Wind Turbine Brake Disc Locking With Micro-Interference Fit
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Solution Overview
Problem
Existing brake systems for large wind turbines are massive, costly, and prone to damage due to incorrect hydraulic actuation, which can lead to severe damage to rolling-element bearing assemblies.
Innovation Solution
A brake-disc-based locking system with a thinner, lighter design that uses an electrical actuator and a sensor system for precise control, eliminating the need for a hydraulic system and ensuring secure locking even in power failures through self-locking mechanisms or secure hydraulic designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a massive, thick disc with axial penetrations and hydraulic locking bolt is used, then reliable rotational locking is achieved, but the system becomes heavy, voluminous, and costly
Solution Approach 1:
The patent replaces the hydraulic locking bolt mechanism with a friction-based brake system. The brake pad applies friction force to the brake disc to create axial clamping force, which generates sufficient friction between the brake disc and the flange to prevent rotation. This substitution eliminates the need for massive mechanical locking components while achieving reliable rotational restraint.
Solution Approach 2:
The brake system operates by applying periodic friction forces through the brake pad. The actuator applies the brake pad to the brake disc only when rotational locking is required, and releases it when not needed. This periodic application of friction force allows the system to maintain reliability while using lighter components compared to continuous mechanical locking.
2Force
If a hydraulic system is used for actuation, then locking force can be controlled, but the risk of damage from incorrect actuation increases
Solution Approach 1:
The patent incorporates a sensor system that detects the rotational position of the rotor blades and provides feedback to the control unit. The control unit processes this information and actuates the brake only when the rotor blades are in the correct position (e.g., horizontal position for maintenance). This feedback mechanism prevents incorrect actuation that could cause damage to the rolling-element bearing assemblies.
Solution Approach 2:
The brake system is designed with self-limiting characteristics where the friction-based locking mechanism naturally prevents over-actuation damage. The brake pad applies friction force rather than rigid mechanical contact, which inherently provides a more forgiving interaction that reduces the risk of severe damage from positioning errors.
3Device complexity
If manual control of bolt retraction position is used, then system simplicity is maintained, but alignment precision and safety are compromised
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated sensor-based control system. Sensors detect the rotational position of the rotor blades, and the control unit automatically actuates the brake at the precise moment when the rotor blades are in the correct position. This substitution of manual control with automated sensing and control achieves high alignment precision without significantly increasing overall system complexity.
4Weight of stationary object
If the disc is made thinner and lighter, then weight and cost are reduced, but the ability to withstand locking forces is compromised
Solution Approach 1:
The patent replaces direct mechanical force transmission through a thick disc with a friction-based force transmission system. The brake pad applies friction force to the brake disc, which then transmits the clamping force to the flange through friction. This allows the brake disc to be much thinner and lighter while still withstanding the necessary forces, because the force transmission is distributed through friction contact rather than concentrated mechanical loads.
Solution Approach 2:
The patent changes the fundamental parameter of force transmission from direct mechanical contact to friction-based contact. By utilizing friction as the primary force transmission mechanism, the system can achieve the same locking capability with a much lighter and thinner brake disc, as the friction force is distributed across the contact surface rather than concentrated at specific penetration points.
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 provides a cost-effective, lightweight brake system that prevents damage from incorrect actuation, maintains secure locking, and allows for remote monitoring and control, ensuring safety and reliability during maintenance and operation.
Implementation Method 1
the brake pad (23) is configured for pressing against the brake disc (29) in order to bring about friction-based locking of the main shaft (10)
Implementation Method 2
the brake base unit (20) is electrically actuated
Data Source
AI summary
A system includes a wind turbine having a fixed part and a rotational part and a brake having a brake disk mounted to the rotational part for rotation with the rotational part. At least one brake block is fixed relative to the fixed part and has a friction surface facing the brake disk. The brake block is shiftable between a first position with the friction surface spaced from the brake disk and a second position with the friction surface in contact with and pressed against the brake disk, and the friction surface and/or the brake disk are configured such that pressing the at least one brake block against the brake disk creates a micro-interference fit between the at least one brake block and the brake disk.