Wind Turbine Coupling Assembly for Misalignment-Tolerant Torque Transfer
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Solution Overview
Problem
Conventional torque couplings for wind turbines are expensive, limited in torque transmission capacity, difficult to disassemble, and prone to misalignment-induced deformation and failure due to overconstrained designs, which are exacerbated by the increasing size and torque demands of modern wind turbines, and pose logistical challenges during transportation and installation.
Innovation Solution
A torque transmitting coupling assembly with a first and second rotatable coupling part supported by bearings and enclosed by a bearing housing, connected via resilient means and coupling flanges to allow flexible coupling, mitigating misalignments and reaction forces through a flexible mechanism that distributes loads and reduces parasitic forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If friction shims with diamonds are used to increase friction coefficient, then torque transmission capacity is improved, but cost increases significantly
Solution Approach 1:
The patent replaces expensive friction shims with diamonds with a more economical coupling design using a compression ring and form-fitted coupling. The coupling members are designed to be cost-effective while maintaining sufficient friction for torque transmission, avoiding the need for expensive diamond-coated shims.
2Reliability
If friction shims are used to reduce slippage, then torque transmission reliability is improved, but disassembly difficulty increases
Solution Approach 1:
The patent employs a compression ring that can be dynamically adjusted to control the clamping force between coupling members. This allows the coupling to be securely fastened during operation to prevent slippage, while enabling easy disassembly when needed by releasing the compression ring mechanism.
3Volume of moving object
If the second rotatable part is arranged at the outer circumferential surface of the first rotatable part, then coupling compactness is improved, but the coupling members become overconstrained
Solution Approach 1:
The patent divides the coupling system into separate coupling members with a form-fitted interface, allowing each member to maintain its structural integrity while accommodating misalignments. The compression ring acts as a separate element that applies force without creating overconstraints, enabling the coupling to handle misalignments effectively.
4Strength
If overconstrained coupling members are used to achieve form-fitted coupling, then coupling strength is improved, but deformation and failure risk due to misalignment increases
Solution Approach 1:
The patent introduces a compression ring as an intermediary element between the coupling members. This compression ring mediates the force transmission, allowing the coupling members to remain strong through form-fitted coupling while the compression ring accommodates misalignments by distributing forces evenly, preventing deformation and failure.
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, allowing for a more compact and manageable load transfer, accommodating larger wind turbines while minimizing logistical constraints.
Implementation Method 1
resilient means connected to the bearing housing and the second coupling part housing... mitigating misalignments and reaction forces through a flexible mechanism
Data Source
AI summary
A torque transmitting coupling assembly for a wind turbine is provided configured to couple a first coupling part to a second coupling part, wherein the first coupling part and the second coupling part are configured to rotate about a longitudinal axis of the torque transmitting coupling assembly, wherein the first coupling part is supported by a first bearing and a second bearing distributed along the longitudinal axis, wherein the first coupling part is enclosed by a bearing housing and the first and second bearings are arranged between the first coupling part and the bearing housing, wherein the second coupling part is enclosed by a second coupling part housing, wherein the first coupling part and the second coupling part are rigidly coupled by a plurality of fastening means.