Wind Turbine Elastic Coupling for Parasitic Force Isolation
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Solution Overview
Problem
Wind turbine drive trains face issues with parasitic forces that can damage gearbox components and main bearings due to variations in load, machining tolerances, thermal effects, and other conditions, leading to reduced reliability.
Innovation Solution
A drive train configuration featuring a rotor shaft, a support structure with a bearing housing, a gearbox input shaft, and an elastic coupling with a single joint between the rotor shaft and the gearbox input shaft, where the elastic coupling has different stiffness in various load directions, allowing for relative rotation and translation while minimizing reaction forces in the torque load direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple elastic elements are used in the coupling, then the reliability of torque transmission is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple elastic elements into a single integrated elastic coupling element that provides the same functional benefits. This single element incorporates the necessary elasticity and compliance characteristics that would otherwise require multiple separate elements, thereby reducing device complexity while maintaining reliability in torque transmission.
Solution Approach 2:
The single elastic coupling element performs multiple functions simultaneously: it provides torque transmission, accommodates misalignment, compensates for thermal expansion, and absorbs shock loads. This multi-functionality eliminates the need for multiple separate components, reducing both complexity and manufacturing cost while maintaining system reliability.
2Power
If a rigid coupling is used between rotor shaft and gearbox input shaft, then the torque transmission efficiency is improved, but parasitic forces damage gearbox components and bearings
Solution Approach 1:
The patent changes the stiffness parameter of the coupling by using an elastic material with appropriate elastic modulus. This allows the coupling to be sufficiently stiff to transmit torque efficiently while being compliant enough to absorb parasitic forces and prevent damage to gearbox components and bearings. The elastic properties are specifically selected to optimize both torque transmission and shock absorption.
Solution Approach 2:
The elastic coupling element acts as a cushioning element that anticipates and absorbs parasitic forces before they can reach the gearbox components and bearings. By placing this elastic element in advance between the rotor shaft and gearbox input shaft, the system is protected from damage caused by load variations, machining tolerances, and thermal effects.
3Manufacturing precision
If precise machining tolerances are maintained in the drive train, then the alignment accuracy is improved, but the manufacturing cost increases
Solution Approach 1:
The elastic coupling serves as an intermediary element that compensates for misalignments caused by machining tolerances. Instead of requiring extremely precise machining of all components, the elastic coupling absorbs the misalignment and maintains proper operational alignment, thereby significantly reducing manufacturing costs while preserving alignment accuracy during operation.
Solution Approach 2:
The patent utilizes the elastic properties of the coupling material to dynamically adjust and maintain optimal alignment parameters during operation, compensating for static misalignments introduced by machining tolerances. This allows for more relaxed manufacturing tolerances while maintaining the necessary operational alignment accuracy.
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 elastic coupling design reduces the number of required elastic elements, simplifies manufacturing and maintenance, and enhances gearbox and bearing reliability by effectively managing and transferring torque loads while minimizing parasitic forces.
Implementation Method 1
an elastic coupling with a single joint between the rotor shaft and the gearbox input shaft, where the elastic coupling has different stiffness in various load directions
Data Source
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AI summary
The invention relates to a drive drain for a wind turbine comprising: a rotor shaft (main shaft) configured to be driven by the rotor about a main axis; a support structure including a bearing housing surrounding the at least one bearing and supporting the rotor shaft for rotation about the main axis, thereby constraining other movements of the rotor shaft; a gearbox input shaft and a gearbox housing supporting the gearbox input shaft for rotation about the main axis while constraining other movements of the gearbox input shaft; and an elastic coupling, wherein the gearbox input shaft is coupled to the rotor shaft by the elastic coupling, the elastic coupling comprising a first coupling part rigidly connected with the rotor shaft, a second coupling part rigidly connected with the gearbox input shaft and elastic elements positioned between the first and the second coupling part, thereby constituting a single joint between the rotor shaft and the gearbox input shaft. The invention also relates to wind turbines comprising such a drive drain and methods of manufacturing or retrofitting wind turbines with such a drive drain.