Yaw Brake Rotor Lock Mechanism for Precise Nacelle Positioning
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Solution Overview
Problem
Existing yaw brake mechanisms for turbines are heavy, costly, and inefficient in accommodating high torque requirements, limiting their ability to maintain multiple azimuth headings with precision.
Innovation Solution
A yaw brake mechanism utilizing multiple rotor locks and receptacles that can be actuated to lock the nacelle at desired orientations, allowing for precise control and maintenance of multiple azimuth headings with a low mass, low height, and low cost solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If disc brakes are used as yaw braking mechanism, then braking torque can be achieved, but the mechanism becomes heavy, tall, and costly
Solution Approach 1:
The braking mechanism is segmented into multiple independent rotor locks (at least two) that can be selectively engaged. Each rotor lock handles a portion of the braking torque requirement, allowing the system to achieve full braking capacity without requiring a single large, heavy brake assembly. This segmentation enables weight reduction while maintaining the necessary braking force.
Solution Approach 2:
The rotor locks are nested within the existing yaw drive powertrain system, utilizing the gear train and gearbox components already present. The rotor locks engage with the pinion gear or intermediate gear, nesting the braking function within the existing mechanical structure rather than adding separate external brake assemblies, thereby reducing overall system weight and complexity.
2Adaptability or versatility
If multiple rotor locks are used, then multiple azimuth headings can be maintained, but device complexity increases
Solution Approach 1:
The rotor locks serve multiple functions: they provide braking torque during yaw rotation and simultaneously enable the nacelle to be held at multiple discrete azimuth headings. By engaging different numbers and combinations of rotor locks, the system can achieve both continuous braking and discrete positioning functions using the same components, reducing overall device complexity despite the multi-heading capability.
Solution Approach 2:
The rotor locks are designed to be selectively and dynamically engaged or disengaged based on operational requirements. The system can transition between having zero, one, or multiple rotor locks engaged depending on whether braking is needed, whether precise positioning is required, or whether full rotational freedom is needed. This dynamic engagement strategy reduces complexity by only activating necessary components rather than requiring all components to be permanently active.
3Force
If high gear ratio gearbox is used to multiply brake torque, then sufficient braking torque is achieved, but the system becomes more complex with multiple powertrains
Solution Approach 1:
The braking function is merged with the existing yaw drive powertrain system rather than being implemented as a separate system. The rotor locks engage with the pinion gear or intermediate gear that are already part of the yaw drive mechanism, combining the braking function with the existing powertrain components. This merging eliminates the need for separate brake assemblies and reduces overall system complexity while achieving sufficient braking torque through the mechanical advantage of the existing gear train.
Data Source
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AI summary
A yaw brake mechanism is described for maintaining a yawing structure, such as a nacelle of a fluid turbine, at a desired orientation or azimuthal heading about a reference or yaw axis. The yaw brake mechanism uses one or more rotor locks and one or more receptacles that cooperate with one another to achieve the locking function. One of the rotor locks is actuatable so that a portion thereof can be engaged in one of the receptacles to lock the yawing structure. The number of rotor locks and receptacles can be selected to allow the yawing structure to achieve any azimuth heading around the full 360 degrees of the yaw axis with various degrees of accuracy. The yaw brake mechanism allows the yawing structure to maintain multiple headings while being subjected to extreme moment and force loads in a low mass, low height, low cost solution.