Module-Handling Tool for Installing/Removing Modules Into/From an Electromagnetic Rotary Machine Having a Modularized Active Portion

Abstract

A module-handling tool for facilitating installation, servicing, and/or dismantling of an electromagnetic rotary machine, such as an electrical power generator or electric motor, having a modularized active portion. In one embodiment, module-handling tool is configured for a machine having a modularized stator having a number of removable modules. In one example of such stator-module-handling tool, the tool is designed and configured to hold a stator module and be temporarily secured to the rotor of the machine during the process of installing the stator module into the machine or removing the module from the machine. In this example, the module-handling tool also acts as a module carrier for transporting a module to or from the machine.

What is claimed is: 
     
         1 . A method of installing an active-portion module having a plurality of electrically conductive coils into a module-receiving region of an active portion of an electromagnetic machine, comprising:
 positioning a module-handling tool into a transfer position adjacent the module-receiving region, the module-handling tool supporting the active-portion module;   moving the active-portion module from the module-handling tool into the module-receiving location within the active portion so as to transfer the active-portion module from the module-handling tool to the module-receiving region; and   removing the module-handling tool from the transfer position.   
     
     
         2 . A method according to  claim 1 , further comprising, prior to said positioning, loading the module-handling tool with the active-portion module. 
     
     
         3 . A method according to  claim 2 , wherein said loading the active-portion module includes using a pivoting tool-handler. 
     
     
         4 . A method according to  claim 3 , wherein said using the pivoting tool-handler includes securing the module-handling tool to the pivoting tool-handler. 
     
     
         5 . A method according to  claim 4 , wherein said using the pivoting tool-handler includes pivoting the pivoting tool-handler to a vertical orientation. 
     
     
         6 . A method according to  claim 5 , further comprising using a wind-power-unit based winch to load the active-portion module into the pivoting tool-handler. 
     
     
         7 . A method according to  claim 1 , wherein said moving the active-portion module includes using a module translator of the module-handling tool. 
     
     
         8 . A method according to  claim 7 , wherein said using an active-portion-module translator includes using a ball-screw translator. 
     
     
         9 . A method according to  claim 1 , further comprising, prior to said moving the active-portion module, removing at least one permanent magnet proximate to the module-receiving location. 
     
     
         10 . A method according to  claim 1 , wherein the electromagnetic machine is a generator of a wind power unit having a tower supporting the generator, the method further comprising, after said moving the active-portion module, lowering the module-handling tool away from the generator. 
     
     
         11 . A method according to  claim 10 , wherein said lowering the module-handling tool includes lowering the module-handling tool onto a pivoting tool-handler. 
     
     
         12 . A method according to  claim 11 , wherein the wind power unit has a winch located proximate the generator, said lowering the module-handling tool includes using the winch. 
     
     
         13 . A method according to  claim 1 , wherein the module-handling tool has a module translation axis and a plurality of bearings spaced along the module translation axis and the electromagnetic machine having a plurality of module supports spaced in a direction parallel to the module translation axis, said moving the active-portion-module including ensuring that the active-portion module is supported by at least two supports in a direction along the module translation axis, wherein the at least two supports consists of any two or more of the plurality of bearings and the plurality of module supports. 
     
     
         14 . A method according to  claim 13 , wherein said ensuring that the active-portion module is supported by at least two supports includes moving at least one bearing into engagement with the active-portion module. 
     
     
         15 . A method according to  claim 14 , wherein said moving at least one bearing into engagement with the active-portion module includes moving a pair of opposing bearing into engagement with the active-portion module. 
     
     
         16 . A method according to  claim 15 , wherein the active-portion-module includes first and second flanges on opposing sides of the active-portion module and said moving a pair of opposing bearings into engagement with the active-portion module includes moving a pair of roller bearings into engagement with, respectively, the first and second flanges. 
     
     
         17 . A method according to  claim 1 , wherein said positioning includes using a tool positioner to precisely position the tool to the transfer position. 
     
     
         18 . A method according to  claim 17 , wherein said using a tool positioner includes using adjustable struts to precisely position the module-handling tool to the transfer position. 
     
     
         19 . A method according to  claim 1 , wherein said positioning includes using matching alignment features disposed on corresponding respective ones of the module-handling tool and the electromagnetic machine. 
     
     
         20 . A method according to  claim 1 , wherein said moving includes using a releasable hitch to move the active-portion-module into the active-portion-module receiving location. 
     
     
         21 . A method according to  claim 1 , wherein the electromagnetic machine includes a rotor and said positioning includes securing the module-handling tool to the rotor. 
     
     
         22 . A method according to  claim 21 , wherein, subsequent to said securing the module-handling tool to the rotor, said positioning includes rotating the rotor to move the module-handling tool proximate to the module-receiving region. 
     
     
         23 . A method of removing an active-portion module from an active portion of an electromagnetic machine, the active portion comprising a plurality of electrically conductive coils, comprising:
 securing a module-handling tool to the electromagnetic machine, the module-handling tool configured to receive the active-portion module;   moving the active-portion-module from the active portion into the module-handling tool;   un-securing the module-handling tool from the electromagnetic machine; and   moving the active-portion module away from the electromagnetic machine using the module-handling tool.   
     
     
         24 . A method of installing an active-portion module into a generator of an in-situ wind power unit, comprising:
 raising a module-handling tool, and an active-portion module supported thereby, proximate to the generator;   positioning the module-handling tool into a transfer position;   moving the active-portion module into module-receiving location in the generator;   removing the module-handling tool from the transfer position; and   lowering the module-handling tool away from the generator.   
     
     
         25 . A method of removing an active-portion module from a generator of an in-situ wind power unit, comprising:
 raising a module-handling tool proximate to the generator;   positioning the module-handling tool into a transfer position;   moving the active-portion module into the module-handling tool from the generator;   removing the module-handling tool in combination with the active-portion module from the transfer position; and   lowering the module-handling tool in combination with the active-portion module away from the generator.