Component Replacement in Wind Turbines

Method for repowering wind turbines by reusing the existing tower instead of dismantling it. The method involves removing the old nacelle from the tower and installing a new, more powerful nacelle on the tower. This allows retrofitting wind turbines with larger capacity by leveraging the existing tower rather than replacing it. The tower has a longer service life compared to the nacelle, so it can be reused multiple times as the nacelles are swapped.

Source

A wind turbine nacelle design that simplifies installation, maintenance, and servicing of the nacelle components like the generator and transformer. The nacelle has a separable main unit that attaches to the tower and an auxiliary unit that contains the operative components like the generator. The auxiliary unit can be connected to the main unit onsite for installation, then disconnected and lowered for maintenance or replacement. This allows easier access and service without lifting the entire nacelle. The separable design also reduces nacelle weight and cost since the main unit can be a standard shipping container.

Source

Cable winch unit for safely lifting and lowering components of wind turbines during assembly/disassembly. The winch has a base, pivot arm, and holding unit. The pivot arm has a winch at the end and the holding unit pivots on the arm. The holding unit attaches to the component and the winch holds the lifting cable. The pivot arm configuration with angled sections prevents the winch from swinging wildly during lifts/lowers.

Source

Method for changing blades on floating offshore wind turbines that enables faster, simpler and less expensive blade swaps compared to bringing the entire turbine to shore. The method involves temporarily mounting a crane on the floating platform and using it to lift and replace blades while the turbine continues operating. The crane attaches to the platform and positions itself near the turbine. It then handles the blade in a horizontal position without needing to move the entire turbine. This allows blades to be swapped without disconnecting the turbine from the grid or exposing workers to extreme sea conditions.

Source

A system and method for replacing a rotor and main shaft in wind turbines that enables faster, safer, and more efficient component swaps. The system uses an integrated structure on the nacelle, lifting jigs on the rotor and main shaft, bottom pulleys, winches, back pulleys, fixed and moving pulleys, and gun tackle arrangements to lift, move, and lower the rotor and shaft for replacement. This allows de-erecting and re-erecting the rotor and shaft without cranes or heavy lifts, reducing downtime, costs, risks, and mobilization needs.

Source

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.

Source

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.

Source

A method to simplify lifting heavy components like drivetrains from a wind turbine nacelle during installation, repair, or replacement. The method involves hooking the component and the nacelle roof together onto a crane hook. This allows lifting both the component and nacelle roof as a single unit, reducing wind loading and enabling lower wind speed thresholds. The roof can be connected to the crane separately. The component is hooked first with a connecting device that passes through the roof opening.

Source

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.

Source

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.

Source

Using drones and cranes together to handle heavy wind turbine components for assembly and maintenance. The method involves coordinating drones and cranes to lift and maneuver components like blades. The drones support some of the weight, allowing smaller cranes to be used. The drones can also attach to the component at a different location than the cranes. This allows more flexible positioning and control of the component. The drones can also be used to install cranes on wind turbines.

Source

Mounting and unmounting wind turbine components inside the nacelle without external cranes. The method involves installing cable guiding structures inside the nacelle with pulleys. Components are connected to hoisting mechanisms via cables, then moved using the hoisting mechanism and pulleys inside the nacelle. This allows internal movement without cranes. The guiding structures can be temporarily installed for specific moves. Other steps like sliding rails and adjustable rails further aid component maneuvering.

Source

Safe installation of heavy wind turbine components like generators and gearboxes into the nacelle at the top of a wind turbine without needing personnel close to the suspended load. The method uses two ropes and winches to lower and guide the component into the nacelle. The component is secured to the nacelle using bolts and nuts after passing the ropes through. Sensors on the winches maintain constant tension to stiffen the ropes as the component approaches, preventing excessive sag. This prevents the need for people near the load during lowering. The component can then be secured in the nacelle.

Source

Method for installing components on offshore wind turbines using existing lifting gear already on the turbine instead of bringing in separate heavy lift equipment. The method involves installing a smaller, lighter lifting system on the turbine, then using that to install or remove components using the turbine's existing heavy lift gear. This allows component replacement and assembly without requiring specialized heavy lift vessels. The smaller lifting system can also be used to install the heavy lifting gear itself.

Source

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

Source

Method for efficiently setting up, maintaining, and disassembling tall wind turbines over 140 meters in height without using large, expensive cranes. The method involves using two separate lifting devices, one for lighter loads and one for heavier loads. The lighter device is used to assemble the tower. Then the heavier device is temporarily mounted on the tower to lift and replace large components like nacelles. This allows efficient installation and maintenance without relying on external cranes.

Source

Lifting device for assembling and disassembling wind turbine components without using cranes. The device is mounted on a truck and has a platform connected to the tower. It has an extendable set with telescoping modules that can reach the turbine components. The last module has wheels and clamps to grasp the component and lift it off. This allows swapping blades or other parts without cranes in any weather conditions, reducing downtime and costs compared to crane-based methods.

Source