Integrated Wind Turbine Drivetrain With Bearing-Protected Generator
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Solution Overview
Problem
Conventional wind turbine drivetrains with geared systems require separate mounting of gearbox and generator units, leading to increased size, weight, and complexity, which affects efficiency and operational life due to the need for separate bearing support and potential exposure to harmful electrical currents.
Innovation Solution
An integrated gearbox/generator unit with a braking system that includes a rotary and stationary component, where the gearbox output shaft and bearings support the braking system, and an insulated rotor joint protects the bearings from electrical voltages, while an offset stator housing and conical coupling disk further reduce size and weight, and a grounding brush provides electrical protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate gearbox and generator units are mounted with discrete mounting structures, then the drivetrain achieves structural stability and reliability, but the overall size, weight, and complexity increase
Solution Approach 1:
The patent combines the gearbox and generator into a single integrated unit where the generator is mounted directly on the gearbox housing. This eliminates separate mounting structures and reduces the number of discrete components, thereby decreasing overall weight while maintaining structural stability through the integrated design.
Solution Approach 2:
The gearbox housing serves multiple functions: it encloses the gearbox mechanism, provides mounting support for the generator, and acts as part of the overall structural framework. This multi-functionality reduces the need for additional separate mounting structures, reducing weight and complexity.
2Reliability
If separate bearing support structures are used for gearbox output shaft and generator input shaft, then the drivetrain achieves proper mechanical support and alignment, but the device complexity and weight increase
Solution Approach 1:
The patent uses a single bearing support structure integrated into the gearbox housing that supports both the gearbox output shaft and the generator input shaft. This shared bearing support eliminates the need for separate mounting structures and reduces overall complexity while providing proper mechanical support for both shafts.
3Weight of moving object
If the braking system is integrated with the gearbox output shaft and bearings, then the drivetrain size and weight are reduced, but the risk of exposure to harmful electrical currents increases
Solution Approach 1:
The patent introduces an insulated rotor joint as an intermediary component between the rotating brake rotor and the gearbox output shaft. This insulation barrier prevents harmful electrical currents from traveling along the brake rotor to the bearings, while still allowing mechanical integration that reduces overall size and weight.
4Device complexity
If the generator rotor center of gravity is offset from the bearing axis, then the braking system can be integrated, but operational life and dynamic response are reduced
Solution Approach 1:
The patent applies local quality by precisely positioning the generator rotor's center of gravity to align with the bearing axis of rotation. This localized adjustment ensures balanced operation and reduces vibrations, extending operational life while maintaining the integrated braking system design.
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
The solution reduces the overall size and weight of the drivetrain, enhances operational life by aligning the generator rotor center of gravity with bearings, and protects against electrical currents, improving dynamic response and efficiency.
Implementation Method 1
a braking system that includes a rotary component and a stationary component
Implementation Method 2
The gearbox further includes at least one bearing positioned between the housing and the output shaft
Implementation Method 3
a generator may convert this mechanical power (i.e., the rotation of a shaft) into electricity
Data Source
AI summary
A drivetrain for a wind turbine includes a gearbox and a generator. The gear box includes a housing and an output shaft that is rotatably coupled within the housing, wherein the gearbox further includes at least one bearing positioned between the housing and the output shaft. The generator includes a stator coupled to the housing such that the stator is positioned radially inward from the housing, and a rotor coupled to the output shaft such that the rotor is positioned radially inward from the stator.