Wire races for wind turbine bearings
10655610 ยท 2020-05-19
Assignee
Inventors
Cpc classification
F05B2240/50
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D80/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C19/166
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C19/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C2226/62
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C33/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C19/38
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C19/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C2300/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C2360/31
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F16C19/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F16C33/58
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C19/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C33/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C19/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C19/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D80/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The present disclosure is directed to a bearing assembly for a wind turbine. The bearing assembly includes an outer race, an inner race rotatable relative to the outer race, a plurality of rolling elements positioned between the inner and outer races, and at least one wire race arranged with the plurality of rolling elements between the inner and outer races.
Claims
1. A bearing assembly for a wind turbine, comprising; an outer race; an inner race, wherein at least one of the inner race or the outer race comprises a plurality of gear teeth; a plurality of rolling elements positioned between the inner and outer races such that at least one of the inner race or the outer race rotates with respect to the other, the plurality of rolling elements comprising at least one row of rolling elements; and at least two wire races arranged with the plurality of rolling elements between the inner and outer races, wherein the inner and outer races are constructed of a first steel alloy and the at least two wire races are constructed of second steel alloy, the second steel alloy having a higher strength and an increased hardness relative to respective characteristics of the first steel alloy.
2. The bearing assembly of claim 1, further comprising at least four wire races arranged with each of at least two rows of rolling elements, thereby forming an eight-point contact bearing.
3. The bearing assembly of claim 1, wherein at least one of the inner race or the outer race is radially split.
4. The bearing assembly of claim 1, wherein the at least two wire races comprise a cross-sectional shape, the cross-sectional shape comprising at least one of a square, an oval, a crescent shape, a hemispherical shape, or a rectangle.
5. The bearing assembly of claim 1, further comprising a wire-retention feature configured to prevent the at least two wire races from rotating, wherein the wire retention feature comprises a dowel pin.
6. A bearing assembly for a wind turbine, comprising; a component of the wind turbine, wherein the component comprises one of a tower, a hub, or a housing of the wind turbine; only a single annular race, wherein the annular race is rotatable relative to the component; a plurality of rolling elements positioned between the component and the annular race; and at least two wire races arranged with the plurality of rolling elements between the component and the annular race, wherein the at least one of the wire races and at least a portion of each rolling element of the plurality of rolling elements are received by a recess defined by the component of the wind turbine, wherein at least one of the wire races is in contact with the component and the plurality of rolling elements, and wherein at least one of the wire races is in contact with the single annular race and the plurality of rolling elements.
7. The bearing assembly of claim 6, wherein the plurality of rolling elements comprises at least two rows of rolling elements.
8. The bearing assembly of claim 7, further comprising at least one wire race arranged with each of the at least two rows of rolling elements.
9. The bearing assembly of claim 8, further comprising at least four wire races arranged with each of the at least two rows of rolling elements, thereby forming an eight-point contact bearing assembly.
10. The bearing assembly of claim 6, wherein the annular race is radially split.
11. The bearing assembly of claim 6, wherein the bearing assembly corresponds to at least of a pitch bearing or a yaw bearing of the wind turbine, and wherein the plurality of rolling elements comprises at least one of ball bearings or roller bearings.
12. The bearing assembly of claim 6, wherein the single annular race is disposed radially inward of the component and in axial alignment with the component.
13. The bearing assembly of claim 12, wherein the component is the hub of the wind turbine, and wherein the single annular race is coupled to a rotor blade of the wind turbine.
14. The bearing assembly of claim 12, wherein the component is the tower of the wind turbine, and wherein the single annular race is coupled to a bedplate of the wind turbine.
15. A main bearing assembly for a wind turbine, comprising; a stationary component of the wind turbine, wherein the stationary component comprises one of a bedplate, a pillow block, or a housing of the wind turbine; a rotatable component of the wind turbine rotatable relative to the stationary component; only a single annular race, wherein the single annular race is rotationally fixed relative to the rotatable component; a plurality of roller bearings positioned between the stationary component and the annular race adjacent to the rotatable component; and at least one wire race arranged with the plurality of roller bearings, wherein the at least one wire race and at least a portion of each rolling element of the plurality of rolling elements are received by a recess defined by the stationary component of the wind turbine.
16. The main bearing assembly of claim 15, wherein the annular race is integrated with the rotatable component.
17. The main bearing assembly of claim 15, wherein the rotatable component comprises a hub of the wind turbine.
18. The main bearing assembly of claim 15, wherein the single annular race is disposed radially inward of the stationary component and in axial alignment with the stationary component.
19. The main bearing assembly of claim 18, wherein the stationary component has an axial length greater than or equal to an axial length of the single annular race.
20. The main bearing assembly of claim 18, wherein the stationary component is the pillow block, wherein the rotatable component is the main shaft, where in the main shaft is supported by the pillow block, and wherein the main bearing assembly comprises at least one of a fix bearing or a float bearing.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) 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:
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DETAILED DESCRIPTION OF THE INVENTION
(14) 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.
(15) In general, the present disclosure is directed to a bearing assembly for a wind turbine having at least one wire race. As such, the bearing assembly of the present disclosure provides numerous advantages not present in the cited art. For example, the wire races of the present disclosure provide raceway surfaces that can be made from a high-strength bearing steel or other specialized material, such that improved reliability of the bearing can be achieved with minimum high-cost material, i.e. the inner and/or outer races can be made from lower cost material and can be sized for maximum stiffness. The resultant bearing assembly is more economical than conventional bearings. Further, the wire races provide stiffer bearing raceways that better distribute rotor loads across the ball or roller bearings and help reduce contact stress, thereby improving bearing reliability. Moreover, the bearing assembly of the present disclosure can handle increased loads due to larger rotor blades without requiring larger ball bearings or more expensive roller bearings.
(16) The present invention is described herein as it may relate to wind turbine bearings, including, at least, yaw bearings, pitch bearings, main bearings, and/or similar. It should be appreciated, however, that the unique bearings in accordance with principles of the present invention is not limited to use with a wind turbine, but is applicable to any suitable bearing application.
(17) Referring now to the drawings,
(18) Referring now to
(19) Additionally, the wind turbine 10 may include one or more yaw drive mechanisms 56 mounted to and/or through a bedplate 58 positioned atop the wind turbine tower 12. Specifically, each yaw drive mechanism 56 may be mounted to and/or through the bedplate 58 so as to engage a yaw bearing 60 coupled between the bedplate 58 and the tower 12 of the wind turbine 10. The yaw bearing 60 may be mounted to the bed plate 58 such that, as the yaw bearing 60 rotates about a yaw axis 62 of the wind turbine 10, the bedplate 58 and, thus, the nacelle 14 are similarly rotated about the yaw axis.
(20) In general, it should be appreciated that the yaw drive mechanisms 56 may have any suitable configuration and may include any suitable components known in the art that allow such mechanisms 56 to function as described herein. For example, as shown in
(21) Referring still to
(22) Referring now to
(23) 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 one of the pitch bearings 68), as will be described in greater detail below.
(24) Referring now to
(25) Referring particularly to
(26) Further, as shown in the embodiment of
(27) Such relative rotation of the outer and inner races 74, 76 may be achieved using a pitch adjustment mechanism 72 (
(28) As shown in
(29) Thus, as shown in
(30) Referring now to
(31) Referring now to
(32) Further, in such embodiments, as shown, the bearing assembly 70 includes a stationary component of the wind turbine 10, a rotatable component of the wind turbine 10, i.e. rotatable relative to the stationary component, an annular race 75 fixed relative to the rotatable component, a plurality of rolling elements 78 positioned adjacent to the rotatable component, and at least one wire race 80 arranged with the plurality of rolling elements 78. More specifically, as shown, the rolling elements 78 may correspond to roller bearings 88. In addition, the stationary component may correspond to a housing 90 of the wind turbine 10. For example, in certain embodiments, the housing 90 may correspond to the bedplate 58 or a pillow block 95 on the wind turbine 10. Further, as shown, the rotatable component may include the hub 18 of the wind turbine 10. In one embodiment, as shown, the annular race 75 may be secured to the hub 18 via any suitable mechanical fasteners (not shown). Alternatively, the annular race 75 may be integrated with the rotatable component, i.e. the hub 18.
(33) In further embodiments, the race(s) 74, 75, 76 may be constructed of a first metal alloy, whereas the wire race(s) 78 may be constructed of second metal alloy. More specifically, the second metal alloy may have at least one improved characteristic in comparison to the first metal alloy. For example, the second metal alloy may have a higher strength, an increased hardness, or improved contact fatigue capability than the first metal alloy. More specifically, in one embodiment, the second metal alloy material may include 52100 alloy steel, whereas the first metal alloy may include a less expensive 42Cr alloy steel. As such, the bearing of the present disclosure provides improved reliability and cost benefits over bearings made of single materials.
(34) In further embodiments, the wire race(s) may optionally include a coating. For example, the coating may include any suitable coating material, including but not limited to black oxide, diamond-like carbon (DLC) and equivalents thereof, and/or a phosphate based coating. In addition, it should be understood that the wire race(s) may have any suitable a cross-sectional shape, including but not limited to a circle, a square, an oval, a crescent shape, a hemispherical shape, a rectangle, or similar.
(35) In another embodiment, the race(s) 74, 75, 76 described herein may have a split configuration, e.g. to help with assembly of the bearing 68. More specifically, as shown in
(36) Additionally, in several embodiments, a plurality of lubrication ports 92 may be defined through the race(s) 74, 75, 76. In general, each lubrication port 92 may be configured to supply a suitable lubricant (e.g., grease, etc.) from a location outside the bearing assembly 70 to a location between the race(s) 74, 75, 76. In addition, to maintain the lubricant within the bearing assembly 70, any gaps defined between the race(s) 74, 75, 76 may be sealed using suitable sealing mechanisms. For instance, as shown in
(37) Referring now to
(38) Further, as shown in
(39) 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.