Wind Turbine Generator Brake Disc Arrangement
Solution Overview
Problem
The existing braking systems in wind turbine generators are large and heavy, contributing to increased weight and size of the power train, which complicates maintenance and restricts access to internal components, while also requiring a significant axial length and weight-bearing capacity.
Innovation Solution
A disc brake arrangement featuring an annulus brake disc mounted concentrically with the rotor shaft and connected to a support ring, with brake calipers arranged concentrically to engage the disc, where the support ring's operative connection is offset to counterbalance the brake disc, reducing the need for axial extension and allowing for enhanced access and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional disc brake is positioned between the gearbox and generator, then the braking function is provided, but the axial length of the power train increases and access to generator internals is restricted
Solution Approach 1:
The brake disc is extracted from its traditional position between the gearbox and generator, and relocated to the generator end shield. This removes the obstacle that blocked access to generator internals and eliminates the need for axial extension of the power train assembly.
Solution Approach 2:
The brake disc is repositioned from an axial arrangement (between components along the shaft length) to a radial arrangement (at the end shield, utilizing the radial space). This dimensional change allows the brake to function without increasing axial length or blocking access paths.
2Power
If a large brake disc is used to provide sufficient braking torque, then the braking capability is adequate, but the weight and size of the brake system increases
Solution Approach 1:
A counterbalancing mass is added to the generator end shield to offset the unbalanced mass of the brake disc. This allows the use of a lighter brake disc while maintaining dynamic balance, thereby reducing overall brake system weight without compromising braking torque capability.
Solution Approach 2:
The counterbalance mass is pre-positioned in the end shield design to anticipate and offset the centrifugal forces generated by the brake disc during rotation. This preliminary balancing action prevents vibration and allows for a more efficient, lighter brake disc design.
3Length of stationary object
If the brake disc is positioned adjacent to the generator end, then the axial length is reduced, but maintenance access to generator internals becomes difficult
Solution Approach 1:
The brake disc is extracted from the axial space between gearbox and generator, and relocated to the end shield position. This extraction opens up the axial space, allowing easy access to generator internals for maintenance while the brake remains functional at the end shield.
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 configuration results in a smaller, lighter brake system that reduces the overall weight and length of the power train, improves rotor stiffness, and enhances maintenance access by eliminating the need for a brake disc between the gearbox and generator, while maximizing braking torque.
Implementation Method 1
the operative connection of the support ring wheel to the support ring is offset from a center of the support ring and adapted to counterbalance the connection of the brake disc to the support ring
Data Source
Figure 1
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Figure 3
AI summary
A disc brake arrangement (350) is provided as adapted for a wind turbine generator (300) incorporating a rotor shaft (320) supporting a rotor wheel and support ring (345) for a rotor structure (365) surrounded by a stator structure (315) within a generator casing (310). The disc brake arrangement (350) includes a brake disc (355) mounted normal to and concentric with the rotor shaft (320) and operatively connected to a support ring arm (346). A plurality of disc brake calipers (375) are arranged concentrically with the rotor shaft (320) and adapted to engage the brake disc (355).