Integral-Stiffened Slewing Ring Races for Load Deformation Control
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Solution Overview
Problem
Conventional slewing ring bearings in wind turbines face structural integrity issues due to uneven load distribution, leading to deformation and premature failure under varying loads, as they require separate stiffeners that complicate manufacturing and increase production inefficiencies.
Innovation Solution
The method involves manufacturing slewing ring bearings using near-net-shape ring rolling techniques to integrate a stiffening region directly into the bearing races, eliminating the need for separate stiffeners and enhancing load distribution by forming inner and outer races with integral stiffening regions, thereby reducing stress and machining waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forging process is used to manufacture inner and outer races, then manufacturing precision and structural integrity can be maintained, but production time and cost increase significantly
Solution Approach 1:
The stiffening regions are integrated into the bearing races during the initial ring rolling process rather than being added separately afterward. This preliminary action eliminates subsequent manufacturing steps and reduces production time while maintaining structural integrity.
Solution Approach 2:
The patent combines the bearing race and stiffening regions into a single integrated component manufactured in one process. The ring rolling process simultaneously forms both the bearing race and the stiffening regions, merging what were previously separate manufacturing operations.
2Strength
If separate stiffeners are added to bearing races, then structural strength under varying loads is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The stiffening regions are merged with the bearing races into a single integrated structure. The ring rolling process forms both components simultaneously, eliminating the need for separate stiffener parts and their associated attachment steps, thereby reducing device complexity while maintaining strength.
Solution Approach 2:
The integrated structure combines the bearing race material with strategically positioned stiffening regions in a composite-like arrangement, where different regions of the same component serve different functional purposes - the bearing race portion handles rolling contact while the stiffening regions provide structural rigidity under varying loads.
3Loss of substance
If conventional manufacturing processes are used, then material waste is generated, but environmental sustainability is compromised
Solution Approach 1:
The near-net-shape ring rolling process forms the bearing races and stiffening regions close to their final dimensions in a single step, minimizing material removal and waste generation. This preliminary forming action preserves material and supports environmental sustainability.
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 approach streamlines the manufacturing process, reduces material waste, and enhances the structural integrity of slewing ring bearings by evenly distributing loads, minimizing the risk of deformation and failure, while allowing for production flexibility with the same equipment.
Implementation Method 1
forming the mass, via ring rolling, into an outer race of the slewing ring bearing
Data Source
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AI summary
The present disclosure is directed to methods for manufacturing a wind turbine slewing ring bearing having an integral stiffener configured to resist deformation of the bearing under a load. More specifically, the present disclosure is directed to methods for manufacturing components of a slewing ring bearing (e.g., an inner, center, and outer race) using near-net-shape (NNS) ring rolling techniques. In particular, the present disclosure is directed to methods for manufacturing slewing ring bearing races, via NNS ring rolling, that are not restricted to conventional (e.g., generally square, rectangular, quadrilateral, trapezoid, quadrilateral) cross-sectional profiles that necessitate attachment of a separate, non-integral stiffener (e.g., a non-integral stiffening plate, stiffening ring, or stiffening assembly).