WIND TURBINE GEARBOX AND METHOD FOR PRODUCING A WIND TURBINE GEARBOX

Abstract

The invention relates to a wind turbine gearbox (7), in particular planetary gearbox, having at least one gear (14) which is mounted on an axle (19), wherein a sliding surface (26) is arranged between the gear (14) and the axle (19). The sliding surface (26) is arranged on at least one layer (25, 33, 34) of a clad material made from a sliding bearing material. Furthermore, the invention relates to a method for producing the wind turbine gearbox (7).

Claims

1. A wind turbine gearbox (7), in particular planetary gearbox, having at least one gear (14) which is mounted on an axle (19), wherein a sliding surface (26) is arranged between the gear (14) and the axle (19) or between the axle (19) and an axle holder (24), wherein the sliding surface (26) is arranged on at least one layer (25, 33, 34) of a clad material made of a sliding bearing material.

2. The wind turbine gearbox according to claim 1, wherein the layer (25, 33, 34) of the clad material is applied directly to an outer shell surface (29) of the axle (19).

3. The wind turbine gearbox according to claim 2, wherein an offset (35) is arranged on the axle (19) and the layer (25, 33, 34) of the clad material is applied directly to the end face (36) of the offset (35).

4. The wind turbine gearbox according to claim 1, wherein the layer (25, 33, 34) of the clad material is applied directly to an inner shell surface (27) of a bore (28) of the gear (14).

5. The wind turbine gearbox according to claim 4, wherein the layer (25, 33, 34) of the clad material is applied directly to the end face (37) of the gear (14).

6. The wind turbine gearbox according to claim 1, wherein a sliding bearing bush (38) is arranged between the gear (14) and the axle (19), wherein the layer (25, 33, 34) of the clad material is applied directly to the sliding bearing bush (38).

7. The wind turbine gearbox according to claim 6, wherein the layer (25, 33, 34) of the clad material is applied directly to an inner shell surface (40) of a bore (41) of the sliding bearing bush (38) and the sliding bearing bush (38) is held in a bore (28) of the gear (14).

8. The wind turbine gearbox according to claim 6, wherein the layer (25, 33, 34) of the clad material is applied directly to an outer shell surface (39) of the sliding bearing bush (38) and the sliding bearing bush (38) is held on the axle (19).

9. The wind turbine gearbox according to claim 6, wherein the layer (25, 33, 34) of the clad material is applied directly to the end face (42) of the sliding bearing bush (38).

10. The wind turbine gearbox according to claim 1, wherein the gear (14) is designed as a planetary gear (11).

11. The wind turbine gear box according to claim 1, wherein the layer (25, 33, 34) of the clad material has a layer thickness (32) of between 0.5 mm and 1.5 mm, in particular between 0.8 mm and 1.2 mm.

12. The wind turbine gear box according to claim 1, wherein the sliding surface (26) has, on the layer (25, 33, 34) of the clad material, an averaged roughness depth Rz of between 0.1 m and 3.2 m, in particular between 0.5 m and 1.6 m.

13. The wind turbine gearbox according to claim 1, wherein the clad material consists of or comprises a material selected from a group comprising aluminum base alloys, tin base alloys, bronze base alloys, brass base alloys.

14. The wind turbine gearbox according to claim 1, wherein the clad material consists of or comprises a material which comprises at least two materials selected from a group comprising aluminum, tin, bronze, brass.

15. The wind turbine gearbox according to claim 1, wherein at least two layers (25, 33, 34) of the clad material, offset to one another at an axial distance, are formed of different materials.

16. The wind turbine gearbox according to claim 1, wherein at least three layers (25, 33, 34) of the clad material, offset to one another at an axial distance, are formed of different materials, wherein the materials of the two outer layers (25, 34) have a lower degree of compressive strength than the material of an intermediate layer (33).

17. A wind turbine (1) having a rotor (4) and a generator (6), wherein a wind turbine gearbox (7), in particular a planetary gearbox, which is operatively connected to the rotor (4) and the generator (6) is arranged between the rotor (4) and the generator (6), wherein the wind turbine gearbox (7) is designed according to claim 1.

18. A method for producing a wind turbine gearbox (7), in particular planetary gearbox, having at least one gear (14) which is mounted on an axle (19), wherein a sliding surface (26) is arranged between the gear (14) and the axle (19), wherein the method comprises the following steps: providing the gear (14) or the axle (19) or a sliding bearing bushing (38); cladding of a sliding bearing material and with that, depositing a layer (25, 33, 34) of a clad material directly onto the gear (14) or the axle (19) or a sliding bearing (38); forming the sliding surface (26) on the layer (25, 33, 34).

19. The method according to claim 18, wherein when cladding, the layer (25, 33, 34) is applied having a raw layer thickness (45) of between 1 mm and 5 mm, in particular between 1.5 mm and 3 mm, and wherein the layer (25, 33, 34) of the clad material is skimmed, in a subsequent processing step by means of machining, to a layer thickness (32) of between 0.5 mm and 1.5 mm, in particular between 0.8 mm and 1.2 mm.

20. The method according to claim 19, wherein the cladding and the machining are carried out in one workpiece setting.

Description

[0044] For the purpose of better understanding of the invention, it will be elucidated in more detail by means of the figures below.

[0045] These show in a respectively very simplified schematic representation:

[0046] FIG. 1 a side view of a wind turbine;

[0047] FIG. 2 a sectional side view of a wind turbine gearbox in the form of a planetary gearbox;

[0048] FIG. 3 a first exemplary embodiment of a sliding bearing having a layer cladded onto the axle;

[0049] FIG. 4 a second exemplary embodiment of a sliding bearing having multiple layers cladded onto the axle;

[0050] FIG. 5 a third exemplary embodiment of a sliding bearing having a layer cladded onto the axle, which layer is also arranged on the end face;

[0051] FIG. 6 a fourth and a fifth exemplary embodiment of a sliding bearing having a layer cladded onto the gear;

[0052] FIG. 7 a sixth and seventh exemplary embodiment of a sliding bearing having a sleeve arranged between the gear and the axle, onto which sleeve the layer is cladded;

[0053] FIG. 8 an eighth exemplary embodiment of a sliding bearing having a sleeve arranged between the gear and the axle, onto which sleeve the layer is cladded also on the end face;

[0054] FIG. 9 a ninth and a tenth exemplary embodiment of a sliding bearing having a layer which is cladded onto the axle holder and/or the axle;

[0055] FIG. 10 a schematic representation of the method steps for producing a clad sliding bearing layer.

[0056] First of all, it is to be noted that in the different embodiments described, equal parts are provided with equal reference numbers and/or equal component designations, where the disclosures contained in the entire description may be analogously transferred to equal parts with equal reference numbers and/or equal component designations. Moreover, the specifications of location, such as at the top, at the bottom, at the side, chosen in the description refer to the directly described and depicted figure and in case of a change of position, these specifications of location are to be analogously transferred to the new position.

[0057] FIG. 1 shows a wind turbine 1. This wind turbine 1 generally corresponds to the prior art, meaning that it comprises a tower 2 on which a nacelle 3 is arranged, on the front end of which a rotor 4 with rotor blades 5 and on the back end of which a generator 6 are arranged. A wind turbine gearbox 7, which is connected on the one hand to the rotor 4 and on the other hand to the moving member of the generator 6, is arranged between the rotor 4 and the generator 6, i.e. a not further represented moving member of the generator. The wind turbine gearbox 7 serves for increasing the rotation speed of the moving member as compared to the rotor 4. On the lower part of the tower 2, lastly, there is a network connection 8. As these components are generally known from the prior art for wind turbines 1, reference is made here to the relevant literature on this subject. However, it should be mentioned that the wind turbine 1 is not obligatorily limited to the type represented in FIG. 1.

[0058] FIG. 2 shows the wind turbine gearbox 7 in the form of a simple planetary gearbox in a side view.

[0059] The planetary gearbox 7 has a sun gear 9 connected in a motion-coupled manner to a shaft 10 leading to the generator rotor. The sun gear 9 is surrounded by multiple planetary gears 11, for example two, preferably three or four. Both the sun gear 9 and the planetary gears 11 have outer end toothings 12, 13 which are engaged in a meshing arrangement, wherein these end toothings 12, 13 are schematically represented in FIG. 2.

[0060] The planetary gears 11 are also referred to generically as gears 14 throughout this document. The group of the gears 14 may also comprise further gears in addition to the planetary gears 11.

[0061] The planetary gears 11 are held in the planetary carrier 16 by means of a planetary gear axle 15, wherein a first receiving section 17 and a second receiving section 18 are provided in the planetary carrier 16, in which receiving sections 17, 18 the planetary gear axle 15 is held, in particular clamped. The two receiving sections 17, 18 are also referred to generically as axle holder 24.

[0062] In an alternative exemplary embodiment, it can also be provided that the planetary gears 11 are solidly coupled with a planetary gear axle 15 and the planetary gear axle 15 is rotatably held in the axle holder 24.

[0063] The planetary gear axles 15 are also referred to generically as axle 19 throughout this document. The group of the axles 19 may also comprise further axles in addition to the planetary gear axles 15.

[0064] An internal gear 21 is arranged to surround the planetary gears 11, which internal gear 21 has an internal toothing 22 which is engaged in a meshing arrangement with the end toothing 13 of the planetary gears 11. The internal gear 21 is motion-coupled with a rotor shaft 23 of the rotor of the wind turbine. The end toothings 12, 13 and/or the internal toothing 22 can be formed as spur toothing, as helical toothing or as double helical toothing.

[0065] As such planetary gearboxes 7 are in principle also already known from the prior art, for example from the previously cited document regarding the prior art, further explanations are superfluous here.

[0066] It should be noted that, in the following, the planetary gear 11 is referred to in the singular form. However, it is self-evident that, in the preferred embodiment, all planetary gears 11 are formed according to the invention.

[0067] FIGS. 3 to 9 show different and independent embodiments of the sliding bearing, wherein again, equal reference numbers and/or component designations are used for equal parts as in the respectively preceding figures. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in the respectively preceding figures.

[0068] FIG. 3 shows a schematic representation of a first exemplary embodiment of a sliding bearing for mounting the gear 14.

[0069] As can be seen in FIG. 3, it can be provided that a layer 25 of a clad material made of a sliding bearing material is arranged on the axle 19. A sliding surface 26 is formed on the layer 25, with which sliding surface 26 an inner shell surface 27 of a bore 28 of the gear 14 can directly cooperate. Therefore, in the exemplary embodiment according to FIG. 3, the gear 14 is rotatably mounted relative to the axle 19 on the same.

[0070] In particular, it can be provided that the layer 25 of the clad material was applied directly to an outer shell surface 29 of the axle 19 by means of cladding.

[0071] In the exemplary embodiment according to FIG. 3, the axle 19 is held solidly in the axle holder 24 and therefore not rotatable relative to the axle holder 24. In particular, it can be provided that the axle 19 directly abuts on an inner shell surface 30 of a bore 31 of the axle holder 24. The layer 25 of the clad material can have a layer thickness 32 of between 0.2 mm and 5 mm.

[0072] In FIG. 4, a further and possibly independent embodiment of the sliding bearing is shown, wherein again equal reference numbers and/or component designations are used for equal parts as in the preceding FIGS. 2 and 3. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 2 and 3 preceding it.

[0073] In the exemplary embodiment according to FIG. 4, a first layer 25, a second layer 33 and a third layer 34 are cladded onto the axle 19, wherein the individual layers 25, 33, 34 have different material properties. In particular, it can be provided that the two outer layers 25, 34 have a lower degree of compressive strength and/or a lower degree of surface hardness than the material of the layer 33 position between them. The individual layers 25, 33, 34 can have a uniform layer thickness 32, so that a continuous sliding surface 26 is formed. As an alternative, it can be provided that the layer thicknesses 32 of the individual layers 25, 33, 34 are slightly different, so that, for example, the two outer layers 25, 34 have a slightly greater layer thickness 32, whereby the run-in properties of the sliding bearing can be improved.

[0074] FIG. 5 shows a further and possibly independent embodiment of the sliding bearing for mounting the gear 14, wherein again, equal reference numbers and/or component designations are used for equal parts as in the preceding FIGS. 2 to 4. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 2 through 4 preceding it.

[0075] As it can be seen in FIG. 5, it can be provided that the axle 19 has an offset 35 which forms an end face 36. The layer 25 of the clad material can be arranged both on the outer shell surface 29 and the end face 36 of the axle 19. These measures allow to also achieve an axial bearing of the gear 14 in addition to the radial bearing.

[0076] In FIG. 6, two further and possibly independent embodiments of the sliding bearing are shown, wherein again equal reference numbers and/or component designations are used for equal parts as in the preceding FIGS. 2 and 5. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 2 through 5 preceding it.

[0077] In the upper half of the section in FIG. 6, the first layer 25 of the clad material is applied directly to the inner shell surface 27 of the bore 28 of the gear 14. The sliding surface 26 is therefore arranged on the gear 14. In such an exemplary embodiment, the axle 19 does not need to have a surface coating.

[0078] In the bottom half of the section in FIG. 6, a similar exemplary embodiment as the one of the upper half of the section is shown, wherein in this exemplary embodiment, the layer 25 of the clad material is also applied to the end face 37 of the gear 14 in addition to being applied on the inner shell surface 27 of the bore 28 of the gear 14. In such an exemplary embodiment, an axial bearing of the gear 14 can be achieved in addition to the radial bearing of the gear 14.

[0079] In FIG. 7, two further and possibly independent embodiments of the sliding bearing are shown, wherein again equal reference numbers and/or component designations are used for equal parts as in the preceding FIGS. 2 and 6. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 2 through 6 preceding it.

[0080] In FIG. 7, also in the upper half of the section, a first exemplary embodiment is represented and in the bottom half of the section, a second exemplary embodiment is represented.

[0081] In the exemplary embodiment of the upper half of the section in FIG. 7, a sliding bearing bush 38 is arranged between the gear 14 and the axle. 19. Here, an outer shell surface 39 of the sliding bearing bush 38 can directly abut on the inner shell surface 27 of the bore 28 of the gear 14. In particular, it can be provided that the sliding bearing bush 38 is pressed into the gear 14. Here, the layer 25 of the clad material can be arranged on an inner shell surface 40 of a bore 41 of the sliding bearing bush 38. Thus, the sliding surface 26 which, in this case, is formed on the sliding bearing bush 38 can directly abut on the outer shell surface 29 of the axle 19. The sliding bearing bush 38 in this exemplary embodiment is solidly coupled with the gear 14 and rotates along with it.

[0082] In the second exemplary embodiment of FIG. 7, which is shown in the bottom half of the section, the inner shell surface 40 of the bore 41 of the sliding bearing bush 38 abuts directly on the outer shell surface 29 of the axle 19 and therefore the sliding bearing bush 38 is held solidly on the axle 19. Here, the layer 25 of the clad material is arranged on the outer shell surface 39 of the sliding bearing bush 38. The sliding surface 26 directly interacts with the inner shell surface 27 of the bore 28 of the gear 14, wherein the gear 14 is rotatable relative to the sliding bearing bush 38 and therefore also relative to the axle 19.

[0083] FIG. 8 shows a further and possibly independent embodiment of the sliding bearing for mounting the gear 14, wherein again, equal reference numbers and/or component designations are used for equal parts as in the preceding FIGS. 2 to 7. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 2 through 7 preceding it.

[0084] FIG. 8 shows a similar exemplary embodiment of the sliding bearing as it is represented in the upper half of the section in FIG. 7. In the exemplary embodiment of FIG. 8, a layer 25 of the clad material is arranged on the end face 42 in addition to the sliding bearing bush 38. A sliding bearing bush 38 formed in this way can therefore also have axial bearing properties in addition to the radial bearing properties.

[0085] In the exemplary embodiments according to FIG. 7 and FIG. 8, multiple layers 25, 33, 34 of the clad material can of course also be formed analogously to FIG. 4.

[0086] In FIG. 9, two further and possibly independent embodiments of the sliding bearing are shown, wherein again equal reference numbers and/or component designations are used for equal parts as in the preceding FIGS. 2 and 8. In order to avoid unnecessary repetitions, it is pointed to/reference is made to the detailed description in FIGS. 2 through 8 preceding it.

[0087] In the upper half of the section in FIG. 9, the gear 14 is held directly on the axle 19 and therefore rotates along with it. Here, the axle 19 is held so as to be rotatable in the axle holder 24. Here, it can be provided that the layer 25 of the clad material is arranged on the inner shell surface 30 of the axle holder 24. Therefore, the sliding surface 26 of the layer 25 cooperates directly with the outer shell surface 29 of the axle 19.

[0088] In the second exemplary embodiment according to FIG. 9, which is represented in the bottom half of the section, the gear 14 is also solidly connected with the axle 19. Here, the sliding bearing between the axle 19 and the axle holder 24 is realized such that the layer 25 of the clad material is applied to the outer shell surface 29 of the axle 19 and thus forms the sliding surface 26. This sliding surface 26 cooperates directly with the inner shell surface 30 of the bore 31 of the axle holder 24.

[0089] Building on the exemplary embodiments of FIG. 9, it can naturally also be provided that there is a layer 25 of a clad material also arranged on an inner surface 43 of the axle holder 24. Such an exemplary embodiment, however, is not represented.

[0090] Moreover, building on the exemplary embodiment according to FIG. 9 and analogously to the previously described exemplary embodiments, a sliding bearing bush 38 can be provided which, in this case, is arranged between the axle holder 24 and the axle 19. Here, the sliding bearing bush 38 can be coupled solidly with the axle 19 and therefore rotate along with it or it can be held in the axle holder 24, wherein the axle 19 rotates relative to the sliding bearing bush 38.

[0091] FIG. 10 shows possible method steps for producing the layer 25 of the clad material. In the exemplary embodiment according to FIG. 10, the layer 25 is cladded onto the outer shell surface 29 of the axle 19. Of course, the same method procedures are also applied in the other described exemplary embodiments.

[0092] As it can be seen in FIG. 10, it can be provided that, in a first method step, the layer 25 is cladded onto the outer shell surface 29 of the axle 19 by means of a welding head 44. Here, the layer 25 can have a raw layer thickness 45. In a subsequent method step, the layer 25 can be processed by means of a machining tool 46, so that the sliding surface 26 can be produced. Thereby, the final layer thickness 32 is produced. The processing tool 46 can be formed, for example, in the form of a turning tool, in the form of a milling tool, or also as a grinding disk. In particular, it can also be provided that the layer 25 is processed in different processing steps, so that, for example, the surface is first skimmed by means of a turning tool and subsequently ground.

[0093] The exemplary embodiments show possible embodiment variants, and it should be noted in this respect that the invention is not restricted to these particular illustrated embodiment variants of it, but that rather also various combinations of the individual embodiment variants are possible and that this possibility of variation owing to the teaching for technical action provided by the present invention lies within the ability of the person skilled in the art in this technical field.

[0094] The scope of protection is determined by the claims. However, the description and the drawings are to be adduced for construing the claims. Individual features or feature combinations from the different exemplary embodiments shown and described may represent independent inventive solutions. The object underlying the independent inventive solutions may be gathered from the description.

[0095] All indications regarding ranges of values in the present description are to be understood such that these also comprise random and all partial ranges from it, for example, the indication 1 to 10 is to be understood such that it comprises all partial ranges based on the lower limit 1 and the upper limit 10, i.e. all partial ranges start with a lower limit of 1 or larger and end with an upper limit of 10 or less, for example 1 through 1.7, or 3.2 through 8.1, or 5.5 through 10.

[0096] Finally, as a matter of form, it should be noted that for ease of understanding of the structure, elements are partially not depicted to scale and/or are enlarged and/or are reduced in size.

TABLE-US-00001 List of reference numbers 1 wind turbine 2 tower 3 nacelle 4 rotor 5 rotor blade 6 generator 7 wind turbine gearbox 8 network connection 9 sun gear 10 shaft 11 planetary gear 12 end toothing sun gear 13 end toothing planetary gear 14 gear 15 planetary gear axle 16 planetary carrier 17 first receiving section 18 second receiving section 19 axle 20 bearing seat 21 internal gear 22 internal toothing 23 rotor shaft 24 axle holder 25 first layer 26 sliding surface 27 inner shell surface bore gear 28 bore gear 29 outer shell surface axle 30 inner shell surface bore axle holder 31 bore axle holder 32 layer thickness 33 second layer 34 third layer 35 offset axle 36 end face offset 37 end face gear 38 sliding bearing bush 39 outer shell surface sliding bearing bush 40 inner shell surface bore sliding bearing bush 41 bore sliding bearing bush 42 end face sliding bearing bush 43 inner surface axle holder 44 welding head 45 raw layer thickness 46 processing tool