Tiltable Planet Shaft for Load-Induced Gear Misalignment
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Solution Overview
Problem
Existing planetary stages in wind turbines face issues with gear misalignment due to deformations under load, leading to premature failure and increased wear, which requires rigid manufacturing tolerances and higher mass, space, and cost requirements.
Innovation Solution
A tiltable planetary shaft that can be orthogonally tilted relative to the planet carrier, allowing for self-alignment of gears to minimize load-induced misalignment, and a two-piece design for the planetary carrier and shaft for simplified assembly and reduced friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the planetary carrier is designed with high rigidity to maintain gear alignment, then gear misalignment is reduced, but mass and manufacturing costs increase
Solution Approach 1:
The invention replaces the static rigid fixation of planet gears with a dynamic tilting mechanism. The planet gears are mounted on tiltable planet shafts that can automatically adjust their orientation in response to load-induced deformations, maintaining proper meshing alignment without requiring excessive carrier rigidity or mass.
Solution Approach 2:
The invention changes the mounting parameter from fixed rigid connection to tiltable connection with one degree of freedom. This allows the planet shafts to adapt their angular position dynamically, compensating for deformations and maintaining gear alignment under varying load conditions.
2Reliability
If the planetary carrier is designed with high rigidity to maintain gear alignment, then gear misalignment is reduced, but manufacturing costs increase
Solution Approach 1:
The invention replaces the static rigid fixation of planet gears with a dynamic tilting mechanism. The planet gears are mounted on tiltable planet shafts that can automatically adjust their orientation in response to load-induced deformations, maintaining proper meshing alignment without requiring excessive carrier rigidity or mass.
Solution Approach 2:
The invention changes the mounting parameter from fixed rigid connection to tiltable connection with one degree of freedom. This allows the planet shafts to adapt their angular position dynamically, compensating for deformations and maintaining gear alignment under varying load conditions.
3Manufacturing precision
If the planet gears are rigidly fixed in the planet carrier, then positioning is precise at rest, but alignment deteriorates under load deviations
Solution Approach 1:
The invention replaces the static rigid fixation of planet gears with a dynamic tilting mechanism. The planet gears are mounted on tiltable planet shafts that can automatically adjust their orientation in response to load-induced deformations, maintaining proper meshing alignment without requiring excessive carrier rigidity or mass.
Solution Approach 2:
The tiltable planet shafts provide self-alignment functionality, automatically adjusting their orientation in response to load-induced deformations without external control. The system self-corrects alignment deviations through the natural tilting motion enabled by the spherical bearing mounting.
4Weight of moving object
If the planet carrier is designed with reduced mass and space requirements, then cost and efficiency improve, but gear alignment stability deteriorates
Solution Approach 1:
The invention replaces the static rigid fixation of planet gears with a dynamic tilting mechanism. The planet gears are mounted on tiltable planet shafts that can automatically adjust their orientation in response to load-induced deformations, maintaining proper meshing alignment without requiring excessive carrier rigidity or mass.
Solution Approach 2:
The invention changes the mounting parameter from fixed rigid connection to tiltable connection with one degree of freedom. This allows the planet shafts to adapt their angular position dynamically, compensating for deformations and maintaining gear alignment under varying load conditions.
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 solution reduces the need for a stiff planet carrier design, tolerates deformations, minimizes wear, and decreases mass, space, and cost requirements while improving durability and assembly efficiency.
Implementation Method 1
A tiltable planetary shaft that can be orthogonally tilted relative to the planet carrier, allowing for self-alignment of gears to minimize load-induced misalignment
Implementation Method 2
a two-piece design for the planetary carrier and shaft for simplified assembly and reduced friction
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a planetary stage (101) comprising a planet carrier (119), at least one planetary gear (107, 109), and at least one planet shaft (115); the planetary gear (107, 109) is mounted in the planet shaft (115) in such a way as to be rotatable about an axis of rotation. The planet shaft (115) is secured in the planet carrier (119) in such a way that the planet shaft (115) can be tilted perpendicularly to the axis of rotation relative to at least one part of the planet carrier (119).