Wind Turbine Bearing Gear Teeth Coating via Additive Manufacturing

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Solution Overview

Problem

The conventional manufacturing process of yaw and pitch bearings for wind turbines via forging is time-consuming and expensive, necessitating an improved method for their production.

Innovation Solution

A method involving additive manufacturing to form the base material for the bearing races and gear teeth, followed by applying a different coating material via processes like cold spraying or laser cladding to enhance hardness, strength, and durability, particularly focusing on the gear teeth interfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional forging process is used to manufacture pitch and yaw bearings, then the bearings achieve required strength and durability, but the manufacturing time and cost increase significantly

Engineering Contradiction:

Improvebearing strengthVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The bearing is divided into two functional parts: the base structure (raceways and general body) made via additive manufacturing for efficiency, and the critical gear teeth surfaces enhanced with hard coating for durability. This segmentation allows each part to be optimized by the most suitable manufacturing method.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite construction by combining the base material (from additive manufacturing) with a hard coating material (such as ceramic or metal matrix composite) applied to the gear teeth. This creates a composite structure that leverages the advantages of both materials: the toughness of the base material and the hardness of the coating.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional forging process is used to manufacture pitch and yaw bearings, then the bearings achieve required durability, but the manufacturing cost increases

Engineering Contradiction:

Improvebearing durabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of treating the entire bearing with expensive hard materials through conventional forging, the invention applies hard coating only to the specific regions where it is most needed - the gear teeth contact surfaces. This local quality approach reduces material costs while maintaining durability where it matters most.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the material parameter (hardness) only in the regions requiring it, by applying a hard coating layer with different material properties than the base material. This selective parameter change reduces overall material costs while achieving the required durability at critical interfaces.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If additive manufacturing is used to form base material, then production time and cost are reduced, but the hardness and strength at critical interfaces decrease

Engineering Contradiction:

Improveproduction efficiencyVSAvoidinterface hardness

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The base structure is first formed using additive manufacturing to achieve production efficiency, then the hard coating is applied subsequently to the gear teeth surfaces. This preliminary action of creating the base structure followed by surface enhancement ensures both productivity and interface hardness requirements are met.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hard coating acts as an intermediary layer between the additive-manufactured base material and the external environment/loads. This intermediate layer provides the necessary hardness and wear resistance at the gear teeth interfaces, compensating for the softer base material while allowing the base to be produced efficiently via additive manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach reduces production time and costs while providing enhanced material properties specifically at critical interfaces, improving the performance and efficiency of wind turbine bearings.

Implementation Method 1

applying a coating material to at least a portion of the plurality of gear teeth via an additive manufacturing process

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

The coating material provides at least one of increased hardness, strength, or durability to the base material

Methodology Applied

Scientific EffectMaterial deposition: Deposition (physical)

Data Source

PatentUS11333200B2Method for manufacturing a pitch bearing or a yaw bearing of a wind turbine via additive manufacturing

Publication Date: 2022.05.17 GE INFRASTRUCTURE TECH LLC

AI summary

A method for manufacturing a pitch bearing or a yaw bearing for a wind turbine includes forming an outer race of the bearing of a base material. The method also includes forming an inner race of the bearing of the base material. Further, one of the inner race or the outer race defines a circumferential surface comprising a plurality of gear teeth. The method further includes arranging the inner race within the outer race. In addition, the method includes providing a plurality of roller elements between the outer and inner races. Moreover, the method includes applying a coating material to at least a portion of the plurality of gear teeth via an additive manufacturing process. The coating material is different than the base material. As such, the coating material provides at least one of increased hardness, strength, or durability to the base material.