Split Wind Turbine Bearing Housing for Flexible Clean Assembly
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Solution Overview
Problem
The manufacturing, transportation, and assembly of large wind turbine bearings are complicated and expensive due to their size and weight, requiring a single large bearing housing that complicates the construction of the nacelle and limits assembly flexibility.
Innovation Solution
A split bearing arrangement with a bearing housing and drive shaft formed from multiple pieces, joined by fasteners and flange portions, allowing for easier machining, handling, and assembly, and enabling offline assembly without dedicated cranes or large fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single large bearing housing is used to maintain lubrication cleanliness, then reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The bearing housing is divided into multiple segments (first bearing housing segment, second bearing housing segment, third bearing housing segment) that can be assembled together to form the complete housing. This segmentation allows for easier manufacturing, transportation, and assembly while maintaining the integrity of the lubrication system through proper sealing between segments.
2Reliability
If a single large bearing housing is used, then lubrication cleanliness is maintained, but ease of manufacture deteriorates
Solution Approach 1:
The bearing housing is divided into multiple segments that can be manufactured separately using standard machining processes, then assembled together. This approach makes manufacturing more feasible by breaking down a complex large-scale casting into manageable parts that can be produced with conventional equipment.
Solution Approach 2:
The bearing housing segments are pre-assembled offline before installation in the nacelle. This preliminary assembly allows for quality control and cleanliness to be established during assembly rather than requiring the entire housing to be manufactured as a single clean component.
3Reliability
If a single large bearing housing is used, then lubrication cleanliness is maintained, but ease of operation deteriorates
Solution Approach 1:
The segmented bearing housing can be assembled in a modular fashion, allowing for greater flexibility in assembly operations. The segments can be positioned and secured independently, facilitating easier installation and maintenance operations compared to a monolithic housing structure.
Solution Approach 2:
The bearing arrangement is pre-assembled offline in a controlled environment, which simplifies the on-site installation process. The pre-assembly allows for all bearing components to be positioned and secured before the housing segments are closed, improving operational ease during final installation.
4Reliability
If the bearing housing and drive shaft are made in one piece, then reliability is improved, but weight increases
Solution Approach 1:
The bearing housing is segmented into multiple parts that are joined together, allowing for weight optimization in each segment rather than requiring a single heavy monolithic structure. The segmentation enables more efficient material distribution and reduced overall weight while maintaining structural integrity through proper joint design.
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
Enhances assembly flexibility and reduces costs by facilitating easier handling and assembly of smaller, separable components, maintaining cleanliness and reducing the need for large assembly fixtures.
Implementation Method 1
downwind bearing and an upwind bearing as radial fluid bearings
Implementation Method 2
the bearing arrangement (70) comprises an axial bearing
Data Source
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AI summary
The invention relates to a bearing arrangement (70) for a wind turbine (10) comprising a bearing housing (80) and a drive shaft (90), whereby the drive shaft (90) is arranged within the bearing housing (80) in an axial direction along a longitudinal axis (A) of the bearing housing (80), the bearing arrangement (70) further comprising a downwind bearing (100) and an upwind bearing (200) as radial fluid bearings, whereby the downwind bearing (100) and the upwind bearing (200) are arranged between the bearing housing (80) and the drive shaft (90), whereby the bearing housing (80) is formed from at least two separate bearing housing pieces (81, 82, 83), whereby the at least two separate bearing housing pieces (81, 82, 83) are joined with each other and/or the drive shaft (90) is formed from at least two separate drive shaft pieces (91, 92, 93), whereby the at least two separate drive shaft pieces (91, 92, 93) are joined with each other. The invention further relates to a wind turbine (10) comprising a bearing arrangement (70), whereby the wind turbine (10) further comprises a rotor (50) operatively connected to drive the drive shaft (90) and a generator (40) operatively connected to be driven by the drive shaft (90).