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 generator, a gearbox, a nacelle, and one or more rotor blades. The nacelle includes a rotor assembly coupled to the gearbox and to the generator. The rotor assembly and the gearbox are mounted on a bedplate support frame located within the nacelle. More specifically, in many wind turbines, the gearbox is mounted to the bedplate via one or more torque arms or arms. The one or more rotor blades capture kinetic energy of wind using known airfoil principles. The rotor blades transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.

More specifically, the majority of commercially available wind turbines utilize multi-stage geared drivetrains to connect the turbine blades to electrical generators. The wind turns the turbine blades, which spin a low speed shaft. The low speed shaft is coupled to an input shaft of a gearbox, which has a higher speed output shaft connected to a generator. Thus, the geared drivetrain aims to increase the velocity of the mechanical motion. The gearbox and the generator are typically separately mounted to the bedplate. More specifically, the output shaft of the gearbox and the input shaft of the generator are separately supported by gearbox bearings and generator bearings, respectively. Thus, the gearbox and corresponding input shaft are typically mounted to the bedplate via one or more torque arms.

In some instances, mounting the gearbox via torque arms presents certain design challenges. Specifically, the torque arms increase the overall width of the gearbox. Depending on the design of the gearbox and the torque arms, the overall width of the assembled gearbox may exceed standard shipping parameters, yet it may remain desirable to transport the gearbox in an assembled configuration. Documents <CIT>, <CIT> and <CIT> are examples of a gearbox having torque arms. Additionally, the presence of the torque arms may limit the available manufacturing techniques for forming the assembly. Specifically, the presence of the torque arms may mean that certain pieces of manufacturing equipment will lack sufficient clearance to form a ring gear on the inside face of the gearbox.

In view of the aforementioned, the art is continuously seeking new and improved systems and methods for reducing the transport width of a gearbox while maintaining the maximal installed width of the gearbox. Thus, a system and method that includes a gearbox having a transport width which is less than an installed width would be advantageous.

In one aspect, the present disclosure is directed to a gearbox assembly for a wind turbine. The gearbox assembly includes a gearbox having an installed width and a transport width. The installed width is greater than the transport width. The gearbox includes a gearbox housing including an exterior surface, which defines the transport width, and an inner cavity. The gearbox also includes a gearing arrangement arranged within the inner cavity. The gearbox assembly includes a first torque arm coupled to a first side of the gearbox housing and a second torque arm coupled to an opposing, second side of the gearbox housing. Each of the first and second torque arms includes a proximal end and a distal end. The proximal ends are removably coupled to the exterior surface of the gearbox housing such that a distance between the distal ends of the first and second torque arms define the installed width. The gearbox assembly also includes at least one support element coupling the plurality of torque arms to a bedplate of the wind turbine.

In one embodiment, the installed width is a maximal installed width and the transport width is a maximal transport width. Additionally, In at least one embodiment, the first and second torque arms each may include a base portion including the proximal ends thereof and at least one detachable endcap positioned radially outward from the base portion.

In another embodiment, the at least one support element may include a pedestal bracket secured to the bedplate and may support a mounting pin. The pedestal bracket may include opposing bracket arms defining a gap therebetween that receives the at least one endcap. The mounting pin may be secured between the at least one endcap and the base portion of one of the first and second torque arms. In an additional embodiment, the gearbox assembly may also include a segmented bushing arranged between the opposing bracket arms that receive the mounting pin.

In yet another embodiment, the first and second torque arms each may include a pair of detachable end caps positioned radially outward therefrom. In at least one embodiment, the pedestal bracket may be disposed between the pair of detachable end caps. The mounting pin may be secured through the base portion and may be secured between the pair of detachable end caps and the base portion of one of the first and second torque arms.

In further embodiments, the proximal end of at least one torque arm may be removably coupled to the exterior surface of the gearbox housing via at least one of a dovetail joint, a mortise-and-tenon joint, a bolted joint, or a bonded joint. In certain embodiments, the mortise-and-tenon joint may include an additional securing pin positioned therethrough. In yet another embodiment, the first and second torque arms or the exterior surface of the gearbox housing may include a recess and the other of the first and second torque arms or the exterior surface of the gearbox housing may include a flange received within the recess the flange forming the bolted joint or the bonded joint. In certain embodiments, the maximal transport width of the gearbox assembly may be less than or equal to <NUM> meters.

In another aspect, the present disclosure is directed to a method for assembling a gearbox assembly for a wind turbine. The method includes coupling a plurality of support elements to a bedplate of a wind turbine. The method also includes positioning a gearbox having a gearbox housing defining a maximal transport width between the plurality of support elements. A further step of the method includes coupling at least a portion of a plurality of torque arms to opposing sides of an exterior surface of the gearbox housing so as to transition the gearbox to a maximal width. The method also includes securing each of the plurality of torque arms to one of the plurality of support elements.

In one embodiment, coupling at least a portion of the plurality of torque arms to the gearbox housing may also include coupling at least one detachable endcap radially outward from a base portion. In another embodiment, securing each of the plurality of torque arms to one of the plurality of support elements may also include securing each of the plurality of torque arms to a pedestal bracket secured to the bedplate.

In a particular embodiment, coupling at least a portion of the plurality of torque arms to opposing sides of an exterior surface of the gearbox may further include coupling a proximal end of at least one of the plurality of torque arms to the exterior surface of the gearbox housing via a dovetail joint, a mortise-and-tenon joint, a bolted joint, and/or a bonded joint. It should be understood that the method may further include any of the additional steps and/or features as described herein.

In another aspect, the present disclosure is directed to a wind turbine. The wind turbine includes a tower, a nacelle mounted atop the tower, and a rotor. The wind turbine includes a gearbox positioned within the nacelle. The gearbox assembly has a maximal installed width which is greater than a maximal transport width. The gearbox includes a gearbox housing having an inner surface and an outer surface and a gearing arrangement. The inner surface defines an inner cavity and a portion of the gearing arrangement is contained within the inner cavity. The wind turbine also includes a plurality of torque arms coupled to the gearbox housing. Each torque arm of the plurality of torque arms includes a proximal end and a distal end opposite thereof. A distance between respective distal ends of two torque arms of the plurality of torque arms define the maximal installed width. The wind turbine also has at least one support element coupled to the plurality of torque arms and a bedplate support frame. A rotor shaft rotatably couples the rotor to the gearbox.

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, the scope of which is defined by the appended claims.

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 of the invention which is defined by the appended claims.

Generally, the present disclosure is directed to a gearbox assembly for a wind turbine that is configured to have a reduced transport width. The gearbox assembly includes a gearbox having a maximal installed width that is greater than a maximal transport width of a gearbox housing. This is achieved through the utilization of support structures having the unique features of the present disclosure. Specifically, the gearbox may include a first torque arm and a second torque arm. The torque arms may be coupled to the exterior surface of the gearbox housing and the distance between the radially distal ends of the torque arms may define the maximal installed width. In at least one embodiment, the torque arms may include base portions coupled to the gearbox housing and detachable endcaps positioned radially outward from the base portions. In another embodiment, the torque arms may be removably coupled to the exterior surface of the gearbox housing via at least one of a dovetail joint, a mortise-and-tenon joint, a bolted joint, and/or a bonded joint.

Referring now to the drawings, <FIG> illustrates a perspective view of one embodiment of a wind turbine <NUM> according to the present disclosure. 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>. The rotor <NUM> includes a rotatable hub <NUM> and at least one rotor blade <NUM> coupled to and extending outwardly from the hub <NUM>. For example, in the illustrated embodiment, the rotor <NUM> includes three rotor blades <NUM>. However, in an alternative embodiment, 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 rotating the rotor <NUM> to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy. For instance, the hub <NUM> may be rotatably coupled to an electric generator <NUM> (<FIG>) positioned within the nacelle <NUM> to permit electrical energy to be produced.

The wind turbine <NUM> may also include a wind turbine controller <NUM> centralized within the nacelle <NUM>. However, in other embodiments, the controller <NUM> may be located within any other component of the wind turbine <NUM> or at a location outside the wind turbine. Further, the controller <NUM> may be communicatively coupled to any number of the components of the wind turbine <NUM> in order to control the components. As such, the controller <NUM> may include a computer or other suitable processing unit. Thus, in several embodiments, the controller <NUM> may include suitable computer-readable instructions that, when implemented, configure the controller <NUM> to perform various different functions, such as receiving, transmitting and/or executing wind turbine control signals.

Referring now to <FIG>, a simplified, internal view of one embodiment of the nacelle <NUM> of the wind turbine <NUM> shown in <FIG> is illustrated. As shown, the generator <NUM> may be coupled to the rotor <NUM> for producing electrical power from the rotational energy generated by the rotor <NUM>. For example, as shown in the illustrated embodiment, the rotor <NUM> may include a rotor shaft <NUM> coupled to the hub <NUM> for rotation therewith. The rotor shaft <NUM> may, in turn, be rotatably coupled to a generator shaft <NUM> of the generator <NUM> through a gearbox <NUM> connected to a bedplate support frame <NUM> by one or more torque arms <NUM>. As is generally understood, 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 be configured to 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>.

Each rotor blade <NUM> may also include a pitch adjustment mechanism <NUM> configured to rotate each rotor blade <NUM> about its pitch axis <NUM>. Further, each pitch adjustment mechanism <NUM> may include a pitch drive motor <NUM> (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox <NUM>, and a pitch drive pinion <NUM>. In such embodiments, the pitch drive motor <NUM> may be coupled to the pitch drive gearbox <NUM> so that the pitch drive motor <NUM> imparts mechanical force to the pitch drive gearbox <NUM>. Similarly, the pitch drive gearbox <NUM> may be coupled to the pitch drive pinion <NUM> for rotation therewith. The pitch drive pinion <NUM> may, in turn, be in rotational engagement with a pitch bearing <NUM> coupled between the hub <NUM> and a corresponding rotor blade <NUM> such that rotation of the pitch drive pinion <NUM> causes rotation of the pitch bearing <NUM>. Thus, in such embodiments, rotation of the pitch drive motor <NUM> drives the pitch drive gearbox <NUM> and the pitch drive pinion <NUM>, thereby rotating the pitch bearing <NUM> and the rotor blade <NUM> about the pitch axis <NUM>. Similarly, the wind turbine <NUM> may include one or more yaw drive mechanisms <NUM> communicatively coupled to the controller <NUM>, with each yaw drive mechanism(s) <NUM> being configured to change the angle of the nacelle <NUM> relative to the wind (e.g., by engaging a yaw bearing <NUM> of the wind turbine <NUM>).

Referring now to <FIG>, front views of a gearbox assembly <NUM> in accordance with an embodiment of the present disclosure are illustrated. As shown, the gearbox assembly <NUM> includes the gearbox <NUM> described herein and the gearbox <NUM> has a gearbox housing <NUM>. As depicted in <FIG>, the gearbox <NUM> may include any suitable gear assembly that uses one or more gears and/or gear trains to provide speed and/or torque conversions from the rotor shaft <NUM> to the generator <NUM>. For example, as shown, the gearbox <NUM> may include a gearing arrangement <NUM> arranged within an inner cavity <NUM> of the gearbox housing <NUM>. The gearing arrangement <NUM> may have one or more outer or planet gears <NUM> revolving about a central or sun gear <NUM>. In addition, the planet gears <NUM> are typically mounted on a movable arm or carrier (not shown) which itself may rotate relative to the sun gear <NUM>. The gearbox <NUM> may also include at least one outer ring gear <NUM> configured to mesh the planet gears <NUM>. Thus, a typical ring gear <NUM>, such as that shown in <FIG>, generally includes a set of gear teeth on an inner circumferential surface thereof that are configured to mesh with corresponding teeth of the planet gears <NUM>.

As shown in <FIG>, the gearbox assembly <NUM> may be supported atop the bedplate support frame <NUM>, which may, in turn, be mounted on the nacelle <NUM>. The gearbox assembly <NUM> may further include at least one torque arm <NUM> and at least one support element <NUM>. Thus, as shown, the gearbox <NUM> may be secured to the bedplate support frame <NUM> via the torque arm(s) <NUM>, which may, in turn, be coupled to the support element(s) <NUM>. More specifically, the torque arm(s) <NUM> may include a first torque arm <NUM> and a second torque arm <NUM> coupled to opposing sides of the gearbox <NUM>. It should be appreciated that, in certain embodiments, the torque arm(s) <NUM> may be integral with the bedplate support frame <NUM>.

Referring still to <FIG>, the gearbox housing <NUM> may have an exterior surface <NUM> and an inner cavity <NUM>. The exterior surface <NUM> may, as particularly depicted in <FIG>, define the transport width (TW) of the gearbox <NUM>, which may be the maximal transport width. For example, in a cross-sectional view of the gearbox housing <NUM>, such as <FIG>, the exterior surface <NUM> may be the perimeter of the depicted shape and may define the transport width (TW). When the gearbox <NUM> is installed in the wind turbine <NUM>, the gearbox <NUM> may have an installed width (IW) which may be the maximal installed width and which is greater than the maximal transport width (TW). Furthermore, the gearbox <NUM> may be in a transport configuration when the gearbox housing has the maximal transport width (TW) and may be in an installed configuration when the gearbox has the maximal installed width (IW). In at least one embodiment, the maximal transport width may be less than or equal to <NUM> meters (e.g., greater than <NUM> meters and less than or equal to <NUM> meters).

It should be appreciated that in an embodiment wherein the maximal transport width (TW) is less than or equal to <NUM> meters, the transportation of the gearbox assembly <NUM> may be facilitated. For example, the maximal transport width (TW) of the gearbox assembly <NUM> may be less than the standard width of a standardized shipping container (e.g., an ISO or intermodal shipping container), which may facilitate standardized shipping of the gearboxes <NUM> or may allow multiple gearboxes <NUM> to be shipped in a single shipping container. Alternatively, in at least one embodiment, the maximal transport width may be less than or equal to <NUM> meters (e.g., greater than or equal to <NUM> meters and less than or equal to <NUM> meters). Limiting the maximal transport width to less than or equal to <NUM> meters may facilitate trucking the gearbox on United States roads without requiring special permitting. Additionally, the maximal transport width (TW) being less than the maximal installed width (IW) may ensure sufficient clearance exist between the gearbox housing <NUM> and a piece of machining equipment, so as to facilitate the formation of the ring gear <NUM> within the inner cavity <NUM> of the gearbox housing <NUM>.

Still referring to <FIG>, the first torque arm <NUM> and the second torque arm <NUM> may include respective proximal ends <NUM>, <NUM> and respective distal ends <NUM>, <NUM>. A distance between the distal ends <NUM>, <NUM> defines the maximal installed width (IW) of the gearbox <NUM>. The proximal ends <NUM>, <NUM> may be coupled to, or integrated with, the exterior surface <NUM> of the gearbox housing <NUM>. As used herein, the term "couple" may include embodiments wherein a first component is attached to a second component (e.g., by welding, gluing, brazing, adhering, or otherwise mechanically joining) or may include embodiments wherein the first component is formed integrally with the second component by any known manufacturing method (e.g., additive manufacturing, casting, machining, molding, composite layup, extruding, or any combination thereof).

As will be discussed in more detail below, in at least one embodiment, the proximal ends <NUM>, <NUM> may be removably coupled to the gearbox housing <NUM> or may be permanently coupled to the gearbox housing <NUM> following delivery to the wind turbine <NUM>. In such an embodiment, the maximal transport width (TW) may be established by a maximal width dimension of the gearbox housing <NUM>. Alternatively, in at least one embodiment, the proximal ends <NUM>, <NUM> may be permanently coupled to the gearbox housing <NUM> prior to delivery to the wind turbine <NUM>. In such an embodiment, the proximal ends <NUM>, <NUM> may be integrated into the exterior surface <NUM> so that a maximal distance between the respective proximal ends <NUM>, <NUM> establishes the maximal transport width (TW).

Referring now to <FIG>, perspective views of one embodiment of a portion of the gearbox assembly <NUM> in accordance with aspects of the present disclosure are illustrated. As depicted in <FIG>, at least one of the torque arms <NUM> may include a base portion <NUM>, which includes the respective proximal end. For example, as shown, the second torque arm <NUM> may include a base portion <NUM>, which includes the proximal end <NUM>. At least one of the torque arms <NUM> may include at least one detachable endcap <NUM> positioned radially outward from the base portion <NUM>. The detachable endcap(s) <NUM> may be secured to the base portion <NUM> via one or more fasteners <NUM>. The securing of the detachable endcap <NUM> to the base portion <NUM> may, in at least one embodiment, be facilitated by a plurality of alignment pins <NUM> configured to be received by corresponding recesses <NUM> in the detachable endcap <NUM> and the base portion <NUM>. It should be appreciated that, while the second torque arm <NUM> is depicted in <FIG>, the discussion above applies equally to the first torque arm <NUM>, as well as to any additional torque arms. It should further be appreciated that the securing of the detachable endcap caps <NUM> to the respective base portions <NUM> may serve to define the maximal installed width (IW) of the gearbox <NUM> and may be accomplished during the installation of the gearbox assembly <NUM> in the wind turbine <NUM>.

Referring still to <FIG>, in at least one embodiment, in accordance with aspects of the present disclosure, the support element <NUM> may be a pedestal bracket <NUM> secured to the bedplate <NUM> of the wind turbine <NUM>. As shown, the pedestal bracket <NUM> may support a mounting pin <NUM>. In certain embodiments, as shown particularly in <FIG>, a portion of the mounting pin <NUM> may be encased within a segmented bushing <NUM>. It should be appreciated that, in certain embodiments, the segmented bushing <NUM> may be an elastomeric member which serves to limit the effects of vibration on the functionality of the wind turbine <NUM>.

In at least one embodiment, such as is depicted by <FIG>, the pedestal bracket <NUM> may have opposing bracket arms <NUM>, <NUM>. The pedestal bracket <NUM> may, thus, generally have a U-shaped configuration. The opposing bracket arms <NUM>, <NUM> may define a gap therebetween that receives the detachable endcap <NUM>. The mounting pin <NUM> may have a mounting pin first end <NUM> and a mounting pin second end <NUM>. The mounting pin first end <NUM> may be supported by the bracket arm <NUM>, while the mounting pin second end <NUM> may be supported by the opposing bracket arm <NUM>. A portion of the mounting pin <NUM> between the opposing bracket arms <NUM>, <NUM> may be encased within the segmented bushing <NUM>, so that, in turn, the segmented bushing <NUM> and the mounting pin <NUM> may be secured between the detachable endcap <NUM> and the base portion <NUM>. It should be appreciated that the pedestal bracket <NUM> and the mounting pin <NUM> may be formed as a single, integrated component without seams or joints.

Referring now to <FIG>, an alternative embodiment of the one of the torque arms, i.e. the second torque arm <NUM>, and at least one support element <NUM> in accordance with aspects of the present disclosure is depicted. Though described with reference to the second torque arm <NUM>, the embodiment depicted in <FIG> is equally applicable to the first torque arm <NUM>. As depicted in <FIG>, and as discussed above, the torque arms <NUM>, <NUM> may include a base portion <NUM>, which includes the respective proximal end <NUM>, <NUM>. The base portion <NUM> may include a first base arm <NUM> and an opposing second base arm <NUM>. The torque arms <NUM> may, thus, generally have a U-shaped configuration. The torque arms <NUM>, <NUM> may each include a pair of detachable endcaps <NUM> positioned radially outward from the base portion <NUM>. The pair of detachable endcaps <NUM> may be secured to the respective base arms <NUM>, <NUM> via one or more fasteners <NUM>. It should be appreciated that the securing of the detachable endcap caps <NUM> to the respective base portions <NUM> may serve to define the maximal installed width (IW) of the gearbox <NUM> and may be accomplished during the installation of the gearbox assembly <NUM> in the wind turbine <NUM>.

In an embodiment, such as depicted in <FIG>, the support element(s) <NUM> may be a columnar pedestal bracket <NUM>. The columnar pedestal bracket <NUM> may be disposed between the pair of detachable end caps <NUM> and coupled to the bedplate <NUM> of the wind turbine <NUM>. In at least one embodiment, the columnar pedestal bracket <NUM> may be a unitary component. Alternatively, the columnar pedestal bracket may have a pedestal base <NUM> coupled to the bedplate <NUM>. The columnar pedestal bracket <NUM> may also have a pedestal cap <NUM> coupled to the pedestal base <NUM> by a plurality of fasteners <NUM>.

As further illustrated by <FIG>, the mounting pin <NUM> may be secured through the columnar pedestal bracket <NUM>. The mounting pin <NUM> may also be secured between the pair of detachable end caps <NUM> and the base portion <NUM> of the torque arms <NUM>, <NUM>. Specifically, the mounting pin first end <NUM> may be secured between one of the pair of detachable endcaps and the first base arm <NUM>, while the mounting pin second end <NUM> may be secured between one of the pair of detachable end caps <NUM> and the second base arm <NUM>. With the mounting pin ends <NUM>, <NUM> secured between the detachable end caps <NUM> and the base portion <NUM>, the portion of the mounting pin <NUM> between the opposing base arms <NUM>, <NUM> may be encapsulated by the segmented bushing <NUM>. The segmented bushing <NUM> and the corresponding portion of the mounting pin <NUM> may be secured between the pedestal base <NUM> and the pedestal cap <NUM>. In an alternative embodiment, the mounting pin <NUM> and the support element <NUM> may be integrally formed so as to develop a generally T-shaped component. It should be appreciated that integrally forming a generally T-shaped component may include manufacturing a unitary component, without seams or joints, or alternatively, permanently coupling the mounting pin <NUM> to the support element <NUM> during the manufacturing of the support element <NUM>.

Referring now to <FIG>, several different embodiments in accordance with aspects of the present disclosure are presented. As depicted in <FIG>, the first and second torque arms <NUM>, <NUM> may be removably coupled to the exterior surface <NUM> of the gearbox housing <NUM>. More specifically, as shown, the torque arms <NUM> may be coupled to the gearbox housing <NUM> via at least one of a dovetail joint, a mortise-and-tenon joint, a bolted joint and/or a bonded joint. In such an embodiment, the maximal width of the gearbox housing <NUM> defines the maximal transport width (TW) of the gearbox <NUM>. The maximal installed width (IW) is defined by the coupling of the torque arms <NUM> to the gearbox housing <NUM> following delivery to the wind turbine <NUM> and during the installation of the gearbox <NUM> in the wind turbine <NUM>. In other words, the gearbox <NUM> may be manufactured and delivered to the worksite without the torque arms <NUM> being installed. It should be appreciated that manufacturing the gearbox <NUM> without the torque arms <NUM> will facilitate the shipment of the gearbox <NUM> via standardized means and will eliminate certain manufacturing limitations related to the effect of the torque arms <NUM> on machining clearances.

It should be appreciated that in certain embodiments, the torque arms <NUM> being removably coupled to the gearbox housing <NUM> may be combined with other aspects of the present disclosure discussed above with regards to <FIG>. For example, a torque arm <NUM> may be configured so that the base portion <NUM> is removably coupled to the exterior surface <NUM> of the gearbox housing <NUM>. The torque arm <NUM> may also, as discussed above in reference to <FIG>, include at least one detachable endcap <NUM> positioned radially outward from the base portion <NUM>. A portion of the mounting pin <NUM> may be secured between the detachable endcap <NUM> and the base portion <NUM>.

In yet another embodiment, the torque arm <NUM> and the support element <NUM> may be integrally formed so as to establish a unitary component. The unitary component may then be coupled to the gearbox housing <NUM> and to the bedplate <NUM> of the wind turbine <NUM>. In such a configuration, the unitary component may perform the functions of the torque arm <NUM> and the support element <NUM>. In one embodiment, the unitary component may likewise be formed integrally with the bedplate <NUM> of the wind turbine <NUM>.

Referring now to <FIG>, a torque arm <NUM> may, as previously mentioned, be removably coupled to the exterior surface <NUM> of the gearbox housing <NUM>. <FIG> specifically depict the torque arm <NUM> being coupled to the exterior surface <NUM> via a dovetail joint. As such, the torque arm <NUM> may be formed with a dovetail <NUM> which is configured to be received by a corresponding dovetail mortise <NUM> and the exterior surface <NUM> so as to establish a secure interface between the torque arm <NUM> and the gearbox <NUM>. It should be appreciated that while a single dovetail joint is illustrated, additional dovetails and corresponding dovetail mortises may be included in order to establish the removable coupling.

<FIG> depict an alternative embodiment for removably securing the torque arms <NUM> to the gearbox <NUM>. In the depicted embodiment, the torque arm <NUM> is formed with a tenon <NUM> which is configured to be received by a corresponding mortise <NUM> formed in the exterior surface <NUM> of the gearbox housing <NUM>. The tenon <NUM> may be mechanically secured within the mortise <NUM> through the inclusion of a securing pin <NUM>, which is positioned therethrough. The tenon <NUM> may, in some embodiments, be at least one rounded protrusion, such as a pin, and the mortise <NUM> may be at least one corresponding hole. Just as in the dovetail joint discussed above, multiple mortise-and-tenon joints may be included in order to establish the removable coupling. However, it should be appreciated that, a single securing pin <NUM> may be employed to lock multiple mortise-and-tenon joints. It should be further appreciated that the securing pin <NUM> is not limited to a linear, smooth-sided pin, but may also include a threaded fastener, a curved element, or even a ring which may circumscribe the gearbox housing <NUM>.

<FIG> depicts yet another alternative embodiment for removably securing the torque arms <NUM> to the gearbox <NUM>. In the illustrated embodiment, the first and second torque arms <NUM>, <NUM> or the exterior surface <NUM> of the gearbox housing <NUM> include a recess <NUM>. The other of the first and second torque arms <NUM>, <NUM> or the exterior surface <NUM> of the gearbox housing <NUM> may include a flange <NUM> configured to be received within the recess <NUM>. The flange <NUM> may be employed in conjunction with a plurality of fasteners <NUM> to form a bolted joint between the gearbox <NUM> and the torque arm <NUM>. Alternatively, a bonded joint may be formed during the installation of the gearbox <NUM> in the wind turbine <NUM> by welding or adhering the flange <NUM> within the recess <NUM>.

Referring to <FIG>, a flow diagram of one embodiment of a method <NUM> for assembling a gearbox assembly for a wind turbine is illustrated. The method <NUM> may be implemented using, for instance, the gearbox assembly <NUM> discussed above with reference to <FIG>. <FIG> depicts steps performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that various steps of the method <NUM> or any of the other methods disclosed herein may be adapted, modified, rearranged, performed simultaneously or modified in various ways without deviating from the scope of the present disclosure.

As shown at (<NUM>), the method <NUM> includes coupling a plurality of support elements to a bedplate of a wind turbine. As shown at (<NUM>), the method <NUM> includes positioning a gearbox having a gearbox housing defining a maximal transport width between the plurality of support elements. As shown at (<NUM>), the method <NUM> includes coupling at least a portion of a plurality of torque arms to opposing sides of an exterior surface of the gearbox housing so as to transition the gearbox to a maximal width. As shown at (<NUM>), the method <NUM> includes securing each of the plurality of torque arms to one of the plurality of support elements.

In additional embodiments, coupling at least a portion of the plurality of torque arms to the gearbox housing may include coupling at least one detachable endcap positioned radially outward from a base portion to the base portion. Further, securing each of the plurality of torque arms to one of the plurality of support elements may include securing each of the plurality of torque arms to a pedestal bracket secured to the bedplate. In another embodiment, securing each of the plurality of torque arms to one of the plurality of support elements may include securing the mounting pin between a pair of detachable end caps positioned radially outward from the base portion of a torque arm of the plurality of torque arms.

Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents for each such methods and feature, can be mixed and matched by one of ordinary skill in this art to construct additional systems and techniques in accordance with the scope of the invention as defined by the appended claims. Of course, it is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

Claim 1:
A gearbox assembly (<NUM>) for a wind turbine (<NUM>), the gearbox assembly (<NUM>) comprising:
a gearbox (<NUM>) having an installed width (Iw) and a transport width (Tw), the installed width (Iw) being greater than the transport width (Tw), the gearbox (<NUM>) comprising:
a gearbox housing (<NUM>) comprising an exterior surface (<NUM>) and an inner cavity (<NUM>), the exterior surface (<NUM>) defining the transport width (Tw); and,
a gearing arrangement (<NUM>) arranged within the inner cavity (<NUM>);
a first torque arm (<NUM>) coupled to a first side of the gearbox housing (<NUM>);
a second torque arm (<NUM>) coupled to an opposing, second side of the gearbox housing (<NUM>), each of the first and second torque arms (<NUM>, <NUM>) comprising a proximal end (<NUM>, <NUM>) and a distal end (<NUM>, <NUM>), the proximal ends (<NUM>, <NUM>) removably coupled to the exterior surface (<NUM>) of the gearbox housing (<NUM>) such that a distance between the distal ends (<NUM>, <NUM>) of the first and second torque arms (<NUM>, <NUM>) define the installed width (Iw); and,
at least one support element (<NUM>) configured to couple a plurality of torque arms (<NUM>, <NUM>) to a bedplate (<NUM>) of a wind turbine (<NUM>).