Wind Turbine Main Shaft Integrated Locking Disc

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Solution Overview

Problem

Current rotor locking systems in wind turbines are cumbersome, adding weight and complexity, leading to increased assembly costs and handling difficulties due to the use of large, separate components.

Innovation Solution

A rotor locking disc is integrally formed with the main shaft, featuring a peripheral region with fastener holes for securing the main shaft to the rotor hub, allowing axial movement of locking pins for simplified assembly and reduced weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate locking ring with multiple components is used, then the rotor can be locked against rotation, but the weight and complexity of the assembly increases

Engineering Contradiction:

Improverotor locking capabilityVSAvoidnumber of separate components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The locking disc is integrally formed with the main shaft as a single piece, combining what were previously separate components (main shaft and locking ring) into one unified structure. This eliminates the need for separate locking rings while maintaining the rotor locking capability through pins that engage with recesses in the integrated locking disc.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If multiple large scale components are assembled together, then the rotor locking function is achieved, but assembly and installation become more difficult

Engineering Contradiction:

Improverotor locking functionVSAvoidassembly and installation difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By integrating the locking disc with the main shaft into a single component, the number of assembly steps is reduced. The integrated structure eliminates the need to separately assemble and align multiple large components, making installation easier while maintaining the complete rotor locking function.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate locking components are used, then the rotor can be secured, but handling and assembly costs increase

Engineering Contradiction:

Improverotor securityVSAvoidhandling and assembly costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The integration of the locking disc with the main shaft reduces the total number of components that need to be handled during assembly. This single-piece construction eliminates the need for separate locking rings, reducing handling requirements and assembly costs while maintaining secure rotor locking through the pin-and-recess mechanism.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10961985B2Wind turbine and methods including main shaft integrated with locking disc

Publication Date: 2021.03.30 VESTAS WIND SYSTEMS AS

AI summary

A wind turbine includes a main shaft (34), a rotor hub (22), a plurality of blades coupled to the rotor hub (22), and a rotor locking disc (32), (32′). The main shaft (34) includes a front end portion (34a), and the front end portion (34a) includes a first connecting structure (36). The rotor hub (22) includes a second connecting structure (40). The first connecting structure (36) of the main shaft (34) is fixed to the second connecting structure (40) of the rotor hub (22). The rotor locking disc (32), (32′) is integrally formed on the front end portion (34a) of the main shaft (34), and includes a peripheral region. A plurality of rotor locking elements (50), (50′) are located in the peripheral region for receiving one or more rotor locking pins (30).