Modular Wind Turbine Gearbox for Symmetrical Force Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Wind turbine gearboxes face high strain due to asymmetrical force flow and mechanical imbalances, leading to complex and costly replacements, especially in offshore settings where only complete gearbox replacement is feasible, resulting in prolonged downtime.
Innovation Solution
A modular gearbox design with satellite units having two gear shafts and an output shaft, allowing for independent operation and replacement of generators, with symmetrical force distribution and easy handling, enabling individual part replacement and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional gearbox design with satellite units is used, then power transmission is achieved, but asymmetrical force flow causes planetary shafts to twist and reduces tooth contact surface area
Solution Approach 1:
The satellite unit is divided into multiple independent satellite gears (first satellite gear, second satellite gear, etc.) that can be independently replaced. Each satellite gear forms a separate operative connection with the sun gear and output pinion shaft, allowing individual component replacement without dismantling the entire gearbox.
Solution Approach 2:
The satellite unit is designed with a replaceable structure where satellite gears can be removed and replaced independently. This dynamic configuration allows maintenance personnel to replace only the damaged satellite gear rather than the entire planetary shaft assembly, reducing downtime and maintenance complexity.
2Reliability
If the sun gear is damaged in a conventional gearbox, then the entire gearbox must be dismantled for replacement
Solution Approach 1:
The gearbox is segmented into modular components including the sun gear, multiple satellite units, and housing. Each satellite unit can be independently removed from the sun gear, allowing selective replacement of damaged components without affecting other parts of the system.
Solution Approach 2:
Damaged satellite gears can be discarded and replaced individually while retaining the sun gear, output pinion shafts, and other intact components. This selective replacement approach recovers valuable components and avoids the need to discard the entire gearbox assembly.
3Volume of moving object
If a compact gearbox structure is used, then space is saved but service friendliness is reduced and replacement becomes more complex
Solution Approach 1:
The compact gearbox maintains its space-efficient design while incorporating segmented satellite units that can be independently accessed and replaced. The modular satellite gears are designed to be removable from the sun gear without requiring complete gearbox disassembly, enabling easy maintenance despite the compact overall structure.
4Weight of moving object
If the gearbox weight exceeds crane capacity, then complete replacement is required, but this increases downtime and cost
Solution Approach 1:
The gearbox is divided into lighter modular components including individual satellite units that can be replaced separately. This segmentation enables replacement of damaged parts using available crane capacity without requiring complete gearbox replacement, significantly reducing downtime and maintenance costs.
Data Source
AI summary
A method of replacing components of a gearbox and a gearbox of the wind power plant for a wind turbine includes a gearbox with a sun gear couplable to a rotor of a wind power plant. The sun gear is arranged rotatably about a rotor axis. The gearbox has a plurality of satellite units and a plurality of generators. Each satellite unit has two gear shafts and one output shaft. The two gear shafts are respectively in engagement with the sun gear and the output shaft. Each generator is associated with one of the plurality of satellite units. The plurality of satellite units are arranged and distributed over a periphery of the sun gear and are operatively connected with the sun gear. The plurality of satellite units have a modular configuration design and are releasably arranged at the sun gear.