CN108361356A - System and method for the bearing hole for repairing wind turbine gearbox - Google Patents

Abstract

A method (300) for repairing a bearing bore (202, 204) in a wind turbine gearbox (100) having a bearing bore (202) defining a first bearing bore (202) and a second bearing bore ( 204), the method (300) may generally include installing a shaft support member (230) at least partially within the second bearing bore (204), and placing the rotatable shaft (232) Inserted through shaft opening (256) defined through shaft support member (230), such that rotatable shaft (232) is rotatably supported within shaft opening (256). Additionally, the method (300) may include establishing a machining cavity (240) between the first axial end (206) and the second axial end (208) of the first bearing bore (202), and The rotation of (232) rotates the drill bit (242) positioned within the machining cavity (240) to machine the inner surface (210) of the first bearing bore (202).

Description

Systems and methods for repairing bearing bores of wind turbine gearboxes

technical field

The present subject matter relates generally to wind turbines, and more particularly to systems and methods for repairing bearing bores of wind turbine gearboxes.

Background technique

Wind power is considered to be one of the cleanest and most environmentally friendly energy sources available, and wind turbines are gaining more attention in this regard. A modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more turbine blades. The turbine blades capture kinetic energy from the wind using known airfoil principles and transfer the kinetic energy through rotational energy to turn the shaft coupling the rotor blades to the generator via a gearbox.

Wind turbine gearboxes typically include a housing defining various bearing bores configured to receive corresponding gearbox bearings. Over time, one or more of the bearing bores may become worn due to sliding and/or rotation of the associated bearing(s) relative to the housing. Such wear can cause the bearing bore to become out of round. For example, the wear experienced by a given bearing bore will initially be along one side of the bore, causing the bore to assume an elliptical shape. If left unattended, increased bore wear often leads to further slippage of the associated bearing(s), thereby reducing the operational efficiency of the gearbox and increasing the likelihood of damage occurring on the bearings.

Conventionally, when a wind turbine gearbox experiences significant bearing bore wear, the gearbox must be replaced, often a very expensive, difficult and time consuming process. There is currently a need to replace the gearbox due to the lack of suitable repair methods for repairing the bearing bores in the upper part of the tower inside the pod.

Therefore, what would be appreciated in the art would be a simple and efficient system and method for repairing a bearing bore of a wind turbine gearbox in situ (eg, on a tower within a nacelle).

Contents of the invention

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 by practice of the invention.

In one aspect, the present subject matter is directed to a method for repairing a bearing bore in a wind turbine gearbox, wherein the gearbox includes a gearbox housing defining first and second bearing bores axially spaced from each other. The method may generally include mounting a shaft support member at least partially within the second bearing bore, and inserting a rotatable shaft through a shaft opening defined through the shaft support member such that the rotatable shaft is rotatably supported in the inside the shaft opening. Additionally, the method may include establishing a machining cavity between the first axial end and the second axial end of the first bearing bore, and rotating a drill bit positioned within the machining cavity via rotation of the rotatable shaft to The inner surface of the first bearing bore is machined between the first axial end and the second axial end.

In another aspect, the subject matter is directed to a system for repairing a bearing bore within a wind turbine gearbox. The system can generally include a gearbox housing defining a first bearing bore and a second bearing bore. The first bearing hole and the second bearing hole may be axially spaced apart from each other. The first bearing bore may define an inner surface extending between the first axial end and the second axial end. The system may also include a hole repair tool having a rotatable shaft and a drill bit coupled to the rotatable shaft; a first cavity plate mounted on or adjacent to the first bearing bore relative to the housing with the first shaft and a second cavity plate mounted relative to the housing at or adjacent to the second axial end of the first bearing bore such that a machining cavity is defined between the first cavity plate and the second cavity plate. Additionally, the system may include a shaft support member at least partially mounted within the second bearing bore. The shaft support member may define a shaft opening within which the rotatable shaft is rotatably supported. The drill bit may be configured to be positioned within a machining cavity defined between the first cavity plate and the second cavity plate such that when the rotatable shaft is rotated relative to the support member, the drill bit machines an inner bore surface of the first bearing bore .

Embodiment 1. A method for repairing a bearing bore in a wind turbine gearbox comprising a gearbox housing defining a first bearing bore and a second bearing bore, the first bearing bore and the second bearing bore The two bearing bores are axially spaced apart from each other, the method comprising:

mounting a shaft support member at least partially within said second bearing bore;

inserting a rotatable shaft through a shaft opening defined through the shaft support member such that the rotatable shaft is rotatably supported within the shaft opening;

establishing a machining cavity between a first axial end and a second axial end of the first bearing bore; and

rotation of the rotatable shaft rotates a drill bit positioned within the machining cavity to machine the first bearing bore between the first axial end and the second axial end The inner surface.

Embodiment 2. The method of embodiment 1, wherein establishing the machining cavity between the first axial end and the second axial end of the first bearing bore comprises:

mounting a first cavity plate at or adjacent to said first axial end of said first bearing bore; and

A second cavity plate is mounted at or adjacent to the second axial end of the first bearing bore such that the process cavity is defined between the first cavity plate and the second cavity plate.

Embodiment 3. The method of embodiment 2, further comprising removing the first output bearing and oil injection ring of the gearbox from the first bearing bore where the first cavity plate is mounted Or said first axial end adjacent to a first bearing bore comprises mounting said first cavity plate in a previously mounted position of said oil injection ring.

Embodiment 4. The method of embodiment 2, further comprising sealing the first bearing bore defined in or adjacent to the first bearing bore between the first chamber plate and the housing. Axial interface.

Embodiment 5. The method of embodiment 2, further comprising sealing the second cavity defined between the second cavity plate and the housing at or adjacent to the first bearing bore. Axial interface.

Embodiment 6. The method of Embodiment 2, wherein the second cavity plate defines a central opening configured to receive the rotatable shaft.

Embodiment 7. The method of embodiment 6, further comprising rotating the rotatable shaft via a rotating member positioned within the central opening between the rotatable shaft and the second cavity plate. A shaft of rotation is rotatably supported within the central opening defined through the second cavity plate.

Embodiment 8. The method of Embodiment 6, further comprising sealing a radial gap defined in the central opening between the rotatable shaft and the second cavity plate.

Embodiment 9. The method of embodiment 6, wherein the second chamber plate defines a second opening radially offset from the central opening, further comprising passing from the process chamber through the second opening. The opening removes at least one of metal debris or coolant.

Embodiment 10. The method of embodiment 1, further comprising rotating the rotatable shaft via a rotating member positioned within the shaft opening between the rotatable shaft and the shaft support member. A shaft is rotatably supported within the shaft opening defined through the shaft support member.

Embodiment 11. The method of embodiment 1, further comprising inserting the distal end of the rotatable shaft after the distal end of the rotatable shaft has been inserted through the shaft support member and into the housing. A drill bit is coupled to the rotatable shaft.

Embodiment 12. The method of embodiment 1, wherein the shaft support member includes a support portion extending within the second bearing bore, the support portion defining one of a cylindrical shape or a conical shape.

Embodiment 13. The method of embodiment 1, further comprising removing material from the inner surface of the first bearing bore with the drill to enlarge the first bearing bore The removed material is accommodated by a machining cavity defined between the first axial end and the second axial end.

Embodiment 14. A system for repairing a bearing bore in a wind turbine gearbox, the system comprising:

a gearbox housing defining a first bearing bore and a second bearing bore axially spaced from one another, the first bearing bore defined at a first axial end and an inner surface extending between the second axial end;

a hole repair tool comprising a rotatable shaft and a drill coupled to the rotatable shaft;

a first cavity plate mounted at or adjacent to the first axial end of the first bearing hole relative to the housing;

A second cavity plate mounted relative to the housing at or adjacent to the second axial end of the first bearing bore such that a second cavity plate is defined between the first cavity plate and the second cavity plate machining cavity; and

a shaft support member mounted at least partially within said second bearing bore, said support member defining a shaft opening within which said rotatable shaft is rotatably supported,

wherein the drilling tool is configured to be positioned within the machining cavity defined between the first cavity plate and the second cavity plate such that when the rotatable shaft is rotated relative to the support member, The drill bit processes an inner hole surface of the first bearing hole.

Embodiment 15. The system of embodiment 14, further comprising one of a seal or sealing material positioned at or adjacent to the first axial end of the first bearing bore and Defined at the interface between the first chamber plate and the housing.

Embodiment 16. The system of embodiment 14, further comprising one of a seal or sealing material positioned at or adjacent to the second axial end of the first bearing bore and Defined at the interface between the second chamber plate and the housing.

Embodiment 17. The system of embodiment 14, further comprising a rotatable member positioned within the shaft opening defined through the shaft support member, the rotatable member configured relative to the A shaft support member rotatably supports the rotatable shaft within the shaft opening.

Embodiment 18. The system of Embodiment 14, wherein the second chamber plate defines a central opening configured to receive the rotatable shaft, further comprising One of a rotating member or a seal is positioned within the central opening between the shaft of rotation.

Embodiment 19. The system of embodiment 18, wherein the second cavity plate defines a second opening radially offset from the central opening, the second opening configured to allow metal debris or coolant At least one of is removed from the processing chamber.

Embodiment 20. The system of embodiment 14, wherein the shaft support member includes a support portion extending within the second bearing bore, the support portion defining one of a circle or a cone.

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.

Description of drawings

The full and open disclosure of the invention, including the best mode thereof, to those skilled in the art is set forth in the specification with reference to the accompanying drawings in which:

Figure 1 shows a perspective view of an embodiment of a wind turbine;

Figure 2 shows a perspective, inside view of one embodiment of a nacelle suitable for use with the wind turbine shown in Figure 1;

Figure 3 shows a cross-sectional view of one embodiment of a gearbox suitable for use in the wind turbine shown in Figures 1 and 2;

Figure 4 shows a simplified cross-sectional view of a part of the gearbox shown in Figure 3, in particular the output shaft and associated output bearing of the gearbox mounted within a part of the gearbox housing;

Figure 5 shows a similar cross-sectional view of a portion of the gearbox shown in Figure 4 with the output shaft and associated output bearings removed from the housing;

Figure 6 shows a similar cross-sectional view of a portion of the gearbox shown in Figure 5 with one embodiment of a system for repairing a bearing bore of a gearbox mounted relative to a housing in accordance with aspects of the present subject matter components, particularly showing the shaft support part and the first cavity plate of the system mounted relative to the housing;

Figure 7 shows a similar cross-sectional view of a portion of the gearbox shown in Figure 6 with additional components of one embodiment of the disclosed system mounted relative to the housing, particularly showing Drilling cutter and rotatable shaft of the hole repair tool;

Figure 8 shows a similar cross-sectional view of a portion of the gearbox shown in Figure 7 with additional components of one embodiment of the disclosed system mounted relative to the housing, particularly showing the second chamber plate;

9 shows a similar cross-sectional view of a portion of the gearbox shown in FIG. 8 with components of another embodiment of the disclosed system mounted relative to a housing in accordance with aspects of the present subject matter; and

Figure 10 shows a flowchart of one embodiment of a method for repairing a bearing bore of a wind turbine gearbox in accordance with aspects of the present subject matter.

parts list

10 wind turbines

12 towers

14 surfaces

16 pods

18 rotors

20 rotatable hub

22 rotor blades

24 generators

26 controllers

28 directions

32 adjustment mechanism

34 pitch axis

36 yaw axis

38 drive mechanism

40 rotor shaft

42 generator shaft

46 seats

52 boxes

100 gear box

102 shell

104 input side housing member

108 output side housing components

112 planet carrier

118 planetary pinion

114 axes

120 first planetary bearing

122 second planetary bearing

124 ring gear

126 helical gear teeth

128 external gear teeth

130 planetary gear

132 sun gear

134 helical gear teeth

136 external gear teeth

142 output shaft

144 output gear

146 including gear teeth

148 corresponding gear teeth

150 first output bearing

152 second output bearing

200 systems

202 first bearing hole

204 second bearing hole

206 First inner end

208 second inner end

210 bore surface

212 second outer end

214 second inner end

216-well surface

218 outer race

220 inner race

222 fuel injection ring

224 second bearing

230 shaft support parts

232 rotatable shafts

234 repair tool

236 first chamber plate

238 second chamber plate

240 processing cavity

242 drilling knife

244 drive equipment

246 entrance

248 sealing material

250 mounting flange

252 support part

254 suitable fasteners

256 shaft opening

258 rotating parts

260 remote

264 suitable fasteners

266 seals

268 rotating parts

270 seals

272 openings

300 ways.

Detailed ways

Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the accompanying 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 example, 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.

In general, the subject matter of the present invention is directed to a system and method for repairing a bearing bore of a wind turbine gearbox. In several embodiments, various components in the disclosed systems can be configured relative to the bearing bore to be repaired (e.g., the first bearing bore) and the associated bearing bore (e.g., the first bearing bore) that is axially aligned with the bore being repaired. Two bearing holes) both are installed. As described below, the system may include first and second cavity plates configured to fit at or adjacent axial ends of the first bearing bore such that a sealed or substantially sealed process is defined or established between the cavity plates. cavity. Additionally, the system may include a shaft support member mounted relative to the second bearing bore configured to rotatably support a rotatable shaft of an associated bore repair tool. In such an embodiment, the first bearing bore may be machined in such a manner (eg, by removing material from the housing) when the drill bit of the hole repair tool is positioned within the machining cavity and driven in rotation via the shaft : Increase its inner diameter to correct any out-of-roundness caused by wear. Furthermore, due to the installation of the cavity plate, any metal fragments generated during the repair procedure can be contained in the machining cavity, preventing these fragments from contaminating other parts of the gearbox housing.

Referring now to the drawings, FIG. 1 shows a perspective view of one embodiment of a wind turbine 10 . As shown, wind turbine 10 includes a tower 12 extending from a support surface 14 , a nacelle 16 mounted on tower 12 , and a rotor 18 coupled to nacelle 16 . Rotor 18 includes a rotatable hub 20 and at least one rotor blade 22 coupled to and extending outward from hub 20 . For example, in the illustrated embodiment, rotor 18 includes three rotor blades 22 . However, in alternative embodiments, rotor 18 may include more or less than three rotor blades 22 . Each rotor blade 22 may be spaced about hub 20 to facilitate rotating rotor 18 to enable the conversion of kinetic energy from the wind into usable mechanical energy and, subsequently, electrical energy. For example, the hub 20 may be rotatably coupled to a generator 24 ( FIG. 2 ) positioned within the pod 16 to allow generation of electrical power.

As shown, wind turbine 10 may also include a turbine control system or turbine controller 26 centrally located in nacelle 16 . However, it will be appreciated that turbine controller 26 may be disposed anywhere on or in wind turbine 10 , on support surface 14 or substantially any other location. Turbine controller 26 may generally be configured to control various operating modes (eg, startup or shutdown sequences) and/or components of wind turbine 10 . For example, controller 26 may be configured to control the blade pitch or pitch angle (i.e., the angle that determines the perspective of rotor blade 22 relative to direction 28 of the wind) of each rotor blade 22 to adjust at least one rotor blade 22 relative to the wind The angular position of rotor blade 22 is used to control the load on rotor blade 22 . For example, turbine controller 26 may individually or simultaneously control the pitch angle of rotor blades 22 by passing adapted control signals/commands to a pitch controller of wind turbine 10, which may be configured to control multiple pitch angles of the wind turbine. Operation of pitch drive or pitch adjustment mechanism 32 (FIG. 2). Specifically, the rotor blades 22 are rotatably mounted on the hub 20 by one or more pitch bearings (not shown) such that the pitch angle can be adjusted by rotating the rotor blades along their pitch axis 34 using a pitch adjustment mechanism 32 . 22 to adjust the pitch angle. Additionally, as the direction of the wind 28 changes, the turbine controller 26 may be configured to control the yaw direction of the nacelle 16 about the yaw axis 36 to position the rotor blades 22 with respect to the direction of the wind 28 , thereby controlling the effects on the wind turbine 10 . load. For example, turbine controller 26 may be configured to communicate control signals/commands to yaw drive mechanism 38 ( FIG. 2 ) of wind turbine 10 such that pod 16 may rotate about yaw axis 30 .

Referring now to FIG. 2 , a simplified, interior view of one embodiment of nacelle 16 of wind turbine 10 shown in FIG. 1 is shown in accordance with aspects of the present subject matter. As shown, a generator 24 may be disposed within the nacelle 16 . In general, generator 24 may be coupled to rotor 18 of wind turbine 10 for generating electrical energy from rotational energy generated by rotor 18 . For example, rotor 18 may include a main rotor shaft 40 coupled to hub 20 for rotation therewith. Generator 24 may then be coupled to rotor shaft 40 such that rotation of rotor shaft 40 drives generator 24 . For example, in the illustrated embodiment, generator 24 includes a generator shaft 42 rotatably coupled to rotor shaft 40 through a gearbox 44 . It will be appreciated that rotor shaft 40 may generally be supported within nacelle 16 by a bracket or stand 46 atop wind turbine tower 12 .

Additionally, as noted above, the turbine controller 26 may also be located within the nacelle 16 of the wind turbine 10 . For example, as shown in the illustrated embodiment, the turbine controller 26 is disposed in a control box 52 mounted to a portion of the nacelle 16 . However, in other embodiments, turbine controller 26 may be disposed at any other suitable location on and/or within wind turbine 10 or at any suitable location remote from wind turbine 10 . Additionally, as noted above, turbine controller 26 may also be communicatively coupled to various components of wind turbine 10 for generally controlling the wind turbine and/or the components. For example, turbine controller 26 may be communicatively coupled to yaw drive mechanism(s) 38 of wind turbine 10 for controlling and/or varying the yaw of nacelle 16 relative to wind direction 28 ( FIG. 1 ). direction. Similarly, turbine controller 26 may also be communicatively coupled to each pitch adjustment mechanism 32 of wind turbine 10 (one of which is shown) through pitch controller 30 for controlling pitch relative to direction 28 of the wind. And/or change the pitch angle of the rotor blades 22 . For example, turbine controller 26 may be configured to communicate control signals/commands to each pitch adjustment mechanism 32 such that one or more actuators (not shown) of pitch adjustment mechanisms 32 may be used to 20 rotating blades 22 .

Referring now to FIG. 3 , a cross-sectional view of one embodiment of a gearbox 100 suitable for use within a wind turbine 10 is shown in accordance with aspects of the present subject matter. As shown, the gearbox 100 may include an outer housing 102 configured to enclose the various internal components of the gearbox 100 . In one embodiment, the housing 102 may be formed from a plurality of housing members, such as an input side housing member 104 , a central housing member 106 , and an output side housing member 108 . Housing 102 may be supported within nacelle 16 of associated wind turbine 10 via support pins 110 .

As shown in FIG. 3 , the housing 102 may enclose a planet carrier 112 configured to rotate relative to the housing 102 about a carrier axis 114 . Input hub 116 disposed at a first end of planet carrier 112 may be configured to couple to rotor shaft 40 of wind turbine 10 . As shown in FIG. 3 , the planet carrier 112 may be configured to support a plurality of planet pinions 118 (one of which is shown) therein for orbital movement about the carrier axis 114 . Additionally, the first and second planet bearings 120 , 122 may be configured to engage and support the planet pinions 118 for rotation relative to the planet carrier 112 .

The gearbox 100 may also include a ring gear 124 that is fixed relative to the housing 102 . As shown in FIG. 3 , the ring gear 124 may include an array of inner spur or helical gear teeth 126 configured to engage or mesh with corresponding outer gear teeth 128 of the planetary pinions 118 . Accordingly, the planet pinions 118 may rotate about their own axes relative to the planet carrier 112 as rotational motion is transferred from the rotor shaft 40 to the planet carrier 112 (eg, via the input hub 116 ).

Additionally, gearbox 100 may include a plurality of planet gears 130 (only one of which is shown), where each planet gear 130 is coupled to one of the planet pinions 118 for rotation therewith. The planet gears 130 may in turn be configured to rotationally drive a sun gear 132 mounted within the planet carrier 112 . For example, as shown in FIG. 3 , sun gear 132 may include a plurality of outer spur or helical gear teeth 134 configured to mesh with outer gear teeth 136 of corresponding planet gears 130 . As a result, rotational action of the planet gears 130 may cause rotation of the sun gear 132 about the carrier axis 114 .

Additionally, as shown in FIG. 3 , gearbox 100 may include an output stage 140 including an output shaft 142 and an output gear 144 . The output gear 144 is configured to be rotationally coupled between the output shaft 142 and the sun gear 132 . For example, as shown in FIG. 3 , the output gear 144 may be fixed at its inner periphery to a portion of the sun gear 132 and may include gears around its outer periphery configured to mate with an output pinion (not shown) mounted on the output shaft 142. The gear teeth 146 mesh with the corresponding gear teeth 148 . Likewise, rotation of the sun gear 132 may be transmitted through the output gear 144 to rotationally drive the output shaft 142 . As shown in FIG. 3 , a portion of output shaft 142 may extend outwardly from housing 102 to allow output shaft 142 to be coupled to generator 24 of wind turbine 10 . Additionally, as shown in FIG. 3 , the output shaft 142 may be supported for rotation within the housing 102 by one or more output bearings 150 , 152 . For example, as will be described below, the first output bearing 150 may be installed in a first bearing hole (not shown in FIG. In the second bearing hole (not shown in Figure 3).

Referring now to FIGS. 4-8 , one embodiment of a system 200 for repairing a bearing bore of a wind turbine gearbox 100 will be described in accordance with aspects of the present subject matter. In particular, FIG. 4 shows a simplified, schematic cross-sectional view of a portion of the output stage 140 of the gearbox 100 described above, particularly showing the output shaft 142 and the first and second output bearings mounted within the gearbox housing 102. 150, 152. FIG. 5 shows the same cross-sectional view of a portion of the gearbox housing 102 shown in FIG. 4 with various other gearbox components removed for illustrative purposes. In addition, FIGS. 6-8 show the same cross-sectional views of the gearbox housing 102 shown in FIGS. 4 and 5, in particular illustrating installation of the disclosed system 100 within the housing 102, in accordance with aspects of the present subject matter. One or more components to allow the associated bearing bore of the housing 102 to be repaired.

As shown in the illustrated embodiment, the gearbox housing 102 may be configured to define a upwind or first bearing bore 202 and a leeward or second bearing bore 204 axially spaced apart from the first bearing bore 202 . As particularly shown in FIG. 5, the first bearing bore 202 can extend axially between a first outer end 204 and a first inner end 206 opposite the first outer end 204, wherein the first inner end 206 is positioned closest to the first inner end 206. The second bearing hole 204 and the second outer end 204 are located further away from the second bearing hole 204 . Additionally, the first bearing bore 202 may include a first inner bore surface 210 ( FIG. 5 ) extending between the axial ends 206 , 208 thereof that defines an inner perimeter of the first bearing bore 202 . Similarly, as shown in FIG. 5, the second bearing bore 204 may extend axially between a second outer end 212 and a second inner end 214 opposite the second outer end 212, wherein the second inner end 214 is positioned as The second outer end is located closest to the first bearing hole 202 and is further away from the first bearing hole 202 . Additionally, the second bearing bore 204 may include a second inner bore surface 216 extending between the axial ends 212 , 214 thereof that defines an inner perimeter of the second bearing bore 204 .

As noted above, the output bearings 150 , 152 of the gearbox 100 may be configured to be received within the bearing bores 202 , 204 to allow the output shaft 142 to be rotatably supported relative to the housing 102 . For example, as shown in FIG. 4 , the upwind or first output bearing 150 may be configured to fit within the first bearing bore 202 , while the downwind or second output bearing 152 may be configured to fit within the second bearing bore 204 . In this embodiment, the outer race 218 of each bearing 150, 152 may be configured to pass between the outer race 218 and the inner bore surface 210, 216 (FIG. 5) of its corresponding bearing bore 202, 204. The friction interface of is fixed relative to the housing 102. Additionally, as shown in FIG. 4 , the inner race 220 of each bearing 150 , 152 may be configured to be rotatably coupled to the output shaft 142 . Likewise, the output shaft 142 and inner race 220 of each output bearing 150 , 152 may be configured to rotate relative to both the housing 102 and the outer race 218 of each output bearing 150 , 152 .

It should be appreciated that various other gearbox-related components may be mounted in operative association with the output shaft 142 , one or both of the output bearings 150 , 152 , and/or the associated bearing bores 202 , 25 . For example, as shown in FIG. 4 , the oil spray ring 222 may be configured to fit over the first outer end 206 of the first bearing bore 202 at a location adjacent to the first output bearing 150 ( FIG. 5 ). As is generally understood, the oil spray ring 222 may be configured to allow oil to be supplied between the outer and inner races 218 , 220 of the first output bearing 150 to lubricate the bearing 150 . Additionally, as shown in FIG. 4 , in one embodiment, a second bearing 224 may be mounted adjacent to the second output shaft 152 to provide additional rotational support for the output shaft 142 relative to the housing 102 .

As noted above, after an extended period of operation, the outer race 218 of one or both of the output bearings 150, 152 will begin to define between the bearing(s) 150, 152 and the adjacent bearing bores 202, 204. Sliding on the interface of the bearing bore causes the inner bearing bore surface(s) 210, 216 to become worn over time. As the inner bearing bore surface(s) 210, 216 wear and become more out of round, the occurrence of slippage between the adjacent outer race 218 of the associated bearing(s) 150, 152 and the housing 102 increases significantly , thereby negatively affecting the performance and operation of the gearbox 100 . In this example, the disclosed system 200 and associated method may be used to perform in-situ, on-tower repair of worn bearing bores. It should be appreciated that for purposes of description, the system 200 will generally be described herein as being used to repair the upwind or first bearing bore 202 of the output stage 140 of the gearbox 100 . However, in other embodiments, the disclosed system 200 may be used to repair the downwind or second bearing bore 204 of the output stage 140 of the gearbox 100 or any other suitable bearing bore of the gearbox 100 .

As shown particularly in FIG. 8 , in several embodiments, the system 200 may include a shaft support member 230 configured to fit at least partially within the second bearing bore 204 of the gearbox housing 102 . As will be described below, the shaft support member 230 may be configured to rotatably support a boring bar or rotatable shaft 232 of a hole repair tool 234 . Additionally, as shown in FIG. 8, the system 200 may include first and second tooling cavity plates 236, 238 mounted at or adjacent to opposite axial ends 206, 208 (FIG. 5) of the first bearing bore 204 such that the cavity A process cavity 240 is defined or established between the plates 236 , 238 . As will be described below, the drill bit 242 of the hole repair tool 234 may be positioned within the machining cavity 240 formed between the cavity plates 236 , 238 and rotated via the shaft 232 to allow machining of the first bearing hole 202 . Specifically, the inner bore surface 210 of the first bearing bore 202 is machined by removing adjacent material from the housing 142 to increase the inner diameter of the bearing bore 202 as the drill bit 242 rotates within the machining cavity 240 . In this case, metal shavings or other metal debris generated during the repair process may be contained within the machining cavity 240 between the cavity plates 236 , 238 .

It should be appreciated that, in addition to rotatable shaft 232 and drill bit 242 , hole repair tool 234 may also include a drive device 244 positioned outside gearbox housing 102 for rotationally driving shaft 232 . For example, drive device 244 may correspond to a drive motor or any other suitable drive device configured to rotate shaft 232 at a sufficient cutting speed to allow drill bit 244 to machine inner bore surface 210 of first bearing bore 202 . It should also be appreciated that the reaming tool 242 may generally correspond to any suitable hole cutting tool configured to machine the inner surface of a hole, such as a single point cutting tool, a flying knife, or any other suitable configuration as described herein. A cutting mechanism that functions descriptively.

To begin the repair process, various components of the output stage 140 of the gearbox 100 may be removed from the housing. For example, as shown in FIG. 5 , output shaft 142 , output bearings 150 , 152 , injector ring 222 and second bearing 224 have been removed from housing 102 . It should be appreciated that these components may be removed from housing 102 using any suitable disassembly process. For example, in one embodiment, the second output bearing 152 and the second bearing 224 are removable from the housing 102 through the second outer end 212 of the second bearing bore 204 . Once these bearings 152 , 224 are removed, the output shaft 142 can be removed from the housing 102 by pulling the shaft axially through the second bearing bore 204 . The first output bearing 150 and the oil injection ring 222 may then be removed from the housing 102 . In one embodiment, the first output bearing 150 and the injector ring 222 are accessible via an access port 246 (shown in dashed lines in FIGS. shown) is removed from the housing 102.

After the gearbox components have been removed, the components of the disclosed system 200 may be installed in the housing 102, for example, as shown in FIG. Both are initially installed within the gearbox housing 102. In one embodiment, the first cavity plate 236 may be mounted within the housing 102 via the access port 246 . For example, the first cavity plate 236 may be inserted through the access port 246 and then moved into its installed position.

In general, the first cavity plate 236 may correspond to the outer end 206 ( FIG. 5 ) configured to fit over the first bearing bore 202 to serve as an outer shield or barrier for metal shavings and/or other metal debris generated during the repair process. solid blanks or baffles. For example, in one embodiment, the first cavity plate 236 may be configured to fit at a typical location of the injector ring 222 . In this embodiment, the first cavity plate 236 may generally be configured to define an outer diameter that is only slightly smaller than the inner diameter of the first bearing bore 202 such that between the first cavity plate 236 and the housing 102 there is a gap between the first bearing bore 202 Provides a remarkably tight fit on the outer end 206 of the . Additionally, as shown in FIG. 6, a seal and/or suitable sealing material 248 may be provided at the interface between the first cavity plate 236 and the first bearing bore 202 to prevent metal fragments from entering any space defined between these components. Radial clearance. For example, in one embodiment, clay or grease may be used to seal the radial gap(s) defined between the first cavity plate 236 and the inner bore surface 210 of the first bearing bore 202 .

Furthermore, as shown in FIG. 6 , the shaft support member 230 may be configured to be mounted relative to the housing 102 such that a portion of the support member 230 is received within the second bearing hole 204 . For example, in several embodiments, shaft support member 230 may include an outer mounting flange 250 configured to be coupled to housing 102 and a support portion 252 extending axially from outer mounting flange 250 to a location within second bearing bore 204 . As shown in FIG. 6 , in one embodiment, the outer mounting flange 250 may be configured to extend radially outward relative to the second bearing bore 204 to allow the mounting flange 250 to couple to the housing 102 around the periphery of the bearing bore 204 . For example, outer mounting flange 250 may be configured to define an annular array of fastener openings (not shown) that aligns with a corresponding array of fastener openings (not shown) defined in housing 102 . In this embodiment, suitable fasteners 254 (eg, bolts) may be inserted through the aligned openings to couple the mounting flange 250 to the housing 102 .

As shown in FIG. 6 , the support portion 252 of the shaft support member 230 may be configured to extend axially within the second bearing hole 204 . In one embodiment, support portion 252 may be tapered so as to define a tapered profile. In this embodiment, when the shaft support member 230 is installed relative to the housing 102, the support portion 252 may be configured to be axially pushed into the second bearing hole 204 until the outer surface of the support portion 252 contacts the surface of the second bearing hole 204. inner bore surface 216 , thereby ensuring that the support portion 252 is centered relative to the bearing bore 204 . Alternatively, support portion 252 of shaft support member 230 may be configured to have any other suitable shape that allows it to function as described herein. For example, as will be described below with reference to FIG. 9 , the support portion 252 may be cylindrical.

Additionally, as shown in FIG. 6 , an axially extending shaft opening 256 may be defined through the shaft support member 230 . In several embodiments, the shaft opening 256 may be configured to receive one or more members of the rotatable shaft 232 for rotationally supporting the associated hole repair tool 234 . For example, as shown in FIG. 6 , a rotating member 258 (eg, a bearing or bushing) may be mounted within shaft opening 256 of shaft support member 230 for supporting rotatable shaft 232 of repair tool 234 .

Referring now to FIG. 7 , following installation of the shaft support member 230 , the rotatable shaft 232 and drill bit 242 of the hole repair tool 234 may be mounted relative to the housing 102 . Specifically, as shown in FIG. 7 , shaft 232 may be inserted through shaft opening 256 defined by shaft support member 230 such that shaft 232 is rotatably supported relative to shaft support member 230 via rotation member 258 . Once a portion of the shaft 232 has been inserted through the shaft support member 230 and into the axial space defined between the first and second holes 202 , 204 , the reamer 242 can be mounted to the distal end 260 of the shaft 232 via the access port 246 . For example, shaft 232 may be axially inserted into housing 102 until distal end 260 of shaft 232 is aligned with access port 246 . A maintenance operator would then be able to access the housing 102 through the access port 246 and install the reamer 242 on the shaft 232 . The shaft 232 is then pushed further axially into the housing 102 until the drill 242 is positioned within the first bearing bore 202 .

Referring now to FIG. 8 , after the rotational shaft 232 and drill bit 242 of the hole repair tool 234 are installed, the second cavity plate 238 may be inserted into the housing 102 (eg, via the access port 246 ) and mounted about the repair tool shaft 232 . Specifically, in one embodiment, the second cavity plate 238 may correspond to a circular or disc-shaped component formed in a two-piece construction, such as by forming the second cavity plate 238 as separate halves of a circular or disc-shaped plate. department. In this embodiment, the second cavity plate 238 may define a central opening 262 through which the shaft 232 extends when the separate members of the second cavity plate 238 are assembled about the rotatable shaft.

Additionally, as shown in FIG. 8 , the second cavity plate 238 may be configured to be secured within the housing 102 at the inner end 214 ( FIG. 5 ) of the first bearing bore 202 . For example, in several embodiments, a portion of the second cavity plate 238 may be configured to extend radially outward relative to the first bearing bore 202 to allow the second cavity plate 238 to couple to the housing 102 around the periphery of the bearing bore 202 . In these embodiments, the second cavity plate 238 can define an annular array of fastener openings (not shown) configured to match a corresponding array of fastener openings (not shown) defined in the housing 102 . align. Thereafter, suitable fasteners 264 (eg, bolts) may be inserted through the aligned openings to secure the second cavity plate 238 to the housing 102 at the inner end 214 of the first bearing bore 202 . Additionally, as shown in FIG. 8, when coupling the second cavity plate 238 to the housing 102, a seal 266 (eg, an O-ring) or suitable sealing material may be installed between the first cavity plate 238 and the housing. 102 on the interface to seal the interface.

It should be appreciated that in one embodiment, the second cavity plate 238 may also be configured to serve as a second shaft support member for the rotatable shaft 232 of the hole repair tool 234 . For example, as shown in FIG. 8 , a rotating member 268 (eg, a split bearing or bushing) may be mounted within the central opening 262 defined by the second cavity plate 238 . Likewise, the rotating member 268 may be configured to rotatably support the shaft 232 relative to the second cavity plate 238 . Alternatively, the rotatable shaft 232 may be configured to extend through the central opening 262 of the second cavity plate 238 without being rotationally supported therein, as will be described below with reference to FIG. 9 .

As noted above, by mounting first and second cavity plates 236, 238 at opposite axial ends 206, 208 (FIG. 5) of first bearing bore 202, a sealed or substantially sealed process cavity 240 may be defined in the cavity plates. Between 236 , 238 , a drill 242 may traverse along the machining cavity 240 when machining the first bearing bore 202 . Thus, while the first bearing bore 202 is being machined, any metal debris generated during the repair process will remain contained within the cavity 240 , thereby preventing the debris from contaminating other portions of the gearbox 202 .

It should be appreciated that the bore repair tool 234 may be used to machine or otherwise repair the first bearing bore 202 once the various system components have been installed relative to the housing 102 . Specifically, by rotating the drill bit 242 within the machining cavity 240 relative to the housing 102 (eg, via the shaft 232 and associated drive device 244 ) and by moving the drill bit axially along the entire axial length of the cavity 240 242, the drilling knife 242 can remove material from the housing 102 in a manner that increases the diameter of the bearing hole 202 to form a completely circular, machined hole that is still concentric with the second bearing hole 204 (e.g., with Opposite the ellipse previously defined by the wear surface of the hole). In this case, the machining cavity 240 may be cleaned periodically during the machining process or may be cleaned after the repair process is complete. For example, in one embodiment, after each axial passage of the drill bit 242 between the first and second cavity plates 236, 238, the second cavity plate 238 is removed to allow Clean out metal debris.

After the first bearing bore 202 has been repaired, the various system components may then be removed from the housing 102 (eg, by reversing the installation procedure described above). Thereafter, the various gearbox components are reinstalled back into the housing 102 . However, it should be appreciated that given the new larger diameter first bearing bore 202, the first output bearing 152 could be replaced with a new output bearing or bushing with a correspondingly larger outer diameter that could be installed in the existing There is a gap between the output bearing 152 and the repaired bearing bore 202 to accommodate the increased bore diameter.

It should be appreciated that in alternative embodiments, one or more of the system components described above may have any other suitable configuration that allows the component(s) to be used in connection with the disclosed hole repair procedures. For example, FIG. 9 illustrates an embodiment of the above-described system 200 in which the configuration of both the shaft support member 230 and the second cavity plate 238 have been altered in accordance with aspects of the present subject matter.

As shown in FIG. 9 , the support portion 252 of the shaft support member 230 may be cylindrical as opposed to the above-mentioned tapered shape. In this embodiment, the support portion 252 may be configured to define an outer diameter that is only slightly smaller than the diameter of the second bearing bore 204 such that a substantially tight fit is provided between the support portion 252 and the second bearing bore 204, thereby allowing The support portion 204 is properly centered within the bearing bore 204 .

Furthermore, as shown in FIG. 9 , as opposed to configuring the second cavity plate 238 as a second shaft support member, the rotatable shaft 232 may be configured to extend through the central opening 262 of the second cavity plate 238 without passing through the rotating member. supported in rotation. In this embodiment, a seal or suitable sealing material may be installed within the central opening 262 to seal the radial gap defined between the shaft 232 and the second cavity plate 238 . For example, as shown in FIG. 9 , a seal 270 (eg, a brush seal) may be installed in the central opening 262 between the shaft 232 and the second cavity plate 238 to seal the radial gap defined therebetween. This embodiment may be utilized, for example, when the rotatable shaft 232 can be supported by the shaft support member 230 alone without deflecting in a manner that significantly affects the desired size/shape of the hole being repaired.

Additionally, in one embodiment, one or more second openings 272 may be defined through the second cavity plate 238 in addition to the central opening 262 . For example, as shown in FIG. 9 , a second opening 272 may be defined through the second cavity plate 238 radially offset from the central opening 262 . In this embodiment, the second opening 272 may be utilized to remove metal debris and (optionally) coolant from the machining cavity 240 during a repair procedure. For example, a vacuum hose may be coupled to second opening 272 to allow metal debris (and/or coolant) to drain from process chamber 240 .

Referring now to FIG. 10 , a flowchart of one embodiment of a method 300 for repairing a bearing bore in a wind turbine gearbox is shown in accordance with aspects of the present subject matter. In general, method 300 will be described herein with reference to system 200 described above with reference to FIGS. 4-9 . However, it should be appreciated that the disclosed method 300 may be implemented in a system having any other suitable system configuration. Additionally, although FIG. 10 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or permutation. Those skilled in the art using the disclosure provided herein will appreciate that various steps of the methods disclosed herein may be omitted, rearranged, combined, and/or rewritten in various ways without departing from the scope of the disclosure.

As shown in FIG. 10 , at ( 302 ), the method 300 may include at least partially installing a shaft support member within a bearing bore coaxially aligned with the bearing bore to be repaired. Specifically, as described above, the shaft support member 230 may be installed relative to the second bearing hole 204 of the output stage 140 of the gearbox 100 when the first bearing hole 202 of the output stage 140 of the gearbox 100 is under repair. For example, the support portion 252 of the shaft support member 230 may be inserted into the second bearing hole 204 such that the shaft support member 230 is centered relative to the bearing hole 204 .

Additionally, at (304), method 300 may include installing a first cavity plate at or adjacent to the first axial end of the repaired bearing bore. For example, as described above, in one embodiment, the first cavity plate 236 may be mounted to the outer end 206 of the first bearing bore 202 . In this embodiment, for example, the first cavity plate 236 may be positioned at a typical installation location of the oil injection ring 222 of the gearbox 100 .

Additionally, at (306), method 300 may include inserting a rotatable shaft through a shaft opening defined through the shaft support member such that the rotatable shaft is rotatably supported within the opening. Specifically, as described above, the rotatable shaft 232 can be inserted through the rotating member 258 installed in the shaft opening 256 defined by the shaft support member 230 to allow the rotatable shaft 232 to be rotatably supported relative to the shaft support member 230 in shaft opening 256 . Additionally, in one embodiment, once the shaft 232 has been inserted through the shaft support member 230 , the reamer 242 of the hole repair tool 234 may be mounted on the distal end 260 of the shaft 232 .

Still referring to FIG. 10 , at (308), method 300 may include mounting a second cavity plate at or adjacent to a second axial end of the bearing bore being repaired such that a machining cavity is defined between the first and second cavity plates . For example, as described above, a second cavity plate 238 may be mounted on the inner end 208 of the first bearing bore 202 opposite the first cavity plate 236 to allow a sealed or substantially sealed process cavity 240 to be defined in the cavity plate 236, Between 238. In this embodiment, for example, the second cavity plate 238 may be formed as a two-piece construction to allow the second cavity plate 238 to be mounted about the rotatable axis 232 .

Additionally, at ( 310 ), method 300 may include rotating, via rotation of a rotatable shaft, a drill bit positioned within the machining cavity to machine an inner surface of the repaired bearing bore. Specifically, once the cavity plates 236 , 238 have been installed relative to the hole being repaired, the reamer 242 may be rotated in the machining cavity 240 to repair or otherwise machine the inner bore surface 210 of the bearing bore 202 . In this case, any metal fragments generated during the machining process will be contained within the machining cavity 240 defined between the cavity plates 236 , 238 .

It should be appreciated that method 300 may also include various other steps and/or elements. For example, after each machining pass and/or upon completion of the machining process, the repaired bearing bore may be cleaned to remove any metal debris contained within the machining cavity 240 . Additionally, method 300 may include one or more measuring steps to allow for measuring the concentricity between the repaired bearing bore and the opposing bore. For example, in one embodiment, the drill bit 242 may be removed from the shaft 232 and replaced with a measuring device (eg, a micrometer) configured to measure concentricity between bearing bores. In this embodiment, the shaft 232 can be rotated relative to the repaired bearing bore to allow measurement equipment to be used to verify concentricity.

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 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.

Claims (10)

1. method (300) of the one kind for repairing the bearing hole (202,204) in wind turbine gearbox (100), the gear Case (100) includes the gear box casing (102) for limiting first axle bearing bore (202) and second bearing hole (204), the first bearing Hole (202) and the second bearing hole (204) are axially apart from one another, and the method (300) includes：

Shaft support part (230) is at least partially installed in the second bearing hole (204)；

Rotatable axis (232) is inserted through to the axis opening (256) for being defined through the shaft support part (230) so that The rotatable axis (232) is rotationally supported in the axis opening (256)；

Processing cavity is set up between the first axis end (206) and the second axial end (208) of the first axle bearing bore (202) (240)；And

The bore cutter (242) being located in the processing cavity (240) is set to rotate via the rotation of the rotatable axis (232), To process the interior table of the first axle bearing bore (202) between the first axis end (206) and second axial end (208) Face (210).

2. according to the method for claim 1 (300), which is characterized in that described the first of the first axle bearing bore (202) The processing cavity (240) is set up between axial end (206) and second axial end (208) includes：

First cavity plate (236) is mounted on or is adjacent to the first axis end (206) of the first axle bearing bore (202)；With And

Second cavity plate (238) is mounted on or is adjacent to second axial end (208) of the first axle bearing bore (202), is made It obtains and limits the processing cavity (240) between first cavity plate (236) and second cavity plate (238).

3. according to the method for claim 2 (300), which is characterized in that second cavity plate (238) limits and is configured to receive The central opening (262) of the rotatable axis (232).

4. according to the method for claim 3 (300), which is characterized in that further include via in the rotatable axis (232) The rotary part (268) being located between second cavity plate (238) in the central opening (262) will be described rotatable Axis (232) is rotationally supported in the central opening (262) for being defined through second cavity plate (238).

5. according to the method for claim 3 (300), which is characterized in that further include being sealed in the rotatable axis (232) The radial gap being limited between second cavity plate (238) in the central opening (262).

6. according to the method for claim 1 (300), which is characterized in that further include via in the rotatable axis (232) The rotary part (258) being located between the shaft support part (230) in the axis opening (256) will be described rotatable Axis (232) is rotationally supported in the axis opening (256) for being defined through the shaft support part (230).

7. according to the method for claim 1 (300), which is characterized in that further include in the remote of the rotatable axis (232) End (260) has been inserted through shaft support part (230) and enters after the shell (102), by the bore cutter (242) It is attached to the rotatable axis (232).

8. according to the method for claim 1 (300), which is characterized in that the shaft support part (230) is included in described the The support section (252) extended in two bearing holes (204), the support section (252) limit one in cylindrical or taper.

9. according to the method for claim 1 (300), which is characterized in that further include with the bore cutter (242) from described the The inner surface (210) of one bearing hole (202) removes material, to expand the internal diameter of the first axle bearing bore (202), removal Material, which is used in the processing cavity (240) limited between the first axis end (206) and second axial end (208), to be held It receives.

10. system (200) of the one kind for repairing the bearing hole (202,204) in wind turbine gearbox (100), the system System (200) include：

Gear box casing (102) limits first axle bearing bore (202) and second bearing hole (204), the first axle bearing bore (202) and the second bearing hole (204) is axially separated from each other, and the first axle bearing bore (202) is limited to first axis The inner surface (210) extended between end (206) and the second axial end (208)；

Hole fix tool (234) comprising rotatable axis (232) and the bore cutter for being attached to the rotatable axis (232) (242)；

First cavity plate (236) is mounted on or is adjacent to the institute of the first axle bearing bore (202) relative to the shell (102) State first axis end (206)；

Second cavity plate (238) is mounted on or is adjacent to the institute of the first axle bearing bore (202) relative to the shell (102) State the second axial end (208) so that limit processing cavity between first cavity plate (236) and second cavity plate (238) (240)；And

Shaft support part (230) is at least partially installed in the second bearing hole (204), the support member (230) Axis opening (256) is limited, the rotatable axis (232) is rotationally supported in axis opening (256),

The wherein described bore cutter (242) is configured to be located between first cavity plate (236) and second cavity plate (238) and limit In the fixed processing cavity (240) so that when the rotatable axis (232) rotates relative to the support member (230), The bore cutter (242) processes the bore area (210) of the first axle bearing bore (202).