Sun Shaft Spline Integration for High-Torque Planetary Transmissions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Wind turbine transmissions with two planetary stages face challenges in efficiently transmitting torque while minimizing material costs and stress, particularly in designing compact structures that can handle higher torques.
Innovation Solution
The integration of a spline joint with an internal toothing formed by the sun gear and an external toothing formed by a web of the planet carrier or sun shaft allows for conjoint rotation, reducing material costs by enabling the use of less expensive materials and accommodating higher torque transmission, while the axial overlap and bearing arrangements help in load compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional spline joint design is used to connect the sun gear and planet carrier, then the structure can transmit torque, but the material costs increase and the structure becomes more complex
Solution Approach 1:
The invention merges the spline joint functionality directly into the sun gear structure by integrating the internal toothing with the sun gear body, eliminating the need for a separate spline joint component. This integration reduces the number of parts, simplifies manufacturing, and lowers material costs while maintaining torque transmission capability between the sun gear and planet carrier
Solution Approach 2:
The sun gear is designed to serve multiple functions: it acts as both the driving element in the first planetary stage and as part of the connection structure to the planet carrier of the second stage through its integrated internal toothing. This multi-functionality reduces the overall component count and simplifies the transmission structure
2Power
If high-strength materials are used for the sun shaft to handle higher torques, then torque transmission capacity increases, but material costs increase
Solution Approach 1:
The sun shaft and the first web of the planet carrier are merged into a single integrally formed component. This integration eliminates the need for a separate sun shaft made of high-strength material, as the combined structure achieves the required torque transmission capacity through its optimized geometry and the integral connection, thereby reducing material costs
3Power
If the sun gear and planet carrier are connected by a separate spline joint, then torque transmission is possible, but the device complexity increases
Solution Approach 1:
The invention combines the sun gear and the connection structure into a unified design where the sun gear's internal toothing directly forms the spline joint interface. This merging eliminates separate connection components, reduces assembly steps, and simplifies the overall device structure while maintaining the torque transmission function between the first and second planetary stages
Data Source
AI summary
A wind turbine transmission including a first planetary stage and a second planetary stage, wherein a sun gear of the first planetary stage and a planet carrier of the second planetary stage are interconnected for conjoint rotation by means of a spline joint, the sun gear integrally forms an internal toothing, and a first web of the planet carrier or a sun shaft integrally connected to the first web integrally forms an external toothing of the spline joint.