Wind Turbine Drive Train Coupling Unit for Modular Gearbox Reuse
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Solution Overview
Problem
Existing wind turbine drive trains require individual configuration for specific applications, leading to high manufacturing costs due to design adjustments in the gearbox, which is not cost-effective for varying wind loads, generator designs, and differing input speeds.
Innovation Solution
A series of drive trains with a separately designed coupling unit that supports the input gearbox component outside the gearbox, allowing adaptation to different requirement profiles without modifying the gearbox design, using a coupling unit with adjustable bearings and damping elements to manage varying loads and generator power profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the gearbox is individually configured for specific applications, then the drive train can meet varying requirements (wind loads, generator designs, input speeds), but the manufacturing costs increase due to design adjustments to the gearbox
Solution Approach 1:
The drive train is segmented into modular components: a standardized gearbox and a separately designed coupling unit. The coupling unit is divided into a first coupling component (connected to rotor shaft), a second coupling component (connected to gearbox input), and a bearing component. This segmentation allows the coupling unit to be adapted to different requirement profiles while the gearbox remains standardized, reducing manufacturing costs.
Solution Approach 2:
The bearing component is extracted from the gearbox and placed in the separately designed coupling unit. This extraction allows the gearbox to maintain a uniform design across different applications while the coupling unit absorbs the variability requirements through different bearing arrangements (single bearing, double bearing, adjustable bearing).
2Adaptability or versatility
If the gearbox design is adjusted for different wind loads and generator designs, then the drive train can accommodate varying operational conditions, but the development time and costs increase
Solution Approach 1:
The gearbox is designed as a universal component that can be used across different drive train configurations. The coupling unit serves multiple functions: connecting the rotor shaft to the gearbox, supporting the gearbox input component, and adapting to different operational requirements through variable bearing arrangements. This multi-functionality eliminates the need for custom gearbox designs for each application.
Solution Approach 2:
The coupling unit provides dynamic adaptability through different bearing configurations (single bearing, double bearing, adjustable bearing) that can be selected based on specific operational conditions. This dynamic approach allows the same gearbox to be used with different coupling units tailored to specific wind load conditions, generator designs, and input speed requirements.
3Device complexity
If the input gearbox component is supported within the gearbox, then the gearbox structure is simplified, but the coupling unit cannot provide flexible adaptation to different requirement profiles
Solution Approach 1:
The bearing component is extracted from the gearbox and placed in the separately designed coupling unit. This extraction maintains a simple, uniform gearbox structure while enabling the coupling unit to provide flexible adaptation to different requirement profiles through variable bearing arrangements.
Solution Approach 2:
The coupling unit acts as an intermediary between the rotor shaft and the gearbox. It contains the bearing component that supports the gearbox input component, thereby decoupling the gearbox structure from the adaptation requirements. This intermediary role allows the gearbox to remain simple while the coupling unit handles the adaptability to different operational conditions.
4Power
If a torsionally rigid coupling is used to connect the rotor shaft to the gearbox, then torque transmission is efficient, but vibrations caused by blade pitch adjustment cannot be dampened
Solution Approach 1:
The coupling unit serves as an intermediary between the rotor shaft and the gearbox, containing the bearing component that supports the gearbox input component. This intermediary structure allows for potential vibration dampening while maintaining torque transmission, as the coupling unit can be designed with appropriate damping characteristics without compromising the torsional rigidity needed for efficient power transmission.
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
Enables cost-effective drive trains adaptable to different wind turbine requirements by reusing existing gearbox designs, reducing development costs and time, and facilitating easy adaptation to varying loads and generator power profiles without gearbox modifications.
Implementation Method 1
the coupling unit has a bearing for supporting the unsupported input gearbox component within the coupling unit
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a drive train (14) for a wind turbine (10), with a transmission (18) for transferring and converting a torque originating from a rotor shaft (16) of a rotor (12), wherein the transmission (18) has an input transmission component, more particularly a planet carrier (32), that is unsupported at least on the rotor side for introducing the torque into the transmission (18), and a coupling unit (46), designed separately from the rotor shaft (16) and from the transmission (18), for the torque-transferring coupling of the rotor shaft (16) to the input transmission component, wherein the coupling unit (46) has a bearing (48) for supporting the unsupported input transmission component within the coupling unit (46). By adapting the bearing of the input transmission component within the separately designed coupling unit (46) to different requirement profiles, a change to the structure of the transmission (18) can be avoided, therefore enabling a cost-effective drive train (14) for different wind turbines.