Modular Wind Turbine Gear Unit for Easier Satellite Replacement
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Solution Overview
Problem
Current wind turbine gearbox designs face challenges with asymmetrical power flow, high maintenance complexity, and the need for replacing entire systems due to high weight and mechanical imbalances, making individual part replacement difficult and costly, especially in offshore environments.
Innovation Solution
The design features modular, detachable satellite units with two splined shafts and an output shaft, allowing for symmetrical power distribution and easy maintenance, where satellite units can be rotated and removed using an on-board crane, and the gearbox housing is designed to rotate around the sun wheel for improved accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional planetary gearbox design is used with fixed satellite units, then power transmission is achieved, but maintenance complexity increases and individual part replacement becomes difficult due to high weight and mechanical imbalances
Solution Approach 1:
The gearbox is divided into modular satellite units that can be independently removed and replaced. Each satellite unit is a self-contained module with its own bearings and gear components, allowing individual replacement without disassembling the entire gearbox structure.
Solution Approach 2:
The satellite units are designed with detachable connections to the sun wheel, enabling dynamic reconfiguration and removal. The units can be detached and reattached during maintenance operations, transforming the static gearbox into a maintainable system.
2Reliability
If entire gearbox replacement is performed due to damage, then reliability is restored, but loss of time and productivity increase due to prolonged downtime and complex replacement procedures
Solution Approach 1:
By segmenting the gearbox into replaceable satellite units, only the damaged component needs to be replaced rather than the entire system. This dramatically reduces replacement time and restores reliability faster.
Solution Approach 2:
Damaged satellite units can be quickly removed and replaced with new or refurbished units. The ability to swap individual modules enables rapid recovery of system operation with minimal downtime.
3Power
If asymmetric power flow through planetary shafts is used, then power transmission is achieved, but the shafts twist under load reducing tooth contact areas and increasing loads
Solution Approach 1:
The invention intentionally introduces asymmetry through adjustable shims between the satellite unit and sun wheel. This asymmetric adjustment compensates for the asymmetric loads, pre-loading the tooth contacts to prevent twisting and maintain optimal contact areas under operational loads.
4Volume of moving object
If gearbox is designed for compact size, then space is saved, but weight increases making individual part replacement impossible without mechanical assistance
Solution Approach 1:
Dividing the compact gearbox into smaller satellite units reduces the weight of individual components. Each unit is light enough to be handled by standard wind turbine maintenance equipment, enabling replacement in the confined nacelle space without external cranes.
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 solution enables easier maintenance, reduced weight, and increased power throughput with a lighter and smaller transmission design, allowing for independent operation of multiple generators and reducing the complexity of replacing individual parts, thus enhancing the overall maintenance friendliness and efficiency of the gearbox.
Implementation Method 1
The satellite units have two toothed shafts, which interact with each other via an output shaft, wherein the tooth ratios are designed in such a way that the output shaft has a higher rotational speed than the toothed shafts
Data Source
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AI summary
The subject matter of the invention is a gear unit (1) for a wind power plant, having a sun gear (11) which is arranged such that it can be rotated about a rotor axis (10), and which can be coupled to a rotor of the wind power plant, and wherein a plurality of satellite units (12) are arranged distributed over the circumference of the sun gear (11), which satellite units (12) are operatively connected to the sun gear (11) and can be driven via the generators (13) which can be assigned to the satellite units (12). According to the invention, the satellite units (12) have two splined shafts (14), which are in engagement in each case with the sun gear (11), and an output shaft (15), wherein the output shaft (15) is in engagement with the two splined shafts (14) and can be coupled to an associated generator (13), and wherein the satellite units (13) are of modular configuration and are arranged releasably on the sun gear (11).