Integrated Rotor Main Bearing for Simpler Wind Turbine Nacelles
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Solution Overview
Problem
Existing rotor bearings for wind turbines have complex structures, leading to high manufacturing costs and a propensity for errors, and they do not provide a reliable long service life.
Innovation Solution
A nacelle design with a rotor bearing featuring an inner and outer ring element, where a plain bearing element is inseparably connected to one of the ring elements, providing a simple structure, improved reliability, and the ability to be designed for both radial and axial bearing, with the option of being applied as a coating or through magnetic pulse welding, and featuring a surface structuring for enhanced connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex structure is used for the rotor bearing, then the bearing can provide sufficient support functionality, but the manufacturing cost increases and the bearing becomes more prone to errors
Solution Approach 1:
The patent merges the plain bearing element directly with one of the ring elements (inner or outer) to form an integrated component. This eliminates the need for separate bearing elements and their associated fastening mechanisms, thereby reducing structural complexity while maintaining the load-bearing functionality and improving reliability through fewer potential failure points.
Solution Approach 2:
The integrated ring element with embedded plain bearing material serves multiple functions simultaneously: it provides structural support as a ring element, delivers bearing functionality through the plain bearing material, and eliminates the need for separate fastening elements. This multi-functionality reduces the overall number of components while maintaining adequate support capabilities.
2Adaptability or versatility
If a complex structure with multiple separate elements is used, then the bearing can accommodate different loading conditions, but the manufacturing cost and error probability increase
Solution Approach 1:
By combining the plain bearing element with the ring element into a single integrated component, the patent simplifies manufacturing processes while maintaining the ability to accommodate radial and axial loads. The integrated design eliminates complex assembly requirements for multiple separate elements, making the bearing easier to manufacture.
Solution Approach 2:
The patent employs composite construction by integrating plain bearing material with the ring element structure. This composite approach allows the bearing to handle different loading conditions (radial and axial loads) while maintaining a simplified single-component structure that is easier to manufacture compared to assemblies of multiple separate elements.
3Adaptability or versatility
If separate bearing elements are used for radial and axial support, then the bearing can handle different loads, but the structure becomes more complex and expensive
Solution Approach 1:
The integrated ring element with plain bearing material serves as a universal bearing component that can handle both radial and axial loads simultaneously. This eliminates the need for separate bearing elements for different load directions, reducing the quantity of bearing components while maintaining full load-bearing capability in multiple directions.
Solution Approach 2:
The patent merges the functionality of multiple separate bearing elements (for radial and axial support) into a single integrated ring element with embedded plain bearing material. This consolidation reduces the number of components from multiple separate elements to one unified structure, thereby reducing the quantity of substance while maintaining adaptability to different load directions.
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 results in a rotor bearing with a simple structure, increased reliability, and a long service life, with the ability to be easily assembled and maintain high functionality, while reducing manufacturing errors and costs.
Implementation Method 1
the plain bearing element is designed as a coating that is applied directly to the inner ring element or the outer ring element
Implementation Method 2
or through magnetic pulse welding
Data Source
Figure 1
Figure 2
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AI summary
The invention relates to a nacelle (2) for a wind turbine (1), the nacelle (2) comprising: - a nacelle housing (4); - a rotor hub (6); - a rotor bearing (8) for supporting the rotor hub (6) on the nacelle housing (4), the rotor bearing (8) having at least an inner ring element (12) and at least an outer ring element (13), at least one sliding bearing element (14) being formed between the inner ring element (12) and the outer ring element (13). The sliding bearing element (14) is inseparably connected to the inner ring element (14), or the sliding bearing element (14) is inseparably connected to the outer ring element (13).