Advanced Repairing Techniques for Wind Turbines

A wind turbine nacelle design that optimizes load-carrying capability while facilitating the serviceability of internal components. The nacelle features a skeleton made of interconnected, non-parallel elongated members that efficiently distribute loads. For servicing, these non-parallel members can be disconnected one by one to create a removal path for components. This design allows for a high degree of nacelle structure optimization without compromising the ability to service internal components.

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Wind turbine transmissions are designed to be 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, coupled with a sun gear shaft from the previous stage. This eliminates the need for a hollow shaft and expensive key/shrink connections, allowing for better bearing placement.

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A method for safely and efficiently opening a nacelle cover door on a wind turbine to access interior components for maintenance and service. This method involves using an onboard service crane or a removable tool to pivot the door open around a hinge line. Once opened, the door is secured to the exterior cooler unit.

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A method to repair cracks in wind turbine blade attachment rings to prevent blade failures. This method involves drilling radial holes through the ring, perpendicular to the axial bolt holes. The radial holes are positioned between the threaded holes and the edge of the ring. When the bolts are tightened, these radial holes compress the ring, preventing crack propagation.

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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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Repairing wind turbines by optimizing the scheduling of repairs based on weather conditions. The method involves analyzing weather information such as wind speed, precipitation, wave height, and temperature at the wind farm location, and comparing it to pre-established thresholds for safe working conditions. This weather analysis is used to determine suitable times for repairing different parts of the wind turbine, accounting for factors like the part needing repair, available personnel, and the estimated repair duration.

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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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A wind turbine rotor servicing system that allows rotor blades to be individually serviced without lowering the whole rotor. The system uses a sling that attaches to rotor blades in two positions and supports the blade in a lowered position while detaching from the hub.

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Temporary maintenance enclosures for wind turbine blades to enable efficient maintenance and repair. The enclosures have a platform that partially surrounds the blade, walls, and a roof that extends towards the blade. The enclosure seals onto the blade to create a protected volume for maintenance. The enclosures collapse for transport and then inflate on site.

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Temporary maintenance enclosure for wind turbine blade repairs that can be quickly deployed and provide weather protection. The enclosure has inflatable sides and a roof with an opening for the blade. A platform inside the enclosure allows workers to access and repair the blade. The enclosure is mounted on the turbine tower and inflated to surround the blade section.

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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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Easy access drive drain design for wind turbines that improves reliability and simplifies maintenance. The drive train uses an elastic coupling to connect the rotor shaft to the gearbox input shaft. This allows torque transfer while accommodating misalignment and reducing parasitic loads. The coupling is accessible through openings in the bearing and coupling housings.

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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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Facilitating the removal and replacement of wind turbine pitch bearings to improve maintenance access without requiring a large crane. An extension assembly is added between the blade and hub to create a gap. The pitch bearing unit is then detached and slid out through the gap.

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