Semi-Direct Wind Drive System Coupling and Integrated Gearbox
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Solution Overview
Problem
Current semi-direct driven wind generating sets face challenges in maintaining gearbox reliability, reducing cabin weight and length, and lowering production costs while ensuring performance, reliability, and maintainability.
Innovation Solution
A drive system structure featuring a main shaft double-bearing structure, integrated gearbox and generator design, and a coupling mechanism with a sun gear and torque limiter, which enhances gearbox rigidity, provides overload protection, and facilitates maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a split structure with main shaft bearing, gearbox and generator integrated separately is used, then the structure is simple and easy to maintain, but the dimensional chain is longer, the load on gearbox is complicated, reliability is poor, and weight and size are increased
Solution Approach 1:
The patent integrates the main shaft bearing, gearbox, and generator into a unified structure where the main shaft bearing is positioned inside the gearbox and the generator is directly coupled to the gearbox output. This merging reduces the dimensional chain length, simplifies the load transmission path, and improves overall system reliability while maintaining ease of maintenance through modular design elements.
Solution Approach 2:
The patent segments the drive system into distinct functional modules (main shaft bearing assembly, gearbox assembly, generator assembly) that can be independently designed, manufactured, and maintained. This segmentation allows for optimized load distribution, reduced complexity in each module, and improved maintainability through targeted replacement and repair of individual components.
2Device complexity
If a partially integrated structure with main shaft bearing integrated with gearbox is used, then the structure is simpler with no couplings, but the gearbox has no overload protection and is easily affected by shaft current
Solution Approach 1:
The patent introduces a coupling device as an intermediary component between the gearbox output shaft and the generator input shaft. This coupling serves multiple functions: it provides overload protection by disconnecting the load when limits are exceeded, shields the gearbox from shaft current through electromagnetic isolation, and maintains structural simplicity by eliminating the need for separate mounting brackets and alignment mechanisms.
Solution Approach 2:
The coupling device performs multiple functions simultaneously: it transmits torque from the gearbox to the generator, provides overload protection through slip or break mechanisms, shields against shaft current through magnetic isolation, and accommodates misalignment between shafts. This multi-functionality reduces overall system complexity while improving reliability.
3Weight of stationary object
If a fully integrated structure with main shaft bearing, gearbox and generator fully integrated is used, then the structure is compact with light and small cabin, but high requirements for design and manufacturing capabilities and poor maintainability are required
Solution Approach 1:
The patent divides the integrated drive system into separable modules (main shaft bearing assembly, gearbox assembly, generator assembly) connected by standardized interfaces. This modular segmentation achieves compact overall dimensions and reduced weight while enabling independent removal and replacement of individual components for maintenance, thereby improving maintainability without sacrificing integration benefits.
Solution Approach 2:
The patent incorporates preliminary design features such as pre-assembled module units, standardized mounting interfaces, and pre-configured coupling mechanisms that facilitate quick disassembly and reassembly during maintenance operations. These preliminary preparations reduce the complexity and time required for field maintenance while maintaining the compact integrated structure.
Data Source
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AI summary
The present invention discloses a drive system of a semi-direct driven wind power generator, comprising a wind turbine system, a main shaft system, a gearbox, a generator, and a coupling, wherein the main shaft system comprises a main shaft, a transition flange, and a main shaft double-bearing structure, and the wind turbine system is connected to an end of the main shaft; the gearbox and the generator are of an integrated structure, comprising the gearbox, the generator, a gearbox flange, and a sun gear; the main shaft system is connected to the gearbox through the transition flange and the gearbox flange, and the sun gear passes through a hollow drive shaft of the generator and is connected to the coupling at the rear end of the generator; and an external wind load is transmitted to the generator through the wind turbine system, the main shaft system, the gearbox, and the coupling. The rigidity of the main shaft system and the reliability of the gearbox can be improved; the drive system is compact in structure, light in weight and high in reliability; and the drive system is designed with a coupling, which can effectively solve the overload protection of the gearbox and the influence of shaft current, and can compensate the alignment error of the generator and the gearbox and the offset of the sun gear of the gearbox.