Wind Turbine Gearbox Sliding Layer for Easier Bearing Replacement
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Solution Overview
Problem
The maintenance and replacement of sliding bearings in wind turbine gearboxes are complex and cost-intensive due to their location and susceptibility to creep and relaxation effects, which complicates positional losses and increases maintenance costs.
Innovation Solution
A wind turbine gearbox with a deposition welded sliding layer made from a sliding bearing material, allowing for easier maintenance and preventing positional losses by creating a accessible sliding surface, which can be applied directly to various components such as axles, gear holders, and sliding bearing bushes, enabling both radial and axial bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sliding bearing bushes are shrunk onto the axle or pressed into the planetary gear, then the gear can be mounted on the axle, but the replacement and maintenance becomes complex and cost-intensive
Solution Approach 1:
The sliding bearing is segmented into a reusable bush component and a replaceable deposition welded layer. The bush remains in place while only the worn sliding surface layer needs replacement, simplifying maintenance procedures.
Solution Approach 2:
The deposition welded sliding layer is designed as a consumable, inexpensive component that can be easily replaced when worn. This layer acts as a sacrificial element that protects the more expensive bush and axle components.
2Reliability
If sliding bearing bushes are used, then the gear can be mounted on the axle, but positional losses due to creep effects or relaxation effects occur
Solution Approach 1:
The material properties of the sliding surface are changed through deposition welding, creating a layer with optimized creep and relaxation resistance. This thermal process alters the microstructure and mechanical properties of the sliding surface material.
Solution Approach 2:
The sliding bearing system uses composite construction with different materials for the bush and the deposition welded sliding layer. This combination leverages the advantages of each material to achieve both durability and positional stability.
3Ease of repair
If sliding bearing bushes are shrunk onto the axle, then the gear can be mounted, but the maintenance requires disassembly and is time-consuming
Solution Approach 1:
The sliding surface layer is extracted as a separate, accessible component that can be removed and replaced independently from the bush and axle assembly. This allows maintenance without complete disassembly of the bearing system.
Solution Approach 2:
The design enables simplified self-service maintenance where the sliding layer can be quickly replaced by maintenance personnel without requiring specialized tools or extensive disassembly procedures.
4Ease of manufacture
If sliding bearing bushes are pressed into the planetary gear, then the gear can be mounted on the axle, but the replacement is complex and cost-intensive
Solution Approach 1:
The sliding bearing system is segmented into the pressed-in bush (which remains installed) and the replaceable deposition welded sliding layer. This segmentation allows the bush to be installed once during manufacturing while the sliding layer can be replaced during maintenance.
Solution Approach 2:
The bush is preliminarily installed and secured in the gear during manufacturing, creating a stable foundation. The deposition welded sliding layer is then added as a separate maintenanceable component, separating the installation complexity from the replacement complexity.
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
Facilitates easier and less costly maintenance, prevents positional losses due to creep or relaxation effects, and simplifies the production process of the wind turbine gearbox by using deposition welding for the sliding layer, enhancing the gearbox's operational efficiency and service life.
Implementation Method 1
a sliding surface is arranged between the gear and the axle or between the axle and an axle holder, which is arranged on at least one layer of a deposition welded material made from a sliding bearing material
Data Source
AI summary
A wind turbine gearbox, in particular planetary gearbox, has at least one gear which is mounted on an axle, wherein a sliding surface is arranged between the gear and the axle. The sliding surface is arranged on at least one layer of a deposition welded material made from a sliding bearing material. Furthermore, a method produces the wind turbine gearbox.