Generator Rotor Mounting Bearing for Easier Gearbox Decoupling

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Solution Overview

Problem

The maintenance of wind turbines with integrated gearbox and generator is complicated due to the need to decouple the generator from the output shaft, requiring precise angular positioning and fixed connections that hinder easy access and maintenance.

Innovation Solution

A mounting bearing system allows the generator rotor to be rotatably mounted on the output shaft, enabling it to be detached and axially displaced for maintenance, with features like screw flanges and splined connections facilitating easy rotation and axial movement, and a mounting lock for secure fixation during operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the generator rotor is fixedly connected to the output shaft, then the structural integration and operational reliability are improved, but the maintenance complexity and accessibility worsen

Engineering Contradiction:

Improveoperational reliabilityVSAvoidmaintenance complexity

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The fixed connection between generator rotor and output shaft is segmented into a modular coupling system with separate components (coupling device, mounting bearing, fixing mechanism) that can be independently assembled and disassembled, enabling maintenance without complete disintegration of the integrated structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system transitions from a static fixed connection to a dynamic system that can switch between locked (operational) and unlocked (maintenance) states, allowing the generator rotor to be rotated and positioned freely during maintenance while maintaining rigid connection during operation

Inventive Principle:

Principle #15Dynamics

2Power

If the generator rotor is fixedly connected to the output shaft, then the power transmission efficiency is improved, but the accessibility for maintenance worsens

Engineering Contradiction:

Improvepower transmission efficiencyVSAvoidaccessibility for maintenance

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

A coupling device acts as an intermediary element between the generator rotor and output shaft, providing a controlled interface that ensures efficient power transmission through precise mechanical engagement while allowing easy disengagement and repositioning for maintenance activities

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If precise angular positioning is required for fixing devices, then the operational connection stability is improved, but the maintenance time and complexity worsen

Engineering Contradiction:

Improveconnection stabilityVSAvoidmaintenance time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The system incorporates preliminary positioning features such as keyed connections, splines, or pre-aligned mounting surfaces that automatically guide the generator rotor into the correct angular position during assembly, eliminating the need for time-consuming manual alignment and ensuring stable operational connection from the outset

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4120521B1Rotary decoupling for mounting and demounting a generator rotor mounted on a gearbox

Publication Date: 2025.12.03 ZF FRIEDRICHSHAFEN AG

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AI summary

The invention relates to an arrangement comprising a gearbox and a generator; wherein a generator rotor (207) is or can be connected to an output shaft (103) of the gearbox in a rotationally fixed manner. The arrangement includes a mounting bearing (201) with which the generator rotor (207) is supported in the output shaft (103).