Bearing Bore Repair Insert for Precise Radius Restoration
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Solution Overview
Problem
Wind turbine bearing bores experience wear due to friction, leading to misalignment and potential failure of gearbox components, with existing repair methods being either expensive 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 gap between the bearing housing and the insert's edge, which solidifies to restore the bore's radius, and the insert is removed once solidified, allowing for precise repair without manual skill requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual application of metal glue or epoxy glue is used to restore the bore radius, then the bearing bore can be repaired, but it is difficult to achieve the correct dimension of the bore due to manual operation limitations
Solution Approach 1:
A bore insert is introduced as an intermediary tool during the repair process. The insert includes a reference surface that defines the correct bore radius, and liquid resin is applied between this reference surface and the bearing housing inner surface. This intermediary device enables precise dimensional control without requiring manual skill, as the insert itself provides the dimensional reference.
Solution Approach 2:
The manual mechanical application method is replaced by a system using liquid resin and a bore insert with reference surfaces. Instead of relying on manual skill to apply and shape the glue, the liquid resin is applied and then constrained by the bore insert's reference surface, which automatically ensures the correct dimension is achieved.
2Manufacturing precision
If a metal plate is formed and attached to fill the gap created by wear, then the bore radius can be restored, but it is expensive and laborious to form a metal plate of the correct dimensions
Solution Approach 1:
The invention replaces expensive, laboriously formed metal plates with a simpler, more economical approach using liquid resin and a bore insert. The resin serves as a temporary filling material that is applied, allowed to set, and then the insert is removed, leaving the repaired bore. This disposable-like approach (where the insert is removed after serving its purpose) is much more cost-effective and easier to manufacture than custom metal plates.
Solution Approach 2:
The invention changes the material parameter from metal plate to liquid resin, which offers advantages in ease of application and cost. The liquid resin can be easily applied and conforms to the required shape defined by the bore insert, whereas metal plates require complex forming operations. The parameter change also affects the manufacturing complexity, making the process simpler and more economical.
3Manufacturing precision
If the bearing housing inner surface is manually treated to restore the bore, then repair can be performed, but it is difficult to achieve the correct dimension without skilled manual operation
Solution Approach 1:
The bore insert acts as an intermediary reference device that ensures consistent and reliable dimensional accuracy. The reference surface of the insert provides a fixed, precise geometric reference that guarantees the correct bore radius is achieved every time, eliminating variability associated with manual skill levels and ensuring repair consistency.
Solution Approach 2:
The bore insert is prepared in advance with the correct reference dimensions before the repair process. This preliminary preparation of the insert with precise reference surfaces ensures that when it is used during repair, the correct dimension is automatically imposed on the resin, guaranteeing consistency and reliability without requiring skilled manual operation during the actual repair.
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 repairs wind turbine bearing bores to the required radius, preventing misalignment and extending the lifespan of gearbox components while being cost-effective and straightforward to implement.
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
applying a liquid resin to at least part of the inner surface of the bearing housing
Implementation Method 3
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, so that the liquid resin fills the gap
Data Source
Figure 1
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Figure 3(a)
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.