DRIVETRAIN SYSTEM FOR A WIND TURBINE GENERATOR AND METHOD OF ASSEMBLING THE SAME

• US 20100329867A1
• Filed: 06/30/2009
• Published: 12/30/2010
• Est. Priority Date: 06/30/2009
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (General Electric Company)
• Original Assignee: General Electric Company
• Inventors: Johnson, Stephen B., Madge, James H., Patel, Priyangu C., Jansen, Patrick Lee, Nies, Jacob Johannes, Buskirk, Eric Steven, Hidding, Edwin, Wilson, Blake Weldon, Lokhandwalla, Murtuza, Barnes, Gary R., Minadeo, Adam Daniel
• Granted Patent: US 8,376,708 B2
• Time in Patent Office: Days
• US Class Current: 416/169R
• CPC Class Codes: F03D 15/00 Transmission of mechanical power
• CPC Class Codes: F03D 15/10 using gearing not limited to rotary motion, e.g. with oscillating or reciprocating members
• CPC Class Codes: F03D 80/70 Bearing or lubricating arrangements
• CPC Class Codes: F03D 80/88 of mechanical components
• CPC Class Codes: F05B 2260/40311 of the epicyclic, planetary or differential type
• CPC Class Codes: F05B 2260/902 using frictional mechanical forces
• CPC Class Codes: F16H 1/46 Systems consisting of a plurality of gear trains each with orbital gears, i.e. systems having three or more central gears
• CPC Class Codes: H02K 1/28 Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
• CPC Class Codes: H02K 7/102 with friction brakes
• CPC Class Codes: H02K 7/116 with gears
• CPC Class Codes: H02K 7/1838 Generators mounted in a nacelle or similar structure of a horizontal axis wind turbine
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 74/19637 with brake means for gearing

Abstract

A drivetrain for a wind turbine includes a gearbox and a generator. The gear box includes a housing and an output shaft that is rotatably coupled within the housing, wherein the gearbox further includes at least one bearing positioned between the housing and the output shaft. The generator includes a stator coupled to the housing such that the stator is positioned radially outward from the housing, and a rotor coupled to the output shaft such that the rotor is positioned radially inward from the stator.

Claims

1. A drivetrain for a wind turbine, said drivetrain comprising:

a gearbox comprising a housing and an output shaft rotatably coupled within said housing, said gearbox further comprising at least one bearing positioned between said housing and said output shaft;

a braking system operatively coupled to said gearbox, said braking system comprising a rotary component and a stationary component; and

,

a generator comprising;

a stator coupled to said housing such that said stator is positioned radially outward from said housing; and

,

a rotor coupled to said output shaft such that said rotor is positioned radially inward from said stator;

wherein said gearbox output shaft and said at least one bearing facilitate supporting said braking system rotary component.

2. A drivetrain for a wind turbine in accordance with claim 1, wherein said generator further comprises a plurality of generator bearings, wherein a rotor center of gravity (CG) is substantially axially aligned with said plurality of generator bearings.

3. A drivetrain for a wind turbine in accordance with claim 1, wherein said stator facilitates supporting said braking system stationary component.

4. A drivetrain for a wind turbine in accordance with claim 1, wherein said rotor is coupled to said output shaft via a coupling disk such that a center of gravity of said rotor is positioned substantially about said at least one bearing.

5. A drivetrain for a wind turbine in accordance with claim 1, wherein said braking system comprises:

at least one disk brake coupled to said output shaft via a brake torque tube; and

,

at least one braking pad coupled to a brake caliper, wherein said brake caliper is coupled to and extends from a stator external frame.

6. A drivetrain for a wind turbine in accordance with claim 1, wherein said braking system comprises:

a brake drum coupled to said output shaft via a brake torque tube; and

,

at least one braking shoe configured to engage said brake drum during braking operations.

7. A drivetrain for a wind turbine in accordance with claim 6, wherein said braking system is at least one of pneumatic and hydraulic.

8. A drivetrain for a wind turbine in accordance with claim 6, wherein said at least one braking shoe is positioned within said brake drum to facilitate engaging said brake drum during braking operations.

9. A drivetrain for a wind turbine in accordance with claim 1, wherein said output shaft comprises an axially aft end including a plurality of gear teeth, said drivetrain further comprising an encoder operatively coupled to output shaft via a corresponding plurality of gear teeth, said encoder configured to determine a position of said rotor.

10. A drivetrain for a wind turbine in accordance with claim 1, further comprising a brush element extending from a portion of said rotor to a portion of said housing, said brush element configured to provide an electrical connection between said rotor and said gearbox.

11. A drivetrain for a wind turbine in accordance with claim 1, further comprising an insulating ring, wherein said rotor is coupled to said output shaft via a coupling disk such that a substantially insulated joint is defined between said coupling disk and said rotor using said insulating ring.

12. A wind turbine comprising:

a nacelle;

a drivetrain positioned within said nacelle, said drivetrain comprising;

a gearbox comprising a housing and an output shaft rotatably coupled within said housing, said gearbox further comprising at least one bearing positioned between said housing and said output shaft;

a braking system operatively coupled to said gearbox, said braking system comprising a rotary component and a stationary component; and

,

a generator comprising;

a stator coupled to said housing such that said stator is positioned radially outward from said housing; and

,

a rotor coupled to said output shaft such that said rotor is positioned radially inward from said stator;

wherein said gearbox output shaft and said at least one bearing facilitates supporting said braking system rotary component.

13. A wind turbine in accordance with claim 12, wherein said generator further comprises a plurality of generator bearings, wherein a rotor center of gravity (CG) is substantially axially aligned with said plurality of generator bearings.

14. A wind turbine in accordance with claim 12, wherein said stator facilitates supporting said braking system stationary component.

15. A wind turbine in accordance with claim 12, wherein said rotor is coupled to said output shaft via a coupling disk such that a center of gravity of said rotor is positioned substantially about said at least one bearing.

16. A wind turbine in accordance with claim 12, wherein said braking system comprises:

at least one disk brake coupled to said output shaft via a brake torque tube; and

,

at least one braking pad coupled to a brake caliper, wherein said brake caliper is coupled to and extends from a stator external frame.

17. A wind turbine in accordance with claim 12, wherein said braking system comprises:

a brake drum coupled to said output shaft via a brake torque tube; and

at least one braking shoe configured to engage said brake drum during braking operations.

18. A wind turbine in accordance with claim 12, wherein said braking system is at least one of pneumatic and hydraulic.

19. A wind turbine in accordance with claim 12, wherein said output shaft comprises an axially aft end including a plurality of gear teeth, said drivetrain further comprising an encoder operatively coupled to output shaft via a corresponding plurality of gear teeth, said encoder configured to determine a position of said rotor.

20. A drivetrain for a wind turbine in accordance with claim 12, further comprising a brush element extending from a portion of said rotor to a portion of said housing, said brush element configured to provide an electrical connection between said rotor and said gearbox.

21. A drivetrain for a wind turbine in accordance with claim 12, further comprising an insulating ring, wherein said rotor is coupled to said output shaft via a coupling disk such that a substantially insulated joint is defined between said coupling disk and said rotor using said insulating ring.

22. A method for assembling a drivetrain for a wind turbine, said method comprising:

rotatably coupling an output shaft within a gearbox housing;

positioning at least one bearing between the gearbox housing and the output shaft to facilitate rotation of the output shaft;

operatively coupling a braking system to the gearbox housing, wherein the braking system comprises a rotary component and a stationary component

supporting the braking system rotary component with the gearbox output shaft and the at least one bearing;

coupling a stator to the housing such that the stator is positioned radially outward from the housing; and

,

coupling a rotor to the output shaft such that the rotor is positioned radially inward with respect to the stator.

23. A method in accordance with claim 22, wherein coupling a rotor to the output shaft further comprises positioning a center of gravity of the rotor substantially about the at least one bearing.

24. A method in accordance with claim 22, wherein operatively coupling a brake system to the gearbox housing further comprises:

coupling at least one disk brake to the output shaft via a brake torque tube; and

,

coupling at least one braking pad to a brake caliper, wherein the brake caliper is coupled to and extends from a stator external frame.

25. A method in accordance with claim 22, wherein operatively coupling a brake system to the gearbox housing further comprises:

coupling a brake drum to the output shaft via a brake torque tube; and

,

providing at least one braking shoe configured to engage the brake drum during braking operations.

26. A method in accordance with claim 22, wherein operatively coupling a brake system to the gearbox housing further comprises engaging the braking system using at least one of pneumatic and hydraulic power.

27. A method in accordance with claim 22, wherein providing at least one braking shoe further comprises positioning the at least one braking shoe within the brake drum to facilitate engaging the brake drum during braking operations.