Wind Turbine Generator-Gearbox Brake Layout for Compact Axial Space
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Solution Overview
Problem
Existing wind turbine generator-gearbox arrangements are bulky and inefficient due to large axial installation space requirements, necessitating a compact and high-performance solution.
Innovation Solution
A generator-gearbox arrangement with a magnetic rail brake system where the magnetic rail brake arrangement is integrated within the rotor's interior space, utilizing electromagnetic attraction for braking, reducing axial length and enabling efficient energy conversion without mechanical wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical brake system is arranged on the side facing away from the generator, then braking function is provided, but axial installation space is increased
Solution Approach 1:
The magnetic rail brake arrangement is nested within the interior space of the rotor, utilizing the existing hollow cylindrical structure. The grinding shoes are positioned inside the rotor's hollow cylinder, allowing the braking function to be integrated without increasing axial dimensions. This nesting principle enables the brake system to occupy space that would otherwise be unused, resolving the contradiction between providing braking function and maintaining compact axial length.
Solution Approach 2:
The brake system transitions from a conventional axial arrangement to a radial arrangement within the rotor's hollow cylinder. By utilizing the radial dimension of the rotor's interior space, the brake arrangement achieves compact axial length while maintaining effective braking capability. The grinding shoes are positioned radially within the hollow cylinder, converting the spatial arrangement from axial to radial to resolve the dimensionality conflict.
2Reliability
If friction-based mechanical brakes are used, then braking action is achieved, but mechanical wear occurs
Solution Approach 1:
The conventional friction-based mechanical brake system is replaced with a magnetic rail brake arrangement that uses electromagnetic forces. Electromagnets generate magnetic fields that attract the grinding shoes to the brake surface, providing braking action through electromagnetic attraction rather than pure mechanical friction. This substitution reduces mechanical wear by eliminating the need for high-contact-force friction mechanisms while maintaining effective braking capability.
3Reliability
If conventional brake arrangements are used, then braking function is provided, but device complexity and maintenance needs increase
Solution Approach 1:
The magnetic rail brake arrangement is merged with the rotor structure, utilizing the hollow cylindrical space that already exists in the rotor design. The brake components (electromagnets, grinding shoes, and brake surface) are integrated into the rotor's existing structural framework, eliminating the need for separate, complex brake assemblies. This merging reduces device complexity by consolidating the brake function within the existing rotor architecture rather than adding independent brake subsystems.
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
The compact design reduces axial structural length, enhances efficiency, and allows for high-performance operation with reduced maintenance needs, while maintaining a wear-free braking mechanism.
Implementation Method 1
a braking action of the magnetic rail brake arrangement is based on an operating principle of electromagnetic attraction between the magnetic rail brake arrangement and the rotor and/or the functional component
Data Source
AI summary
A generator-gearbox arrangement for a wind turbine includes a generator having a stator and a rotor interacting with one another, a functional component arranged on an end side of the generator and including an extension which points toward the rotor, and a magnetic rail brake arrangement including component parts fastened to the extension. The magnetic rail brake arrangement is designed to apply a braking action which is based on an operating principle of electromagnetic attraction between the magnetic rail brake arrangement and at least one of the rotor and the functional component.