US20100275442A1 - Method and system for disengaging a shrink coupling on a turbine generator - Google Patents
Method and system for disengaging a shrink coupling on a turbine generator Download PDFInfo
- Publication number
- US20100275442A1 US20100275442A1 US12/566,952 US56695209A US2010275442A1 US 20100275442 A1 US20100275442 A1 US 20100275442A1 US 56695209 A US56695209 A US 56695209A US 2010275442 A1 US2010275442 A1 US 2010275442A1
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- shrink coupling
- shrink
- coupling
- reaction plate
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P11/00—Connecting or disconnecting metal parts or objects by metal-working techniques not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
- B23P19/04—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes for assembling or disassembling parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
- B25B27/00—Hand tools, specially adapted for fitting together or separating parts or objects whether or not involving some deformation, not otherwise provided for
- B25B27/02—Hand tools, specially adapted for fitting together or separating parts or objects whether or not involving some deformation, not otherwise provided for for connecting objects by press fit or detaching same
- B25B27/06—Hand tools, specially adapted for fitting together or separating parts or objects whether or not involving some deformation, not otherwise provided for for connecting objects by press fit or detaching same inserting or withdrawing sleeves or bearing races
- B25B27/064—Hand tools, specially adapted for fitting together or separating parts or objects whether or not involving some deformation, not otherwise provided for for connecting objects by press fit or detaching same inserting or withdrawing sleeves or bearing races fluid driven
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D15/00—Transmission of mechanical power
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D15/00—Transmission of mechanical power
- F03D15/10—Transmission of mechanical power using gearing not limited to rotary motion, e.g. with oscillating or reciprocating members
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
- F03D80/50—Maintenance or repair
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D1/00—Couplings for rigidly connecting two coaxial shafts or other movable machine elements
- F16D1/06—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end
- F16D1/08—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end with clamping hub; with hub and longitudinal key
- F16D1/0852—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end with clamping hub; with hub and longitudinal key with radial clamping between the mating surfaces of the hub and shaft
- F16D1/0858—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end with clamping hub; with hub and longitudinal key with radial clamping between the mating surfaces of the hub and shaft due to the elasticity of the hub (including shrink fits)
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H57/00—General details of gearing
- F16H57/0018—Shaft assemblies for gearings
- F16H57/0025—Shaft assemblies for gearings with gearing elements rigidly connected to a shaft, e.g. securing gears or pulleys by specially adapted splines, keys or methods
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/0006—Disassembling, repairing or modifying dynamo-electric machines
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2240/00—Components
- F05B2240/60—Shafts
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
- H02K7/003—Couplings; Details of shafts
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
- H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
- H02K7/1807—Rotary generators
- H02K7/1823—Rotary generators structurally associated with turbines or similar engines
- H02K7/183—Rotary generators structurally associated with turbines or similar engines wherein the turbine is a wind turbine
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T29/49822—Disassembling by applying force
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T403/535—Split end with laterally movable opposed portions with separate force-applying means
Definitions
- the present invention relates generally to a method and related system for disengaging a shrink coupling, and, more particularly, to removal of a shrink coupling used to couple a main shaft to gearbox in a turbine generator.
- Shrink couplings are widely used in drive trains to couple a rotating shaft to another component, such as a gearbox.
- a shrink coupling is used to secure the main drive shaft (“low speed shaft”) to the gearbox.
- This coupling can be quite large, often weighing in the range of about 2,000 lbs, and various maintenance procedures require removal of the shrink coupling.
- inspection or replacement of the low speed shaft seal (also referred to as the “front seal”) in the gearbox can only be accomplished with removal of the shrink coupling.
- Modern wind turbines can be quite large, with many designs having a rotor height exceeding 100 meters, and maintenance of these wind turbines often requires the use of a large construction crane in order to repair/replace components in the turbine nacelle. Removal of the main drive shaft shrink coupling is an example of just such a procedure that, to date, typically requires a crane. The logistic requirements, turbine down time, and expense associated with this maintenance procedure can be tremendous.
- 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.
- the cost/benefit economics of wind energy is a constant consideration.
- the cost of producing the energy, including maintenance of the wind turbines, cannot outweigh the benefits.
- the industry would benefit from improvements or advancements in wind turbine operation and maintenance that would reduce the requirements (and associated expense and logistical burdens) for an on-site crane in the performance of maintenance or repair work on the turbines.
- a method for disengaging a shrink coupling that secures a shaft to a drive train component.
- the method includes erecting a reaction plate around the shaft at a location axially displaced from the shrink coupling such that the reaction plate is anchored axially in place relative to the shaft.
- a shim member may be placed around at least a portion of the circumference of the shaft in an axial position between the shrink coupling and reaction plate.
- a plurality of jacking devices are disposed between the reaction plate and the shrink coupling and are equally circumferentially spaced around the shaft. The jacking devices have a first end engaged against the reaction plate and a second, opposite end in a pull-engagement configuration with the shrink coupling.
- the shrink coupling is released from its clamped state, and the jacking devices are activated to exert a pulling force on the shrink coupling to pull the coupling off of the drive train component and axially along the shaft to a resting position on the shaft.
- the shim member is configured so that the shrink coupling remains concentrically aligned with the drive train component in its rest position on the shaft for subsequent re-engagement with the drive train component.
- the present invention also encompasses a system for disengaging a shrink coupling that secures a shaft to a drive train component.
- the system includes a reaction plate erected around the shaft at a location displaced from the shrink coupling and anchored axially in place relative to the shaft.
- a shim member may be disposed circumferentially around at least a portion of the circumference of the shaft at an axial location between the shrink coupling and the reaction plate.
- a plurality of jacking devices are operationally disposed between the reaction plate and the shrink coupling. The jacking devices are equally circumferentially spaced around the shaft and have a first end engaged against the reaction plate and a second, opposite end mechanically fastened to the shrink coupling in a pull-engagement configuration.
- the shrink coupling can be released from its clamping state and removed from the drive train component by activating the jacking devices, which exert a pulling force on the shrink coupling to pull the coupling off of the drive train component and axially along the shaft to a resting position on the shaft.
- the invention also includes a method for performing a maintenance procedure on a front seal of a turbine generator gearbox wherein a drive shaft is coupled to the gearbox with a shrink coupling.
- the method includes erecting a reaction plate around the drive shaft at a location axially displaced from the shrink coupling.
- a plurality of jacking devices are disposed between the reaction plate and the shrink coupling, with the jacking devices being circumferentially spaced around the shaft.
- the jacking devices have a first end that is engaged against the reaction plate, and a second opposite end configured in a pull-engagement configuration with the shrink coupling.
- the shrink coupling is released from its clamped state and the jacking devices are activated to exert a pulling force on the shrink coupling.
- the pulling force causes the shrink coupling to be pulled off of the gear box axially along the shaft to a resting position on the shaft. In this manner, access is provided to the front seal for the maintenance procedure.
- the shrink coupling is moved from its rest position on the shaft back into position for securing the shaft to the gearbox by reversing the direction of the jacking devices and moving the shrink coupling axially along the shaft to an operational position on the gearbox. The shrink coupling is then activated into its clamped state.
- FIG. 1 is a perspective view of a conventional wind turbine
- FIG. 2 is a perspective view of an embodiment of a system in accordance with aspects of the invention configured for removal of a shrink coupling from a turbine generator gearbox;
- FIG. 3 is a perspective view of an alternate embodiment of a system in accordance with aspects of the invention configured for subsequent re-attachment of a shrink coupling on a turbine generator gearbox;
- FIGS. 4 through 6 are sequential operational views of a process for removing a shrink coupling from a turbine generator gearbox in accordance with the invention.
- FIGS. 7 through 9 are sequential operational views of a process for subsequent re-attachment of a shrink coupling onto a turbine generator gearbox.
- FIG. 1 illustrates a wind turbine 10 of conventional construction.
- the wind turbine 10 includes a tower 12 with a nacelle 14 mounted thereon.
- a plurality of turbine blades 16 are mounted to a rotor hub 18 , which is in turn connected to a main flange 20 that turns a main rotor shaft 22 .
- the main rotor shaft 22 is coupled to a gearbox 30 via a shrink coupling 32 , which generates a compression fitting between a sleeve 31 ( FIGS. 4C and 5A ) in the gearbox 30 and the shaft 22 .
- the gearbox 30 is connected to a generator 15 via a high speed shaft (not shown).
- the blades 16 convert motive force of wind into rotational mechanical energy via the shaft 22 and gearbox 30 to generate electricity with the generator 15 .
- FIG. 2 illustrates components of a wind turbine generator supported by a bedplate 28 .
- the bedplate 28 and generator components may be housed within a nacelle 14 ( FIG. 1 ).
- the main rotor shaft 22 is supported by a bearing 24 relative to the bedplate 28 .
- a main flange 20 is attached to the shaft 22 at the forward end thereof and connects with a rotor hub 18 of the wind turbine 10 ( FIG. 1 ).
- the opposite end of the main rotor shaft 22 is coupled to a gearbox 30 via a shrink coupling 32 .
- the shrink coupling 32 is a conventional dual-ring coupling that may be hydraulically actuated.
- a number of head bolts 34 (which may include jacking screws) are located around a front face of the shrink coupling 32 and are used for installation and actuation of the shrink coupling 32 . Operation of shrink couplings 32 is well known by those skilled in the art and a detailed explanation thereof is not necessary for purposes of the present disclosure.
- any number of other components related to the turbine generator drive train or operation of the wind turbine may be configured on the bedplate 28 , for example yawl drives 26 , control equipment, coolers, and the like.
- the perspective view of FIG. 2 is provided for illustrative purposes only, and the invention is not limited to any particular type of drive train or other equipment configuration within a nacelle 14 or other structure.
- a system 35 in accordance with aspects of the invention is provided for removing the shrink coupling 32 from a drive train component, such as the gearbox 30 .
- the system 35 includes a reaction plate 36 that is erected around the shaft 22 at a location that is axially displaced from the front face of the shrink coupling 32 .
- the reaction plate 36 is anchored relative to the bedplate 28 at anchor locations 38 by any conventional means so that the reaction plate 16 is axially fixed in position relative to the shrink coupling 32 .
- the reaction plate 36 may be formed from a plurality of individual frame members that are mechanically fastened together by any conventional means.
- the reaction plate 36 includes a forward-most section 41 that extends partially around the circumference of the shaft 22 and is anchored to the bedplate 28 at anchor points 38 , and a head plate 40 that extends completely around the shaft 22 .
- the head plate 40 may be connected to the forward section 41 by any conventional means.
- a plurality of jacking devices 42 are disposed between the reaction plate 36 and the shrink coupling 32 .
- the jacking devices 42 are equally spaced around the circumference of the shaft 42 and have a first end (not visible in FIG. 2 ) engaged against the head plate 40 , and an opposite engagement end 46 configured in a pull-engagement with the shrink coupling 32 .
- the first end of the jacking devices 42 may be rigidly connected to the head plate 40 .
- the head plate 40 may be provided in sections with the jacking devices 42 rigidly attached thereto.
- the head plate 40 may be provided in three circumferential sections, with a jacking device 42 attached to each section. The sections may then be assembled around the circumference of the shaft 22 so that the three jacking devices 42 are equally spaced around the shaft 22 .
- the engagement ends 46 of the jacking devices 42 may be configured in the pull-engagement with the shrink coupling 32 in various ways.
- the engagement end 46 of the jacking devices 42 includes a hook 48 .
- This hook 48 engages in eye bolts 50 that are substituted for head bolts 34 in the shrink coupling 32 .
- a plurality of circumferentially equally spaced head bolts 34 may be removed from the shrink coupling 32 and eye bolts 50 threaded into the shrink coupling 32 in place of the head bolts 34 .
- the engagement end 46 of the jacking devices 42 may include a threaded member that threads directly into the threaded bores in the face of the shrink coupling 32 .
- any manner of pull-engagement configuration may be utilized in this regard to mechanically couple the engagement end 46 of the jacking devices 42 with the shrink coupling 32 .
- the eye bolt 50 and hook 48 engagement configuration illustrated in FIG. 2 may be reversed so that the hooks 48 are threaded into bores in the shrink coupling 32 , and eye bolts 50 are configured on the engagement ends 46 of the jacking devices 42 .
- the system 35 may also include a shim member 54 that is provided on the shaft 22 at an axial position between the shrink coupling 32 and reaction plate 36 .
- This shim member 54 may be made from any suitable rigid material that has a shape or physical property so as to conform to the circumference of the shaft 22 .
- the shim member 54 may be modular in nature in that it is formed from a plurality of suitable composite material pieces that are assembled at least partially around the upper circumferential section of the shaft 22 .
- the shim member 54 should be of sufficient rigidity and strength so as to fully support the weight of the shrink coupling 32 on the shaft 22 .
- the coupling 32 is pulled axially onto the shim member 54 to a rest position on the shaft 22 .
- the shim member 54 has a radial thickness such that the shrink coupling 32 is maintained in an aligned concentric relationship with the gearbox 30 (sleeve 31 ) while at its resting position on the shim member 54 (and shaft 22 ).
- the shim member 54 would have a correspondingly shaped stepped profile so that the shrink coupling 32 is maintained in an aligned concentric relationship with respect to the gearbox sleeve 31 .
- the system 35 is not limited to any particular type of jacking device 42 .
- the jacking devices 42 may be portable hydraulic jacks that are supplied with pressurized hydraulic fluid from a suitable source.
- a portable hydraulic pump, reservoir, and manifold may be brought into the nacelle 14 for this purpose.
- the individual hydraulic jacks 44 are supplied from a common manifold header to ensure that the jacks are equally pressurized.
- the jacking devices 42 are reversible in operational direction so that the same jacking devices 42 may be used to subsequently re-attach the shrink coupling 32 , as described in greater detail below.
- FIGS. 4 through 6 are sequential operational views of the system 35 being used to remove the shrink coupling 32 from a turbine generator gearbox 30 .
- FIG. 4 illustrates initial preparation of the gear train components.
- certain of the head bolts 34 in the shrink coupling 32 have been removed and replaced with eye bolts 50 .
- the shim member 54 has been assembled around at least a portion of the circumference of the main rotor shaft 22 . It should be appreciated that it is not necessary to assemble the shim member 54 completely around the shaft 22 .
- the shim member 54 is used to support the shrink coupling 32 on a shaft 22 in concentrically aligned relationship with the gearbox sleeve 31 and, in this regard, need only extend partially around the shaft 22 , for example about halfway around the shaft 22 .
- FIG. 5 illustrates the system 35 after the reaction plate 36 has been assembled and anchored axially in position relative to the shrink coupling 32 at anchor points 38 .
- the jacking devices (hydraulic jacks 44 in this embodiment) are equally spaced around the head plate 40 and hooks 48 at the engagement end 46 of the hydraulic jacks 44 are engaged with the eye bolts 50 .
- the shrink coupling 32 has been released from its clamped state by conventional means.
- the hydraulic jacks 44 are then actuated to apply a pulling force on the shrink coupling 32 in the direction of the arrows indicated in FIG. 5 .
- the shrink coupling 32 is controllably pulled from the gearbox sleeve 31 to a resting position on the shim 54 (and shaft 22 ) as illustrated in FIG. 6 .
- the shrink coupling 32 may remain in this position while any manner of maintenance procedure is performed on the gearbox 30 .
- the shrink coupling 32 may be re-attached utilizing the system 35 .
- the jacking devices (hydraulic jacks 44 in this embodiment) are configured in a push-engagement at the engagement end 46 with the shrink coupling 32 and are reversed in direction as indicated by the arrows in FIG. 7 .
- the shrink coupling 32 is maintained in an aligned concentric relationship with respect to the gearbox sleeve 31 and, thus, can be mechanically pushed into the sleeve 31 by the action of the hydraulic jacks 44 , as illustrated in FIG. 8 .
- the shrink coupling 32 may be actuated to its clamped configuration by conventional means, and the system 35 removed from the drive train components, as depicted in FIG. 9 .
- FIG. 3 is similar to the view of FIG. 2 but illustrates a particular type of push-engagement configuration at the ends 46 of the jacking devices 42 that may be useful for re-attaching the shrink coupling 32 in the procedure illustrated in FIGS. 7 through 9 .
- the hooks 48 have been removed from the engagement ends 46 and a push plate 52 substituted therefore.
- the eye bolts 50 have been removed from the shrink coupling 32 and replaced with the appropriate head bolts 34 or jacking screws.
- the push plates 52 simply engage against the head bolts 34 and axially push the shrink coupling 32 into engagement with the gearbox 30 . It should be appreciated, however, that any other manner of push-engagement configuration between the jacking devices 42 and front face of the shrink coupling 32 may be utilized for this purpose.
- the present invention also encompasses a method for removing a shrink coupling in accordance with certain aspects discussed above.
- the method includes, for example, erecting a reaction plate around the shaft at a location displaced from the shrink coupling, and anchoring the reaction plate axially in place relative to the shaft.
- a plurality of jacking devices are disposed between the reaction plate and the shrink coupling, and are equally circumferentially spaced around the shaft.
- the jacking devices have a first end that is engaged against the reaction plate, and a second opposite end that is in a pull-engagement configuration with the shrink coupling.
- the shrink coupling is released from its clamped state and the jacking devices are actuated to exert a pulling force on the shrink coupling.
- the shrink coupling is pulled off of the drive train component and moved axially along the shaft to a resting position on the shaft.
- the method may also include providing a shim member around at least a portion of the circumference of the shaft at a location axially between the shrink coupling and the reaction plate.
- the shrink coupling is pulled onto the shim member in its resting position on the shaft.
- the shim member is constructed to have a radial thickness such that the shrink coupling is maintained in an aligned concentric relationship with the drive train component at its resting position on the shim member.
- the method may further include erecting the reaction plate around the main drive shaft from a plurality of individual frame members. This method may be particularly useful in practice of the method within a relatively confined nacelle of a wind turbine, wherein individual components of the reaction plate would need to be brought into the turbine nacelle and subsequently erected.
- the method may further include moving the shrink coupling from its rest position on the shaft back into an operational position on the drive train component by reversing the direction of the jacking devices and moving the shrink coupling axially along the shaft to its final operational position.
- the shrink coupling can be actuated to its clamped state and any devices used in the method removed from the drive train components.
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Abstract
Description
- The present invention relates generally to a method and related system for disengaging a shrink coupling, and, more particularly, to removal of a shrink coupling used to couple a main shaft to gearbox in a turbine generator.
- Shrink couplings (also known as “shrink disks”) are widely used in drive trains to couple a rotating shaft to another component, such as a gearbox. In many conventional wind turbine designs, a shrink coupling is used to secure the main drive shaft (“low speed shaft”) to the gearbox. This coupling can be quite large, often weighing in the range of about 2,000 lbs, and various maintenance procedures require removal of the shrink coupling. For example, inspection or replacement of the low speed shaft seal (also referred to as the “front seal”) in the gearbox can only be accomplished with removal of the shrink coupling.
- Modern wind turbines can be quite large, with many designs having a rotor height exceeding 100 meters, and maintenance of these wind turbines often requires the use of a large construction crane in order to repair/replace components in the turbine nacelle. Removal of the main drive shaft shrink coupling is an example of just such a procedure that, to date, typically requires a crane. The logistic requirements, turbine down time, and expense associated with this maintenance procedure can be tremendous.
- 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. However, the cost/benefit economics of wind energy is a constant consideration. The cost of producing the energy, including maintenance of the wind turbines, cannot outweigh the benefits. In this regard, the industry would benefit from improvements or advancements in wind turbine operation and maintenance that would reduce the requirements (and associated expense and logistical burdens) for an on-site crane in the performance of maintenance or repair work on the turbines.
- 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.
- Although aspects of the invention will be described herein as they relate to maintenance procedures on a wind turbine, it should be appreciated that this is for purposes of illustrating particular useful embodiments of the present method and system for removal of a shrink coupling. The invention is not limited to wind turbines, and is applicable in any situation that requires removal of a relatively large shrink coupling from between a shaft and another component.
- In accordance with aspects of the invention, a method is provided for disengaging a shrink coupling that secures a shaft to a drive train component. The method includes erecting a reaction plate around the shaft at a location axially displaced from the shrink coupling such that the reaction plate is anchored axially in place relative to the shaft. A shim member may be placed around at least a portion of the circumference of the shaft in an axial position between the shrink coupling and reaction plate. A plurality of jacking devices are disposed between the reaction plate and the shrink coupling and are equally circumferentially spaced around the shaft. The jacking devices have a first end engaged against the reaction plate and a second, opposite end in a pull-engagement configuration with the shrink coupling. The shrink coupling is released from its clamped state, and the jacking devices are activated to exert a pulling force on the shrink coupling to pull the coupling off of the drive train component and axially along the shaft to a resting position on the shaft. If used, the shim member is configured so that the shrink coupling remains concentrically aligned with the drive train component in its rest position on the shaft for subsequent re-engagement with the drive train component.
- The present invention also encompasses a system for disengaging a shrink coupling that secures a shaft to a drive train component. The system includes a reaction plate erected around the shaft at a location displaced from the shrink coupling and anchored axially in place relative to the shaft. A shim member may be disposed circumferentially around at least a portion of the circumference of the shaft at an axial location between the shrink coupling and the reaction plate. A plurality of jacking devices are operationally disposed between the reaction plate and the shrink coupling. The jacking devices are equally circumferentially spaced around the shaft and have a first end engaged against the reaction plate and a second, opposite end mechanically fastened to the shrink coupling in a pull-engagement configuration. With this system, the shrink coupling can be released from its clamping state and removed from the drive train component by activating the jacking devices, which exert a pulling force on the shrink coupling to pull the coupling off of the drive train component and axially along the shaft to a resting position on the shaft.
- The invention also includes a method for performing a maintenance procedure on a front seal of a turbine generator gearbox wherein a drive shaft is coupled to the gearbox with a shrink coupling. The method includes erecting a reaction plate around the drive shaft at a location axially displaced from the shrink coupling. A plurality of jacking devices are disposed between the reaction plate and the shrink coupling, with the jacking devices being circumferentially spaced around the shaft. The jacking devices have a first end that is engaged against the reaction plate, and a second opposite end configured in a pull-engagement configuration with the shrink coupling. The shrink coupling is released from its clamped state and the jacking devices are activated to exert a pulling force on the shrink coupling. The pulling force causes the shrink coupling to be pulled off of the gear box axially along the shaft to a resting position on the shaft. In this manner, access is provided to the front seal for the maintenance procedure. Once the maintenance procedure on the front seal has been performed, the shrink coupling is moved from its rest position on the shaft back into position for securing the shaft to the gearbox by reversing the direction of the jacking devices and moving the shrink coupling axially along the shaft to an operational position on the gearbox. The shrink coupling is then activated into its clamped state.
- 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.
- 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:
-
FIG. 1 is a perspective view of a conventional wind turbine; -
FIG. 2 is a perspective view of an embodiment of a system in accordance with aspects of the invention configured for removal of a shrink coupling from a turbine generator gearbox; -
FIG. 3 is a perspective view of an alternate embodiment of a system in accordance with aspects of the invention configured for subsequent re-attachment of a shrink coupling on a turbine generator gearbox; -
FIGS. 4 through 6 are sequential operational views of a process for removing a shrink coupling from a turbine generator gearbox in accordance with the invention; and, -
FIGS. 7 through 9 are sequential operational views of a process for subsequent re-attachment of a shrink coupling onto a turbine generator gearbox. - Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not as a 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.
-
FIG. 1 illustrates awind turbine 10 of conventional construction. Thewind turbine 10 includes atower 12 with anacelle 14 mounted thereon. A plurality ofturbine blades 16 are mounted to arotor hub 18, which is in turn connected to amain flange 20 that turns amain rotor shaft 22. Themain rotor shaft 22 is coupled to agearbox 30 via ashrink coupling 32, which generates a compression fitting between a sleeve 31 (FIGS. 4C and 5A ) in thegearbox 30 and theshaft 22. Thegearbox 30 is connected to agenerator 15 via a high speed shaft (not shown). Theblades 16 convert motive force of wind into rotational mechanical energy via theshaft 22 andgearbox 30 to generate electricity with thegenerator 15. -
FIG. 2 illustrates components of a wind turbine generator supported by abedplate 28. As discussed, thebedplate 28 and generator components may be housed within a nacelle 14 (FIG. 1 ). Briefly, themain rotor shaft 22 is supported by abearing 24 relative to thebedplate 28. Amain flange 20 is attached to theshaft 22 at the forward end thereof and connects with arotor hub 18 of the wind turbine 10 (FIG. 1 ). The opposite end of themain rotor shaft 22 is coupled to agearbox 30 via ashrink coupling 32. In the embodiment illustrated, theshrink coupling 32 is a conventional dual-ring coupling that may be hydraulically actuated. A number of head bolts 34 (which may include jacking screws) are located around a front face of theshrink coupling 32 and are used for installation and actuation of theshrink coupling 32. Operation ofshrink couplings 32 is well known by those skilled in the art and a detailed explanation thereof is not necessary for purposes of the present disclosure. - Any number of other components related to the turbine generator drive train or operation of the wind turbine may be configured on the
bedplate 28, for example yawl drives 26, control equipment, coolers, and the like. The perspective view ofFIG. 2 is provided for illustrative purposes only, and the invention is not limited to any particular type of drive train or other equipment configuration within anacelle 14 or other structure. - Still referring to
FIG. 2 , asystem 35 in accordance with aspects of the invention is provided for removing theshrink coupling 32 from a drive train component, such as thegearbox 30. Thesystem 35 includes areaction plate 36 that is erected around theshaft 22 at a location that is axially displaced from the front face of theshrink coupling 32. Thereaction plate 36 is anchored relative to thebedplate 28 atanchor locations 38 by any conventional means so that thereaction plate 16 is axially fixed in position relative to theshrink coupling 32. Thereaction plate 36 may be formed from a plurality of individual frame members that are mechanically fastened together by any conventional means. In the illustrated embodiment, thereaction plate 36 includes aforward-most section 41 that extends partially around the circumference of theshaft 22 and is anchored to thebedplate 28 at anchor points 38, and ahead plate 40 that extends completely around theshaft 22. Thehead plate 40 may be connected to theforward section 41 by any conventional means. - A plurality of jacking
devices 42 are disposed between thereaction plate 36 and theshrink coupling 32. In the illustrated embodiment, the jackingdevices 42 are equally spaced around the circumference of theshaft 42 and have a first end (not visible inFIG. 2 ) engaged against thehead plate 40, and anopposite engagement end 46 configured in a pull-engagement with theshrink coupling 32. - The first end of the jacking
devices 42 may be rigidly connected to thehead plate 40. In this embodiment, thehead plate 40 may be provided in sections with the jackingdevices 42 rigidly attached thereto. For example, thehead plate 40 may be provided in three circumferential sections, with a jackingdevice 42 attached to each section. The sections may then be assembled around the circumference of theshaft 22 so that the three jackingdevices 42 are equally spaced around theshaft 22. - The engagement ends 46 of the jacking
devices 42 may be configured in the pull-engagement with theshrink coupling 32 in various ways. For example, in the illustrated embodiment, theengagement end 46 of the jackingdevices 42 includes ahook 48. Thishook 48 engages ineye bolts 50 that are substituted forhead bolts 34 in theshrink coupling 32. In other words, a plurality of circumferentially equally spacedhead bolts 34 may be removed from theshrink coupling 32 andeye bolts 50 threaded into theshrink coupling 32 in place of thehead bolts 34. In an alternate embodiment, theengagement end 46 of the jackingdevices 42 may include a threaded member that threads directly into the threaded bores in the face of theshrink coupling 32. It should be appreciated that any manner of pull-engagement configuration may be utilized in this regard to mechanically couple theengagement end 46 of the jackingdevices 42 with theshrink coupling 32. It should also be appreciated that theeye bolt 50 andhook 48 engagement configuration illustrated inFIG. 2 may be reversed so that thehooks 48 are threaded into bores in theshrink coupling 32, andeye bolts 50 are configured on the engagement ends 46 of the jackingdevices 42. - The
system 35 may also include ashim member 54 that is provided on theshaft 22 at an axial position between theshrink coupling 32 andreaction plate 36. Thisshim member 54 may be made from any suitable rigid material that has a shape or physical property so as to conform to the circumference of theshaft 22. In a particular embodiment, theshim member 54 may be modular in nature in that it is formed from a plurality of suitable composite material pieces that are assembled at least partially around the upper circumferential section of theshaft 22. Theshim member 54 should be of sufficient rigidity and strength so as to fully support the weight of theshrink coupling 32 on theshaft 22. As described in greater detail below, once theshrink coupling 32 has been removed from thegearbox 30, thecoupling 32 is pulled axially onto theshim member 54 to a rest position on theshaft 22. Theshim member 54 has a radial thickness such that theshrink coupling 32 is maintained in an aligned concentric relationship with the gearbox 30 (sleeve 31) while at its resting position on the shim member 54 (and shaft 22). In embodiments wherein theshaft 22 has a stepped circumferential contour, theshim member 54 would have a correspondingly shaped stepped profile so that theshrink coupling 32 is maintained in an aligned concentric relationship with respect to thegearbox sleeve 31. - The
system 35 is not limited to any particular type of jackingdevice 42. In a particular embodiment, the jackingdevices 42 may be portable hydraulic jacks that are supplied with pressurized hydraulic fluid from a suitable source. For example, in the embodiment wherein thesystem 35 is utilized within awind turbine nacelle 14, a portable hydraulic pump, reservoir, and manifold may be brought into thenacelle 14 for this purpose. Desirably, the individualhydraulic jacks 44 are supplied from a common manifold header to ensure that the jacks are equally pressurized. - It is desirable that the jacking
devices 42 are reversible in operational direction so that the same jackingdevices 42 may be used to subsequently re-attach theshrink coupling 32, as described in greater detail below. -
FIGS. 4 through 6 are sequential operational views of thesystem 35 being used to remove theshrink coupling 32 from aturbine generator gearbox 30.FIG. 4 illustrates initial preparation of the gear train components. In particular, certain of thehead bolts 34 in theshrink coupling 32 have been removed and replaced witheye bolts 50. Also, theshim member 54 has been assembled around at least a portion of the circumference of themain rotor shaft 22. It should be appreciated that it is not necessary to assemble theshim member 54 completely around theshaft 22. Theshim member 54 is used to support theshrink coupling 32 on ashaft 22 in concentrically aligned relationship with thegearbox sleeve 31 and, in this regard, need only extend partially around theshaft 22, for example about halfway around theshaft 22. -
FIG. 5 illustrates thesystem 35 after thereaction plate 36 has been assembled and anchored axially in position relative to theshrink coupling 32 at anchor points 38. The jacking devices (hydraulic jacks 44 in this embodiment) are equally spaced around thehead plate 40 and hooks 48 at theengagement end 46 of thehydraulic jacks 44 are engaged with theeye bolts 50. At this stage, theshrink coupling 32 has been released from its clamped state by conventional means. Thehydraulic jacks 44 are then actuated to apply a pulling force on theshrink coupling 32 in the direction of the arrows indicated inFIG. 5 . Theshrink coupling 32 is controllably pulled from thegearbox sleeve 31 to a resting position on the shim 54 (and shaft 22) as illustrated inFIG. 6 . Theshrink coupling 32 may remain in this position while any manner of maintenance procedure is performed on thegearbox 30. - Once maintenance procedures are completed on the
gearbox 30, theshrink coupling 32 may be re-attached utilizing thesystem 35. This process is conceptually illustrated in the sequential views ofFIGS. 7 through 9 . The jacking devices (hydraulic jacks 44 in this embodiment) are configured in a push-engagement at theengagement end 46 with theshrink coupling 32 and are reversed in direction as indicated by the arrows inFIG. 7 . Theshrink coupling 32 is maintained in an aligned concentric relationship with respect to thegearbox sleeve 31 and, thus, can be mechanically pushed into thesleeve 31 by the action of thehydraulic jacks 44, as illustrated inFIG. 8 . At this stage, theshrink coupling 32 may be actuated to its clamped configuration by conventional means, and thesystem 35 removed from the drive train components, as depicted inFIG. 9 . -
FIG. 3 is similar to the view ofFIG. 2 but illustrates a particular type of push-engagement configuration at theends 46 of the jackingdevices 42 that may be useful for re-attaching theshrink coupling 32 in the procedure illustrated inFIGS. 7 through 9 . In this embodiment, thehooks 48 have been removed from the engagement ends 46 and apush plate 52 substituted therefore. Also, theeye bolts 50 have been removed from theshrink coupling 32 and replaced with theappropriate head bolts 34 or jacking screws. In this embodiment, thepush plates 52 simply engage against thehead bolts 34 and axially push theshrink coupling 32 into engagement with thegearbox 30. It should be appreciated, however, that any other manner of push-engagement configuration between the jackingdevices 42 and front face of theshrink coupling 32 may be utilized for this purpose. - The present invention also encompasses a method for removing a shrink coupling in accordance with certain aspects discussed above. The method includes, for example, erecting a reaction plate around the shaft at a location displaced from the shrink coupling, and anchoring the reaction plate axially in place relative to the shaft. A plurality of jacking devices are disposed between the reaction plate and the shrink coupling, and are equally circumferentially spaced around the shaft. The jacking devices have a first end that is engaged against the reaction plate, and a second opposite end that is in a pull-engagement configuration with the shrink coupling. The shrink coupling is released from its clamped state and the jacking devices are actuated to exert a pulling force on the shrink coupling. The shrink coupling is pulled off of the drive train component and moved axially along the shaft to a resting position on the shaft.
- The method may also include providing a shim member around at least a portion of the circumference of the shaft at a location axially between the shrink coupling and the reaction plate. The shrink coupling is pulled onto the shim member in its resting position on the shaft. The shim member is constructed to have a radial thickness such that the shrink coupling is maintained in an aligned concentric relationship with the drive train component at its resting position on the shim member.
- The method may further include erecting the reaction plate around the main drive shaft from a plurality of individual frame members. This method may be particularly useful in practice of the method within a relatively confined nacelle of a wind turbine, wherein individual components of the reaction plate would need to be brought into the turbine nacelle and subsequently erected.
- The method may further include moving the shrink coupling from its rest position on the shaft back into an operational position on the drive train component by reversing the direction of the jacking devices and moving the shrink coupling axially along the shaft to its final operational position. At this stage, the shrink coupling can be actuated to its clamped state and any devices used in the method removed from the drive train components.
- While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
Claims (20)
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US12/566,952 US7836595B1 (en) | 2009-09-25 | 2009-09-25 | Method and system for disengaging a shrink coupling on a turbine generator |
ES10178466T ES2767977T3 (en) | 2009-09-25 | 2010-09-22 | Procedure and system for decoupling a retractable coupling in a wind turbine |
EP10178466.8A EP2301710B1 (en) | 2009-09-25 | 2010-09-22 | Method and system for disengaging a shrink coupling on a wind turbine generator |
DK10178466.8T DK2301710T3 (en) | 2009-09-25 | 2010-09-22 | Method and system for disconnecting a shrink coupling on a wind turbine generator |
CN201010506895.8A CN102029514B (en) | 2009-09-25 | 2010-09-25 | Method and system for disengaging a shrink coupling on a turbine generator |
US12/951,650 US8695196B2 (en) | 2009-09-25 | 2010-11-22 | Method and system for disengaging a shrink coupling on a turbine generator |
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Also Published As
Publication number | Publication date |
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DK2301710T3 (en) | 2020-01-27 |
US8695196B2 (en) | 2014-04-15 |
US20110072627A1 (en) | 2011-03-31 |
CN102029514A (en) | 2011-04-27 |
CN102029514B (en) | 2015-01-14 |
EP2301710A2 (en) | 2011-03-30 |
US7836595B1 (en) | 2010-11-23 |
EP2301710A3 (en) | 2018-01-10 |
EP2301710B1 (en) | 2019-10-30 |
ES2767977T3 (en) | 2020-06-19 |
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