Insulated Shaft Joint With Ceramic Rollers for Detachable Torque Transfer
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Solution Overview
Problem
Existing insulated shafts in wind turbines are fixedly arranged between the gearbox and generator, leading to electrocorrosion issues due to electrical currents and lack of detachability for maintenance.
Innovation Solution
An insulated shaft joint with grooves and electrically insulating members, including ceramic rollers or balls, is designed to provide axial misalignment tolerance and even torque transfer, using an annular insulating cage to prevent electrical discharge between the shaft and rotational member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating shafts are used to prevent electrocorrosion, then electrical insulation is improved, but the shaft becomes fixedly arranged and non-detachable
Solution Approach 1:
The shaft connection is divided into modular segments: a shaft flange, a detachable insulating element, and a rotational member flange. This segmentation allows the insulating component to be easily installed and removed without permanently fixing the entire shaft assembly, resolving the contradiction between maintaining electrical insulation and enabling detachability for maintenance.
2Reliability
If traditional fixed insulating shafts are used, then electrical insulation is ensured, but assembly and maintenance become complex
Solution Approach 1:
The insulating element is designed with dynamic characteristics through grooves that accommodate axial misalignment between the shaft flange and rotational member flange. This dynamic design allows the insulating component to adapt to assembly variations automatically, simplifying the assembly process while maintaining reliable electrical insulation without requiring precise alignment.
3Object-affected harmful factors
If insulating members are added to prevent electrical discharge, then electrocorrosion is prevented, but the device structure becomes more complex
Solution Approach 1:
The insulating function is merged with the structural connection function by integrating the insulating element directly into the shaft joint assembly. The insulating component serves dual purposes: providing electrical insulation to prevent electrocorrosion and facilitating mechanical connection between shaft and rotational member, thereby preventing harmful electrical discharge without significantly increasing structural complexity.
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
The solution effectively prevents electrocorrosion by ensuring efficient electrical insulation and allowing for disassembly, maintaining high torque transmission and durability in wind turbines.
Implementation Method 1
an insulated shaft joint for electrically insulating a rotational member from an end section of a shaft
Implementation Method 2
the insulating members are arranged in the through-going openings of the insulating cage and in the first and second grooves, so as to be adapted to transfer torque from the shaft to the rotational member via the insulating members
Data Source
AI summary
The present invention relates to an insulated shaft joint (1) for electrically insulating a rotational member (2) from an end section of a shaft (3) to which the rotational member (2) is connected. The insulated shaft joint (1) comprises a plurality of first grooves (4) arranged in an outer surface of the end section of the shaft (3) and extending in an axial direction of the shaft (3), one or more rows of electrically insulating members (5), and an annular electrically insulating cage (6) arranged circumferentially around the plurality of first grooves (4). The insulating cage (6) comprises one or more rows of through-going openings (7), arranged circumferentially. The through-going openings (7) is being shaped and dimensioned so that they are adapted to surround and guide the insulating members (5). The rotational member (2) is arranged circumferentially around the annular electrically insulating cage (6). The rotational member (2) comprises a plurality of second grooves (8) arranged in an inner surface of the rotational member (2) and extending in an axial direction of shaft (3). The through-going openings (7) in the insulating cage (6) are arranged aligned with the plurality of first grooves (4) and the plurality of second grooves (8). The insulating members (5) are arranged in the through-going openings (7) of the insulating cage (6) and in the first and second grooves, so as to be adapted to transfer torque from the shaft to the rotational member (2) via the insulating members (5).