Wind Turbine Bearing Support Wedge for Easier Assembly
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Solution Overview
Problem
Existing bearing support arrangements for wind turbines face challenges in reliable operation and maintenance due to tight manufacturing tolerances and complex assembly processes, which complicate the mounting and demounting of components.
Innovation Solution
A bearing support arrangement that utilizes a removable wedge to clamp the bearing between the rotor shaft and the bearing housing, allowing for radial force application and easy mechanical tensioning, enabling the use of larger manufacturing tolerances and simplifying maintenance by allowing the entire assembly to be removed as a unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bearing support arrangements are used with tight manufacturing tolerances, then reliable operation is achieved, but assembly and disassembly processes become complex and time-consuming
Solution Approach 1:
The bearing support arrangement is divided into separable components: a bearing housing containing the bearing, a support structure, and a removable wedge. This segmentation allows the bearing housing to be pre-assembled with the bearing in a controlled environment, then easily installed and removed from the support structure using the wedge, simplifying both assembly and maintenance while maintaining reliability
Solution Approach 2:
A removable wedge is introduced as an intermediary element between the bearing housing and support structure. The wedge enables simple mechanical tensioning and clamping of the bearing without requiring complex assembly procedures or tight tolerances. The wedge can be easily inserted and removed, facilitating quick installation and disassembly while ensuring reliable bearing operation
2Reliability
If traditional bearing support arrangements with tight tolerances are used, then reliable operation is achieved, but manufacturing costs increase due to narrow tolerances and preheating requirements
Solution Approach 1:
By segmenting the bearing support arrangement into separable components, the bearing can be manufactured and pre-assembled in the bearing housing with more relaxed tolerances. The final assembly with the support structure is simplified through the wedge mechanism, reducing manufacturing costs while maintaining reliable operation
Solution Approach 2:
The invention replaces complex mechanical tensioning systems and preheating processes with a simple removable wedge mechanism. This mechanical substitution eliminates the need for expensive preheating equipment and tight tolerance machining, reducing manufacturing costs while achieving the same reliable bearing installation
3Reliability
If the bearing is tightly clamped to the support structure, then reliable operation is achieved, but maintenance and disassembly become difficult
Solution Approach 1:
The clamping mechanism is made dynamic through the removable wedge, which can be inserted to provide tight clamping for reliable operation, then removed to enable easy disassembly for maintenance. This dynamic approach allows the same mechanism to serve both reliability and ease of repair requirements at different operational stages
Solution Approach 2:
The removable wedge acts as an intermediary that enables both tight clamping and easy removal. When inserted, the wedge provides the necessary clamping force for reliable bearing operation. When removed, it immediately releases the clamping, allowing easy disassembly for maintenance without compromising the bearing's operational reliability
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 solution ensures reliable clamping and centering of the bearing, simplifies maintenance by allowing easy disassembly, and reduces the need for precise tolerances and preheating of components, while enabling the wind turbine to operate efficiently with improved assembly and disassembly processes.
Implementation Method 1
The wedge is designed to apply a radial force on the bearing housing and on the support structure to clamp the bearing
Implementation Method 2
The wedge presses the support structure and the bearing housing apart from each other. Thereby a radial force is exerted on the bearing against the rotor shaft
Data Source
Figure 1
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Figure 4
AI summary
A bearing support arrangement (200) for a wind turbine (100) comprises: - a support structure (201); - a bearing housing (203), the bearing housing (203) being arranged inside the support structure (201); - a bearing (204, 240), the bearing (204, 240) being radially supported by the bearing housing (203); - a rotor shaft (205), the rotor shaft (205) being radially supported by the bearing (204); - a removable wedge (210, 220), the wedge (210, 220) being arranged between the support structure (201) and the bearing housing (203) to clamp the bearing (204, 240) between the rotor shaft (205) and the bearing housing (203).