Wind Turbine Gearbox Joint Structure Without Interference Spline
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Solution Overview
Problem
The conventional connection of a sun shaft and planet carrier in wind turbine gearboxes using an interference spline is complex, costly, and not conducive to in-plant assembly or outdoor on-site construction due to thermal expansion requirements and high manufacturing costs.
Innovation Solution
A wind turbine gearbox connecting structure that uses mutually matching butting surfaces with mounting holes for fixing members, such as bolts, to rigidly connect the sun shaft and planet carrier, eliminating the need for thermal expansion and simplifying assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an interference spline is used to rigidly connect the sun shaft and planet carrier, then the connection strength is improved, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The interference spline is segmented into multiple fixing members (bolts, screws, or rivets) distributed around the circumference. Each fixing member independently contributes to the connection strength, while the modular arrangement simplifies manufacturing and assembly compared to a single complex interference spline structure.
Solution Approach 2:
The fixing members act as intermediaries between the sun shaft and planet carrier, providing a simplified connection mechanism. Instead of directly implementing a complex interference spline, the fixing members mediate the force transmission while allowing for easier manufacturing and assembly.
2Strength
If thermal expansion is used to assemble the planet carrier with the sun shaft, then the interference fit is achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The thermal expansion mechanism is replaced with a purely mechanical fastening system using fixing members. Instead of heating the planet carrier to achieve interference fit, standard mechanical fasteners are used that can be installed at ambient temperature, eliminating the need for thermal processing equipment and reducing assembly time.
Solution Approach 2:
The fixing members can be standard, readily available fasteners that are inexpensive and easy to replace. This approach trades the permanent, complex interference fit for a simpler, replaceable fastening system that reduces assembly complexity and time.
3Stability of the object's composition
If an interference spline structure is used, then the rigid connection is achieved, but the manufacturing cost increases
Solution Approach 1:
The monolithic interference spline is segmented into multiple independent fixing members. This allows each fixing member to be manufactured separately using standard processes, reducing tooling costs and manufacturing complexity compared to producing a single complex interference spline component.
Solution Approach 2:
The fixing members can be made from the same material as the sun shaft and planet carrier, eliminating the need for specialized materials or surface treatments required by interference splines. This material homogeneity simplifies the supply chain and reduces manufacturing costs.
4Strength
If the planet carrier is heated for assembly, then the interference spline meshing is achieved, but the operational complexity increases
Solution Approach 1:
The thermal processing operation is replaced with a simple mechanical fastening operation. Instead of heating equipment and thermal expansion calculations, workers simply install standard fixing members using conventional tools, dramatically improving ease of operation.
Solution Approach 2:
The fixing members are designed to be self-aligning or self-locating, requiring minimal precision alignment during assembly. This self-service feature allows workers to install the connection without specialized training or equipment, improving operational ease.
Data Source
Figure 1~2
AI summary
A wind turbine gearbox connecting structure and a gearbox. The wind turbine gearbox connecting structure is used for connecting a sun shaft (1) and a planet carrier (2); and mutually matching butting surfaces are configured between the sun shaft (1) and the planet carrier (2), a plurality of mounting holes are formed in the butting surfaces to rigidly connect the sun shaft (1) to the planet carrier (2) by means of fixing members. In a wind turbine gearbox, the sun shaft (1) and the planet carrier (2) are connected by using the wind turbine gearbox connecting structure. The wind turbine gearbox connecting structure is simple in design and easy to operate, and the rigid connection of parts can be effectively achieved without heating the planet carrier, so that the manufacturing cost and the difficulty in field operation are reduced.