The present subject matter relates generally to wind turbines and, more particularly, to a pitch bearing assembly having a stiffener.
Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades capture kinetic energy from wind using known airfoil principles and transmit the kinetic energy through rotational energy to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.
To ensure that wind power remains a viable energy source, efforts have been made to increase energy outputs by modifying the size and capacity of wind turbines. One such modification has been to increase the length of the rotor blades. However, as is generally understood, the loading on a rotor blade is a function of blade length, along with wind speed and turbine operating states. Thus, longer rotor blades may be subject to increased loading, particularly when a wind turbine is operating in high-speed wind conditions.
During the operation of a wind turbine, the loads acting on a rotor blade are transmitted through the blade and into the blade root. Thereafter, the loads are transmitted through a pitch bearing disposed at the interface between the rotor blade and the wind turbine hub. Typically, the hub has a much higher stiffness than the rotor blades. Thus, due to the stiffness differential between the hub and the rotor blades, the pitch bearings are often subjected to extreme, varying and/or opposing loads. For example, the inner race of each pitch bearing (i.e., the portion coupled to the rotor blades) may be subjected to varying, localized loads resulting from flapwise or edgewise bending of the rotor blades, whereas the outer race of each pitch bearing (i.e., the portion coupled to the hub) may be subjected to lower and/or differing loads. Such a variation in loading across the inner and outer races can result in substantial damage and/or deformation (e.g. ovalization) to the pitch bearings.
Accordingly, a pitch bearing assembly having a stiffener configured to distribute loads and, thus, to reduce the localized stress within the pitch bearing would be welcomed in the technology.
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one aspect, the present subject matter is directed to a pitch bearing assembly for a wind turbine. The pitch bearing assembly may include an outer race and an inner race rotatable relative to the outer race. The inner race may define an inner circumference and may include a plurality of gear teeth around the inner circumference. Further, the pitch bearing assembly includes a stiffener having a body and at least one gear pinion. The body extends at least partially around the inner circumference of the inner race and the at least one gear pinion engages a portion of the plurality of gear teeth.
In another aspect, the present subject matter is directed to a pitch bearing assembly for a wind turbine. The pitch bearing assembly may include an outer race and an inner race rotatable relative to the outer race. The inner race may define an inner circumference. Further, the inner circumference may define a volume within the inner race. The inner race may also include a plurality of gear teeth around the inner circumference. Further, the pitch bearing assembly includes a stiffener disposed within the volume. The stiffener includes a fixed portion and a rotatable portion, the fixed portion configured to attach to the hub, the rotatable portion configured to accommodate rotation of the inner race.
In a further aspect, the present subject matter is directed to a rotor blade assembly for a wind turbine. The rotor blade assembly may include a rotor blade having a body shell extending between a blade root and a blade tip. The rotor blade assembly may also include a pitch bearing coupled to the blade root. The pitch bearing may include an outer race and an inner race rotatable relative to the outer race. The inner race defines an inner circumference and includes a plurality of gear teeth around the inner circumference. The rotor blade assembly also includes a stiffener having a body and at least one gear pinion engaged with the body. The body extends at least partially around the inner circumference and the at least one gear pinion engages a portion of the plurality of gear teeth. Additionally, the rotor blade is configured to be coupled to the pitch bearing and the pitch bearing is configured to be coupled to a hub of the wind turbine.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
In general, the present subject matter is directed to a pitch bearing assembly for a wind turbine having a stiffener configured to resist deformation of the pitch bearing under a load. More specifically, the pitch bearing assembly may include an outer race and an inner race rotatable relative to the outer race. The inner race defines an inner circumference and includes a plurality of gear teeth around the inner circumference. The stiffener includes a fixed portion and a rotatable portion. The fixed portion is configured to attach to the hub, whereas the rotatable portion is configured to accommodate rotation of the inner race. For example, in one embodiment, the fixed portion of the stiffener corresponds to an annular body affixed to the hub via one or more mounting supports. In another embodiment, the rotatable portion corresponds to a plurality of gear pinions configured to engage the plurality of gear teeth around the inner circumference of the inner race. Such a configuration allows the gear pinions to rotate along with the pitch bearing when the inner race rotates to pitch the corresponding rotor blade. As such, if the pitch bearing deforms under a load, the gear pinions are capable of resisting the deformation. Accordingly, the loads transmitted through the rotor blade and into the pitch bearing may be more evenly distributed, thereby protecting the pitch bearing from uneven or excessive loads which may result in bearing failure.
Referring now to the drawings,
Referring now to
Moreover, as shown, the rotor blade 20 may also include a plurality of T-bolts or root attachment assemblies 40 for coupling the blade root 20 to the hub 18 of the wind turbine 10. In general, each root attachment assembly 40 may include a barrel nut 42 mounted within a portion of the blade root 22 and a root bolt 44 coupled to and extending from the barrel nut 42 so as to project outwardly from a root end 46 of the blade root 22. By projecting outwardly from the root end 46, the root bolts 44 may generally be used to couple the blade root 22 to the hub 18 (e.g., via a pitch bearing 52 (FIG. 3)), as will be described in greater detail below.
Referring now to
As depicted, the pitch bearing 52 may include an outer bearing race 54, an inner bearing race 56, and a plurality of roller elements (e.g., balls 58) disposed between the outer and inner races 54, 56. The outer race 54 may generally be configured to be mounted to a hub flange 60 of the hub 18 using a plurality of hub bolts 62 and/or other suitable fastening mechanisms. Similarly, the inner race 56 may be configured to be mounted to the blade root 22 using the root bolts 44 of the root attachment assemblies 40. For example, as particularly shown in
As is generally understood, the inner race 56 may be configured to rotate relative to the outer race 54 (via the roller elements 58) to allow the pitch angle of each rotor blade 20 to be adjusted. As shown in
Referring to
As mentioned, the pitch bearing assembly 50 as described herein includes a stiffener 100. Referring particularly to
In various embodiments, the web portion 110 may extend generally perpendicularly between the top and bottom portions 106, 108 so as to define a generally “U” shape. In further embodiments, the web portion 110 may extend between the top and bottom portions 106, 108 so as to define a generally “C” shape. In still further embodiments, the web portion 110 may extend between the top and bottom portions 106, 108 to define any suitable shape so as to accommodate the gear pinions 104 therebetween.
In an alternative embodiment, the body 102 may include only the top and bottom portions 106, 108 (i.e. the web portion 110 may be eliminated). As such, the top and bottom portions 106, 108 may be two separate plates connected by a plurality of pins or any other suitable fastening members. For example, in one embodiment, a top plate may be separated from a bottom plate by a plurality of gear pinions 104 disposed therebetween. As such, a plurality of pins and/or fastening members may connect the plates and gear pinions together to form the stiffener 100.
Referring to
In still additional embodiments, the stiffener 100, 200 may extend around a portion of the inner circumference 86 of the inner race 56 or may extend around the entire inner circumference 86 of the inner race 56. Further, the body 102, 202 of the stiffener 100, 200 may be constructed of a single segment or may be constructed of a plurality of segments. In the latter embodiment, the stiffener 100, 200 may be installed up tower of the wind turbine 10 without the use of costly cranes.
As shown in
Referring now to
It should also be appreciated that the stiffener 100 may be coupled to the wind turbine 10 using any suitable means. For example, as shown in various illustrated embodiment, the stiffener 100 is coupled to the hub 18 via one or more mounting supports 116. Further, the mounting supports 116 may be coupled between the body 102 and the hub 18 using any suitable means. For example, in one embodiment, the mounting support may be secured to the body 102 by welding and may be secured to the hub 18 using a mechanical fastener 120 (as shown), or vice versa.
In addition, the mounting supports 116 may correspond to mounting brackets spaced circumferentially about the outer periphery 112 of the bottom portion 108 of the body 102. For example, as shown in
The mounting supports 116 may be any suitable shape and/or material so as to couple the stiffener 100 to the hub 18. As such, the mounting supports 116 may secure the body 102 to the hub 18 such that the body 102 remains fixed relative to the inner race 56, while the gear pinions 104 may freely rotate along with the inner race 56. For example, in one embodiment, the mounting supports 116 may be a relatively rigid material, such as metal. In one particular embodiment, the mounting supports 116 are made of steel. Further, in another embodiment, the mounting supports 16 may be shaped so as to correspond to the shape of the body 102 of the stiffener 100, the inner race 56, and the hub flange 60.
In an alternative embodiment, as shown in
It should also be appreciated that the stiffener and all of the stiffener components as described herein may be constructed of any suitable material to provide the appropriate stiffness to the pitch bearing. For example, in one embodiment, the stiffener and the various components that make up the stiffener (e.g. the body and the gear pinions) is constructed of steel. In further embodiments, the stiffener and/or the various components that make up the stiffener may be constructed of any other suitable metal.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.