Modular Generator Module with Belt Pulley Transmission
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Solution Overview
Problem
Conventional wind turbines, particularly direct-drive and doubly-fed types, face issues with center of gravity imbalance, increased maintenance costs due to complex transmission systems, and potential oil leakage leading to environmental pollution.
Innovation Solution
A modular generator module with a belt-pulley transmission system that allows flexible arrangement and separate maintenance, reducing the need for oil lubrication and enhancing mechanical stability, thereby improving maintenance efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a direct-drive wind turbine configuration is used, then the structure is simplified, but the center of gravity shifts forward causing increased bending moment on the tower and requiring enhanced tower strength
Solution Approach 1:
The transmission system is segmented into modular components: a generator module containing the generator unit, a separate belt pulley assembly, and a transmission belt. This segmentation allows the generator to be positioned optimally while maintaining structural balance through the distributed transmission components.
Solution Approach 2:
A transmission belt acts as an intermediary element connecting the main shaft to the generator rotating shaft through belt pulleys. This intermediary mechanism transmits mechanical energy while allowing flexible positioning of the generator, thereby balancing the center of gravity and reducing the bending moment on the tower.
2Volume of moving object
If a doubly-fed wind turbine with gear box is used, then the generator size is reduced, but the transmission chain becomes longer leading to increased malfunctions and maintenance requirements
Solution Approach 1:
The gear box and its associated lubrication system are completely extracted from the transmission system and replaced with a belt-pulley transmission mechanism. This elimination of high-speed rotating gears and lubricant removes the primary sources of malfunctions and maintenance requirements while preserving the reduced generator size benefit.
Solution Approach 2:
The complex mechanical gear transmission system is substituted with a simpler belt-pulley mechanical transmission. This substitution maintains the speed multiplication function while eliminating the need for lubrication, reducing maintenance requirements, and improving reliability over the 20-year design life.
3Volume of moving object
If a doubly-fed wind turbine with gear box is used, then the generator size is reduced, but oil leakage occurs polluting the interior and environment
Solution Approach 1:
All lubricant and oil systems are extracted from the transmission mechanism by using a belt-pulley transmission instead of a gear box. This complete removal of lubricant eliminates the source of oil leakage pollution to the interior and environment while maintaining the reduced generator size.
4Power
If more high-speed transmission members are used, then the power transmission capability is enhanced, but the maintenance cost increases due to more regular lubrication requirements
Solution Approach 1:
High-speed gear transmission members are replaced with a belt-pulley transmission system that achieves the same power transmission capability without requiring lubrication. This substitution eliminates maintenance costs associated with regular lubrication while preserving the power transmission function.
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 modular generator module allows for flexible positioning of the generator, reduces maintenance costs, prevents oil leakage, and enhances mechanical stability, leading to improved power generation efficiency and reduced environmental impact.
Implementation Method 1
a belt pulley, and the belt pulley is configured to be connected to a main shaft of the wind turbine by a transmission belt
Data Source
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AI summary
A generator module and a wind turbine having the same are provided according to the present application. The generator module includes a generator module housing, a generator unit and a generator rotating shaft. The generator unit is arranged in the generator module housing and includes a rotor and a stator. One end of the generator rotating shaft is connected to the rotor, and the generator rotating shaft is provided with a belt pulley. The generator module according to the present application may be flexibly arranged above a nacelle or inside the nacelle according to requirements, and may be separately replaced and maintained as an independent subsystem, which reduces the maintenance cost.