Patent Application
20150204308
This application claims priority to EP Application No. 14151794.6, having a filing date of Jan. 20, 2014, the entire contents of which are hereby incorporated by reference.
The following relates to a component for a brake system for a wind turbine generator, a brake system for a wind turbine generator, for example, a direct drive generator (DD-generator), and a wind turbine. The following further relates to a method for assembling a wind turbine generator.
In principle there are two main types of wind turbines in view of the direct drive configuration of a wind turbine. The first type of a wind turbine is the more classical type of a wind turbine comprising a gearbox arranged between a main shaft and a generator of the wind turbine. The second type of a wind turbine is a gearless type, where the gearbox and the conventional generator are substituted by a multipolar generator, a so-called direct drive or directly driven generator. Such a direct drive generator can be made as a synchronous generator with winded rotor or with permanent magnets attached to the rotor, or it can be designed as an alternative type of a generator. One of the challenges with the direct drive generator is the mechanical brake system. The brake system needs to be located at the slowing rotating axis as no gear box is used. The brake system needs to withstand a large braking moment and large brake discs and callipers are necessary.
An example for a typical brake system consists of three individual mounted brake consoles, as disclosed in EP 2333326 A1. A difficulty with this solution is that the brake consoles are hard to mount and have a limited structural strength. The rotor lock in the previous design works by engaging the brake disc radially. This design has met its structural limit and is difficult to upgrade without having influence on braking area and brake integrity. The system used up to now takes a long time and additional manpower for mounting. Moreover, to mount the system, the mounting personnel has to be in situation which is exhausting.
An aspect relates to a brake system for a wind turbine generator, an advantageous brake system for a wind turbine generator, an advantageous wind turbine, and an advantageous method for assembling a wind turbine generator.
Aspects relate to a component for a brake system for a wind turbine generator, a brake system for a wind turbine generator, a wind turbine and a method for assembling a wind turbine generator.
The inventive component for a brake system is applicable for a wind turbine generator. The wind turbine generator comprises a stator assembly, a rotor assembly and a rotation axis. The rotor assembly comprises an outer portion which is located radially outward of the stator assembly (outer rotor configuration). The component has the shape of a ring. The component comprises means, preferably a plurality of holes, for connecting the component to a flange of the stator assembly. The component further comprises a number of, preferably at least three, radially outwardly protruding portions (wings). The radially outwardly protruding portions comprise means, preferably a plurality of holes, for connecting the radially outwardly protruding portions to frictional members operatively configured for frictionally engaging at least a portion of a brake disc and/or for connecting the radially outwardly protruding portions to a rotor lock system.
Preferably the outwardly protruding portions (wings) are made in one piece with the component. In other words, the outwardly protruding portions and the component are no separate components connected with each other. Advantageously, the outwardly protruding portions are equally spaced in circumferential direction of the component.
Furthermore, the component and/or a brake disc, for example, a corresponding ring-shaped brake disc, can be prefabricated away from the generator production line and applicable for different generator types. Then a crane can take the component or the complete brake system and it can be mounted onto the generator line by only adding bolts and/or pins and/or shims to align stator with rotor in the braking system.
The frictional members operatively configured for frictionally engaging at least a portion of a brake disc may be brake callipers.
The inventive component has the advantage that the structural strength of the brake system is increased and the forces acting on frictional members, for instance, the brake callipers, and the forces acting on the rotor lock system can be divided over a larger area. Moreover, a fixed shaft in the generator may have a flange casted on, for example, instead of pads. The component can be mounted on this flange. Brake callipers and/or a rotor lock can easier be mounted onto the outwardly protruding portions than in previously known solutions.
The inventive brake system for a wind turbine generator comprises a previously described component and a brake disc. Generally, the inventive brake system has the same advantages as the previously described component. Preferably the brake disc has the shape of a ring. Advantageously, the brake system comprises a rotor lock system.
Moreover, the brake disc can have the shape of a ring and can comprise means, preferably a plurality of holes, for connecting it to the rotor assembly, preferably by means of a flange. Furthermore, pins may be placed in an interface between a fixed shaft flange and the component and may insure placement accuracy and additional strength in the assembly.
Preferably the brake disc comprises a number of holes or recesses and the brake system comprises a number of rotorlock pins configured for engaging into the holes or recesses. Advantageously, the holes or recesses are equally spaced in circumferential direction of the component or the ring portion of the component.
The inventive brake system can comprise a number of rotorlock pins and at least one plate, for instance, a static plate, configured for supporting the rotorlock pins. For example, a plate can be placed on each side of the brake disc. The rotorlock pins can be engaged through a hole in the brake disc and supported by a plate on each side of the brake disc. This reduces bending of the rotorlock pins. For example, one plate can be located on one side of the brake disc and a second plate can be located on the other side of the brake disc.
The inventive wind turbine generator comprises a stator assembly, a rotor assembly and a rotation axis. The rotor assembly comprises an outer portion which is located radially outward of the stator assembly (outer rotor configuration).
The inventive wind turbine generator further comprises a brake system as previously described. The inventive wind turbine generator has the previously mentioned advantages.
Preferably, the stator assembly comprises a flange and the inventive component is connected to the flange. The generator may be a direct drive generator. The generator has advantageously a nominal power or effective power of at least 1 MW, for instance at least 3 MW.
Moreover, the brake disc may extend radially inward from the outer portion of the rotor assembly to the rotation axis. The rotor assembly may comprise a flange and/or threads in the rotor material. The brake disc may be fastened directly into the rotor assembly or to the flange. Furthermore, the at least one frictional member, for instance, brake calliper, can extend radially outward regarding the rotation axis.
The inventive wind turbine comprises a brake system as previously described and/or a generator as previously described. The wind turbine is preferably a horizontal axis wind turbine. The wind turbine may comprise a generator and/or a hub. The brake system may be connected to the generator and/or to the hub. The inventive wind turbine has the same advantages as the inventive brake system and the inventive generator.
The inventive method for assembling a wind turbine generator relates to a generator comprising a stator assembly, a rotor assembly and a rotation axis, wherein the rotor assembly comprises an outer portion which is located radially outward of the stator assembly. The method comprises the step of connecting an inventive component to the stator assembly, preferably by means of a flange. For this purpose, the stator assembly and/or the component may comprise a flange.
The inventive method is in principle applicable for manufacturing a generator or repairing or rebuilding or converting an existing generator.
The method may further comprise the step of aligning the component connected to the stator assembly with a brake disc. The brake disc may be connected to the rotor assembly by means of a flange. Generally, the outer portion of the rotor assembly may comprise the brake disc.
The method may further comprise the step of placing pins in an interface between a fixed shaft flange and the component. This may ensure placement accuracy and additional strength in the assembly.
Furthermore, the component and/or a brake disc, for example, a corresponding ring-shaped brake disc, can be prefabricated away from the generator production line and applicable for different generator types. Then a crane can take the component or the complete brake system and it can be mounted onto the generator line only adding bolts and/or pins and/or shims to align stator with rotor in the braking system.
Embodiments of the invention are advantageous in that the entire brake system and/or rotorlock system can be completely pre-assembled away from the line. It has only to be figured out which thickness shims are needed to be added during the assembly state of the brake and/or rotorlock system on the rest of the generator. Mounting a component or console ring for brakes and rotorlock on a flange of a fixed shaft is an uncomplicated procedure and with the use of pins it helps easy aligning and centering placement of the rotorlock and brake caliper.
As the lock system may require a plurality of locks, for instance three locks, to be engaged simultaneously, making one piece component or console ring in one machining negates almost entirely the inter alignment between the locks, for instance three locks. One inventive component or console ring can also avoid unexpected wear from calliper pads, as they are placed in the same machined plane. Thereby the system is more cost efficient and more serviceable than previous systems.
Further features, properties and advantages of embodiments of the present invention will become clear from the following description of embodiments in conjunction with the accompanying drawings. The embodiments do not limit the scope of embodiments of the present invention which is determined by the appended claims. All described features are advantageous as separate features or in any combination with each other. Corresponding elements are designated with the same reference numerals.
The stator assembly 7 further comprises a frictional member, in the present embodiment a brake calliper system 13. The brake calliper system 13 is operatively configured for frictionally engaging at least a portion of the brake disc 12. The brake calliper system 13 extends radially outward from the stationary shaft 10 to the brake disc 12. The brake calliper system 13 comprises at least one brake calliper on each side of the brake disc 12 in order to enclose the brake disc 12.
The brake system comprises at least one rotor lock system 17. The rotor lock system 17 comprises at least one piston 16. The piston is located inside the console or flange 14 or is located inside of a lock casing. The lock casing can be connected to the console or flange 14. Alternatively, the brake system can comprise separate consoles or flanges for housing the pistons or for being connected with at least one lock casing of the rotor lock system 17 and separate consoles or flanges 14 being connected with the brake system, especially the brake calliper system 13. The pistons 16 are located such that they are prepared to engage with the recesses 15 in the inner surface 21 of the brake disc 12.
The component 20 further comprises a central axis 26 and at least three radially outwardly protruding portions (wings) 22. The component 20 and the radially outwardly protruding portions 22 are made in one piece.
The radially outwardly protruding portions 22 may comprise means (not shown in
The protruding portions (wings) 22 are staggered about an angle of 120° regarding the circumference of the component 20. Alternatively, any other number or angle of the protruding portions 22 is possible. Preferably, the protruding portions 22 are arranged around the circumference of the component 20 such that adjacent protruding portions 22 have an equal distance to each other.
The inventive brake system further comprises a brake disc 12. The brake disc 12 may have the shape of a ring. The brake disc 12 comprises a plurality of holes 19 for connecting it to the rotor assembly 8 by means of a flange or threaded holes. The brake disc 12 may further comprise a number of holes 18 or other means for rotorlock pins configured for engaging into the holes.
In the context of the inventive method for assembling a wind turbine generator the component 20 is connected to the stator assembly 7, preferably to the stationary shaft 10 by means of the flange 25. The inventive method is applicable for manufacturing a generator or repairing or rebuilding or converting an existing generator.
After connecting the component 20 to the stator assembly 7, the component 20 can be aligned with a brake disc 12. The brake disc 12 may be connected to the rotor assembly 8 by means of the flange 24 or by means of threaded holes/pins in the rotor assembly. Generally, the outer portion 11 of the rotor assembly 8 may comprise the brake disc 12.
The method may further comprise the step of placing pins in an interface between a fixed shaft flange 25 as well as for the rotor assembly 11 and the component 20 (not shown in
Furthermore, the component 20 and/or a brake disc 12, for example a corresponding ring-shaped brake disc, can be prefabricated away from the generator production line and applicable for different generator types. Then a crane can take the component or the complete brake system and it can be mounted onto the generator line only adding bolts and/or pins and/or shims to align stator with rotor in the braking system.
Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.
| Number | Date | Country | Kind |
|---|---|---|---|
| 14151794.6 | Jan 2014 | EP | regional |
