Innovations in Installation & Replacement of Wind Turbine Components

A segmented wind turbine blade designed for easy transport, assembled from two separable segments. The blade features an aeroelastically optimized joint that allows it to bend and twist like a continuous blade. This joint includes a beam that connects the segments, capable of flexing and twisting, mounted on an elastic support that permits movement. This design enables the beam to deform similarly to a flexible blade, with the elastic support providing the necessary restoring force.

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Modular wind turbine blade design and manufacturing method that simplifies assembly of turbine blades on-site. The modular blade design uses double-tapered connections between blade sections. A connecting member with double-tapered ends links two blade modules. Each module has an internal double-tapered channel. The matching double-tapered connections allow modules to be aligned and easily joined. The double tapers provide self-aligning assembly and strong connections. A blade module manufacturing process using tapered molds is also described.

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Detachable stator teeth in electric motors facilitate easier servicing and repair of electric motors. The stator teeth of the motor can be detached individually while leaving the others intact. This allows easier access to the coil windings on the detached stator tooth for repair or replacement. The detachable stator teeth can be attached to the stator using fasteners.

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Modular wind turbine blade design with continuous spars across the module joints that allow the blade to be split into multiple transportable sections. The spars extend from one blade module into the next when assembled, providing a continuous load path through the joint.

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Replacement system for wind turbine rotor blades that allows quick and cost-effective blade installation and replacement without using large cranes. The system uses clamps, hoist blocks, and a platform to lift and maneuver the blades. The clamps attach to the blade near the root and tip. The hoist blocks suspend the blade. The platform provides access to the hub. The blade can then be guided into place. It offers efficient blade installation and replacement that doesn't require large cranes and provides more control and safety.

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A wind turbine blade with a durable erosion shield that can be easily and quickly repaired without removing the blade from the turbine. The blade has a composite shell body made of fibers and resin. Along the leading edge is an erosion shield with two layers. The first layer is a thermoplastic material that can be heat welded to the composite shell. The second layer is a tougher thermoplastic for erosion resistance. The shield layers can be welded in place, and then repaired by welding on new material if eroded. This avoids removing and replacing the entire shield.

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Wind turbine transmissions that are lower cost and easier to service. The design moves the high-speed gear stage to a direct drive configuration. The high-speed spur gear is directly mounted in the transmission housing with a sun gear shaft from the previous stage coupled to it. This eliminates the need for a hollow shaft, and expensive key/shrink connections, and allows better bearing placement.

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A wind turbine with a removable electronics module to improve the serviceability of the electronics. The tower has a space below the lower end where a removable module is located. This module holds the wind turbine's electronics like converters and controllers. This allows easy removal and replacement of the electronics for maintenance. The module can be detached from inside the tower and lowered out the bottom through the space below the tower. The module is shaped to fit through the tower diameter and shipping containers.

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Wind turbine blade with integrated anchoring sites for attaching devices like spoilers or serrations. The sites are made of thermoplastic that bonds well with surface-mounted devices and the composite blade shell material. The thermoplastic anchoring sites are easier to attach devices to compared to adhesive. The thermoplastic can be welded to the blade composite to provide durability. The blade can have recesses to integrate devices flush with the surface.

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A modular pitch tube design for wind turbine installations that enables easy assembly and disassembly in a reduced space. The pitch tube is split into two detachable parts that can be connected and disconnected to pass through the rotor shaft and other components.

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Method for performing main bearing maintenance on a wind turbine uptower without removing the drive train assembly. It involves locking the main shaft to prevent rotation, lifting the shaft clear of the bearing housing, removing the bearing, installing a split bearing, and replacing the housing. A rotor lock is installed between the blades and bearing housing. A lifting device elevates the shaft.

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Surface mounted lightning receptor for wind turbine blades that reduces damage and improves lightning protection. The receptor uses current carriers around the mounting bolts that contact the blade. The carriers allow the majority of lightning current to pass through them rather than the bolts. The carriers are insulated from the bolts and have plugs to cover the bolt heads. This protects the bolts, prevents damage, and allows easier replacement.

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A cable interface system to simplify installation of internal cables in wind turbines. The system has fixed support structures in the nacelle and tower that hold the internal cables in a pre-aligned configuration. The tower support docks with the nacelle support to align the cables. The supports have locking mechanisms to secure the connection. This allows technicians below to connect the exposed cable ends while the supports manage the alignment.

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Wind harnessing device with a lightweight, simple and adjustable blade design for lower cost, weight and easy maintenance compared to conventional wind turbine blades. The device has an axle with poles extending out at each end and blade assemblies that can swing about their attachment points to the poles. This allows the blades to adjust their angle to the wind for improved efficiency compared to fixed angle blades. The swinging blade design allows the device to harness wind power from wider angles.

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A sliding bearing arrangement for a wind turbine that allows easy replacement of bearing pads without weakening the bearing structure.

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