Split Wind Turbine Bearing Arrangement for Easier Assembly
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Solution Overview
Problem
The manufacturing and assembly of large wind turbine bearing arrangements are complicated and expensive due to the size and weight of single-piece bearing housings and drive shafts, which are difficult to manufacture, transport, and assemble, and require specific cleanliness and handling procedures.
Innovation Solution
A split bearing arrangement where the bearing housing and drive shaft are formed from multiple separate pieces that can be easily joined, allowing for more flexible assembly and reduced costs, with radial fluid bearings and axial bearings that enable efficient load transfer and maintenance without the need for large assembly fixtures or dedicated cranes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece bearing housing and drive shaft are used, then the structural integrity and load-bearing capacity are improved, but the manufacturing difficulty, transportation complexity, and assembly cost increase significantly
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 manufactured separately and then assembled together. The drive shaft is also segmented into multiple pieces that can be manufactured and transported independently. This segmentation resolves the contradiction by enabling easier manufacturing and transportation while maintaining structural integrity through proper joining of segments.
2Reliability
If a single-piece bearing housing is used, then the lubrication cleanliness is maintained, but the size and weight make transportation and assembly difficult
Solution Approach 1:
The bearing housing is segmented into multiple smaller sections that can be manufactured and transported separately. The segments are designed to be assembled in a controlled manner that preserves lubrication cleanliness, resolving the contradiction between maintaining reliability and reducing weight/transportation difficulty.
Solution Approach 2:
The segmented bearing housing sections are designed to fit together in a nested or telescoping arrangement, allowing the segments to be transported in a compact configuration and then assembled to form the complete bearing housing. This approach maintains lubrication cleanliness while enabling easier transportation.
3Manufacturing precision
If a single-piece drive shaft is used, then the rotational precision is improved, but the machining and handling become very difficult and expensive
Solution Approach 1:
The drive shaft is divided into multiple segments that can be manufactured with standard tolerances and then joined together to form the complete drive shaft. The joining interfaces are designed to maintain the required rotational precision and bearing raceway tolerance, resolving the contradiction between manufacturing precision and machining complexity.
4Area of stationary object
If a large single-piece bearing housing is used, then the bearing arrangement can accommodate large drive shafts, but the nacelle assembly requires dedicated cranes and large fixtures
Solution Approach 1:
The bearing housing is segmented into smaller sections that can be assembled in a more flexible manner without requiring dedicated cranes and large fixtures. The segments can be assembled in a modular fashion that improves ease of operation while maintaining the capacity to accommodate large drive shafts.
Solution Approach 2:
The segmented bearing housing design allows for dynamic assembly procedures where segments can be positioned and joined in sequence, providing greater flexibility in nacelle assembly operations compared to handling a single large rigid housing.
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 simplifies the manufacturing, handling, and assembly of wind turbine bearing arrangements, reducing costs and enhancing assembly flexibility while maintaining high load-bearing capacity and cleanliness independence.
Implementation Method 1
a downwind bearing and an upwind bearing as radial fluid bearings
Data Source
AI summary
Provided is a bearing arrangement for a wind turbine including a bearing housing and a drive shaft, whereby the drive shaft is arranged within the bearing housing in an axial direction along a longitudinal axis of the bearing housing, the bearing arrangement further comprising a downwind bearing and an upwind bearing as radial fluid bearings, whereby the downwind bearing and the upwind bearing are arranged between the bearing housing and the drive shaft, whereby the bearing housing is formed from at least two separate bearing housing pieces, whereby the at least two separate bearing housing pieces are joined with each other and/or the drive shaft is formed from at least two separate drive shaft pieces, whereby the at least two separate drive shaft pieces are joined with each other.