Wind Turbine Blade Bearing Hub Integration
Solution Overview
Problem
Existing wind turbine blade bearings suffer from wear and play issues, leading to reduced efficiency and increased maintenance, particularly due to the large height of adapter systems which shorten the aerodynamically usable inflow area and cause twisting of pinion axes, resulting in gear play and control instabilities.
Innovation Solution
A blade bearing assembly with a closed system design featuring a toothed connecting element and non-toothed connecting element, where the gear wheels are directly mounted on the non-toothed element, reducing the overall height and minimizing wear, with a speed reduction mechanism that optimizes motor efficiency and allows for independent rotor blade angle adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a traditional adapter system with motor and gear components is used, then the rotor blade angle of attack can be adjusted, but the overall height increases which shortens the aerodynamically usable inflow area
Solution Approach 1:
The patent merges the motor, gear mechanism, and adapter into a single integrated hub unit. The motor is mounted directly on the hub, and the gear mechanism is positioned within the hub structure, eliminating the need for a separate adapter assembly. This integration dramatically reduces the overall height of the angle of attack adjustment system while preserving all necessary functional components.
Solution Approach 2:
The patent redistributes components from a vertical stack arrangement to a radial and horizontal layout within the hub. Instead of stacking motor, gear, and adapter vertically, the design places the motor on the hub with the gear mechanism extending radially or horizontally, utilizing the hub's internal volume more efficiently and reducing the vertical dimension.
2Ease of operation
If the motor is mounted on the adapter rather than the hub, then the adapter can rotate independently, but the pinion axis twists during rotation causing gear play and control instabilities
Solution Approach 1:
The patent extracts the motor from the adapter and mounts it directly on the hub. This separation eliminates the twisting problem because the motor remains stationary on the hub while the adapter and rotor blade rotate independently. The pinion is repositioned to engage with the adapter's toothing without experiencing axial twisting forces.
Solution Approach 2:
The patent introduces a stationary toothing ring mounted on the hub as an intermediary between the motor's pinion and the rotating adapter. This toothing ring remains fixed in position while the adapter rotates, allowing continuous gear engagement without axis twisting. The pinion rotates within the stationary toothing ring, maintaining stable meshing throughout the rotation cycle.
3Use of energy by moving object
If multiple gear stages are used for speed reduction, then motor efficiency is improved, but the device complexity and number of components increase
Solution Approach 1:
The single gear mechanism in the patent serves multiple functions simultaneously: it provides speed reduction, transmits torque from the motor to the rotor blade, and enables the angle of attack adjustment. By designing the gear system to fulfill all these roles, the patent eliminates the need for multiple separate gear stages while maintaining motor efficiency and operational effectiveness.
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 minimizes wear and play, maximizes the rotor blade's inflow area, and enhances the efficiency of wind energy conversion by using a compact design that reduces the distance between the blade end and hub, allowing for precise alignment and easier maintenance, while using fewer and smaller gear components for improved motor performance.
Implementation Method 1
at least one Rolling bearing is arranged as a main bearing for supporting the two connecting elements together, rotatably about a main bearing axis of rotation
Data Source
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AI summary
The invention relates, firstly, to a blade bearing for the rotatable mounting of a rotor blade on the hub of a wind turbine, comprising a device for adjusting the rotor blade pitch angle, and comprising two rotationally symmetrical connection elements, each with a flat connection surface for rotationally fixed connection to the hub of the wind turbine on the one hand and to the rotor blade on the other, wherein the two rotationally symmetrical connection elements are aligned such that their axes of symmetry are coaxial with each other and their connection surfaces face away from each other, wherein, furthermore, a gap is located between the two connection elements, in which at least one rolling bearing is arranged as a main bearing for mounting the two connection elements to each other, rotatably about a main bearing axis of rotation which corresponds to the common axis of symmetry of both connection elements.wherein at least one cylindrical surface of a connecting element is provided with a circumferential toothing, and wherein the untoothed connecting element has a cylindrical section facing the toothing of the toothed connecting element with one or more cavities open towards the toothing for receiving toothed gear wheels, wherein in the untoothed connecting element an end-face opening for the rotary connection of the respective gear wheel is provided for each gear wheel, and at least a closed annular area approximately aligned with this for supporting a bearing arranged axially between the connecting surfaces of the two connecting elements for the gear wheel in question as its wheel bearing, so that the gear wheel in question is offset eccentrically from the main bearing axis of rotation,but also rotates on a parallel secondary axis of rotation and meshes with the toothing of the toothed connecting element; and secondly, on a wind turbine equipped with such a blade bearing.