Slewing Ring Bearing Races With Integral Stiffeners for Load Distribution
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Solution Overview
Problem
Conventional slewing ring bearings in wind turbines face challenges due to uneven load distribution and high stress levels, leading to potential damage and deformation from varying loads and stiffness differences between the hub and rotor blades.
Innovation Solution
The method involves manufacturing slewing ring bearings with integral stiffeners using near-net-shape ring rolling techniques, which integrate a stiffening region into the bearing races, reducing the need for separate stiffeners and enhancing load distribution.
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 strength can be achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The bearing race manufacturing process is segmented into two stages: (1) near-net-shape forming via ring rolling to create the basic geometry, and (2) selective forging only for critical load-bearing areas. This segmentation allows the majority of the component to be produced efficiently through rolling while maintaining strength where needed through targeted forging operations.
Solution Approach 2:
The ring rolling process performs preliminary forming of the bearing race to near-final dimensions and geometry before any forging operations. This preliminary action removes the bulk of material and establishes the basic shape, so that subsequent forging only needs to refine critical areas, significantly reducing total manufacturing time.
2Reliability
If separate stiffeners are added to bearing races, then load distribution improves, but device complexity and assembly steps increase
Solution Approach 1:
The stiffening function and the bearing race structure are merged into a single integrated component. The ring rolling process directly forms the bearing race with built-in stiffening geometries (such as flanges, ribs, or thickened sections) that provide load distribution without requiring separate stiffener components or additional assembly steps.
Solution Approach 2:
The bearing race is designed to perform multiple functions simultaneously: it serves as the load-bearing surface for roller elements, provides structural support through its geometry, and incorporates integrated stiffening features for load distribution. This multi-functionality eliminates the need for separate dedicated stiffener components.
3Strength
If bearing races are designed with high stiffness to resist deformation, then strength under load improves, but stress concentration increases leading to premature failure
Solution Approach 1:
The bearing race structure employs local quality variations where different regions have different stiffness characteristics. High-stiffness zones are concentrated in areas experiencing maximum loads (such as under roller element contact points), while other regions maintain lower stiffness to allow stress redistribution. This gradient in local stiffness prevents stress concentration while maintaining overall structural strength.
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 reduces stress on the bearings, decreases the likelihood of premature failure, and streamlines the manufacturing process by eliminating the need for additional assembly steps and equipment changes, while allowing for efficient production of bearing races with or without integral stiffeners.
Implementation Method 1
forming the mass, via ring rolling, into an outer race of the slewing ring bearing
Data Source
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).