Patent Description:
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. A modem wind turbine typically includes a tower, a nacelle mounted on the tower, a generator positioned in the nacelle, and one or more rotor blades. The one or more rotor blades convert kinetic energy of wind into mechanical energy using known airfoil principles. A drivetrain transmits the mechanical energy from the rotor blades to the generator. The generator then converts the mechanical energy to electrical energy, which may be supplied to a utility grid.

Wind turbines typically include one or more yaw adjustment mechanisms, which rotate the nacelle relative to the tower to properly orient the rotor blades relative to the direction of the wind. To control such rotation, a wind turbine may include one or more brake assemblies having brake pads that frictionally engage the tower (e.g., a tower ring gear). The frictional sliding between the brake pads and the tower causes the pads to wear over time. As such, it is necessary to periodically replace the brake pads. In certain instances, brake pistons to which the brake pads are coupled may become stuck in the brake assembly, especially when the brake pads are severely worn. When this occurs, it becomes necessary to use time-consuming and expensive processes, such as cutting, to remove the brake pistons from the brake assembly. Document <CIT> shows an example of an assembly according to the preamble of claim <NUM> and a method for inserting and withdrawing a piston component of a disc brake assembly.

Accordingly, a tool and associated method of use for removing a brake piston from a brake assembly of a wind turbine would be welcomed in the art.

Various aspects and advantages of the technology will be set forth in part in the following description, or may be clear from the description, or may be learned through practice of the technology.

In one aspect, the present disclosure is directed to a tool for removing a brake piston from a brake assembly of a wind turbine as defined by claim <NUM>.

In another aspect, the present disclosure is directed to a method for removing a brake piston from a brake assembly of a wind turbine according to claim <NUM>.

Various features, aspects and advantages of the present technology will become better understood with reference to the following description and appended claims.

Reference will now be made in detail to present embodiments of the technology, one or more examples of which are illustrated in the accompanying drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the technology.

Each example is provided by way of explanation of the technology, not limitation of the technology. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present technology without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present technology covers such modifications and variations as come within the scope of the appended claims and their equivalents.

Referring now to the drawings, <FIG> is a perspective view of an exemplary wind turbine <NUM>. As shown, the wind turbine <NUM> generally includes a tower <NUM> extending from a support surface <NUM>, a nacelle <NUM> mounted on the tower <NUM>, and a rotor <NUM> coupled to the nacelle <NUM>. For example, in the embodiment shown in <FIG>, the rotor <NUM> includes three rotor blades <NUM>. In alternative embodiments, however, the rotor <NUM> may include more or less than three rotor blades <NUM>. Each rotor blade <NUM> may be spaced about the hub <NUM> to facilitate rotation of the rotor <NUM> to convert kinetic energy from the wind into usable rotational, mechanical energy. A generator <NUM> positioned in the nacelle <NUM> may generate electrical power from the rotational energy of the rotor <NUM>.

Referring now to <FIG>, a drivetrain <NUM> rotatably couples the rotor <NUM> to the electric generator <NUM>. As shown, the drivetrain <NUM> may include a rotor shaft <NUM>, which rotatably couples the hub <NUM> of the rotor <NUM> to a gearbox <NUM>. The gearbox <NUM> may be supported by and coupled to a bedplate <NUM> in the nacelle <NUM>. The drivetrain <NUM> may also include a generator shaft <NUM>, which rotatably couples the gearbox <NUM> to the generator <NUM>. In this respect, rotation of the rotor <NUM> drives the generator <NUM>. More specifically, the rotor shaft <NUM> may provide a low speed, high torque input to the gearbox <NUM> in response to rotation of the rotor blades <NUM> and the hub <NUM>. The gearbox <NUM> may then convert the low speed, high torque input to a high speed, low torque output to drive the generator shaft <NUM> and, thus, the generator <NUM>. In alternate embodiments, however, the generator <NUM> may be directly rotatably coupled to the rotor shaft <NUM> in a direct-drive configuration.

The wind turbine <NUM> may also include one or more yaw adjustment mechanisms <NUM> for adjusting a yaw angle of the nacelle <NUM> (i.e., the angular orientation of the nacelle <NUM> relative to the tower <NUM>). In particular, the nacelle <NUM> may be rotatably coupled to the tower <NUM> by a yaw bearing (not shown). As such, the yaw adjustment mechanisms <NUM> may rotate the nacelle <NUM> about a yaw axis <NUM> (<FIG>) relative to the tower <NUM>, thereby adjusting the yaw angle of the nacelle <NUM>. Although <FIG> only illustrates two yaw adjustment mechanisms <NUM>, the wind turbine <NUM> may include any suitable number of yaw adjustment mechanisms <NUM>, such as a single yaw adjustment mechanism <NUM> or more than two yaw adjustment mechanisms <NUM>.

<FIG> illustrates an exemplary embodiment of the yaw adjustment mechanisms <NUM>. More specifically, each yaw adjustment mechanism <NUM> may include an electric motor <NUM> mounted to and/or through the bedplate <NUM>. Each electric motor <NUM> may include a pinion gear <NUM> coupled thereto, which engages a tower ring gear <NUM> coupled to the tower <NUM>. During operation of the yaw adjustment mechanisms <NUM>, the electric motors <NUM> rotate the corresponding pinion gear <NUM>, which rotates the tower ring gear <NUM>. The rotation of the pinion gears <NUM> relative to the tower ring gear <NUM> causes the nacelle <NUM> to rotate about the yaw axis <NUM>. In alternate embodiments, the yaw adjustment mechanisms <NUM> may include any suitable type of actuator and/or any suitable structure or mechanism for transmitting movement between the tower <NUM> and the nacelle <NUM>.

Referring still to <FIG>, the wind turbine <NUM> may also include one or more brake assemblies <NUM> for controlling the rotation of the nacelle <NUM> about the yaw axis <NUM>. For example, as shown in the illustrated embodiment, the brake assemblies <NUM> may be mounted to and/or through the bedplate <NUM>. As such, each brake assembly <NUM> may frictionally engage the tower ring gear <NUM> or another suitable friction surface of the wind turbine <NUM> to stop, slow, and/or otherwise control the rotation of the nacelle <NUM> about the yaw axis <NUM>. The wind turbine <NUM> may include any suitable number of yaw brake assemblies <NUM>. For instance, in an exemplary embodiment, the wind turbine <NUM> may include between twelve and twenty brake assemblies <NUM>. In other embodiments, however, the wind turbine <NUM> may include less than twelve brake assemblies <NUM> or more than twenty brake assemblies <NUM>.

<FIG> illustrates an exemplary embodiment of one of the brake assemblies <NUM>. As shown, the brake assembly <NUM> may include a brake piston sleeve <NUM> extending through the bed plate <NUM> of the nacelle <NUM>. The brake assembly <NUM> may also include a brake piston <NUM> slideably positioned within the brake piston sleeve <NUM>. In particular, an outer surface <NUM> of the brake piston <NUM> may slide relative to an inner surface <NUM> of the brake piston sleeve <NUM>. The brake piston <NUM> may also define an inner cavity <NUM>. In some embodiments, the cavity <NUM> may receive a thrust piece (not shown) or other suitable structure for pushing or pressing the brake piston <NUM> against the tower ring gear <NUM>. Furthermore, the brake piston <NUM> may include a puck or brake pad <NUM> coupled to a bottom surface <NUM> of the brake piston <NUM>. In this respect, the brake piston <NUM> may be configured to be pushed or pressed against a friction surface <NUM> of the tower ring gear <NUM> to maintain frictional engagement (e.g., a constant frictional force) between the brake pad <NUM> and the tower ring gear <NUM> during rotation of the nacelle <NUM>. Such frictional engagement may cause the brake pad <NUM> may wear over time.

<FIG> illustrates one embodiment of a tool <NUM> for removing the brake piston <NUM> from the brake assembly <NUM> of the wind turbine <NUM>. As shown, the tool <NUM> generally includes a base member <NUM> configured for placement on the brake piston sleeve <NUM>. The tool <NUM> also includes a puller assembly <NUM> configured for insertion into the cavity <NUM> of the brake piston <NUM>. As will be described in greater detail below, a collet <NUM> of the puller assembly <NUM> engages an inner surface of the brake piston <NUM>. In this respect, moving the puller assembly <NUM> relative to the base member <NUM> causes the brake piston <NUM> to slide relative to the brake piston sleeve <NUM>, thereby removing the brake piston <NUM> from the brake assembly <NUM>.

Referring now to <FIG> and <FIG>, the base member <NUM> may include a pull plate <NUM> and one or more legs <NUM>. As shown, the pull plate <NUM> may generally be oriented perpendicular to the brake piston sleeve <NUM> to extend across at least a portion of the brake piston <NUM>. The pull plate <NUM> may include a top surface <NUM> and an opposing bottom surface <NUM> and may define an aperture <NUM> through which the puller assembly <NUM> extends. The legs <NUM> may extend outward from the bottom surface <NUM> of the pull plate <NUM>. As such, the legs <NUM> may be configured for placement on the brake piston sleeve <NUM>. In particular, a bottom surface <NUM> of the legs <NUM> may be configured for placement on a top surface <NUM> of the brake piston sleeve <NUM>. The legs <NUM> may include projections <NUM> to prevent the base member <NUM> from sliding off of the brake piston assembly <NUM>. In the embodiment shown in <FIG> and <FIG>, the base member <NUM> includes two legs <NUM>. Nevertheless, the base member <NUM> may include any suitable number of legs <NUM>, such as a single leg <NUM> or more than two legs <NUM>, in alternate embodiments. Furthermore, although <FIG> and <FIG> illustrate the base member <NUM> as a single component, the base member <NUM> may also be two or more separate components.

Referring now to <FIG>, <FIG>, and <FIG>, the puller assembly <NUM> includes a first shaft <NUM>. As shown, the first shaft <NUM> may be annular, thereby defining a passage <NUM> extending therethrough. In this respect, the first shaft <NUM> may define an inner surface <NUM>, an outer surface <NUM>, and top surface <NUM>. The first shaft <NUM> is moveable relative to the base member <NUM> to permit the puller assembly <NUM> to move relative to the base member <NUM>. For example, the first shaft <NUM> may extend through the aperture <NUM> in the pull plate <NUM>. As such, the outer surface <NUM> of the first shaft <NUM> may slide relative to the pull plate <NUM>. Furthermore, the first shaft <NUM> couples to the collet <NUM>. The collet <NUM> and the first shaft <NUM> are integrally formed as shown in <FIG>, <FIG>, and <FIG>. In alternate embodiments, however, the first shaft <NUM> may have any suitable configuration. For example, the first shaft <NUM> may be a solid rod.

As mentioned above, the puller assembly <NUM> includes the collet <NUM>, which engages the inner surface <NUM> of the brake piston <NUM>. The , the collet <NUM> includes a plurality of arms <NUM>. For example, the arms <NUM> may have an L-shaped configuration. Each arm <NUM> includes a first arm portion <NUM> extending outward from the first shaft <NUM> and a second arm portion <NUM> extending downward from the corresponding first arm portion <NUM>. As shown, the second arm portions <NUM> may engage the inner surface <NUM> of the brake piston <NUM>. For example, in one embodiment, each second arm portion <NUM> may include a plurality of teeth <NUM>, which engages or otherwise grips the inner surface <NUM> of the brake piston <NUM>. Furthermore, each second arm portion <NUM> may include a surface <NUM> positioned inward from the teeth <NUM>. In some embodiments, the surfaces <NUM> may be oblique relative to the longitudinal axis of first shaft <NUM>. Although the embodiment shown in <FIG>, <FIG>, and <FIG> includes two arms <NUM>, the collet <NUM> may include any suitable number of arms <NUM>, such as more than two arms <NUM>. Additionally, the collet <NUM> may have any suitable configuration or structure for engaging the inner surface <NUM> of the brake piston <NUM>.

Referring now to <FIG> and <FIG>, the puller assembly <NUM> may also include a disk <NUM> positioned in sliding engagement with the collet <NUM>. More specifically, the disk <NUM> may include an angled surface <NUM> in sliding contact with the surfaces <NUM> of the arms <NUM> of the collet <NUM>. In this respect, sliding the disk <NUM> in a first direction (e.g., as indicated by arrow <NUM>) moves the arms <NUM> of the collet <NUM> outward and into engagement with the inner surface <NUM> of the brake piston <NUM>. Conversely, sliding the disk <NUM> in a second, opposite direction (e.g., as indicated by arrow <NUM>) moves the arms <NUM> of the collet <NUM> inward and out of engagement with the inner surface <NUM> of the brake piston <NUM>. Although the disk <NUM> is illustrated as having a frustoconical configuration in <FIG> and <FIG>, the disk <NUM> may have any suitable configuration that allows the collet <NUM> to engage and disengage the inner surface <NUM> of the brake piston <NUM>.

The puller assembly <NUM> may further include a second shaft <NUM> coupled to the disk <NUM>. As such, the second shaft <NUM> may be configured to slide the disk <NUM> relative to the collet <NUM>. In several embodiments, the second shaft <NUM> may extend through the passage <NUM> in the first shaft <NUM> such that the first and second shafts <NUM>, <NUM> may be concentric with each other. The first and second shafts <NUM>, <NUM> may be movable relative to each other. For example, in one embodiment, an outer surface <NUM> of the second shaft <NUM> may threadingly engage the inner surface <NUM> of the first shaft <NUM>. In this respect, rotating the second shaft <NUM> relative to the first shaft <NUM> may cause the second shaft <NUM> to move (i.e., in the first or second directions <NUM>, <NUM>) relative to the first shaft <NUM>, thereby causing the collet <NUM> to engage or disengage the brake piston <NUM>. Some embodiments of the second shaft <NUM> may include a bolt head <NUM> to facilitate rotation of the second shaft <NUM> with, e.g., a socket or wrench. In alternate embodiments, however, the second shaft <NUM> may have any suitable configuration.

Referring now to <FIG>, the tool <NUM> may include a nut <NUM> that moves the puller assembly <NUM> relative to the base member <NUM>. More specifically, the nut <NUM> may threadingly engage the outer surface of the <NUM> of the first shaft <NUM> above the base member <NUM>. In this respect, rotating the nut <NUM> relative to the first shaft <NUM> may cause the puller assembly <NUM> to move relative to the base member <NUM>. In particular, tightening the nut <NUM> may cause the puller assembly <NUM> to move in the first direction <NUM>. When the collet <NUM> is in engagement with the inner surface <NUM> of the brake piston <NUM>, tightening the nut <NUM> may exert an upward force on the brake piston <NUM>, thereby causing the brake piston <NUM> to slide relative to the brake piston sleeve <NUM>. In some embodiments, a thrust bearing <NUM> and/or a washer <NUM> may be positioned between the nut <NUM> and the top surface <NUM> of the pull plate <NUM> to facilitate relative movement between the puller assembly <NUM> and the base member <NUM>.

<FIG> illustrates one embodiment of a method <NUM> for removing a brake piston from a brake assembly of a wind turbine. In general, the method <NUM> will be described below with reference to the wind turbine <NUM> and the tool <NUM>. Nevertheless, the disclosed method <NUM> may be utilized to remove brake pistons from brake assemblies for any wind turbine having any suitable configuration. Furthermore, although <FIG> 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 arrangement. In this respect, the various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

As shown in <FIG>, at (<NUM>), the method <NUM> includes inserting a puller assembly into an inner cavity defined by a brake piston. For example, the puller assembly <NUM> may be inserted into the inner cavity <NUM> of the brake piston <NUM> such that the collet <NUM> is positioned within the inner cavity <NUM>. As such, the teeth <NUM> on the arms <NUM> of the collet <NUM> may engage or otherwise grip the inner surface <NUM> of the brake piston <NUM>. In some embodiments, inserting the puller assembly <NUM> may include positioning the second shaft <NUM> within the passage <NUM> defined by the first shaft <NUM>.

Furthermore, at (<NUM>), the method <NUM> includes positioning a base member on a surface of a brake piston sleeve. For example, the base member <NUM> may be positioned on the brake piston sleeve <NUM> such that the bottom surfaces <NUM> of the legs <NUM> of the base member <NUM> are positioned on the top surface <NUM> of the brake piston sleeve <NUM>. In some embodiments, positioning the base member <NUM> may include aligning the first shaft <NUM> with the aperture <NUM> in the pull plate <NUM>.

Additionally, at (<NUM>), the method <NUM> includes moving the puller assembly relative to the base member. For example, the nut <NUM> may threadingly engage the first shaft <NUM> such that rotation of the nut <NUM> relative to the first shaft <NUM> causes the puller assembly <NUM> to move relative to the base member <NUM>. As mentioned above, this movement may, in turn, cause the brake piston <NUM> to slide relative to the brake piston sleeve <NUM>, thereby facilitating removal of the brake piston <NUM> from the brake assembly <NUM>. In some embodiments, moving the puller assembly <NUM> may include positioning the thrust bearing <NUM> between the nut <NUM> and the pull plate <NUM> of the base member <NUM>.

In some embodiments, the method <NUM> may include sliding a disk of the puller assembly relative to the collet. For example, the disk <NUM> of the puller assembly <NUM> may be slid relative to the collet <NUM> in the first direction <NUM> to move the collet <NUM> into engagement with the inner surface <NUM> of the brake piston <NUM>. The disk <NUM> of the puller assembly <NUM> may also be slid in a second direction <NUM> to move the collet <NUM> out of engagement with the inner surface <NUM> of the brake piston <NUM>. In some embodiments, the disk <NUM> may be slid relative to the collet <NUM> by moving the second shaft <NUM> relative to the first shaft <NUM>.

Unlike conventional tools and methods, the tool <NUM> and the method <NUM> described above facilitate the removal of the brake piston <NUM> from the brake assembly <NUM> without the need for cutting or other expensive and time-consuming processes. In this respect, the use of the tool <NUM> and the method <NUM> reduce the cost and decrease the amount of time necessary to remove brake pistons from brake assemblies of wind turbines compared to the use of convention tools and methods.

Claim 1:
A tool (<NUM>) for removing a brake piston (<NUM>) from a brake assembly (<NUM>) of a wind turbine (<NUM>), the tool (<NUM>) comprising:
a base member (<NUM>) configured for placement on a surface (<NUM>) of a brake piston sleeve (<NUM>); and,
a puller assembly (<NUM>) configured for insertion into an inner cavity (<NUM>) defined by the brake piston (<NUM>), the puller assembly (<NUM>) including a first shaft (<NUM>) and a collet (<NUM>) integrally formed with the first shaft (<NUM>), the first shaft (<NUM>) being moveable relative to the base member (<NUM>), the collet (<NUM>) being configured to engage an inner surface (<NUM>) of the brake piston (<NUM>),
wherein moving the first shaft (<NUM>) relative to the base member (<NUM>) slides the brake piston (<NUM>) relative to the brake piston sleeve (<NUM>),
characterised in that
the collet (<NUM>) includes a plurality of arms (<NUM>), each arm (<NUM>) including a first arm portion (<NUM>) extending outward from the first shaft (<NUM>) and a second arm portion (<NUM>) extending downward from the corresponding first arm portion (<NUM>).