114, with each yaw drive
mechanism(s) 138 being configured to change the angle of the nacelle 106 relative to
the wind (e.g., by engaging a yaw bearing 140 of the wind turbine 100).
[0034] As depicted in FIGS. 3 and 4, the main bearing 144 may generally
correspond to a tapered roller bearing but may be any suitable bearing, including for
example, a spherical roller bearing, a ball bearing, or any other suitable bearing. In
addition, as shown, the main bearing 144 may be secured in place via a bearing
housing 146. The main bearing 144 may also be mounted to the bedplate support
member 136 of the nacelle 106 via one or more torque supports 148.
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[0035] Referring still to FIG. 4, in an embodiment, the wind turbine 100 may be
outfitted with a rotor lock plate 150. The rotor lock plate 150 may encircle the rotor
shaft 122 of the wind turbine 100. The rotor lock plate 150 may include a plurality of
features 152 which may be engaged in order to secure the rotor 108 and prevent
rotation of the rotor 108 in response to a wind load. In an embodiment, the features
152 may be a plurality of through holes 154 defined by the rotor lock plate 150. The
through holes 154 may define an axis (HA) parallel to and offset from the main shaft
122 of the rotor 108. It should be appreciated that in an embodiment, the features 152
may, for example, be depressions, grooves, ridges, teeth, or high-friction regions
which may be engaged so as to secure the rotor 108.
[0036] In an embodiment, such as depicted in FIG. 3, the wind turbine 100 may
also be outfitted with a low-speed rotor lock 156. As shown, the low-speed rotor lock
156 may be built into, and be integral with, the bedplate support frame 136. The lowspeed rotor lock 156 may include a low-speed rotor lock pin 158 which may be
advanced to engage a corresponding feature 152 of the rotor lock plate 150. The lowspeed rotor lock 156 may be sized so as to resist a force developed by winds up to a
first wind threshold.
[0037] In FIGS. 3 and 4, side and rear views of a rotor lock assembly 200 in
accordance with an embodiment of the present disclosure are illustrated. The rotor
lock assembly 200 may lock a rotor 108 of a wind turbine 100 so as to facilitate
maintenance operations during a period of time wherein the possibility exists to
encounter winds in excess of the first wind threshold. The rotor lock assembly 200
may, in accordance with aspects of the present disclosure, include the removable rotor
lock(s) 202. More specifically, as shown, the removable rotor lock(s) 202 may be
coupled to a quadrant of the bearing housing 146 adjacent to the rotor lock plate 150.
In an embodiment, as shown in FIG. 5A, the removable rotor lock(s) 202 may include
a housing 204, a bushing element 206 a pin shaft 208 and a locking mechanism 210.
It should be appreciated that in at least one embodiment, each rotor lock 202 may
include a single pin shaft 208, with the housing 204 being sized to accommodate the
single pin shaft 208 positioned within the bushing element 206.
[0038] In an embodiment, such as depicted in FIG. 4, the rotor lock assembly 200
may include at least a first removable rotor lock 212 and a second removable lock
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214. The first removable rotor lock 212 may be coupled to a first quadrant of the
bearing housing 146. The second removable rotor lock 214 may be coupled to a
second quadrant of the bearing housing 146 adjacent to the first quadrant. As such, in
an embodiment, the removable rotor locks 202 work in conjunction with the lowspeed rotor lock 156 to resist, a wind load, which includes a 15% safety margin.
[0039] It should be appreciated that the various rotor locks may be subjected to
differing portions of the wind load. For example, in an embodiment, the low-speed
rotor lock 156 may be configured to resist up to 50% of the anticipated wind load,
while a pair of removable rotor locks may each be configured to resist up to 25% of
the anticipated wind load. Alternatively, the low-speed rotor lock 156 may be
configured to resist up to 70% of the anticipated wind load, while the first removable
rotor lock 212 may be configured to resist up to 20% of the anticipated wind load and
the second removable rotor lock 214 may be configured to resist up to 10% of the
anticipated wind load.
[0040] FIGS. 5A and 5B illustrate a perspective view and an exploded perspective
view of the rotor lock(s) 202 according to aspects of the present disclosure. Further,
as shown, the rotor lock(s) 202 may include a housing 204. The housing 204 may
include an opening 216. The opening 216 may extend from a first end 220 to a
second end 222. The housing 204 may also include a mounting portion 218. The
mounting portion 218 may be adapted for mounting to the bearing housing 146
adjacent to the rotor lock plate 150 of the rotor 108. In an embodiment, such as
depicted in FIG. 4, the housing 204 may have a rounded-triangular cross-sectional
shape wherein the housing radially tapers from a maximal width at the mounting
portion 218. The mounting portion 218 may have a surface profile corresponding
with a portion of a main bearing housing 146.
[0041] In an embodiment, the mounting portion 218 may define a plurality of
fastener openings 224. A plurality of fasteners 226 may be inserted through the
plurality of fastener openings 224 so as to secure the mounting portion 218, and thus
the removable rotor lock(s) 202, to the bearing housing 146. The plurality of
fasteners 226 may include screws, bolts, studs and nuts, or removable rivets. It should
be appreciated that, in alternative embodiments, the removable rotor lock(s) 202 may
be coupled to the bearing housing 146 by any suitable means. For example, the rotor
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lock(s) 202 may be coupled to the bearing housing by adhering, fusing, welding, or
other mechanical means such as a dovetail slot. It should be further appreciated that
in an embodiment wherein the fasteners 226 are not employed, the plurality of
fastener openings 224 may be omitted from the mounting portion 218.
[0042] In an embodiment, such as depicted in FIG. 5A, the housing 204 may be
equipped with at least one attachment location 228. The attachment location(s) 228
may be coupled to the housing 204. For example, the attachment location(s) 228 may
be a hoist ring, a pad eye, a lifting eye, an eye nut, or an eye bolt. Alternatively, the
attachment location(s) 228 may include a protrusion, a recess, or a combination
thereof integrally formed with the housing 204.
[0043] The attachment location(s) 228 may provide a lifting point for lifting the
relocatable rotor lock(s) 202 uptower. The housing 204 may be sized so as to have a
lifting footprint which permits the housing 204 to be hoisted through an access hatch
located on an underside of nacelle 106 up tower. Additionally, the housing 204 may
be sized so as to permit the movement of the housing 204 from the access hatch to the
bearing housing 146 without necessitating the removal of the outer shell 160 or the
employment of a ground crane. It should be appreciated that multiple rotor locks 202,
sized as described herein, may facilitate securing the rotor lock plate 150 with
multiple pin shafts 208 in situations where a single housing containing multiple pins
may not be emplaced without removing the outer shell 160.
[0044] Referring now to FIG. 6, a perspective view of a portion of the bearing
housing 146 is presented in accordance with aspects of the present disclosure. As
depicted in FIG. 6, the bearing housing 146 may include a removable rotor lock
mounting point 162. As depicted, the removable rotor lock mounting point 162 may
include a planar surface 164 defining a plurality of fastener openings 166. The
plurality of fastener openings 166 may be configured to couple the removable rotor
lock(s) 202 to mounting point 162 via a plurality of fasteners 226 inserted through a
plurality of fastener openings 224 of the mounting portion 218. The planar surface
164 having a long axis oriented perpendicular to the rotor shaft 122. The removable
rotor lock mounting point 162, may also include a pair of mounting ridges 168
oriented perpendicular to the rotor shaft 122 with the planar surface 164 disposed
between the pair of mounting ridges 168. It should be appreciated that, in an
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alternative embodiment, the planar surface 164 may be a curved surface formed so as
to receive or be received by the mounting portion 218.
[0045] Referring again to FIGS. 3-5B, the rotor lock(s) 202 may include the
bushing element 206. The bushing element 206 may be positioned within the opening
216. The bushing element 206 may have a first portion 230 which may be inserted
into the housing 204. The bushing element 206 may also have a second portion 232,
which may extend outward from the opening second end 220. The bushing element
206 may include a securing feature 234. The securing feature 234 may be configured
as a protrusion or a recess, which may be engaged by a bushing securing mechanism
236 coupled to the housing 204. The bushing securing mechanism 236 may secure
the bushing element 206 within the opening 216 of the housing 204. It should be
appreciated that the bushing element 206 may be a unitary body. Alternatively, the
bushing element 206 may include multiple segments. For example, the first portion
230 may be a first segment, while the second portion 232 may be second segment. In
an additional example, the bushing element 206 may be divided by a vertical plane so
as to create a first half and a second half.
[0046] Referring still to FIGS. 3-5B, the rotor lock(s) 202 may include the pin
shaft 208. The pin shaft 208 may be positioned within the bushing element 206. The
pin shaft 208 may include a proximal end 238 and a distal end 240. The pin shaft 208
may be movable within the bushing element 206. Upon the application of a force, the
distal end 240 may advance or move toward and engage the rotor lock plate 150 of the
rotor 108. In at least one embodiment, the proximal end 238 may be formed with a
feature which may be engaged by the locking mechanism 210 coupled to at least one
of the bushing element 206 or the housing 204 in order to secure the pin shaft 208 in a
forward or engaged position. In at least one embodiment, the locking mechanism 210
may include a lockout-tagout element which may prevent an unauthorized
disengagement of the pin shaft 208. It should be appreciated that in at least one
embodiment, the engagement of the rotor lock plate 150 may be facilitated by an
alignment system operably coupled to the pin shaft 208, which may be configured to
align the pin shaft 208 with the through hole 154 of the rotor lock plate 150.
[0047] In an embodiment, such as depicted in FIGS. 3-5B, the pin shaft 208 may
be movable within the bushing element 206 via at least one of an axial movement or a
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rotational movement along the axis (HA). The movement of the pin shaft 208 may be
motivated by an engagement system 242. The engagement system 242 may be at
least one of a direct-manual engagement system, a hydraulic engagement system, a
geared engagement system, or a motorized engagement system, which is operably
coupled to the pin shaft 208. For example, as depicted in FIG. 5A, a direct-manual
engagement system may involve the direct application, upon an engagement
protrusion 244, of a force, by a technician in order to slide the pin shaft 208 in an
axial direction. Alternatively, the force applied by the technician may cause the pin
shaft 208 and/or the bushing element 206 to rotate in response to a plurality of threads
and advance or be retracted. In yet a further embodiment, a tool may be employed to
turn a crank, which may be coupled to a gearing system configured to move the pin
shaft 208 within the bushing element 206.
[0048] In an embodiment, such as depicted in FIG. 5B, the distal end 240 of the
pin shaft 208 may be relieved so as to facilitate the insertion and/or extraction of the
pin shaft 208 from the rotor lock plate 150. In at least one embodiment, the distal end
240 of the pin shaft 208 may have a tapered cross-sectional profile. The tapered
cross-sectional profile of the distal end 240 may include, for example, an ogive, a
chamfered, or a rounded cross-sectional profile.
[0049] Referring to FIG. 7, a flow diagram of one embodiment of a method 300
for performing a maintenance and/or repair procedure on a component of a wind
turbine is illustrated. The method 300 may be implemented using, for instance, the
rotor lock assembly 200 discussed above with reference to FIGS. 3-5B. FIG. 6
depicts steps performed in a particular order for purposes of illustration and
discussion. Those of ordinary skill in the art, using the disclosures provided herein,
will understand that various steps of the method 300 or any of the other methods
disclosed herein may be adapted, modified, rearranged, performed simultaneously or
modified in various ways without deviating from the scope of the present disclosure.
[0050] As shown at (302), the method 300 includes coupling at least one
removable rotor lock to a main bearing housing. As shown at (304), the method 300
includes preventing rotation of the rotor, and at (306) advancing a built-in low-speed
rotor lock of the wind turbine so as to engage a first corresponding feature of a rotor
lock plate. As shown at (308), the method 300 includes advancing a pin shaft of the
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at least one removable rotor lock to an advanced position so as to engage a second
corresponding feature of the rotor lock plate. Additionally, as shown at (310), the
method 300 includes securing the pin shaft in the advanced position through the
engagement of a locking mechanism.
[0051] In additional embodiments, the method (300) may also include aligning
the pin shaft with the corresponding feature of the rotor lock plate via an alignment
system operably coupled to the pin shaft. Further, advancing the pin shaft may
include advancing the pin shaft via an engagement system operably coupled to the pin
shaft. In another embodiment, the method (300) may include coupling a second rotor
lock to the main bearing housing.
[0052] In additional embodiments, the method (300) may include performing the
maintenance procedure on an assembled nacelle, up tower. In yet another
embodiment, the method (300) may include hoisting the first and second removable
rotor locks through an access hatch located on an underside of nacelle up tower.
[0053] Furthermore, the skilled artisan will recognize the interchangeability of
various features from different embodiments. Similarly, the various method steps and
features described, as well as other known equivalents for each such methods and
feature, can be mixed and matched by one of ordinary skill in this art to construct
additional systems and techniques in accordance with principles of this disclosure. Of
course, it is to be understood that not necessarily all such objects or advantages
described above may be achieved in accordance with any particular embodiment.
Thus, for example, those skilled in the art will recognize that the systems and
techniques described herein may be embodied or carried out in a manner that achieves
or optimizes one advantage or group of advantages as taught herein without
necessarily achieving other objects or advantages as may be taught or suggested
herein.
[0054] This written description uses examples to disclose the invention, including
the best mode, and also to enable any person skilled in the art to practice the
invention, including making and using any devices or systems and performing any
incorporated methods. The patentable scope of the invention is defined by the claims,
and may include other examples that occur to those skilled in the art. Such other
examples are intended to be within the scope of the claims if they include structural
16
elements that do not differ from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from the literal languages
of the claims.
[0055] For reasons of completeness, various aspects of the present disclosure are
set out in the following numbered clauses:
Clause 1. A rotor lock assembly for locking a rotor of a wind turbine, the
rotor lock assembly comprising:
at least one removable rotor lock, comprising:
a housing comprising an opening and a mounting portion, the opening
extending from a first end to a second end thereof, the mounting portion
adapted for mounting to a bearing housing adjacent to a rotor lock plate of the
rotor; and,
a pin shaft positioned within the opening, the pin shaft comprising a
proximal end and a distal end, the pin shaft being movable within the opening
such that the distal end moves toward and engages the rotor lock plate of the
rotor; and,
a locking mechanism for locking the pin shaft in place.
Clause 2. The rotor lock assembly of clause 1, further comprising a
plurality of fasteners for securing the mounting portion of the housing to the bearing
housing through a plurality of fastener openings of the mounting portion.
Clause 3. The rotor lock assembly of clause 1, wherein the pin shaft
engages the rotor lock plate via a through hole configured therethrough, the through
hole defining an axis parallel to and offset from a main shaft of the rotor.
Clause 4. The rotor lock assembly of clause 3, further comprising an
alignment system operably coupled to the pin shaft so as to align the pin shaft with the
through hole of the rotor lock plate.
Clause 5. The rotor lock assembly of clause 1, wherein the at least one
removable rotor lock comprises a first removable rotor lock and a second removable
rotor lock.
Clause 6. The rotor lock assembly of clause 5, wherein the first
removable rotor lock is coupled to a first quadrant of the bearing housing and the
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second removable rotor lock is coupled to a second, adjacent quadrant of the bearing
housing.
Clause 7. The rotor lock assembly of clause 1, wherein the housing
further comprises a bushing element positioned within the opening and a bushing
securing mechanism oriented to engage a corresponding feature of the bushing
element and secure the bushing element within the opening.
Clause 8. The rotor lock assembly of clause 7, wherein the pin shaft is
movable within the bushing element via at least one of an axial movement or a
rotational movement and wherein the pin shaft is moved by at least one of a directmanual engagement system, a hydraulic engagement system, a geared engagement
system or a motorized engagement system operably coupled to the pin shaft.
Clause 9. The rotor lock assembly of clause 1, wherein the proximal end
of the pin shaft engages the locking mechanism.
Clause 10. The rotor lock assembly of clause 1, wherein the distal end of
the pin shaft comprises a tapered cross-sectional profile.
Clause 11. The rotor lock assembly of clause 1, wherein the housing
further comprises at least one attachment location for providing a lifting point for
lifting the removable rotor lock uptower.
Clause 12. A method for performing a maintenance and/or repair
procedure on a component of a wind turbine, the method comprising:
coupling at least one removable rotor lock to a main bearing housing;
preventing rotation of the rotor;
advancing a built-in low-speed rotor lock of the wind turbine so as to engage a
first corresponding feature of a rotor lock plate;
advancing a pin shaft of the at least one removable rotor lock to an advanced
position so as to engage a second corresponding feature of the rotor lock plate; and,
securing the pin shaft in the advanced position through the engagement of a
locking mechanism.
Clause 13. The method of clause 12, further comprising:
aligning the pin shaft with the corresponding feature of the rotor lock plate via
an alignment system operably coupled to the pin shaft.
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Clause 14. The method of clause 12, wherein the advancing the pin shaft
comprises advancing the pin shaft via at least one of a direct-manual engagement
system, a hydraulic engagement system, a geared engagement system or a motorized
engagement system operably coupled to the pin shaft.
Clause 15. The method of clause 12, wherein the at least one removable
rotor lock comprises a first removable rotor lock coupled to a first quadrant of the
bearing housing, the method further comprising:
coupling a second removable rotor lock to an adjacent quadrant of the
main bearing housing.
Clause 16. The method of clause 12, further comprising:
performing the maintenance procedure on an assembled nacelle, up tower.
Clause 17. The method of clause 15, further comprising:
hoisting the first and second removable rotor locks through an access
hatch located on an underside of the nacelle up tower.
Clause 18. A wind turbine repair system comprising:
a rotor lock plate circumferentially mounted to a rotor shaft of the wind
turbine, the rotor lock plate defining a plurality of openings, each of the plurality of
openings having an axis parallel to and offset from the rotor shaft;
a low-speed rotor lock coupled to a bedplate support frame perpendicular to
the rotor lock plate;
a bearing housing; and,
a removable rotor lock mounted to the bearing housing, the removable rotor
lock comprising:
a housing comprising an opening and a mounting portion, the opening
extending from a first end to a second end thereof, the mounting portion
adapted for mounting to a bearing housing adjacent to a rotor lock plate of the
rotor,
a pin shaft positioned within the opening, the pin shaft comprising a
proximal end and a distal end, the pin shaft being movable within the opening
such that the distal end moves toward and engages the rotor lock plate of the
rotor, and
a locking mechanism for locking the pin shaft in place.
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Clause 19. The wind turbine repair system of clause 18, wherein the
bearing housing further comprises a removable rotor lock mounting point, the
removable rotor lock mounting point comprising:
a planar surface defining a plurality of fastener openings, the planar
surface having a long axis oriented perpendicular to the rotor shaft,
a pair of mounting ridges oriented perpendicular to the rotor shaft with
the planar surface disposed between the pair of mounting ridges.
Clause 20. The wind turbine repair system of clause 18, wherein the
removable rotor lock comprises a first removable rotor lock and the rotor lock
mounting point comprises a first rotor lock mounting point located within a first
quadrant of the main bearing housing, the system further comprising:
a second removable rotor lock coupled to a second rotor lock mounting
point located within a second quadrant of the main bearing housing.
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WHAT IS CLAIMED IS:
1. A rotor lock assembly for locking a rotor of a wind turbine, the rotor
lock assembly comprising:
at least one removable rotor lock, comprising:
a housing comprising an opening and a mounting portion, the opening
extending from a first end to a second end thereof, the mounting portion
adapted for mounting to a bearing housing adjacent to a rotor lock plate of the
rotor,
a pin shaft positioned within the opening, the pin shaft comprising a
proximal end and a distal end, the pin shaft being movable within the opening
such that the distal end moves toward and engages the rotor lock plate of the
rotor, and
a locking mechanism for locking the pin shaft in place.
2. The rotor lock assembly of claim 1, further comprising a plurality of
fasteners for securing the mounting portion of the housing to the bearing housing
through a plurality of fastener openings of the mounting portion.
3. The rotor lock assembly of claims 1-2, wherein the pin shaft engages
the rotor lock plate via a through hole configured therethrough, the through hole
defining an axis parallel to and offset from a main shaft of the rotor.
4. The rotor lock assembly of claims 1-3, further comprising an
alignment system operably coupled to the pin shaft so as to align the pin shaft with the
through hole of the rotor lock plate.
5. The rotor lock assembly of claims 1-4, wherein the at least one
removable rotor lock comprises a first removable rotor lock and a second removable
rotor lock.
6. The rotor lock assembly of claim 5, wherein the first removable rotor
lock is coupled to a first quadrant of the bearing housing and the second removable
rotor lock is coupled to a second, adjacent quadrant of the bearing housing.
7. The rotor lock assembly of claims 1-6, wherein the housing further
comprises a bushing element positioned within the opening and a bushing securing
mechanism oriented to engage a corresponding feature of the bushing element and
secure the bushing element within the opening.8. The rotor lock assembly of claim 7, wherein the pin shaft is movable
within the bushing element via at least one of an axial movement or a rotational
movement and wherein the pin shaft is moved by at least one of a direct-manual
engagement system, a hydraulic engagement system, a geared engagement system or
a motorized engagement system operably coupled to the pin shaft.
9. The rotor lock assembly of claims 1-8, wherein the proximal end of the
pin shaft engages the locking mechanism.
10. The rotor lock assembly of claims 1-9, wherein the distal end of the pin
shaft comprises a tapered cross-sectional profile.
11. A method for performing a maintenance and/or repair procedure on a
component of a wind turbine, the method comprising:
coupling at least one removable rotor lock to a main bearing housing;
preventing rotation of the rotor;
advancing a built-in low-speed rotor lock of the wind turbine so as to engage a
first corresponding feature of a rotor lock plate;
advancing a pin shaft of the at least one removable rotor lock to an advanced
position so as to engage a second corresponding feature of the rotor lock plate; and,
securing the pin shaft in the advanced position through the engagement of a
locking mechanism.
12. The method of claim 11, further comprising:
aligning the pin shaft with the corresponding feature of the rotor lock plate via
an alignment system operably coupled to the pin shaft.
13. The method of claims 11- 12, wherein the advancing the pin shaft
comprises advancing the pin shaft via at least one of a direct-manual engagement
system, a hydraulic engagement system, a geared engagement system or a motorized
engagement system operably coupled to the pin shaft.
14. The method of claims 11- 13, wherein the at least one removable rotor
lock comprises a first removable rotor lock coupled to a first quadrant of the bearing
housing, the method further comprising:
coupling a second removable rotor lock to an adjacent quadrant of the main
bearing housing.
15. The method of claim 14, further comprising:
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hoisting the first and second removable rotor locks through an access hatch
located on an underside of the nacelle up tower; and performing the maintenance procedure on an assembled nacelle, up tower.