Wind Turbine Gearbox Lubrication Using Gravity-Fed Siphon Control
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Solution Overview
Problem
Wind turbines in remote locations, such as offshore parks, face challenges in maintaining adequate lubrication of gearboxes and bearings during off-grid conditions, as standard lubrication systems are limited by sealings that restrict oil levels, leaving only part of the gearbox un lubricated.
Innovation Solution
A lubrication system with an oil reservoir, supply valve, drain valve, and siphon configuration that adjusts internal oil levels in the gearbox during off-grid states, using gravity to supply oil from elevated reservoirs to ensure comprehensive lubrication of both stages of a two-stage gearbox.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the oil sump level is increased to provide adequate lubrication, then the lubrication coverage is improved, but the sealings on the gearbox input shaft prevent the oil level from being increased beyond the lowest sealing point
Solution Approach 1:
The gearbox is divided into multiple stages (first stage and second stage) with separate oil level control. Each stage can have different internal oil levels, allowing the first stage to have lower oil level (constrained by sealing) and the second stage to have higher oil level (adequate lubrication), thus resolving the contradiction between sealing constraints and lubrication coverage requirements
Solution Approach 2:
Different parts of the gearbox (different stages) are provided with different oil levels according to their specific lubrication needs. The first stage operates with lower oil level while the second stage operates with higher oil level, optimizing lubrication quality locally in each stage without being constrained by the sealing position throughout the entire gearbox
2Reliability
If a standard lubrication system is used, then the system simplicity is maintained, but adequate lubrication cannot be provided during off-grid conditions when auxiliary power is unavailable
Solution Approach 1:
The lubrication system is designed to be self-regulating during off-grid conditions. The siphon automatically adjusts the internal oil level in the gearbox based on the oil level in the oil reservoir, without requiring any external power or control systems. The system uses passive mechanisms (siphon effect, gravity) to maintain adequate lubrication automatically
Solution Approach 2:
A siphon is introduced as an intermediary component between the oil reservoir and the gearbox. The siphon mediates the oil level adjustment by automatically transferring oil from the reservoir to the gearbox when needed, enabling the system to adapt to off-grid conditions without complex active control mechanisms
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
Ensures continuous and adequate lubrication of wind turbine drive trains, particularly in off-grid situations, by creating an oil sump within the gearbox using gravity-driven oil flow from elevated reservoirs, thereby protecting components and maintaining performance.
Implementation Method 1
a siphon configured to adjust an internal oil level in the gearbox in the off-grid state of the wind turbine
Implementation Method 2
using gravity to supply oil from elevated reservoirs
Data Source
AI summary
A lubrication system for a drive train of a wind turbine includes an oil reservoir having an outlet, a supply valve, a gearbox having an oil inlet and oil outlet, a drain valve and a siphon is provided. The oil reservoir is coupled to the supply valve and the supply valve is coupled to the inlet of the gearbox. The oil outlet of the gearbox is coupled to the drain valve and to a first end of the siphon. The supply valve is configured to open in an off-grid state of the wind turbine and the drain valve is configured to close in the off-grid state of the wind turbine. The siphon is configured to adjust an internal oil level in the gearbox in the off-grid state of the wind turbine.