Insulating Overload Coupling Tube Sliding Surface
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Solution Overview
Problem
Conventional electrically insulating overload clutches for wind turbines are complex and costly due to the need for separate sliding elements and multiple components, which increases manufacturing costs and complexity.
Innovation Solution
An electrically insulating overload clutch design featuring a tube with a built-in sliding surface that can twist relative to an annular flange, eliminating the need for separate sliding elements and reducing component count, with the tube itself serving as the sliding surface, and utilizing a GRP pipe for insulation and high torsional rigidity, and a metallic annular flange for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate sliding elements are used for overload protection, then reliable torque overload protection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the sliding element functionality directly into the tube structure. The tube's inner lateral surface serves as the sliding surface that contacts the annular flange, eliminating the need for separate sliding elements. This merging of functions reduces component count and simplifies the overall clutch mechanism while maintaining reliable overload protection through the same friction-based slippage principle.
2Ease of manufacture
If multiple components are used in the clutch mechanism, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
The tube is designed to integrate multiple functions: it provides electrical insulation, structural support, and the sliding surface for overload protection. By combining these functions into a single component rather than using separate elements, the patent reduces the total number of parts that need to be manufactured, assembled, and inventory-managed, thereby lowering manufacturing costs.
Solution Approach 2:
The tube serves multiple purposes simultaneously: it acts as an electrical insulator between the metallic parts, provides the sliding surface for torque overload protection, and maintains the structural integrity of the clutch assembly. This multi-functionality reduces the need for additional specialized components, simplifying both manufacturing and assembly processes.
3Reliability
If electrical insulation is provided by separate components, then insulation reliability is improved, but device complexity increases
Solution Approach 1:
The tube is designed as a multi-functional component that simultaneously provides electrical insulation and mechanical sliding functions. The electrically insulating material of the tube creates an insulation barrier between metallic parts while its inner lateral surface serves as the sliding surface for overload protection, eliminating the need for separate insulation components.
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 design significantly reduces manufacturing costs and simplifies the clutch mechanism while maintaining effective torque transmission and electrical insulation, with precise control over slippage through mechanical processing and lubrication for a 'stick-slip-free' sliding effect.
Implementation Method 1
a radially outer sliding surface (121) of the annular flange (120) slips relative to a radially inner sliding surface (111)
Implementation Method 2
a tube (3) made of an electrically insulating material
Implementation Method 3
a conical clamping ring (5), which is pulled axially towards the end element (12) by means of a clamping screw (52), and thereby in the radial direction from the inside outwards against the gear-side ring element (11) pressed
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an electrically insulating overload coupling for a wind turbine. The coupling comprises a tube (3) made of an electrically insulating material and a gearbox- or generator-side hub (1, 2). The hub (1, 2) has an axially oriented annular flange (120). The tube (3) has an annularly circumferential sliding surface (31) in an axial section, which bears directly against a corresponding sliding surface (121) of the annular flange (120). In this way, the tube (3) is rotatable relative to the annular flange (120) depending on the torque applied.