Wind Turbine Coupling Assembly for Misalignment Load Relief
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Solution Overview
Problem
Existing torque transmitting couplings in wind turbines face challenges such as high cost, limited torque capacity, difficulty in disassembly, and misalignment-induced deformation due to increased size and load, which can lead to failure and reduced lifespan, and are constrained by transportation and hoisting limitations.
Innovation Solution
A torque transmitting coupling assembly with a first and second rotatable coupling part supported by bearings, enclosed by a bearing housing, and connected by resilient means and coupling flanges to mitigate misalignments and distribute loads, allowing flexible reaction to torque and reducing parasitic loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction shims with diamonds are used to increase friction coefficient, then torque transmission capability is improved, but cost increases significantly
Solution Approach 1:
The patent replaces expensive friction shims with a cost-effective bolted joint design that uses readily available materials. The coupling members are designed to be simple steel components with holes for bolts, eliminating the need for expensive diamond-coated friction shims while maintaining adequate torque transmission through direct mechanical connection.
Solution Approach 2:
The patent removes the friction shim component entirely from the coupling design, extracting the problematic element that caused both high cost and assembly/disassembly difficulties. The torque transmission function is achieved directly through the bolted joint between coupling members without requiring intermediate friction-enhancing components.
2Reliability
If friction shims are used to reduce slippage risk, then torque transmission reliability is improved, but disassembly difficulty increases
Solution Approach 1:
The patent removes the friction shim component that caused disassembly difficulties. The bolted joint design allows for straightforward assembly and disassembly by simply removing and reinstalling bolts, eliminating the need to break microform fits or deal with bonded friction surfaces.
Solution Approach 2:
The coupling is divided into separate coupling members with through-holes that accommodate bolts. This segmentation allows the joint to be easily assembled and disassembled by removing the bolts, providing maintenance access without the difficulties associated with friction shims that create microform fits.
3Manufacturing precision
If coupling members are made overconstrained to prevent misalignment, then positioning precision is improved, but deformation and shear increase
Solution Approach 1:
The patent employs a dynamic bolted joint connection that allows coupling members to accommodate misalignments through controlled movement and deformation of the bolts and coupling member material. The through-holes and bolt configuration enable the joint to adapt to alignment variations without creating excessive constraint forces that would cause deformation or shear.
Solution Approach 2:
The patent changes the constraint parameters by using bolted joints with through-holes instead of rigid fixed connections. This allows the coupling to tolerate certain degrees of misalignment through the compliance of the bolted connection, reducing the risk of deformation and shear while maintaining adequate positioning.
4Strength
If shaft diameter is increased to handle higher torques, then torque transmission capability is improved, but transportation and hoisting limitations are exceeded
Solution Approach 1:
The patent segments the torque transmission function across multiple coupling members connected by bolts, rather than requiring a single large-diameter shaft. This allows the drivetrain components to be designed in modular sections that can be transported and assembled on-site, avoiding the need to move excessively large shafts that would exceed transportation limitations.
Solution Approach 2:
The coupling members are designed with through-holes that allow nesting or compact arrangement during transportation. The modular coupling components can be configured to fit within transportation constraints while maintaining the structural integrity needed for high torque transmission when assembled in the final configuration.
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 solution enables efficient torque transmission with reduced misalignment and deformation, accommodating larger wind turbines while minimizing parasitic loads and adhering to transportation constraints, thus enhancing durability and compactness.
Implementation Method 1
resilient means and coupling flanges to mitigate misalignments and distribute loads
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A torque transmitting coupling assembly (1) for a wind turbine (40) configured to couple a first coupling part (2) to a second coupling part (3), wherein the first coupling part (2) and the second coupling part (3) are configured to rotate about a longitudinal axis (42) of the torque transmitting coupling assembly (1), wherein the first coupling part (2) is supported by a first bearing (48) and a second bearing (49) distributed along the longitudinal axis (42), wherein the first coupling part (2) is enclosed by a bearing housing (13) and the first and second bearings (48, 49) are arranged between the first coupling part (2) and the bearing housing (13), wherein the second coupling part (3) is enclosed by a second coupling part housing, wherein the first coupling part (2) and the second coupling part (3) are rigidly coupled by a plurality of fastening means (6).