Wind Turbine Gearbox Carrier Structure Without Axial Webs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wind turbine gearboxes have expensive carrier components that require significant material and manufacturing costs due to their size and function, necessitating a more efficient design.
Innovation Solution
A gear system with a carrier having separate portions and integrally formed pin shafts that provide structural stability without axially-extending webs, optimized using computer-implemented loads models to minimize mass, and incorporating additive manufacturing for bearings and features like oil passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional carrier design with axially-extending webs is used, then structural stability is achieved, but material usage and weight increase significantly
Solution Approach 1:
The carrier is divided into multiple segments or sections, allowing the structure to achieve stability through distributed support rather than continuous heavy webs. The pin shafts are positioned at strategic locations to provide localized structural reinforcement where needed, eliminating the need for extensive axially-extending webs throughout the entire carrier length.
Solution Approach 2:
The design transitions from relying primarily on axial webs for structural stability to utilizing radial pin shafts and their mounting structures. By distributing structural support across multiple dimensions (radial pin shafts, circumferential bearings, and strategic web placements), the carrier achieves stability without requiring heavy axially-extending webs.
2Strength
If conventional carrier design with extensive material is used, then manufacturing strength is achieved, but manufacturing cost increases
Solution Approach 1:
The carrier structure is segmented into functional zones with material placed only where structurally necessary. Pin shafts and their mounting features are integrated at critical load paths, allowing the carrier to achieve required strength with reduced overall material consumption, thereby lowering manufacturing costs.
Solution Approach 2:
The carrier employs local quality enhancement by concentrating material and structural features (pin shafts, bearings, localized webs) only in regions where high strength is required. Other regions use minimal material, optimizing the strength-to-cost ratio by avoiding unnecessary material throughout the entire carrier structure.
3Stability of the object's composition
If pin shafts are integrally formed with carrier, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The pin shafts are integrally formed with the carrier as a single piece, eliminating the need for separate assembly operations. This merging of components simplifies the overall manufacturing process by reducing the number of parts to be manufactured, handled, and assembled, while simultaneously improving structural stability through integral construction.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A gear system includes a carrier having a first portion and a separate, second portion and a plurality of pin shafts extending from the first portion of the carrier. Each of the plurality of pin shafts includes a first end and a second end. As such, the first ends are integrally formed with the first portion of the carrier. The first and second portions are arranged on opposing sides of the plurality of pin shafts and are spaced apart such that the first and second portions do not contact each other. Further, the second portion of the carrier defines an end plate that is secured to the second ends of the plurality of pin shafts. The gear system also includes a plurality of gears mounted to the plurality of pin shafts, with each of the plurality of gears arranged so as to rotate around one of the plurality of pin shafts.