Axial Rear Brake Disc for Direct Drive Wind Turbine Generator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Direct drive wind turbines face challenges in designing an effective brake system that can withstand high braking moments due to slow rotational speeds, as existing solutions either restrict the size of the brake components or prevent access for maintenance.
Innovation Solution
A brake system with a rotor assembly having an outer rotor configuration, featuring a large brake disc and callipers that can be fully utilized for maximum diameter, integrated with a frictional member for engaging the brake disc, and an automatic rotor lock system for secure parking, allowing for easy maintenance access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the brake system is integrated into the generator with the brake positioned radially inward from the stator, then the size of the construction is minimized, but the size of the brake system is restricted which reduces braking capability
Solution Approach 1:
The brake system is repositioned from a radial arrangement to an axial arrangement behind the rotor assembly, utilizing the axial dimension rather than radial space. This allows the brake disc to be positioned on the rear face of the rotor, freeing up radial space while maintaining compact overall dimensions.
Solution Approach 2:
Instead of positioning the brake radially inward from the stator as in conventional designs, the invention inverts the arrangement by positioning the brake axially behind the rotor. This inversion allows the brake components to utilize space that would otherwise be unused, resolving the conflict between compact size and braking capability.
2Volume of stationary object
If the brake system is positioned radially inward from the stator, then the construction size is minimized, but access for maintenance is prevented
Solution Approach 1:
The brake system is extracted from the radial position between stator and rotor and repositioned to the axial rear face of the rotor. This separation allows maintenance personnel to access the brake components from the rear of the generator without disassembling the stator or rotor assemblies.
Solution Approach 2:
The brake system transitions from a radial positioning that requires disassembly of radial components for access, to an axial positioning on the rear face that allows direct access from the rear, fundamentally changing the maintenance approach from complex disassembly to simple rear-access maintenance.
3Strength
If a large brake disc and callipers are used to withstand high braking moments, then braking capability is improved, but the device complexity and size increase
Solution Approach 1:
The brake disc is positioned on the axial rear face of the rotor rather than radially between stator and rotor. This axial positioning allows the use of larger diameter brake discs without increasing the radial envelope of the generator, as the brake system utilizes the axial dimension rather than consuming radial space.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances brake efficiency by providing a larger contact surface, improved heat management, and easier maintenance access while maintaining the air gap integrity between rotor and stator elements, ensuring safety and efficiency in direct drive generators and wind turbines.
Implementation Method 1
The stator assembly comprises at least one frictional member. The frictional member is operatively configured for frictionally engaging at least a portion of the brake disc.
Data Source
AI summary
A brake system, especially for a generator, including a rotor assembly, a stator assembly and a rotation axis is disclosed. The rotor assembly includes an outer portion which is located radially outward of the stator assembly. The outer portion includes a brake disc, and the stator assembly comprises at least one frictional member operatively configured for frictionally engaging at least a portion of the brake disc.