Wind Turbine Gearbox Torque Arm Assembly for Reduced Transport Width
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Solution Overview
Problem
The existing design of wind turbine gearboxes, which use torque arms for mounting, often results in an increased transport width exceeding standard shipping parameters, limiting manufacturing techniques and requiring special clearance for forming ring gears.
Innovation Solution
A gearbox assembly with a maximal installed width greater than the maximal transport width, utilizing detachable torque arms and support elements like pedestal brackets with endcaps and segmented bushings, allowing for a reduced transport width by reconfiguring the gearbox during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If torque arms are used to mount the gearbox, then the gearbox can be securely mounted to the bedplate, but the overall width of the gearbox assembly increases beyond standard shipping parameters
Solution Approach 1:
The torque arm assembly is divided into separate components: the torque arm itself, detachable endcaps, and support elements. This segmentation allows the gearbox to be transported in a compact configuration without the endcaps, reducing transport width, while enabling secure mounting when the endcaps are attached during installation
Solution Approach 2:
The torque arm configuration transitions from a static, permanently attached structure to a dynamic, reconfigurable assembly. The detachable endcaps and support elements allow the system to adapt between two states: a compact transport state for shipping and a fully extended mounted state for operational use, effectively resolving the width contradiction
2Reliability
If torque arms are present in the gearbox assembly, then the gearbox can be mounted via torque arms, but certain manufacturing equipment lacks sufficient clearance to form the ring gear on the inside face of the gearbox
Solution Approach 1:
By separating the torque arm mounting components (endcaps and support elements) from the main gearbox housing, the patent enables manufacturing equipment to access the inside face of the gearbox for ring gear formation without interference from the torque arm assembly, while still providing mounting capability through the detachable components
3Reliability
If the gearbox is transported in an assembled configuration with torque arms, then mounting security is maintained, but shipping parameters are exceeded and special transportation arrangements are required
Solution Approach 1:
The gearbox assembly is designed to dynamically transition between configurations: a compact state for standardized shipping without endcaps, and a secure mounted state with endcaps attached during installation. This dynamic reconfigurability allows the same assembly to meet both shipping standardization requirements and mounting security requirements at different stages
Data Source
AI summary
The present disclosure is directed to a gearbox assembly for a wind turbine. The gearbox assembly has a maximal installed width and a maximal transport width. The maximal installed width is greater than the maximal transport width. The gearbox assembly includes at least one torque arm coupled to opposing sides of the gearbox housing. Each of the torque arms includes a proximal end and a distal end. The proximal ends are removably coupled to the exterior surface of the gearbox such that the distance between the distal ends define the maximal installed width. The torque arms are coupled to at least one support element and to a bedplate of the wind turbine.