Wind Turbine Coupling Assembly With Friction Ring Torque Transfer
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Solution Overview
Problem
Conventional torque transmitting couplings for wind turbines are expensive and difficult to disassemble, and over-dimensioning the coupling members to handle higher torques in larger turbines leads to inefficiencies and increased costs.
Innovation Solution
A torque transmitting coupling assembly that uses a torque transmitting ring and a compression ring to transfer torque radially and axially between coupling parts, allowing for a compact arrangement without over-dimensioning, and incorporates form-fitted couplings and fastening means to enhance torque transfer and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
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 changes the friction coefficient parameter by using a friction ring with a coefficient of friction between 0.3 and 0.6, which is lower than diamond-friction shims but sufficient for wind turbine applications. This parameter optimization reduces material cost while maintaining reliable torque transmission capability.
Solution Approach 2:
The friction ring is designed as a replaceable, cost-effective component that can be manufactured from conventional materials rather than expensive diamond-coated materials. This allows for easier replacement and reduces overall system cost while maintaining functional reliability.
2Reliability
If friction shims are used to reduce slippage risk, then torque transmission reliability is improved, but disassembly difficulty increases due to microform fits
Solution Approach 1:
The coupling assembly is segmented into distinct components including the friction ring, drive shaft, and driven shaft. The friction ring is designed as a separate, replaceable element that can be removed without damaging the shafts, facilitating easy maintenance and repair while maintaining slippage resistance during operation.
Solution Approach 2:
The friction ring utilizes dynamic friction characteristics with a coefficient between 0.3 and 0.6, allowing for controlled slippage under extreme conditions while preventing slippage during normal operation. This dynamic behavior enables easier disassembly compared to permanent microform fits.
3Ease of operation
If second coupling part is arranged at outer circumferential surface of first coupling part, then coupling is achieved, but coupling members must be over-dimensioned
Solution Approach 1:
The friction ring is nested between the drive shaft and driven shaft, with both shafts arranged coaxially rather than one at the outer circumferential surface of the other. This nested arrangement eliminates the need for over-dimensioning the coupling members while achieving reliable coupling through the friction ring's mediatory function.
Solution Approach 2:
The friction ring acts as an intermediary element between the drive shaft and driven shaft, transferring torque through friction. This intermediary allows for compact, coaxial arrangement of coupling members without requiring one shaft to be significantly larger than the other, reducing overall coupling member dimensions.
4Ease of operation
If torque transmitting region is limited by overlapping surface of rotatable parts, then coupling is achieved, but torque transmission efficiency is reduced
Solution Approach 1:
The patent optimizes the friction ring's contact surface parameters, including its width and friction coefficient (0.3-0.6), to maximize torque transmission efficiency within the available overlapping surface area. This parameter optimization ensures efficient power transmission without requiring excessive coupling member dimensions.
Solution Approach 2:
The friction ring is pre-loaded against both shafts to establish optimal contact pressure before torque transmission begins. This preliminary action ensures that the full friction capability is utilized during operation, maximizing torque transmission efficiency within the limited overlapping surface region.
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
Enables efficient torque transmission with reduced risk of slippage and misalignment, while maintaining a compact design and minimizing assembly complexity and costs.
Implementation Method 1
a friction ring with a coefficient of friction between 0.3 and 0.6, wherein a torque is transferred from a first coupling surface of the first coupling part to a second coupling surface of the second coupling part through the friction ring
Data Source
AI summary
A torque transmitting coupling assembly for a wind turbine configured to rotatably 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 torque transmitting coupling assembly includes a torque transmitting ring and a compression ring.