Wind Turbine Nacelle Self-Aligning Assembly Interface
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Solution Overview
Problem
The assembly of powertrain components in wind turbines is challenging due to the difficulty in aligning and connecting heavy, bulky components without damaging sensitive surface treatments, which increases maintenance needs and requires expensive equipment.
Innovation Solution
A self-aligning interface with inclined protrusions and recesses on the support and housing surfaces, respectively, guides the components into precise contact without direct force, preventing damage and enhancing friction for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional alignment methods are used to assemble powertrain housing onto support base, then assembly can be completed, but the sensitive surface treatment is damaged and maintenance frequency increases
Solution Approach 1:
The patent applies preliminary action by providing alignment protrusions and recesses that are pre-formed on the powertrain housing and support base respectively. These features guide the components into proper alignment during assembly before the surfaces make full contact, preventing damage to the sensitive surface treatment that would otherwise occur during the assembly process.
Solution Approach 2:
The patent uses alignment protrusions and recesses as intermediary elements that facilitate the assembly process. These features act as mediators between the powertrain housing and support base, enabling precise alignment and controlled contact that protects the surface treatment while still allowing successful assembly.
2Ease of operation
If heavy powertrain components are manually aligned and connected, then assembly is possible, but expensive installation equipment is required
Solution Approach 1:
The patent applies self-service by designing the powertrain housing and support base with complementary alignment protrusions and recesses that automatically guide the components into proper alignment during assembly. This self-aligning mechanism eliminates the need for expensive external alignment equipment and reduces the skill level required for assembly operations.
3Reliability
If surface treatment is applied to increase friction and corrosion resistance, then component durability is improved, but the surface becomes sensitive to damage during assembly
Solution Approach 1:
The alignment protrusions and recesses are pre-formed features that establish proper component alignment before the surface treatment layers make full contact. This preliminary alignment action prevents sliding and scraping movements that would damage the corrosion-resistant surface treatment during the assembly process.
Solution Approach 2:
The alignment protrusions and recesses serve as intermediary elements that facilitate assembly while protecting the surface treatment. These features enable controlled, precise contact between components, preventing the harmful sliding and impacting forces that would otherwise damage the friction-enhanced surface treatment.
4Reliability
If alignment protrusions and recesses are used to guide components during assembly, then surface damage is prevented, but manufacturing complexity increases
Solution Approach 1:
The alignment protrusions and recesses are integrated directly into the powertrain housing and support base structures themselves, rather than being separate components. This merging of alignment features with the main structural components eliminates the need for additional parts and simplifies the overall manufacturing process while still providing surface protection.
Data Source
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AI summary
A self-aligning interface for assembling a powertrain housing 210 of a wind turbine onto a support base 220 is provided. The support base 220 comprises a support surface 230 and the powertrain housing 210 comprises a housing surface 240. The support surface 230 and the housing surface 240 are configured to be in contact after assembly. The self-aligning interface comprises: one or more protrusions 250 on the support surface 230, wherein the one or more protrusions 250 comprises one or more walls 260 which are inclined with respect to the support surface 230; and one or more recesses 270 on the housing surface 240. In addition or alternatively, the self-aligning interface comprises one or more protrusions on the housing surface, wherein the one or more protrusions comprises one or more walls which are inclined with respect to the housing surface, and one or more recesses on the support surface. The one or more protrusions 250 are complementary in size and shape to respective ones of the one or more recesses 270, such that, during assembly of the powertrain housing 210 onto the support base 220, the one or more protrusions 250 act as a guide for the one or more recesses 270, and the one or more protrusions 250 fit directly into the respective one or more recesses 270, to enable direct contact between the support surface 230 and the housing surface 240.