Adjustable Rotor Shaft Coupling for Axial Load and Shaft Tilt
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Solution Overview
Problem
Existing rotor shaft assemblies in wind turbines and generator gearboxes face challenges in efficiently transmitting high drive powers while compensating for angular misalignment and axial forces, requiring compact and cost-effective solutions that are difficult to produce and assemble.
Innovation Solution
A rotor shaft assembly featuring a curved tooth coupling with supporting elements that allow for axial positioning and angular adjustability, enabling the gearbox unit to be connected to the generator unit in a torque-transmitting manner, while minimizing axial migration and accommodating thermal expansions through adjustable clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a curved tooth coupling is used to connect the gearbox unit to the generator unit, then angular misalignment can be compensated and torque transmission is improved, but the device complexity increases due to the need for additional supporting elements and axial positioning mechanisms
Solution Approach 1:
The coupling structure is divided into modular components: the curved tooth coupling element, supporting elements for axial positioning, and releasably fastenable connections. This segmentation allows each component to perform its specific function independently while simplifying manufacturing and assembly processes.
Solution Approach 2:
Supporting elements are introduced as intermediary components between the curved tooth coupling and the shafts. These supporting elements specifically handle axial positioning and force transmission, allowing the curved tooth coupling to focus on angular misalignment compensation and torque transmission.
2Volume of moving object
If the curved tooth coupling is made compact along the axial direction, then the overall size of the generator gearbox is reduced, but the ability to accommodate axial forces and thermal expansions is limited
Solution Approach 1:
The supporting elements are designed with releasable fastening mechanisms that allow for adjustable positioning. This dynamic capability enables the coupling to adapt to thermal expansions and axial forces during operation, while maintaining a compact overall structure. The supporting elements can be repositioned or adjusted based on operational conditions.
3Reliability
If supporting elements are added to axially position the curved tooth coupling, then axial migration is prevented and load support is improved, but the ease of manufacture and assembly is reduced
Solution Approach 1:
The supporting elements are designed as separate, modular components that can be manufactured independently using standard machining processes. This segmentation simplifies manufacturing compared to creating an integrated complex structure, and the modular nature facilitates step-by-step assembly.
Solution Approach 2:
The supporting elements are pre-positioned or pre-assembled in specific locations on the shafts before the curved tooth coupling is installed. This preliminary positioning ensures correct axial alignment and simplifies the final assembly process, as the supporting elements are already in place to guide and constrain the coupling.
4Adaptability or versatility
If the curved tooth coupling is designed to allow angular adjustment, then compensation for angular offset is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The curved tooth profile is specifically designed to accommodate angular variations dynamically. The curvature of the teeth allows for automatic adjustment and distribution of loads across multiple tooth contacts, reducing the sensitivity to precise angular positioning and manufacturing tolerances.
Solution Approach 2:
The curved tooth coupling employs curved tooth profiles instead of straight teeth. This curvature allows the coupling to accommodate angular misalignments by distributing contact across the curved surfaces, thereby reducing the precision requirements for manufacturing while maintaining reliable torque transmission.
Data Source
AI summary
A rotor shaft assembly for a torque-transmitting connection of a gearbox unit to a generator unit includes an output shaft for the gearbox unit, a rotor shaft for the generator unit, and a curved tooth coupling designed to connect the output shaft and the rotor shaft to one another The curved tooth coupling includes a releasably fastened supporting element designed to axially position the curved tooth coupling and including a mating face to support an axial force of the curved tooth coupling, with the mating face being designed to slide on a corresponding support face of the output shaft or of the rotor shaft when the output shaft is tilted relative to the rotor shaft.