Intermediate Shaft Mounting With Split Bearings for Tight Gearbox Space
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Solution Overview
Problem
In wind power plants and other applications, the limited installation space poses a challenge for gearbox mountings, particularly due to the large space requirements of traditional bearing units combining radial and axial slide bearings, which hinder compact designs and efficient use of materials.
Innovation Solution
A compact mounting solution for an intermediate shaft of a gearbox is achieved by positioning radial and axial bearings directly on the shaft ends, eliminating the need for a fixed bearing unit, allowing for minimal installation space usage and optimizing the housing structure, with axial bearings integrated into the shaft ends and lubrication provided through oil sumps, enabling efficient lubrication and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed bearing unit combining radial and axial slide bearings is used, then reliable bearing functionality is achieved, but installation space requirements increase significantly
Solution Approach 1:
The fixed bearing unit is divided into separate components: radial slide bearings are positioned independently at shaft ends, and axial slide bearings are integrated into shaft end faces. This segmentation allows each bearing type to occupy minimal space individually rather than requiring a large combined bearing unit, directly resolving the contradiction between reliability and installation space requirements
Solution Approach 2:
Axial slide bearings are integrated into the shaft end faces, utilizing the axial dimension of the shaft structure. This dimensional integration allows axial bearings to be accommodated within the existing shaft geometry rather than requiring additional radial space, effectively reducing the overall installation footprint while maintaining bearing functionality
2Ease of manufacture
If a fixed bearing unit with intermediate body is used, then bearing components are properly accommodated, but device complexity and material usage increase
Solution Approach 1:
The intermediate body component is completely removed from the design. Instead of using an intermediate body to accommodate bearing components, the patent positions radial slide bearings directly at shaft ends and integrates axial slide bearings into shaft end faces. This extraction of the intermediate body simplifies the overall structure, reduces component count, and decreases material usage while maintaining ease of manufacture through direct mounting
Solution Approach 2:
The functions of the intermediate body and shaft end structure are merged. The shaft end faces directly provide the mounting surfaces for both radial and axial bearings, eliminating the need for a separate intermediate body. This merging reduces device complexity and material usage while maintaining the structural integrity needed for bearing accommodation
Data Source
AI summary
A mounting of an intermediate shaft of a gearbox includes a gear element disposed between a first shaft end and a second shaft end of the intermediate shaft. A first radial bearing is disposed at the first shaft end of the intermediate shaft, a second radial bearing is disposed at the second shaft end of the intermediate shaft, a first axial bearing is disposed at the first shaft end of the intermediate shaft, and a second axial bearing is disposed at the second shaft end of the intermediate shaft.