Generator Shaft Break Assembly for Low-Torque Disconnection
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Solution Overview
Problem
Current controlled disconnection systems in gas turbines do not provide effective protection across their entire operational range, particularly failing to disconnect the electricity generator at low speeds or high speeds, leading to potential damage during torque failures.
Innovation Solution
An assembly with a protection device featuring a calibrated breakable section and an unlocking mechanism that releases a cutting tool to disconnect the generator from the accessory gearbox at a low torque, allowing for a controlled breakage mechanism operated by an external control unit, such as an electromagnet or torque motor, to reduce the breakable section's torque to near 0 Nm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a breakable section is calibrated to break under high torque (5 to 10 times maximum nominal torque), then the generator is protected from severe damage, but the breaking torque cannot be lowered to enable timely disconnection during intermediate torque failures
Solution Approach 1:
The protection device is segmented into two independent functional components: a controlled disconnection system (active device) for intermediate torque failures, and a breakable section (passive device) for severe torque failures. This segmentation allows each component to be optimized for its specific torque range without compromising the other, resolving the contradiction between timely disconnection and adequate protection.
Solution Approach 2:
The breakable section serves as an intermediary safety mechanism that activates when the controlled disconnection system fails or is insufficient. It provides a backup protection layer that breaks at a predetermined high torque threshold, ensuring generator protection even when active disconnection is unavailable or inadequate.
2Ease of operation
If a controlled disconnection system is used for intermediate loads and speeds, then mechanical disengagement is enabled for those conditions, but protection is not provided for high speed and high torque conditions beyond the breaking capacity of the active device
Solution Approach 1:
The protection system is segmented into two functional zones: the controlled disconnection system handles intermediate loads and speeds where precise control is needed, while the breakable section provides automatic protection for high-speed, high-torque conditions where the active device's breaking capacity is exceeded. This segmentation ensures comprehensive protection across the entire operational range.
Solution Approach 2:
The system dynamically adapts to different failure scenarios: the controlled disconnection system operates actively for intermediate conditions, while the breakable section provides passive automatic disconnection for severe high-torque failures. This dynamic behavior ensures appropriate protection responses matched to the severity and type of failure condition.
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 solution enhances protection by enabling disconnection at low torque, reducing the risk of damage, allowing for easier generator replacement, and maintaining operational robustness while minimizing the weight and size of the generator.
Implementation Method 1
said unlocking mechanism is an electromagnet or a torque motor
Implementation Method 2
said unlocking mechanism is an electromagnet or a torque motor
Implementation Method 3
releases a cutting tool so as to cut said calibrated breakable section
Data Source
AI summary
An assembly including an accessory gearbox mechanically connected to an electricity generator having a support shaft that includes a calibrated breakable section designed to disconnect the electricity generator physically from the accessory gearbox when an incident is detected on the electricity generator, the protection device including an unlocking mechanism provided with a lock that, under the action of an external control unit, releases a cutting tool so as to cut said calibrated breakable section.