Wind Turbine Gearbox Pre-Aligned Bearing Seating
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Solution Overview
Problem
Current wind turbine gearboxes experience alignment errors due to rotor load, leading to restricted or absent tooth flank play and irregular gear wheel loading, which disrupts the normal interplay of forces and hinders weight reduction efforts.
Innovation Solution
The gearbox design features a deviation between the axis of symmetry of the ingoing shaft's bearing seating and the gear wheel transmission's geometrical axis in the unloaded condition, ensuring alignment compensation under rotor weight, thereby minimizing alignment errors and maintaining optimal tooth play.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the axis of symmetry of the bearing seatings of the ingoing shaft is aligned with the geometrical axis of symmetry of the gear wheel transmission in the unloaded condition, then the alignment is perfect when unloaded, but alignment error occurs when the ingoing shaft is loaded by the rotor
Solution Approach 1:
The patent applies preliminary action by pre-positioning the bearing seatings at an intentional deviation from the geometrical axis of symmetry in the unloaded state. This preliminary misalignment is calculated to compensate for the expected load-induced displacement, so that when the rotor is mounted and the shaft is loaded, the bearing seatings automatically shift into proper alignment with the gear wheel transmission's geometrical axis, eliminating alignment errors during operation
Solution Approach 2:
The patent implements preliminary anti-action by introducing a deliberate reverse deviation in the bearing seating alignment during manufacturing. This reverse deviation acts as a countermeasure that anticipates and neutralizes the harmful alignment error that would otherwise occur under rotor load, ensuring that the net alignment error during operation is minimized or eliminated
2Weight of moving object
If the bearing of the ingoing shaft in the gearbox is eliminated to reduce weight, then weight reduction is achieved, but the relative displacement between the ingoing shaft and the housing of the gearbox increases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-positioning the bearing seatings with a specific deviation from the geometrical axis of symmetry during manufacturing. This preliminary configuration accounts for the increased relative displacement that occurs when the direct bearing is eliminated, ensuring that the bearing seatings are positioned such that they achieve proper alignment under operational load conditions despite the larger relative movements
Solution Approach 2:
The patent implements parameter changes by modifying the alignment parameters of the bearing seatings from the conventional perfectly aligned position to a deliberately deviated position. This parameter change in the seating orientation and position compensates for the effects of eliminating the direct bearing, maintaining adequate alignment between the ingoing shaft and housing under operational conditions while achieving weight reduction
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 design effectively reduces alignment errors and maintains normal gear wheel interplay, even under dynamic loads, allowing for better weight reduction and improved gearbox performance.
Implementation Method 1
elastic deformations under the influence of the rotor load in said bearings or in the housing supporting said bearings
Data Source
AI summary
A gearbox for a wind turbine which consists of a housing and a gear wheel transmission with an ingoing shaft having at least one driving gear wheel which is or can be connected to the rotor of the wind turbine, characterized in that, in the unloaded condition of the gearbox, the axis of symmetry of the seating or seatings of the bearing of the ingoing shaft in the housing does not coincide with the geometrical axis of symmetry of the gear wheel transmission, as a result of which there will be a certain deviation between the abovementioned axes of symmetry in the unloaded condition which is such that, in a static, loaded condition, in other words under the weight of the rotor, the alignment error which is caused by the weight of the rotor is at least partially compensated.