Gear motor suitcase, an innovative tool that reduces inactivity periods, improves safetyness and optimizes the efficiency in the wind turbine maintenance.
Wind turbine maintenance, specifically in relation to Operations & Maintenance (O&M), is a complex process that requires high levels of accuracy and efficiency. The relubrication of the yaw system gear motors is one of the most critical tasks, as these components allow for the correct alignment of the turbines. However, the traditional process is lengthy and complicated, requiring heavy machinery and extended downtime, which impacts energy production and increases risks for operators.
Additionally, due to the challenges mentioned, it is common for gear motor oil not to be changed for several years (sometimes even over a decade) which threatens the turbine’s lifespan. To maximize productivity and minimize energy and financial losses, it is essential to optimize this process by reducing downtime and improving worker safety.
To address these challenges, an innovative and portable solution has been developed for the relubrication of gear motors in wind turbines. This system enables the entire process to be performed without removing the gear motor, eliminating the need for heavy machinery and making the operation faster and safer.
The project consists of a “suitcase” that allows relubrication to be conducted directly from the turbine’s nacelle, reducing the operation time to just 30 minutes. This solution represents a significant advancement in optimizing maintenance processes and ensures greater operational efficiency.
Technical Specifications
The relubrication process is fully automated, allowing operators to save time and complete this O&M task more efficiently and without additional risks. To initiate the process, the operator must enter the amount of oil to be injected into the gear motor via a touchscreen console on the front of the suitcase.
The system begins by extracting all old oil from the gear motor, followed by a flushing process to clean internal parts, and finally, injecting the new oil.
This entire procedure is automated thanks to sensors and actuators within the suitcase. A manual mode is also available, allowing the operator to manually inject or extract oil from the gear motor.
This system offers several key advantages, making it highly efficient and applicable in various situations:
- Broad compatibility: It is applicable to both onshore and offshore wind turbines and is designed to work with Brevini and Bonfiglioli gear motors, widely used in the wind industry.
- Preservation of critical machine configuration: By avoiding the extraction of the gear motor, the system ensures that critical machine configurations remain unaltered, reducing the risk of damage or misalignment in essential turbine components.
- Portability: The suitcase is easy to transport within a wind farm, allowing operators to move from one turbine to another without difficulty, optimizing time and resources.
- Reduced risk for operators: Since it is unnecessary to dismantle the gear motor, high-risk tasks are eliminated, significantly reducing the risk of accidents and improving overall maintenance safety.
- Simplified and safe process from the nacelle: Performing the procedure entirely from the Nacelle eliminates the need to transport heavy machinery, making the operation safer and more efficient.
The new portable relubrication system transforms wind turbine maintenance processes, dramatically reducing operational time to just 30 minutes and improving operator safety. By allowing the procedure to be performed from the nacelle without removing the gear motor, resources are optimized, and risks are minimized, making the operation as streamlined and efficient as possible.
Furthermore, its portability and versatility allow it to be used in both onshore and offshore wind farms, providing significant potential for applications in other industries. This solution not only enhances efficiency and safety but also helps maximize wind turbine lifespan, ensuring more effective and cost-efficient long-term maintenance.
