Wind Turbine Gearbox Torque Arms for Reduced Transport Width
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Solution Overview
Problem
The presence of torque arms in wind turbine gearboxes increases the overall width, exceeding standard shipping parameters and limiting manufacturing techniques, necessitating a solution to reduce transport width while maintaining installed width.
Innovation Solution
A gearbox assembly with removable torque arms and support elements, such as pedestal brackets and segmented bushings, allows for a transport width less than the installed width, utilizing joints like dovetail, mortise-and-tenon, bolted, or bonded connections to facilitate assembly and shipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If torque arms are permanently mounted to the gearbox housing, then the gearbox achieves structural stability and torque transmission capability, but the transport width exceeds standard shipping parameters
Solution Approach 1:
The torque arm assembly is segmented into removable components (torque arms, endcaps, mounting pins) that can be detached during shipping and reassembled during installation. This allows the gearbox to be transported in a compact configuration without torque arms, reducing transport width, while still achieving the required structural stability when torque arms are mounted during installation.
Solution Approach 2:
The torque arm mounting system transitions from a static permanent attachment to a dynamic removable connection. The torque arms can be removed for shipping and installed for operation, allowing the system to adapt its configuration based on whether it is in transport mode or operational mode, thus resolving the contradiction between transport width and structural stability.
2Length of stationary object
If torque arms are mounted on the gearbox, then the installed width is sufficient for operational requirements, but the transport width exceeds standard shipping parameters requiring special permits
Solution Approach 1:
The gearbox assembly is segmented into core components (gearbox housing, gearing arrangement) and auxiliary components (torque arms, endcaps, support elements). The auxiliary components are designed to be removable, allowing the core gearbox to be transported at its compact housing width, while the auxiliary components are added during installation to achieve the required installed width for operational requirements.
Solution Approach 2:
The gearbox housing is prepared with pre-formed mounting features (exterior surfaces, coupling interfaces) that accommodate torque arms during installation. This preliminary preparation allows the torque arms to be easily attached after shipping, achieving the required installed width without increasing transport width.
3Strength
If torque arms are present in the gearbox assembly, then the structural integrity is maintained, but manufacturing clearance is insufficient for certain equipment to form the ring gear
Solution Approach 1:
The manufacturing process is segmented into two phases: Phase 1 manufactures the gearbox housing and internal gearing (including ring gear) without torque arms, ensuring sufficient manufacturing clearance; Phase 2 installs the torque arms after the housing is complete. This segmentation allows the housing to be manufactured with optimal clearance for internal components, while torque arms are added as a separate assembly step that does not interfere with gear formation.
Solution Approach 2:
The gearbox housing is manufactured in advance with all internal features (gearing arrangement, inner cavity, mounting surfaces) completed before torque arms are installed. This preliminary completion of the housing ensures that manufacturing equipment has adequate clearance to form the ring gear and other internal components, and the torque arms are added as a final assembly step that preserves these manufacturing clearances.
Data Source
Figure 1
Figure 2
Figure 3A~3B
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.