Wind Turbine Segment Locking via Expansion Plug Radial Force
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Solution Overview
Problem
Existing segment locking systems for wind turbine rotating electric machines lack precision, reliability, and ease of use in maintaining a constant air gap and tangential connection, especially when handling segments from one end.
Innovation Solution
A segment locking system featuring a supporting structure with axial grooves and segments with complementary grooves, utilizing an expansion plug that exerts a radial locking force through inclined projections and recesses, allowing for controlled locking and centring of segments, and optionally incorporating a reversible actuating mechanism and cooling capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional locking systems are used, then assembly is possible, but manufacturing precision and reliability of constant air gap are insufficient
Solution Approach 1:
The locking system is divided into multiple independent expansion plugs, each responsible for locking a specific segment to the supporting structure. This segmentation allows precise control of the air gap at multiple locations independently, ensuring constant air gap dimensions and high manufacturing precision while maintaining reliability through distributed locking points.
Solution Approach 2:
The expansion plugs utilize radial expansion force (perpendicular to the axial direction of assembly) to achieve axial and tangential positioning precision. By applying force in the radial dimension, the system achieves precise control of the air gap in the axial dimension, resolving the contradiction between manufacturing precision and reliability.
2Ease of operation
If segmented active parts are used for easy assembly, then ease of operation improves, but connection precision and reliability deteriorate
Solution Approach 1:
The active part is divided into multiple segments that can be assembled independently and then locked to the supporting structure using expansion plugs. This maintains the ease of operation benefit of segmentation while the expansion plugs provide precise radial locking that ensures high connection precision and reliability, resolving the contradiction between ease of assembly and connection precision.
Solution Approach 2:
The expansion plug acts as an intermediary element between the segment and the supporting structure. It provides a controlled locking mechanism that ensures precise connection while allowing easy assembly through the grooves, bridging the gap between ease of operation and manufacturing precision.
3Reliability
If locking force is increased for reliability, then connection strength improves, but ease of operation from one end deteriorates
Solution Approach 1:
The locking system uses multiple independent expansion plugs distributed along the segment, each providing localized locking force. This segmentation of the locking function allows the system to achieve high overall reliability through distributed forces while maintaining ease of operation, as each plug can be actuated independently from one end through the groove structure.
Solution Approach 2:
The expansion plugs are actuated in the axial direction (through the groove from one end) but generate locking force in the radial direction. This dimensional transformation allows easy operation from one end while achieving reliable radial locking, resolving the contradiction between locking reliability and ease of operation.
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 system provides a precise, reliable, and easy-to-use method for locking wind turbine segments, ensuring a constant air gap and tangential connection, with controlled radial force distribution and centring, facilitating easy maintenance and reduced heat buildup through cooling.
Implementation Method 1
the expansion plug, when expanded, exerts a force with a radial component to lock the segment to the supporting structure along the respective second and first mating face
Implementation Method 2
the expansion plug contacting the supporting structure and the segment along inclined faces sloping with respect to the radial axis
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A system for locking wind turbine rotating electric machine segments has a supporting structure (10) extending about an axis of rotation (A) and having a first mating face (16), and a plurality of first axial grooves (23), each communicating with the first mating face (16); a plurality of segments (12), each having a second mating face (18), and a second axial groove (24) which is positioned facing and adjacent to one of the first grooves (23); and an expansion plug (25) designed to engage a first and second groove (23, 24) facing each other; the first and second groove (23, 24) and the expansion plug (25) being designed so that the expansion plug, when expanded, exerts a force with a radial component to lock the segment (12) to the supporting structure (10) along the respective second and first mating face (18, 16).