Multiple Sun Gear Planetary Gearbox Torque Distribution
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Solution Overview
Problem
Wind turbine gearboxes, particularly those with planetary gear systems, face high torque loads that lead to increased wear and failure due to the concentration of torque on a single sun gear, affecting durability and reliability.
Innovation Solution
The implementation of multiple sun gears within the gearbox, with torque distributed among them, either through separate planet stages or configurations that allow for the distribution of rotational force across multiple sun gears, reducing the load on individual components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sun gear is used in the planetary gearbox, then the structure is simpler, but the torque concentration leads to increased wear and failure rates
Solution Approach 1:
The single sun gear is segmented into multiple sun gears (first sun gear and second sun gear) that are distributed around the planet carrier. This segmentation divides the torque load among multiple components, reducing the stress on each individual sun gear and thereby improving reliability without significantly complicating the overall structure.
2Reliability
If multiple sun gears are implemented to distribute torque, then the reliability and durability improve, but the device complexity increases
Solution Approach 1:
Multiple sun gears are merged with the planet carrier structure, where the planet carrier simultaneously supports both the planet pinions and the multiple sun gears. This merging approach allows torque distribution across multiple sun gears while maintaining a compact integrated structure, minimizing the increase in device complexity.
3Device complexity
If torque is concentrated on a single sun gear, then the gearbox structure is more compact, but the wear and failure rates increase
Solution Approach 1:
The torque load is segmented across multiple sun gears arranged circumferentially on the planet carrier. This segmentation distributes the harmful torque concentration into multiple smaller load paths, reducing wear and failure rates while maintaining a compact radial arrangement that does not significantly increase the gearbox envelope.
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 enhances the durability and reliability of the gearbox by distributing the high torque across multiple sun gears, reducing wear and failure rates and improving overall gearbox performance.
Implementation Method 1
The planet pinions are at spaced locations on the planet carrier around the central axis, with the axes of the planet pinions extending generally parallel to the central axis of the planet carrier. A planet gear is located on each of the planet pinions, and a plurality of sun gears rotate about the central axis and are engageable by the planet gears.
Data Source
AI summary
A gearbox is provided having multiple sun gears and one or more planet stages. The planet stages can include a first planet stage and a second planet stage. A first sun gear is connected to the first planet stage, and a second sun gear is connected to the second planet stage. The torque transmitted from the planet stages is at least partially distributed among the first sun gear and the second sun gear.