Indexed Gear Tooth Replacement for Smooth Circumferential Cuts
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Solution Overview
Problem
The wear on gear teeth in wind turbine pitch systems leads to aerodynamic imbalance and mechanical stress, necessitating time-consuming and expensive solutions like indexing or replacing the bearing.
Innovation Solution
A tool jig with indexing features and a tool-supporting feature is used to guide a material-removal tool in generating a smooth circumferential gear cut, allowing for the removal and replacement of damaged gear teeth with a denture apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If indexing or bearing replacement is used to correct wear damage, then gear functionality is restored, but time consumption and cost increase significantly
Solution Approach 1:
The invention segments the gear repair process into modular components: a bearing carrier that can be independently removed and replaced, separate from the entire bearing assembly. This allows only the damaged portion (bearing carrier with worn teeth) to be replaced rather than the entire bearing, significantly reducing repair time and cost while restoring gear functionality
Solution Approach 2:
The invention extracts the bearing carrier as a separate replaceable component from the overall bearing assembly. By designing the bearing carrier with an independent outer race and tooth structure, the damaged carrier can be removed and replaced without affecting other bearing components, enabling rapid repair and minimizing downtime
2Reliability
If indexing or bearing replacement is used to correct wear damage, then gear functionality is restored, but cost increases significantly
Solution Approach 1:
The bearing assembly is segmented into replaceable modules (bearing carrier, inner race, outer race) allowing selective replacement of only the damaged carrier. This modular approach reduces repair costs by avoiding replacement of intact components and enables cost-effective restoration of gear functionality
Solution Approach 2:
The invention enables selective discarding of only the damaged bearing carrier while recovering and retaining other functional bearing components (inner race, outer race, rollers). This selective replacement strategy significantly reduces repair costs compared to replacing the entire bearing assembly
3Manufacturing precision
If a tool jig with indexing features is used to guide material removal, then precise gear cut is achieved, but device complexity increases
Solution Approach 1:
The bearing carrier is designed with multi-functionality: it serves both as a structural component supporting the gear teeth and as a self-indexing tool jig during the tooth removal process. The outer race with its circumferential groove provides both bearing functionality and precise positioning guidance for the removal tool, eliminating the need for separate complex indexing fixtures
Solution Approach 2:
The bearing carrier's outer race structure provides self-indexing capability through its circumferential groove and flat surfaces, which automatically guide the removal tool to precise angular positions. This self-service positioning feature eliminates the need for external complex indexing mechanisms, reducing device complexity while maintaining manufacturing precision
Data Source
AI summary
A method of replacing at least one tooth of a gear includes providing a tool jig including a mounting block with a plurality of indexing jig features. The tool jig also includes a tool-supporting feature in laterally movable contact with a jig rail feature. With at least one indexing jig feature, relative motion of the tool jig relative to the gear is resisted. A material-removal tool is operated, while attached to the tool-supporting feature in the tooth-removal position, to remove at least a portion of a working circumference of the gear including a native gear tooth to be replaced. Motion of the material-removal tool is guided to generate a circumferential gear cut including a relatively smooth first cut surface formed by removal of at least the native gear tooth to be replaced. The material-removal tool is removed from the tool-supporting feature. The tool jig is removed from the gear.