Integrated Rotor Shaft Gear Layout for Compact Wind Turbine Drivetrains
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Solution Overview
Problem
Existing drive train arrangements in wind power plants are complex, heavy, and difficult to assemble and maintain due to their sequential component design, which hinders weight reduction and compactness.
Innovation Solution
A drive train arrangement where the gear is at least partially integrated into the rotor shaft, supported by a machine support, and connected to the generator via a torsionally rigid coupling, allowing for a compact and disassemblable design without requiring rotor disassembly, and incorporating a planetary gear with multiple stages for enhanced power density and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a gear is connected between rotor and generator to enable fast-running generators, then weight of rotor with machine nacelle is reduced, but device complexity increases
Solution Approach 1:
The gear is integrated directly into the rotor shaft, merging two previously separate components (gear and rotor shaft) into a single unified structure. This eliminates the need for separate mounting mechanisms and reduces the number of parts, thereby maintaining weight reduction benefits while simplifying the overall device complexity.
Solution Approach 2:
The gear is positioned within the rotor shaft structure, with the gear housing forming part of the rotor shaft assembly. This nested arrangement allows the gear to be contained within the existing rotor shaft volume, reducing overall structural length and simplifying the mechanical arrangement without adding external complexity.
2Power
If all components are sequentially arranged behind one another, then power transmission is achieved, but structural length increases
Solution Approach 1:
Instead of arranging components in a linear sequential manner along the axial direction, the invention positions the gear radially within the rotor shaft structure. This dimensional reorganization allows power transmission to occur through a compact radial arrangement rather than a lengthy axial sequence, significantly reducing the overall structural length while maintaining effective power transmission from rotor to generator.
3Power
If gear and generator are sequentially arranged, then power transmission is achieved, but assembly and maintenance becomes very involved
Solution Approach 1:
The drive train is segmented into modular components: the integrated gear-rotor shaft assembly and the generator, connected through a flange interface. This segmentation allows the gear and generator to be assembled and disassembled as separate modules without requiring rotor disassembly, significantly simplifying maintenance and manufacturing processes while maintaining effective power transmission.
Solution Approach 2:
A flange connection serves as an intermediary element between the gear-rotor shaft assembly and the generator. This intermediary interface enables easy coupling and decoupling of the generator from the drive train, facilitating simplified assembly and maintenance operations without affecting the core power transmission function between the rotor and gear.
4Stability of the object's composition
If a machine support is added to support reaction moments, then stability improves, but device complexity increases
Solution Approach 1:
The machine support structure performs multiple functions simultaneously: it provides bearing support for the rotor shaft, supports the gear assembly, and resists reaction moments from both the generator and gear. By designing a single multi-functional support structure rather than separate components for each function, the invention achieves improved stability without proportionally increasing device 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
This design achieves a more compact and lighter weight drive train with simplified assembly and maintenance, while maintaining high torsional rigidity and power efficiency, enabling reduced structural length and weight without compromising performance.
Implementation Method 1
the gear is connected to the rotor shaft by a torsionally rigid coupling
Data Source
AI summary
A drive train arrangement preferentially for a wind power plant having a rotor shaft, a generator, and a gear, which is indirectly or directly connected to the rotor shaft and the generator. The gear is at least partly or completely integrated in the rotor shaft.