Wind Turbine Gear Unit Cooling via Generator Thermal Integration
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Solution Overview
Problem
Conventional wind turbines have a complex and expensive structure due to separate and inefficient cooling systems for the generator and gear unit, which increases operational costs and complexity.
Innovation Solution
Integration of a recooling unit within the generator cooling system to share thermal energy between the gear unit and generator cooling systems, using air or oil as cooling fluids and heat exchangers to efficiently transfer thermal energy, reducing the need for additional components and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling systems are used for generator and gear unit, then each component can be cooled independently, but the structure becomes complex and expensive
Solution Approach 1:
The patent combines the generator cooling system and gear unit cooling system into a single integrated cooling system. The cooling circuit includes a heat exchanger for the generator and a recooling unit for the gear unit that are thermally coupled, allowing both components to be cooled through a unified system rather than separate independent systems, thereby reducing structural complexity while maintaining cooling effectiveness
Solution Approach 2:
The integrated cooling system serves multiple functions: it cools the generator through the heat exchanger and simultaneously cools the gear unit through the recooling unit. The system uses a single cooling medium circulating through both cooling paths, making the cooling system universal for both components rather than requiring separate specialized systems
2Reliability
If separate cooling systems are used for generator and gear unit, then each system can be optimized independently, but manufacturing costs increase
Solution Approach 1:
By merging the generator cooling system and gear unit cooling system into one integrated system with a shared cooling medium circuit, the patent reduces the total number of components, heat exchangers, and piping required. This consolidation lowers manufacturing costs while the system maintains optimized cooling performance for both the generator and gear unit through its dual-path design
3Reliability
If separate cooling systems are used for generator and gear unit, then cooling can be tailored to each component, but the system volume increases
Solution Approach 1:
The patent merges the cooling systems by using a single cooling medium that circulates through both the generator heat exchanger and the gear unit recooling unit. This shared cooling circuit eliminates the need for separate cooling medium reservoirs, pumps, and heat exchangers for each component, significantly reducing the overall system volume while maintaining efficient cooling for both the generator and gear unit
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 integration simplifies the wind turbine structure, reduces costs, and achieves energy savings by using shared cooling fluids and heat exchangers, resulting in a more efficient and cost-effective cooling system.
Implementation Method 1
the recooling unit being configured as an air-to-oil heat exchanger which is integrated into the generator cooling system and configured to transmit during normal operation of the wind turbine thermal energy from the cooling fluid of the gear unit cooling system to the cooling fluid of the generator cooling system
Data Source
AI summary
A wind turbine includes a generator having a generator cooling system configured for passage of a cooling fluid, and a gear unit including a gear unit cooling system configured for passage of a cooling fluid. The gear unit cooling system includes a recooling unit which is configured to transmit during normal operation of the wind turbine thermal energy from the cooling fluid of the gear unit cooling system to air inside the generator or to the cooling fluid of the generator cooling system.