Planetary Wind Gearbox Layout for Compact High-Power Transmission
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Solution Overview
Problem
Traditional wind power gearboxes are bulky and complex, making them difficult to manufacture, transport, and assemble, and they occupy significant space, which is a challenge for the development of high-power wind power units with improved efficiency and cost-effectiveness.
Innovation Solution
A compact wind power generation transmission system is designed with a multi-stage planetary gearset configuration, including a hollow sun gear and external/internal splines for connecting planetary carriers, reducing weight and axial dimensions, and integrating the gearbox, main shaft system, and generator for reduced space occupation and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional wind power gearbox structure is used with main shaft connected through shrink disk or flange, then torque transmission is achieved, but the structure becomes complicated and bulky
Solution Approach 1:
The patent merges the main shaft connection function directly into the planetary carrier structure. The planetary carrier integrates both the torque transmission function and the connection interface for the main shaft, eliminating the need for separate shrink disks or flanges. This integration reduces structural complexity and removes unnecessary components while maintaining torque transmission capability.
Solution Approach 2:
The patent employs nested structure where the planetary carrier is positioned within the planetary gear assembly, and the main shaft connects directly to this nested configuration. The planetary gears are arranged around the sun gear with the planetary carrier nested in the middle, creating a compact layered structure that reduces overall gearbox volume and weight.
2Power
If high-power units are used to replace small-power units, then power generation efficiency improves, but the volume and weight of gearbox increase making transportation and assembly difficult
Solution Approach 1:
The patent uses nested arrangement where planetary gears are positioned around the sun gear, and the planetary carrier is nested within the ring gear. This concentric nesting allows high-power torque transmission while minimizing the radial and axial dimensions of the gearbox, keeping weight manageable despite increased power capacity.
Solution Approach 2:
The patent optimizes the spatial arrangement by utilizing three-dimensional concentric positioning. The sun gear is at the center, planetary gears are arranged radially around it, and the ring gear encloses the entire planetary mechanism. This dimensional optimization allows high power transmission through efficient load distribution across multiple gears in three-dimensional space, reducing the need for excessive material and weight.
3Power
If high-power units are used to replace small-power units, then power generation efficiency improves, but the volume of gearbox increases making machining and transportation difficult
Solution Approach 1:
The patent employs nested concentric arrangement where the planetary gears are positioned within the annular space between the sun gear and ring gear. This nested configuration maximizes the use of available space, allowing high-power torque transmission without proportionally increasing gearbox volume. The compact nested structure enables efficient power density.
Solution Approach 2:
The patent combines multiple functional elements into integrated components. The planetary carrier serves multiple functions: supporting planetary gears, transmitting torque, and providing the connection interface for the main shaft. This functional merging reduces the number of separate components and minimizes overall gearbox volume while maintaining high power transmission capability.
4Power
If traditional gearbox structure with separate connection components is used, then torque transmission is achieved, but space occupation increases
Solution Approach 1:
The patent merges the connection function into the planetary carrier structure itself. The planetary carrier is designed with an integrated interface that directly connects to the main shaft, eliminating the need for separate shrink disks or flanges. This integration reduces the axial length and overall volume of the gearbox while maintaining full torque transmission capability.
Solution Approach 2:
The planetary carrier serves multiple functions simultaneously: it supports the planetary gears, transmits torque from the sun gear to the ring gear, and provides the connection interface for the main shaft. This multi-functionality reduces the number of separate components needed, minimizing gearbox volume while achieving all necessary mechanical functions.
Data Source
AI summary
Provided is a wind power generation transmission system. A first sun gear is a hollow gear. The first sun gear includes a first end surface and a second end surface opposite to the first end surface. A second planetary carrier includes a third connection end. An outer circumferential surface of the third connection end is provided with external splines. An inner circumferential surface of the first sun gear is provided with internal splines. The third connection end of the second planetary carrier extends from the second end surface to the first end surface and is disposed in the first sun gear so that the external splines of the third connection end are connected to the internal splines of the first sun gear.