Integrated Electromechanical Device Rotor Support
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Solution Overview
Problem
The combination of a gear-box and an electrical machine in power generating systems, such as wind turbines, faces challenges in size and weight, which complicates design and support structures, and requires complex lubrication and cooling systems compared to gearless systems.
Innovation Solution
An integrated electromechanical device where the gear-box and electrical machine are combined into a single unit, with the rotor supported directly by the outer frame of the gear stage, forming a single load-bearing entity, and sharing a lubrication system, reducing size, weight, and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a gear-box and electrical machine are combined into a single unit, then the size and weight of the combination is reduced, but the structural complexity of the integration increases
Solution Approach 1:
The patent merges the gear-box and electrical machine into a single integrated unit where the rotor is directly supported by the outer frame of the gear stage. This consolidation eliminates separate mounting structures and reduces overall weight while maintaining functional independence of each component through careful structural design.
Solution Approach 2:
The outer frame of the gear stage serves multiple functions: it acts as both the structural support for the gear stage and the support structure for the rotor. This multi-functionality reduces the need for separate support components, simplifying the overall structure while achieving weight reduction.
2Device complexity
If the rotor is supported directly by the outer frame of the gear stage, then the load bearing structure is simplified, but the forces and stresses on the gear stage frame increase
Solution Approach 1:
The support structures for both the gear stage and rotor are merged into a single integrated frame system. This allows the frame to be optimized as a unified load-bearing structure, distributing stresses more efficiently than separate support structures would allow.
Solution Approach 2:
The patent employs composite material construction for the frame, combining materials with different mechanical properties to achieve both strength for handling increased stresses and weight reduction. This allows the frame to withstand higher loads while maintaining the weight reduction benefit of integration.
3Device complexity
If the electromechanical device is integrated into a single unit, then the lubrication system can be simplified, but the requirements for lubricant distribution and cooling increase
Solution Approach 1:
The lubrication systems for both the gear stage and rotor bearings are merged into a single integrated lubrication circuit. This allows a single lubricant supply system to serve multiple functions, reducing the number of separate lubrication components while providing centralized monitoring and control.
Solution Approach 2:
The patent introduces an intermediary lubricant circulation system that acts as a mediator between the gear stage and rotor bearing lubrication requirements. This intermediary system distributes lubricant to both components and can incorporate cooling functions to manage the increased heat generation from the integrated design.
Data Source
AI summary
An electromechanical device having a mechanical interface structure for connecting to an external rotating element, an electrical machine, and one or more gear stages on a mechanical power transmission path between the mechanical interface structure and a rotor of the electrical machine. The rotor of the electrical machine is supported by the frame of the gear stage directly connected to the rotor.