Wind Turbine Gearbox Coupling for Torque Transfer and Offset Compensation
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Solution Overview
Problem
Existing couplings in wind power technology and industrial applications face challenges in reliably transmitting torque while compensating for inaccuracies in positioning and orientation, with a need for simple assembly, maintenance, and high economic efficiency.
Innovation Solution
A coupling design featuring a circumferential intermediate piece with longitudinal webs that prevent axial movement between flanges, allowing for torque transmission and compensation of radial, axial, and angular offsets, while being lightweight and easy to mount and maintain, using multiple disk assemblies and conical bolts for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid coupling with multiple separate components (shafts, flanges, intermediate pieces) is used to transmit torque, then the torque transmission reliability is improved, but the assembly complexity and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple separate components (flanges, intermediate pieces, and connecting elements) into a single integrated coupling component. This merging reduces the number of parts that need to be assembled while maintaining the torque transmission function, directly resolving the contradiction between reliability and assembly complexity.
Solution Approach 2:
The intermediate piece is designed to perform multiple functions simultaneously: it provides structural support, enables torque transmission, and allows for positioning adjustments. This multi-functionality reduces the need for separate dedicated components, simplifying the overall assembly while maintaining reliability.
2Strength
If a coupling with high torsional rigidity is designed using solid structure, then the torque transmission capability is improved, but the rotating inertia increases
Solution Approach 1:
The coupling features localized reinforcement through ribs and web structures positioned strategically to provide maximum torsional rigidity where needed, while leaving other areas lighter. This selective strengthening maintains strength requirements without unnecessarily increasing overall mass and rotating inertia.
Solution Approach 2:
The coupling employs composite construction combining different material properties in strategic locations - heavier materials in load-bearing regions for torsional rigidity, and lighter materials in non-critical areas to reduce rotating inertia, optimizing the strength-to-weight ratio.
3Manufacturing precision
If a coupling design with precise positioning features is implemented to compensate for positioning inaccuracies, then the positioning precision is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The coupling incorporates pre-configured positioning features and adjustment mechanisms that are built into the design, allowing for compensation of positioning inaccuracies during assembly rather than requiring extremely tight manufacturing tolerances. This preliminary preparation simplifies the manufacturing process while achieving the desired positioning precision.
Solution Approach 2:
The coupling includes adjustable and adaptable positioning features that can be modified during assembly to compensate for variations in manufacturing tolerances. This dynamic adjustment capability allows the system to achieve precise positioning without requiring high manufacturing precision for all components.
4Ease of manufacture
If a coupling with simplified structure is used to reduce manufacturing cost and ease assembly, then the ease of manufacture is improved, but the capability to compensate for positioning and orientation inaccuracies deteriorates
Solution Approach 1:
The coupling is divided into functional segments or modules, each responsible for specific tasks such as torque transmission, positioning, and adjustment. This segmentation allows the simple assembly of individual modules while collectively providing the complex capability to compensate for positioning and orientation inaccuracies.
Solution Approach 2:
The coupling employs intermediary adjustment elements or mechanisms that bridge the drive shaft and driven component, allowing for the correction of positioning and orientation inaccuracies. These intermediary features add compensation capability without significantly complicating the overall assembly or manufacturing process.
Data Source
AI summary
A coupling for attaching a transmission to a drive shaft includes a circumferential intermediate piece including a drive-side flange, an output-side flange which is axially connected fixedly to the drive-side flange, and longitudinal webs connecting the drive-side flange to the output-side flange and configured in one piece with the drive-side flange and with the output-side flange. Each longitudinal web is configured in one piece or in two pieces.