Wind Generator Power Transmission Shrink Disc Assembly
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Solution Overview
Problem
Conventional wind generators face difficulties in assembly efficiency, are prone to damage from counter torque due to over-current, and lack self-aligning and vibration-reducing features, leading to inaccurate power transmission and reduced lifespan.
Innovation Solution
A power transmission apparatus where the rotor is assembled directly with the main shaft, incorporating a shrink disc to disconnect during over-current conditions, and using toroidal and spherical roller bearings for self-alignment and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator and rotor are assembled separately with the main shaft, then the assembly process is more detailed and controllable, but the assembly becomes troublesome and efficiency deteriorates
Solution Approach 1:
The stator housing and rotor are merged into a single integrated assembly unit that is pre-assembled together before being mounted to the main shaft. This combining of components reduces the number of separate assembly operations required, eliminating the troublesome separate assembly process while maintaining manufacturing control, thus improving assembly efficiency without excessive complexity
2Ease of manufacture
If the main shaft is divided into turbine shaft and generator shaft connected by flange joint, then the shaft can be manufactured and assembled separately, but transmission of rotational torque experiences loss
Solution Approach 1:
The flange joint connection is removed entirely from the shaft design. Instead of dividing the shaft into separate turbine and generator sections connected by a flange, the invention uses a single continuous main shaft that directly connects the turbine to the generator, eliminating the intermediate connection point that causes torque loss while maintaining manufacturing flexibility through other means
3Reliability
If no over-current protection unit is provided, then the device structure remains simple, but counter torque from short causes damage and shortens lifespan
Solution Approach 1:
An over-current protection unit is introduced as an intermediary component between the generator and the main shaft. This unit acts as a protective mediator that detects over-current conditions and prevents counter torque from reaching and damaging the main shaft and other critical components, thereby improving reliability while adding only the necessary protective function without excessive structural complexity
4Manufacturing precision
If the main shaft lacks self-aligning function, then the bearing structure remains simple, but misalignment and tilting cause inaccuracy in power transmission
Solution Approach 1:
Self-aligning bearings with spherical geometry are employed at the main shaft support points. The spherical design allows the bearing to automatically adjust and align itself with the main shaft, compensating for misalignment and tilting errors. This curved geometric solution provides the self-aligning function needed for accurate power transmission while adding minimal complexity compared to rigid fixed bearings
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 simplifies assembly, prevents damage from over-current, ensures accurate power transmission, and reduces vibrations and noise, enhancing the reliability and performance of wind generators.
Implementation Method 1
a shrink disc for disconnecting the rotor from the main shaft when a generator generates counter torque due to over-current
Implementation Method 2
one bearing being a toroidal roller bearing and the other bearing being a spherical roller bearing, thereby having a self-aligning function of compensating for misalignment and tilting of a main shaft
Implementation Method 3
a pair of bearings being disposed at an outer circumference of the rotor bearing, both ends of a main shaft being rotatably supported by a pair of bearings
Data Source
AI summary
Disclosed is a power transmission apparatus for a wind generator having an electric generator connected to an apparatus rotor by a main shaft. The electric generator includes a generator rotor and a generator stator. The electric generator may be assembled to the main shaft via the generator rotor, but the generator stator is not assembled to the main shaft. Instead, the generator stator is connected to a stator housing fixed to bearing housings respectively provided on a pair of bearings disposed on an outer surface of a rotor bearing. The rotor bearing is disposed perpendicular to a vertical rotor frame, is formed integrally with the generator rotor, and is connected to an outer surface of the main shaft. The apparatus permits the generator stator to be assembled with a circumference of the generator rotor. The apparatus provides increased convenience and efficiency in assembly.