Bearing Bore Insert Repair for Worn Wind Turbine Housings
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Solution Overview
Problem
Wind turbine bearing housings experience wear due to friction, leading to misalignment and potential failure of gear components, with existing repair methods being costly, laborious, or difficult to execute accurately.
Innovation Solution
A method involving a bore insert with an arcuate portion and flange portion is used, where a liquid resin is applied to fill the wear gap, and the insert is removed after solidification to restore the bearing bore to its required radius, with overflow holes and ridges aiding in resin management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal plate is formed and attached to fill the wear gap, then the bearing bore radius is restored, but the repair process becomes expensive and laborious
Solution Approach 1:
The patent changes the material state from solid metal plate to liquid resin that can be easily applied and then solidifies. This parameter change allows the resin to flow into the wear gap and be applied without complex manual labor, while still restoring the bore radius precisely after solidification.
Solution Approach 2:
The patent uses a disposable resin material that is cheaper and easier to apply than metal plates. The resin is applied, allowed to solidify, and then the bore insert is removed, leaving the repaired bore. This disposable approach eliminates the need for complex metal plate formation and attachment processes.
2Manufacturing precision
If metal glue is manually applied to restore the bore radius, then the wear gap is filled, but achieving the correct dimension becomes difficult
Solution Approach 1:
The patent introduces a bore insert as an intermediary tool that defines the correct bore radius. The liquid resin is applied between the insert and the housing inner surface, ensuring the resin fills the gap to the precise required dimension. The insert acts as a template that guides the resin application to achieve accurate bore restoration without requiring manual measurement or skill.
Solution Approach 2:
The liquid resin self-levels and fills the gap automatically when applied, eliminating the need for precise manual application. The resin flows to fill the wear gap and solidifies to the correct dimension defined by the bore insert, making the process easier to perform while maintaining precision.
3Ease of operation
If liquid resin is applied to fill the wear gap, then the application process becomes simpler, but controlling the resin amount and distribution becomes challenging
Solution Approach 1:
The bore insert serves as a mediator that controls the resin distribution. By positioning the insert against the housing with its arcuate surface defining the correct bore radius, the insert automatically controls the amount and distribution of resin needed to fill the wear gap uniformly, ensuring precise radial restoration.
Solution Approach 2:
The bore insert is pre-positioned in the bore before resin application, establishing the correct geometry and radius in advance. This preliminary action ensures that when resin is applied, it fills the gap to the precise required dimension without requiring complex control during the application process.
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
This method effectively and efficiently repairs bearing bores without the need for skilled manual application, reducing costs and ensuring precise alignment, thus preventing component damage and extending the lifespan of wind turbine gearboxes.
Implementation Method 1
The liquid resin fills a gap between the inner surface of the bearing housing and the edge of the arcuate portion of the bore insert
Implementation Method 2
after the liquid resin has solidified
Data Source
AI summary
The present invention provides a method of repairing a bearing bore defined by an inner surface of a bearing housing, for instance a bearing housing that is part of a wind turbine. The method includes applying a liquid resin to at least part of the inner surface of the bearing housing. The method includes mounting a bore insert in the bearing bore, where the bore insert includes an arcuate portion having an edge positioned along a line of required radius of the bearing bore, so that the liquid resin fills a gap between the inner surface of the bearing housing and the edge of the arcuate portion of the bore insert. The method includes removing the bore insert from the bearing bore after the liquid resin has solidified to repair the bearing bore to the required radius. Advantageously, the invention provides a relatively simple and inexpensive method for repairing a bearing bore that has suffered wear, that may be performed on-site and which obviates the need for potentially expensive component replacement of the bearing housing.