Multi-Surface Yaw Braking for Wind Turbines
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Solution Overview
Problem
Conventional yaw braking systems in wind turbines face significant loads, material limitations, increased size, high maintenance costs, noise, and vibration due to large loads, and are inefficient in terms of space and energy usage.
Innovation Solution
The implementation of a yaw braking system using multiple braking discs to distribute and reduce loads, allowing for smaller brake components made from conventional materials, reduced actuation forces, and lower wear, noise, and vibration, with the option to scale braking force by adjusting the number of discs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional single brake disc design is used, then braking force can be achieved, but brake size and material requirements increase significantly
Solution Approach 1:
The single brake disc is segmented into multiple brake discs (typically three) that are distributed around the yaw axis. Each disc engages with its own brake caliper, dividing the total braking force requirement across multiple smaller components. This segmentation allows the same total braking force to be achieved with smaller individual brake components, reducing the volume and size requirements for each brake assembly.
2Force
If conventional single brake disc design is used, then braking force can be achieved, but material strength requirements increase
Solution Approach 1:
By dividing the braking system into multiple discs and calipers, the force and stress loads on each individual component are reduced. Each brake caliper and disc experiences only a portion of the total braking force, allowing the use of conventional materials with lower strength requirements compared to a single-disc design that would concentrate all forces on one component.
3Ease of operation
If conventional single brake disc design is used, then braking function is provided, but space consumption increases
Solution Approach 1:
The brake discs are arranged in a distributed pattern around the yaw axis, allowing compact positioning within the available space. This segmentation enables the braking system to fit within the nacelle's limited space envelope, as the multiple smaller discs occupy less total volume and can be positioned more efficiently than a single large disc.
4Force
If conventional single brake disc design is used, then braking force is achieved, but actuating system demands increase
Solution Approach 1:
The actuating system is divided into multiple independent actuators, each controlling a separate brake caliper. This segmentation reduces the power and force requirements for each individual actuator compared to a single actuator that would need to apply the full braking force. The total braking force is achieved through the combined action of multiple lower-power actuators.
5Ease of operation
If conventional single brake disc design is used, then braking function is provided, but wear and failure rates increase
Solution Approach 1:
The braking function is distributed across multiple independent disc-caliper-actuator assemblies. This segmentation means that wear is distributed across multiple friction surfaces, and the failure of one assembly does not necessarily compromise the entire braking system. The redundancy provided by multiple assemblies improves overall reliability and reduces wear rates on individual components.
6Force
If conventional single brake disc design is used, then braking force is achieved, but noise and vibration increase
Solution Approach 1:
The braking force is applied through multiple separate disc-caliper assemblies positioned at different locations around the yaw axis. This segmentation distributes the mechanical impacts and friction-generated vibrations across multiple isolated contact points, reducing the overall noise and vibration levels compared to a single large-brake design where all forces concentrate at one location.
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 reduces maintenance and material costs, decreases noise and vibration, and allows for more efficient use of space and energy, while enabling the use of electrical actuators and noise dampening features.
Implementation Method 1
a first set of brake discs (60, 62) that are interleaved about the yaw axis (36)... each brake (66) urges the brake discs (60, 62) and friction rings (64) towards one another to create friction
Data Source
Figure 1
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AI summary
A wind turbine (20) includes a tower (22) and a nacelle (24) supported on the tower (22) and configured for rotation relative to the tower (22) about a yaw axis (36). One or more brake discs (60 or 94 or 112 or 136 or 166 or 190) are fixed to the tower (22) and disposed about the yaw axis (36). One or more brake discs (62 or 96 or 114 or 138 or 168 or 192) are also fixed to the nacelle (24) and disposed about the yaw axis (36). The brake discs (62 or 96 or 114 or 138 or 168 or 192) fixed to the nacelle (24) are aligned with the brake discs (60 or 94 or 112 or 136 or 166 or 190) fixed to the tower (22). The brake discs (60, 62 or 94, 96 or 112, 114 or 136, 138 or 166, 168 or 190, 192) may be aligned in a direction parallel to the yaw axis (36) or in a radial direction relative to the yaw axis (36). One or more yaw brakes (66 or 100 or 118 or 140 or 172 or 196) are configured for movement between a first position in which the yaw brake (66 or 100 or 118 or 140 or 172 or 196) applies a first braking force to the brake discs (60, 62 or 94, 96 or 112, 114 or 136, 138 or 166, 168 or 190, 192) and a second position in which the yaw brake (66 or 100 or 118 or 140 or 172 or 196) applies a second braking force to the brake discs (60, 62 or 94, 96 or 112, 114 or 136, 138 or 166, 168 or 190, 192) greater than the first braking force.