Wind Turbine Shaft Locking Mechanism Using Axial Retention
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Solution Overview
Problem
Wind turbines pose a safety risk for technicians due to unpredictable rotation caused by wind swirls and gusts, as existing locking mechanisms are bulky, costly, and complex, and occupy valuable space within the nacelle.
Innovation Solution
A rotational locking assembly for wind turbines featuring a retention mechanism, such as a locking ring, that can be axially moved between engaged and disengaged positions to constrain or allow shaft rotation, utilizing housing and shaft engagement formations like splines and grooves, and actuated by hydraulic, electromagnetic, or electrical means, allowing visual confirmation of the locking state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking hub with locking pins is used to prevent shaft rotation, then safety is improved, but device complexity and space usage increase
Solution Approach 1:
The patent extracts the locking function from a separate locking hub component and integrates it directly into the shaft structure through keyways and keys. This eliminates the need for a separate locking hub with multiple locking pins, reducing device complexity while maintaining the safety function of preventing shaft rotation during maintenance.
Solution Approach 2:
The locking mechanism is merged with the shaft and housing structures. The keyways are formed directly in the shaft, and the keys are integrated into the housing, combining the locking function with existing structural components rather than adding separate locking elements.
2Reliability
If a locking hub with locking pins is used to prevent shaft rotation, then safety is improved, but the space available in the nacelle is reduced
Solution Approach 1:
The patent removes the bulky locking hub component and extracts only the essential locking function, implementing it through compact keyway-key structures that occupy minimal space within the nacelle while still providing effective shaft rotation prevention.
Solution Approach 2:
The locking mechanism transitions from a radial flange structure with protruding locking pins to an axial keyway-key arrangement. This dimensional change allows the locking function to be achieved within the existing axial space between bearings without requiring additional radial or axial clearance.
3Reliability
If a locking hub is provided with a shroud or cage to prevent injury, then safety is improved, but bulk, cost and complexity increase
Solution Approach 1:
The patent eliminates the need for protective shrouds or cages by designing the locking mechanism itself to be inherently safe. The keyways and keys provide positive locking without exposed moving parts that could pose injury risks, removing the need for additional protective structures.
4Ease of operation
If a retention mechanism is moved axially between engaged and disengaged positions, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The patent implements a dynamic retention mechanism that can axially translate between engaged and disengaged positions. This allows the locking function to be activated or deactivated as needed, providing ease of operation for maintenance activities while using simple keyway-key geometry that does not significantly increase complexity.
Data Source
AI summary
An assembly (127) for a wind turbine (100) includes a housing (126) having a first bearing (150) and a second bearing (154). A shaft (142) extends axially within the housing (126) and is supported by the first bearing (150) and the second bearing (154) for rotation relative to the housing (126). A radially outer portion of the shaft (142) includes at least one shaft engagement formation (146) positioned between the first bearing (150) and the second bearing (154). A retention mechanism (156) is moveable axially between: an engaged position in which it can engage the shaft engagement formation (146), such that rotation of the shaft (142) is constrained; and a disengaged position in which the retention mechanism (156) cannot engage the shaft engagement formation (146), thereby allowing rotation of the shaft (142). Additionally, a method of operating such an assembly.