Wind Turbine Drive Train Assembly for Stable Generator Air Gaps
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Solution Overview
Problem
Existing wind turbine drive train assemblies face challenges in maintaining air gap stability due to oscillations and deformations caused by bending loads, which can compromise the efficiency and reliability of the generator.
Innovation Solution
The proposed drive train assembly features a generator module with a shaft removably connected to the generator rotor and a bearing assembly comprising a front and rear bearing, positioned closer to the generator rotor and stator, improving air gap stability and facilitating manufacturing and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the air gap is made smaller to improve electromagnetic efficiency, then the generator efficiency is improved, but the risk of contact between rotor and stator increases due to oscillations and deformations
Solution Approach 1:
The patent introduces a shaft as an intermediary component between the rotor hub and generator rotor. This shaft acts as a mediator that absorbs and isolates oscillations and deformations, allowing the air gap to be minimized for efficiency while preventing direct transmission of mechanical instabilities that could cause rotor-stator contact.
Solution Approach 2:
The patent extracts the shaft as a separate, removable component from the direct connection between rotor hub and generator rotor. By taking out this intermediate element as a distinct component with bearing assemblies, the system can maintain tight air gaps for efficiency while the shaft independently handles mechanical oscillations and deformations.
2Device complexity
If a direct connection between rotor hub and generator rotor is used, then the structure is simpler, but the weight of the structure on top of the tower increases
Solution Approach 1:
The patent segments the drive train connection into distinct modular components: rotor hub, shaft with bearing assemblies, and generator rotor. This segmentation allows each component to be optimized independently and facilitates easier maintenance and replacement, reducing overall system weight while maintaining structural integrity.
Solution Approach 2:
The patent introduces dynamic elements in the form of bearing assemblies mounted on the shaft. These bearings dynamically support the shaft during rotation, allowing the system to handle oscillations and deformations flexibly rather than requiring heavy rigid structures, thus reducing overall weight.
3Ease of manufacture
If the generator rotor is directly connected to the rotor hub, then assembly is simpler, but maintenance and assembly become more difficult due to the integrated structure
Solution Approach 1:
The patent divides the drive train into separable modules with the shaft as an intermediate component. This segmentation enables the generator rotor to be accessed and maintained independently by removing the shaft, significantly improving maintenance accessibility without complicating the initial assembly process.
Solution Approach 2:
The shaft is designed as a pre-assembled unit with bearing assemblies already mounted. This preliminary preparation allows for simplified final assembly where the pre-configured shaft is simply installed between the rotor hub and generator rotor, while enabling easy removal and maintenance of the generator rotor without disassembling the entire drive train.
Data Source
AI summary
The present disclosure relates to drive train assemblies for a wind turbine. These assemblies may comprise a rotor hub and a generator module. The generator module comprises a generator stator, and a stationary frame for supporting the generator stator. The generator further comprises a generator rotor, a shaft for supporting the generator rotor, and a bearing assembly for rotatably mounting the shaft on the stationary frame. The shaft is removably connected to the generator rotor, and the bearing assembly comprises a front bearing and a rear bearing. An upwind end of the generator module is attached to a downwind end of the rotor hub. The present disclosure further relates to wind turbines including such wind turbine assemblies and to methods for assembling drive train assemblies.