Wind Turbine Rotor Lock Shaft Angular Drive Mechanism
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Solution Overview
Problem
Current rotor locking mechanisms in wind turbines face challenges in withstanding increasing torque and long-term wear due to larger blade sizes, requiring improved designs that can securely lock the rotor shaft during downtime without causing damage or injury.
Innovation Solution
A rotor lock system featuring a locking unit with a slidably movable locking shaft and angular drive arrangement, allowing for secure engagement with the rotor locking disk and distributing torque across multiple units to prevent rotation, ensuring the rotor shaft remains locked in a stationary position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rotor locking mechanism is designed to counteract large torque from larger blades, then the strength and reliability are improved, but the device complexity and wear resistance requirements increase
Solution Approach 1:
The locking mechanism is divided into multiple locking units (at least two) arranged around the rotor shaft, with each unit containing a locking shaft and barrel. This segmentation distributes the torque load across multiple independent units, allowing each unit to be simpler in design while collectively providing the necessary torque resistance for larger blades.
Solution Approach 2:
The locking shaft is designed with an engagement portion that has an oval vertical cross-section, allowing it to rotate within the barrel about its longitudinal axis. This rotational degree of freedom in a different dimension enables the locking shaft to engage with the rotor locking disk at optimal angles while maintaining a compact overall structure.
2Device complexity
If the locking shaft is designed with fixed orientation for engagement, then the device complexity is reduced, but the adaptability to different positions and orientations is worsened
Solution Approach 1:
The locking shaft is designed with dynamic capability to rotate about its longitudinal axis within the barrel, transforming from a static fixed-orientation component to a dynamic one. This allows the engagement portion to adapt its orientation relative to the rotor locking disk during the locking process, improving versatility without significantly increasing complexity through the use of the helical guide and rider formations.
Solution Approach 2:
The helical guide formation in the barrel and the complementary helical rider formation on the locking shaft act as intermediaries that facilitate the rotational movement. These helical elements translate the linear motion of the locking shaft within the barrel into controlled angular movement, enabling flexible engagement orientations.
3Reliability
If multiple locking units are used to distribute torque, then the reliability and torque distribution are improved, but the device complexity increases
Solution Approach 1:
The locking system is segmented into multiple identical or similar locking units arranged around the rotor shaft, with each unit containing a locking shaft, barrel, and actuator. This modular segmentation provides reliable torque distribution across multiple units while maintaining ease of manufacture and assembly through standardization.
Solution Approach 2:
Each locking unit is designed as a universal module that can perform the same function (locking engagement) independently. The locking shaft in each unit can rotate within its barrel and engage with the rotor locking disk, providing both torque distribution and functional redundancy. This multi-functionality within each unit improves reliability without requiring complex coordination between units.
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
The system effectively secures the rotor shaft by distributing torque and preventing rotation, reducing wear and ensuring safety during maintenance and downtime, while accommodating the increased torque and weight of larger blades.
Implementation Method 1
The angular drive arrangement comprises a helical guide or track formation defined by the barrel and a complementary helical rider or follower formation defined by the locking shaft. Advantageously, engagement between the complementary helical guide and rider formations enables the locking shaft to smoothly and continuously move in an angular manner about its longitudinal axis as it is driven axially within the barrel by the actuator.
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A locking unit (24) for a rotor lock system (20) of a wind turbine (1), the locking unit (24) comprising:a locking shaft (34) that is slidably movable within a barrel (30) under the influence of an actuator (32); and an angular drive arrangement (48, 50) which is configured to enable angular movement of the locking shaft (34) about a longitudinal axis as the locking shaft (34) is moved linearly within the barrel (30) by the actuator (32).