Wind Turbine Gear Lubrication Filter Circuit
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Solution Overview
Problem
Lubrication devices for gear trains in wind power stations face premature damage due to settlement of heavy metal particles in resting zones within the spur wheel stage, leading to frequent failures of planet bearings and gear oil pumps, as the existing systems fail to effectively remove contaminants from the lubricant circuit.
Innovation Solution
A lubrication device that continuously circulates lubricant through a filter unit to prevent stationary resting zones, using a diagonal configuration of suction and injection devices to ensure continuous cleaning and distribution, with a filter unit comprising a fine filter safeguarded by a bypass and a coarse filter to effectively remove fouling particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lubricant is allowed to circulate in the gear housing with large bath areas, then lubrication coverage is improved, but heavy metal particles settle in resting zones causing premature damage
Solution Approach 1:
The patent introduces a circulation pump that continuously moves the lubricant through the gear housing and back, preventing the formation of static resting zones where metal particles could settle. The dynamic circulation ensures all lubricant is periodically renewed, eliminating the harmful settlement effect while maintaining comprehensive lubrication coverage.
Solution Approach 2:
The circulation system operates continuously during gear operation, constantly renewing the lubricant and preventing particle accumulation. This continuous action ensures that lubricant never remains stagnant in any zone, thereby preventing metal particle settlement while maintaining effective lubrication throughout the gear housing.
2Ease of manufacture
If lubricant exchange is performed only in the spur wheel stage area, then local cleaning is simplified, but contaminated lubricant remains in the planet stage area causing damage
Solution Approach 1:
The circulation pump serves multiple functions: it draws lubricant from the spur wheel stage area, transports it through the filtration system, and redistributes it throughout the entire gear housing including the planet stage area. This multi-functional approach ensures complete lubricant renewal system-wide while maintaining operational simplicity.
Solution Approach 2:
The circulation pump acts as an intermediary that connects different gear stage areas to the filtration system. It ensures that lubricant from all regions, including the previously inaccessible planet stage areas, is continuously drawn through the filter and redistributed, preventing localized contamination while maintaining system simplicity.
3Reliability
If filter unit processes large volumes of lubricant continuously, then cleaning effectiveness is improved, but pump workload increases
Solution Approach 1:
The circulation pump is designed to process the entire lubricant volume at controlled intervals rather than continuously at maximum rate. This partial action approach maintains effective cleaning by periodically renewing all lubricant while reducing overall energy consumption compared to continuous high-volume processing.
Solution Approach 2:
The system implements periodic circulation cycles where the pump operates at full capacity to process complete lubricant volumes at defined intervals, then allows brief rest periods. This periodic action maintains thorough cleaning effectiveness while significantly reducing average pump workload and energy consumption compared to continuous operation.
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 extends the lifespan of gear stages and gear oil pumps by continuously removing contaminants, ensuring reliable and long-lasting operation by preventing sedimentation of heavy metal particles and optimizing lubricant distribution, thereby reducing maintenance intervals and improving performance.
Implementation Method 1
the lubricant circulating in the lubricant circuit is drawn off, cleaned by the filter unit and then delivered to the respective other gear stage
Implementation Method 2
lubricant removal includes of a suction device, and the lubricant supply includes an injection device
Implementation Method 3
Due to this diagonal configuration, optimum lubricant distribution within the gear stages takes place. The transit time for the lubricant between the gear stages from the injection side to the suction side is likewise optimized.
Data Source
AI summary
A lubricating device for gear trains (10), especially for wind power stations, includes at least two gear stages (16,18) that are disposed next to each other and are effectively interconnected, and a lubricant circuit (20) into which at least one filter unit (26) is mounted. To prevent stagnant resting zones for the lubricant from being created within the gear train housing including the gear stages, while ensuring that the entire lubricant that circulates in the gear stages is fed to the filter unit to be drawn off and filtered within predefined periods of time, the lubricant circulating inside the lubricant circuit (20) is discharged at one gear stage (18), is drawn off through the filter unit, and can then be fed to the other gear stage (16).