Self-aligning welding rotator

Overview
The turning gear tool is a specialized auxiliary system for wind turbine installation and operation & maintenance, designed for doubly-fed and semi-direct drive generators. Driven by a motor through a reduction mechanism, it rotates the turbine hub to position blades at precise angles required for assembly, inspection and maintenance. The system integrates mechanical locking, blade-following functionality, comprehensive safety protections and high corrosion resistance.

Key functional features

• Multi-motor synchronized operation with intelligent logic control for uniform torque distribution across drive units.
• PLC-based closed-loop servo control enabling high-precision positioning of turning angle.
• Dual mechanical locks with monitoring devices to prevent misoperation and maximize reliability.
• "Blade following" function: allows safe stopping and resumption of operations without disassembly under special conditions.
• Drive redundancy: remaining units can complete turning operations in case of a single drive failure.
• Multiple selectable operation modes with safety interlocks for secure handling.
• Integrated protections against lightning, short circuit, overcurrent and overvoltage.

Major components and roles

• Servo Motor: Closed-loop control for precise speed and torque adjustment, ensuring smooth, controllable rotation.
• Gear Reducer: Planetary gear structure with high load capacity converting high-speed motor input into low-speed, high-torque output required for turning.
• Housing: Optimized mechanical structure providing robust support and protection for the internal transmission.
• Adapter Disc Assembly: Universal interface with high end-face runout and coaxiality precision to avoid additional loads and vibrations from installation deviations.
• Reaction Arm: Transfers reaction forces to the mainframe while compensating installation angle deviations to prevent extra stress and equipment damage.
• Electrical Control Cabinet: Modular layout for maintenance and functional expansion, with layered protection to ensure safe, reliable turning operations.

Technical specifications

• Applicable wind turbine generator: Doubly-fed (also suitable for semi-direct drive models)
• Rated driving torque: 75 kNm - 150 kNm
• Driving type: Motor
• Quantity of drive units: 4
• Motor power: 7.9 kW
• Tool weight: 2780 kg
• Tool dimensions (L × W × H): 1370 mm × 890 mm × 1865 mm
• Operating temperature: -25 °C - +50 °C
• IP rating: IP55
• Corrosion resistance: C5-M
• Operating altitude: ≤ 3000 m