Planetary Gear Shifting Layout for High-Torque Wind Turbines
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Solution Overview
Problem
Conventional wind turbine generator systems face limitations in torque load capacity and transmission ratio due to the simple planetary gear train design, which cannot meet the requirements of high torque load capacity and large transmission ratio simultaneously while maintaining a small volume.
Innovation Solution
A gearbox design featuring a first planetary-gear-train support sleeve with a radially floatable pinion and staggered bull gears, allowing torque sharing between the planetary idle gear and pinion, and utilizing a self-aligning bearing or flexible connection shafts to achieve high torque load capacity and large transmission ratio within a small volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the number of planetary gears is increased to improve torque load capacity, then the torque load capacity is improved, but the transmission ratio decreases
Solution Approach 1:
The planetary gear train is segmented into multiple independent planetary gear sets (first, second, third planetary gear sets) with different transmission ratios. Each planetary gear set processes torque through parallel paths, allowing the system to achieve high torque load capacity while maintaining a large overall transmission ratio. The segmentation enables torque distribution across multiple gear meshes without compromising the transmission ratio of individual sets.
2Volume of stationary object
If a simple planetary gear train is used to maintain small volume, then the volume is reduced, but the torque load capacity is limited
Solution Approach 1:
Multiple planetary gear sets are nested within a compact housing structure, with gear sets arranged concentrically and sharing common mounting features. The first, second, and third planetary gear sets are positioned to utilize shared support sleeves and bearing arrangements, enabling high torque load capacity within a minimized volume envelope.
Solution Approach 2:
Multiple planetary gear sets are combined in parallel within a single gearbox housing, with input and output shafts serving multiple gear sets simultaneously. The combined configuration allows torque to be distributed across multiple planetary gear meshes, achieving high torque load capacity without proportionally increasing the gearbox volume.
3Strength
If the engagement force on each gear tooth is increased to improve torque capacity, then the torque load capacity is improved, but the reliability decreases due to increased stress
Solution Approach 1:
The total torque load is segmented and distributed across multiple planetary gear sets, each handling a portion of the total torque. This segmentation reduces the engagement force on individual gear teeth while maintaining the overall torque load capacity of the gearbox.
Solution Approach 2:
Each planetary gear set is designed with optimized gear tooth geometry and material properties suited to its specific torque requirements. The local quality of each gear mesh is tailored to distribute stress evenly, preventing localized overload and improving reliability.
Data Source
AI summary
A gear shifting device includes a first planetary gear train. The first planetary gear train includes a first ring gear, a first planet carrier, a first planet gear, a sun idler, and a planet idler; the planet idler and the first planet gear are both installed on the first planet carrier; the first planet gear includes a pinion and a bull gear coaxially connected to the pinion; the planet idler and the pinion are both meshed with the inside of the first ring gear and are both meshed with the outside of the sun idler; the pinion can float in the radial direction relative to the first planet carrier; an input shaft is further provided; one end of the input shaft is connected to the first ring gear.