Removable Gearbox Integration for Cantilevered Rotor Wheel Turbomachines
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Solution Overview
Problem
Existing turbomachines with cantilevered rotor wheels and integrated speed reducers/increasers face issues of bulky assemblies, complex disassembly and assembly processes, and mechanical losses due to separate support structures.
Innovation Solution
The turbomachine integrates a speed reducer/increaser with a gearbox that is removably constrained to a fixed case, with the main shaft of the rotor wheel keying the pinion, allowing precise alignment and simplified assembly/disassembly, minimizing mechanical losses and overall dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate speed reducer with complete support structure is used, then the turbine and generator can be coupled with speed adjustment, but the assembly becomes bulky and complex
Solution Approach 1:
The patent merges the speed reducer with the turbine rotor wheel hub into an integrated assembly. The gear mechanism is incorporated directly into the hub structure, eliminating the need for a separate supported speed reducer unit. This integration reduces the number of components and simplifies the overall assembly while maintaining speed adjustment capability between the turbine and generator.
Solution Approach 2:
The hub structure serves multiple functions: it provides structural support for the rotor blades, acts as the mounting interface for the gear mechanism, and functions as the coupling interface with the generator shaft. This multi-functionality eliminates the need for separate support structures that would be required in a conventional separate speed reducer configuration.
2Reliability
If a separate speed reducer with complete case support is used, then the mechanical stresses are properly supported, but the overall dimensions and footprint increase
Solution Approach 1:
The speed reducer case is merged with the turbine housing/casing structure. The gear mechanism is housed within the existing turbine casing volume rather than requiring a separate enclosed case. This integration maintains proper stress support and mechanical protection while utilizing the existing structural envelope, thereby reducing the overall footprint.
Solution Approach 2:
The gear mechanism and speed reducer components are nested within the turbine housing structure. The compact gear assembly is positioned within the existing casing volume, efficiently utilizing the available space without requiring additional external support structures or increasing the overall assembly dimensions.
3Volume of moving object
If the speed reducer is integrated into the turbine, then the footprint is reduced, but the disassembly and assembly processes become complex
Solution Approach 1:
The integrated hub-gear assembly is designed as a modular unit that can be segmented from the rotor wheel for maintenance purposes. This allows the gear mechanism to be accessed and serviced without requiring complete disassembly of the entire turbine, balancing integration benefits with maintenance accessibility.
4Power
If connection joints with toothing are used between speed reducer and turbine, then torque transmission is achieved, but lateral actions and misalignment sensitivity increase
Solution Approach 1:
The connection interface between the turbine shaft and generator shaft is merged into a direct coupling arrangement. The hub-gear assembly integrates the torque transmission function directly into the rotor structure, eliminating separate connection joints with toothing. This reduces lateral actions and misalignment sensitivity while maintaining effective torque transmission from the turbine to the generator.
Data Source
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AI summary
A turbomachine with a cantilevered rotor wheel for industrial power plants comprises a fixed case (3), a main shaft (10) mounted in the fixed case (3) and carrying a bladed rotor wheel (2), a main pinion (20) on the main shaft (10). A gearbox (21) is connected to the fixed case (3) and carries a transmission shaft (27) configured to be connected to an operating or driving machine. A gear assembly is mounted in the gearbox (21), coupled to the transmission shaft (27) and to the main pinion (20), to act as a speed increaser or speed reducer. A portion of the gearbox (21) is removably connected to the fixed case (3) and supports the gear assembly and the transmission shaft (27), so that the gearbox (21) can be separated from the fixed case (3) and the gear assembly with the transmission shaft (27) from the main shaft (10).