Direct-Drive Wind Turbine Brake System Extraction
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Solution Overview
Problem
Direct-drive wind turbines face challenges with the rotor brake system due to space limitations, increased risk of oil leakage, compromised evacuation routes, and reduced accessibility for maintenance, especially as turbines grow larger.
Innovation Solution
A direct-drive wind turbine design with a brake system positioned outside the generator, utilizing a frame with protruding structures and bearings to rotate relative to each other, allowing for a larger brake system size and enhanced accessibility, while maintaining safety and reducing the risk of oil leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the brake system is placed inside the generator, then the braking moment can be provided, but the size of the brake system is limited and accessibility for maintenance is reduced
Solution Approach 1:
The brake system is extracted from the generator interior and positioned in the rotor hub, separating the braking function from the generator assembly. This allows the brake system to be accessed independently for maintenance while the generator remains intact, resolving the accessibility issue while maintaining braking capability.
Solution Approach 2:
The brake system is relocated from the radial/axial space within the generator to the longitudinal space of the rotor hub extension. This dimensional relocation provides sufficient space for a larger brake system with adequate maintenance access without compromising generator dimensions.
2Device complexity
If the brake system is placed inside the generator, then integration is achieved, but the risk of oil leakage reaching the air gap increases
Solution Approach 1:
The brake system is extracted from proximity to the generator air gap and positioned in the rotor hub. This spatial separation eliminates the oil leakage path to the air gap while maintaining functional integration through the rotor hub connection, resolving the harmful factor without sacrificing integration.
Solution Approach 2:
The rotor hub acts as an intermediary structure that hosts the brake system while maintaining connection to the generator rotor. This intermediary positioning allows the brake system to be functionally integrated with the generator while physically separated enough to prevent oil leakage contamination of the air gap.
3Volume of stationary object
If the brake system is placed inside the generator, then space utilization is maximized, but the evacuation route is compromised
Solution Approach 1:
The brake system is extracted from the generator interior, restoring the full evacuation route clearance within the generator. The brake system is relocated to the rotor hub where space is available, maintaining overall space utilization while ensuring the generator's evacuation route meets safety standards.
4Power
If the brake system size is increased to provide larger braking moment, then the braking capability is improved, but the space requirements inside the generator increase
Solution Approach 1:
The brake system is extracted from the constrained generator interior to the more spacious rotor hub environment. This relocation allows for a larger brake system diameter and greater braking moment without increasing the generator dimensions, resolving the space constraint while improving braking capability.
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 design enables larger turbine sizes, improved safety, and easier maintenance by providing increased clearance and separating the brake system from the generator, thus enhancing operational efficiency and safety.
Implementation Method 1
one or more bearings rotatably connecting the first and second structures. The first and second structure are configured to rotate relative to each other and about the rotation axis
Implementation Method 2
adjusting a rotational speed of the rotor hub to the target rotational speed by controlling a friction exerted by the brake system
Data Source
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AI summary
Direct-drive wind turbines (160) are disclosed. The wind turbine comprise a generator (3) mounted on a frame (1), the generator (3) comprising a generator stator (32) and a generator rotor (31) configured to rotate about a rotation axis (RA), the frame (1) has a protruding portion (11) extending beyond the generator (3), the protruding portion (11) comprising a first structure and a second structure; wherein the first and second structures are configured to rotate relative to each other and about the rotation axis (RA); wherein the first structure is attached to the generator stator (32) and the second structure is attached to the generator rotor (31); a brake system (2) attached to the first and second structures, the brake system (2) being spaced away from the generator (3) along the rotation axis (RA). Also disclosed are methods (200) for braking a direct-drive wind turbine (160).