Wind Turbine Rotor Pitch System Wear Distribution
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Solution Overview
Problem
Existing wind turbine pitch systems with gearing mechanisms suffer from fretting corrosion and premature wear due to repetitive contact between gear teeth, leading to reduced lifespan and increased maintenance costs, particularly at nominal wind speeds.
Innovation Solution
A wind turbine rotor design featuring a pitch system with a flange and intermediate support having an off-center opening, allowing the drive pinion to mesh with different sections of the gear, thereby distributing wear across multiple teeth and extending the gear's lifespan without compromising robustness or normal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a pitch system with gearing is used, then the blade can be rotated to adapt to varying wind conditions, but the repetitive contact between gear teeth causes fretting corrosion and premature wear
Solution Approach 1:
The gear is divided into multiple functional sections (first section and second section) that can be selectively engaged by the pinion. The intermediate support enables the pinion to mesh with different gear sections, distributing wear across multiple tooth sets rather than concentrating it on a single section, thereby extending the overall gear system lifespan while maintaining pitch adjustment functionality.
2Device complexity
If the pinion meshes with a fixed section of the gear, then the structure is simple, but wear is concentrated on the same teeth leading to premature failure
Solution Approach 1:
The intermediate support is designed to be movable relative to the flange, enabling dynamic reconfiguration of the pinion-gear meshing position. This allows the system to switch between different gear sections based on wear patterns or operational requirements, transforming a static wear concentration problem into a dynamic wear distribution system that extends component life.
3Reliability
If an automatic lubrication system is provided, then fretting corrosion can be reduced to some extent, but the underlying problem of teeth contact remains and damaged teeth still require whole gear replacement
Solution Approach 1:
The gear is segmented into multiple usable sections that can be independently accessed by the pinion through the movable intermediate support. This segmentation allows the system to bypass worn or damaged tooth sections and engage fresh teeth, eliminating the need for whole gear replacement and reducing dependency on lubrication systems to prevent all wear-related failures.
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 effectively extends the life of the gear by allowing easy reconfiguration of the pinion's contact points, reducing wear concentration and maintaining system robustness, while being cost-effective and simple to maintain.
Implementation Method 1
a gear and a pitch drive. The pitch drive is arranged on a flange and has a motor and a pinion which meshes with the gear
Data Source
AI summary
Wind turbine rotor comprising a hub, a plurality of blades and at least one pitch system for rotating a blade substantially along its longitudinal axis. The pitch system comprises a bearing, a gear and a pitch drive. The pitch drive is arranged on a flange and has a motor and a pinion which meshes with the gear. The flange is provided with a hole and an intermediate support is concentrically arranged with respect to the hole. The intermediate support comprises an off-center opening with respect to a central axis of the hole and the pitch drive is mounted through said off-center opening. The position of the off-center opening is such that the intermediate support can be arranged in a first and a second position in which the drive pinion meshes with a first and second section of the gear respectively.