Central Torque Coupling for Wind Turbine Gearbox Testing
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Solution Overview
Problem
Existing test setups for wind turbine gearboxes face increasing challenges due to higher torque densities, requiring stronger foundations to handle tensile and compressive forces, which is costly and inefficient, as the forces are directly introduced into the foundation, limiting the capacity and longevity of test benches.
Innovation Solution
A test structure incorporating a central torque coupling device that connects the transmission's torque support to the housing part, allowing torque forces to be absorbed within the connection between components rather than the foundation, thereby reducing the load on the foundation and enabling the use of existing test stand foundations even with increased torque demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If torque supports are directly connected to the foundation, then the foundation can withstand the tensile and compressive forces, but the foundation requires increasing strength and size which is costly and inefficient
Solution Approach 1:
The patent introduces a central torque coupling device as an intermediary between the torque supports and the foundation. This device includes a housing section connected to the foundation and a shaft section connected to the gearbox shaft, with torque supports frictionally and/or positively connected to the housing section. This intermediary structure allows the test setup to handle high torque densities without requiring the foundation to directly withstand all tensile and compressive forces, thereby reducing foundation strength requirements and associated costs.
2Power
If higher torque densities are used in wind turbine gearboxes, then the power output increases, but the tensile and compressive forces on the foundation increase requiring stronger foundations
Solution Approach 1:
The patent segments the force transmission path by separating the torque transmission function from the force support function. The central torque coupling device segments the connection between the gearbox and foundation into a housing section (for torque support connections) and a shaft section (for rotational motion), allowing torque forces to be absorbed within the connection between components rather than directly on the foundation.
Solution Approach 2:
The central torque coupling device acts as an intermediary that absorbs and redirects forces. The housing section of the torque coupling device absorbs tensile and compressive forces from the torque supports, while the shaft section transmits only the necessary torque to the gearbox shaft, preventing direct transmission of high forces to the foundation.
3Adaptability or versatility
If the test setup is designed for higher torque densities, then it can test more powerful wind turbine gearboxes, but the foundation load limits are exceeded
Solution Approach 1:
The central torque coupling device serves as a force-absorbing intermediary that enables the test setup to handle higher torque densities. By connecting torque supports to the housing section rather than directly to the foundation, the device allows the test bench to test more powerful wind turbine gearboxes without exceeding foundation load limits, as the housing section absorbs the additional tensile and compressive forces.
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 arrangement significantly increases the performance range of test benches while keeping costs low by minimizing the load on the foundation and central torque coupling device, allowing for efficient testing of high-torque gearboxes without exceeding foundation load limits.
Implementation Method 1
the torque support of the gearbox is frictionally and/or positively connected to the housing part of the central torque coupling device
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a test structure (1) comprising a central torque coupling device (2) and a transmission (3). The central torque coupling device (2) has a shaft part (21) which is rotatably arranged relative to a housing part (22) of the central torque coupling device (2), and the housing part (22) is stationary relative to a foundation (5). The shaft part (21) is connected to a shaft (31) of the transmission (3) in a force-fitting and/or form-fitting manner, wherein the transmission (3) has a torque support (32) which is arranged on a housing (33) or a ring gear of the transmission (3). In order to improve the test structure with respect to testing a component or multiple components of a powertrain, the invention proposes that the torque support (32) of the transmission (3) is connected to the housing part (22) of the central torque coupling device (2) in a force-fitting and/or form-fitting manner. The invention additionally relates to a method for producing a test structure (1). The test structure (1) has a central torque coupling device (2), and the housing (33) and the stators (42) of the components (3, 4) arranged in the test structure are connected together in a force-fitting and/or form-fitting manner and to the housing part (22) of the central torque coupling device (2).