Wind Turbine Gearmotor Coupling Mechanism
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Solution Overview
Problem
Existing wind power generators face operational difficulties due to the complex and time-consuming process of coupling gearmotors with crown gears, requiring the removal and reinstallation of fastening bolts and the use of lifting systems, leading to prolonged setup times and specialized personnel requirements.
Innovation Solution
The wind power generator employs a coupling fork with actuation screws and a locking mechanism using fewer fastening bolts, allowing for simple and rapid positioning of gearmotors without lifting, and uses an epicyclic reduction gear to rotate the output gear, eliminating the need for lifting and reducing the radial dimension of gearmotors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gearmotor is fixed to the support bracket using multiple fastening bolts with small distribution pitch, then the coupling stability is improved, but the setup time and operational complexity increase due to requiring removal and reinstallation of all bolts
Solution Approach 1:
The fastening system is segmented into two functional groups: positioning bolts (fewer in number, larger pitch) for initial alignment and locking bolts (multiple, smaller pitch) for final securing. This segmentation allows the positioning phase to be completed quickly with fewer bolts, reducing setup time while maintaining coupling stability through the subsequent locking phase.
Solution Approach 2:
The positioning bolts are installed first to establish the preliminary position of the gearmotor relative to the support bracket. This preliminary action enables rapid initial alignment without requiring all fastening bolts to be installed, thereby reducing setup time while ensuring stable coupling when the locking bolts are subsequently applied.
2Manufacturing precision
If the gearmotor is rotated around its longitudinal axis to exploit eccentricity for coupling, then the coupling precision is improved, but the operational difficulty and need for specialized personnel increase
Solution Approach 1:
A positioning mechanism acts as an intermediary between the gearmotor and the support bracket, providing guided alignment without requiring manual rotation of the gearmotor. This intermediary device ensures precise coupling while simplifying the operation, as operators only need to engage the positioning mechanism rather than manually rotate and align the gearmotor.
Solution Approach 2:
The gearmotor incorporates self-aligning features such as eccentric mounting holes or automatic positioning elements that enable the coupling process to be performed without specialized knowledge. The system performs its own alignment function, eliminating the need for operators to manually rotate the gearmotor to exploit eccentricity.
3Adaptability or versatility
If a lifting system is used to lift the gearmotor for disengagement and positioning, then the adaptability of the coupling process is improved, but the device complexity and cost increase
Solution Approach 1:
The support bracket incorporates movable elements such as sliding guides or adjustable positioning slots that allow the gearmotor to be dynamically repositioned during coupling. This dynamic capability provides adaptability for different coupling scenarios without requiring a separate lifting system, thereby reducing overall system complexity.
Solution Approach 2:
The positioning mechanism serves multiple functions: it guides the gearmotor into position, maintains alignment during coupling, and secures the final position. This multi-functional design eliminates the need for a dedicated lifting system, reducing device complexity while maintaining coupling adaptability.
4Power
If the output gear axis is parallel to and distinct from the gearmotor longitudinal axis, then the mechanical advantage is improved, but the radial dimension of the gearmotor increases
Solution Approach 1:
The output gear is nested within the gearmotor housing, with its axis offset from the longitudinal axis. This nested arrangement allows the gearmotor to maintain a compact radial dimension while still achieving the desired mechanical advantage through the offset gear configuration. The output gear fits within the existing footprint of the gearmotor.
Solution Approach 2:
Instead of increasing the radial dimension of the gearmotor, the output gear axis is positioned in a different dimensional plane, offset from the longitudinal axis. This dimensional repositioning maintains the gearmotor's compact radial profile while achieving the necessary mechanical advantage through the offset gear arrangement.
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
This solution simplifies the setup process, reduces operational time, and minimizes the need for specialized personnel by allowing gearmotor positioning and disengagement without lifting, thereby enhancing the efficiency and cost-effectiveness of wind power generator installation and maintenance.
Implementation Method 1
uses an epicyclic reduction gear to rotate the output gear
Data Source
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AI summary
A wind power generator having a nacelle (3), which is mounted to an upper end of a support tower (2), supports in rotary manner a rotor (26), and is oriented around a rotation axis (5) by an orienting device (4) provided with at least one gearmotor (7), which presents an output gear (13) coupled with a crown gear (6) fixed to the support tower (2), and is hinged to the nacelle (3) so as to rotate around a fulcrum axis (15) which is substantially parallel to the rotation axis (5) under the thrust of an actuation device (17).