Disc Rotor Generator Bearing Arrangement
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Solution Overview
Problem
Existing wind turbine generators face challenges in creating a space-saving arrangement that allows for efficient conversion of rotational energy into electrical energy with minimal loss, while also requiring a compact design that is accessible for maintenance and repair.
Innovation Solution
A disc rotor generator with a single rolling bearing, such as a double-row angular contact ball bearing, is used to support the rotor, allowing for precise guidance of the rotating disc rotor and absorption of tilting moments without changing its position or orientation, and reducing the number of components and sealing points, thereby enhancing accessibility and reducing assembly and maintenance time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rolling bearings are used to support the rotor shaft at different locations, then the rotor shaft is securely supported and stable operation is achieved, but the device complexity increases and space requirements increase
Solution Approach 1:
The patent combines multiple bearing functions into a single rolling bearing unit. The first and second rolling bearings are integrated such that they share a common outer ring or are positioned in close proximity with shared mounting structures, reducing the overall number of separate bearing components while maintaining the dual support locations necessary for rotor stability.
Solution Approach 2:
The rolling bearing assembly is designed to perform multiple functions simultaneously: supporting the rotor shaft at two different locations, accommodating both radial and axial loads, and providing precise positioning for the rotor shaft. This multi-functional design reduces the need for separate specialized components.
2Reliability
If multiple rolling bearings are used to support the rotor shaft, then the rotor shaft is securely supported, but the space requirements and material consumption increase
Solution Approach 1:
The patent employs a nested configuration where the first and second rolling bearings are arranged concentrically or in close proximity, with one bearing partially or fully positioned within or adjacent to the other. This nesting reduces the overall radial and axial space occupied by the bearing assembly while maintaining dual support functionality.
3Reliability
If multiple rolling bearings are used, then the rotor shaft is securely supported, but the assembly and maintenance time increases
Solution Approach 1:
The patent integrates the mounting and maintenance procedures for both rolling bearings into a single operational sequence. The bearings are positioned and secured simultaneously or in close succession during assembly, and during maintenance, both bearings can be accessed and serviced through a single access point or procedure, reducing the overall time required compared to handling two separate bearing assemblies.
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 solution results in a more compact, cost-effective, and reliable generator assembly with reduced material and space requirements, fewer sealing points, and easier maintenance access, leading to improved service life and reduced risk of leaks and lubricant loss.
Implementation Method 1
mounted in rotation around the axis of rotation by means of a single rolling bearing
Data Source
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AI summary
The invention is directed firstly at a disc-rotor generator for generating electrical energy from the rotation energy of a power installation which is driven in rotation, preferably a continuous-flow power installation, in particular a wind power installation, having at least two stator components which are axially offset in relation to one another along an approximately horizontal rotation axis of the disc rotor, and having at least one ring- or disc-like rotor component of the disc rotor, which rotor component is mounted between said stator components so as to rotate about the rotation axis, having an input-end connection for a gear mechanism, preferably a step-up gear mechanism, in particular a planetary gear mechanism, wherein the output shaft of said gear mechanism, in particular the sun gear of said gear mechanism, which runs coaxially to the rotation axis of the disc rotor is coupled to at least one ring- or disc-like rotor component of the disc rotor, wherein the roller bearing which is associated with a ring- or disc-like rotor component of the disc rotor is in the form of an angular ball bearing or is formed with angular ball bearings, for example with a supporting angle of between 40? and 50? in relation to the rotation axis, preferably in the form of a two-row angular ball bearing, in particular as a two-row angular ball bearing in O-arrangement; and secondly at a wind power installation which is equipped with said disc-rotor generator.