Patent Publication Number: US-9906099-B2

Title: Brake system, generator and wind turbine

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority of European Patent Office application No. 09014766.1 EP filed Nov. 26, 2009, which is incorporated by reference herein in its entirety. 
     FIELD OF INVENTION 
     The invention relates to a brake system, especially for a generator, a generator, especially a direct drive generator, and a wind turbine. 
     BACKGROUND OF INVENTION 
     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. 
     The US 2005/230979 describes a wind turbine which minimizes the size of the nacelle while providing adequate accessibility to components during maintenance operations. The wind turbine comprises: a nacelle and a blade rotor hub adjacent to said nacelle and a main shaft coupled to said hub and said nacelle. The generator is coupled to said shaft between said nacelle and said hub, wherein said generator includes generator rotor adjacent to said shaft, a stator positioned adjacent to and radially outward from said generator rotor; and a brake coupled to said generator and said shaft where the brake is positioned radially inward from said stator. The invention describes a solution that minimizes the brake system as the system can be more or less integrated into the generator. However, the proposed solution minimizes the size of the construction and also restricts the size of the brake system which is unwanted for a direct drive wind turbine where the size of the callipers and the brake disc should be as big as possible in order to withstand the high braking moments due to the slow rotational speed of the rotor. The brake system shown in US 2005/230979 also prevents passage though the generator and it is not possible to go into the hub from the nacelle/generator. Furthermore, the invention relates to a generator with an inner rotor configuration and it not possible to use the configuration for brake system with outer rotor configuration. 
     In US 2009/0026771 A1 a wind turbine comprising an electrical generator that includes a rotor assembly is disclosed. The wind turbine includes a frictional braking system for slowing, stopping or keeping stopped the rotation of the wind rotor and rotor assembly. In one implementation, the wind turbine/generator set includes a generator that includes a stator assembly and a rotor assembly rotatable about a rotational axis. The rotor assembly includes an active portion and an active portion support supporting the active portion. The wind turbine/generator set further includes a wind rotor coupled to the rotor assembly, a generator support fixedly supporting the stator assembly and rotatable supporting the rotor assembly. Furthermore, the wind turbine/generator set includes at least braking device fixed relative to the generator support. The braking device includes at least one frictional member operatively configured for frictionally engaging at least a portion of the active portion support. The rotor assembly is generally located radially inward of the stator assembly. 
     SUMMARY OF INVENTION 
     It is a first objective of the present invention to provide an advantageous brake system. It is a second objective of the present invention to provide an advantageous generator and it is a third objective of the present invention to provide an advantageous wind turbine. 
     The objectives are solved by a brake system, generator, and wind turbine as claimed in the independent claims. The dependent claims define further developments of the invention. 
     The inventive brake system comprises a rotor assembly, a stator assembly and a rotation axis. The rotor assembly comprises an outer portion which is located radially outward of the stator assembly. The outer portion comprises a brake disc. The stator assembly comprises at least one frictional member. The frictional member is operatively configured for frictionally engaging at least a portion of the brake disc. The inventive brake system may especially be used for a generator. 
     The inventive brake system has the advantage, that the brake disc can be mounted on a cylindrical support structure of an outer rotor. In this case the possible large diameter of the machine can be fully used in order to use a brake disc with largest possible diameter. This increases the efficiency of the brake. Moreover, a bigger brake disc and bigger brake callipers can be used which provides a larger effective contact surface. A large effective contact surface is necessary in order to maintain the rotor in a parking position, for example. A further advantage is that more heat can be absorbed and distributed in a large brake disc compared with smaller brake discs. 
     Generally, the inventive brake system can be part of a direct drive generator or it can be connected to a direct drive generator. The generator may have an outer rotor configuration. 
     Advantageously the brake disc extends radially inward from the outer portion of the rotor assembly to the rotation axis. In this case the inventive brake system can be used for a direct drive generator. Furthermore, the inventive brake system may be part of a direct drive wind turbine with an outer rotor configuration. 
     Moreover, the rotor assembly may comprise a flange. The brake disc may be fastened to the flange. For example, the flange may comprise a number of holes, preferably bolt holes. The holes may be radially spaced. Preferably the brake disc is fastened to the flange by bolts or screws. 
     The brake system may be part of a wind turbine with a hub. In this case the brake system, especially the rotor assembly of the brake system, may comprise a near end which faces the hub and a far end which is located opposite to the hub. Preferably the flange, to which the brake disc is fastened, may be located at the fast end of the rotor assembly, which means opposite of the hub. 
     The inventive brake system may comprise a rotor support. In this case the brake disc may be fastened to a flange of the rotor support, for example by bolts or screws. 
     The stator assembly may comprise a stationary shaft. The at least one frictional member may be connected to the stationary shaft. The stator assembly may comprise a bed frame of a wind turbine. The at least one frictional member may be connected to the bed frame of the wind turbine. The stator assembly may comprise a stator support structure. The at least one frictional member may be connected to the stator support structure. For example, the at least one frictional member, for example at least one brake calliper, may be directly mounted to the stationary shaft or the bed frame of a wind turbine or a stator support structure. 
     Preferably the at least one frictional member may extend radially outward regarding the rotation axis. For example, the at least one frictional member may extend radially outward from the stator support structure or from the stationary shaft or from the bed frame of a wind turbine. 
     Especially, the frictional member may comprise at least one brake calliper. Preferably the frictional member comprises at least one brake calliper on each side of the brake disc, preferably in order to enclose the brake disc. Advantageously the at least one frictional member comprises at least one brake calliper system. The at least one calliper system may comprise at least to brake callipers located on each side of the brake disc opposite to each other. For example, the brake calliper system may comprise at least one calliper bracket. The calliper bracket may be used for mounting the callipers and/or the brake calliper system to another component of the brake system, for example for mounting to the stationary shaft. Each brake calliper system may be connected to a calliper bracket. 
     Advantageously the brake calliper system may be designed such that it is aligned to the brake disc in axial direction in such a way that no bending moment, especially no axial bending moment, is experienced at a fixation point of the brake calliper system. For example, the brake calliper system may be aligned to the brake disc in axial direction or it may be configured in such a way that no bending moment or substantially no bending moment is experienced at a fixation point of the brake calliper system to the calliper brackets. 
     Moreover, the inventive brake system may comprise a rotor lock system. Preferably, the rotor lock system is integrated in the brake system. Preferably, the rotor lock system comprises an automatic actuator. For example, the rotor lock system may comprise an interlock, a snap-in lock, a block, an arrest or a barricade, preferably a number of the afore mentioned components. 
     The rotor lock system can be realised such that the brake disc comprises a number of recesses, preferably in the inner surface of the brake disc, for example radially and/or symmetrically spaced. The stator assembly may comprise at least one piston, preferably a number of pistons. Preferably, the piston/pistons is/are located such that it/they are prepared to engage with the recess/recesses. For example, the pistons or the piston are/is prepared to engage with the corresponding recesses in the brake disc in order to lock the rotor in a parking position. 
     Preferably, the lock system may comprise an automatic actuator. The automatic actuator can advantageously be configured for pushing the pistons or the piston into the corresponding recesses. The actuator may comprise hydraulic or electrical means, for example a hydraulic cylinder. In this case the pistons can be pushed into the corresponding recesses of the brake disc by hydraulic or electrical means. This way, it is possible to lock the rotor in an automated manner. 
     Furthermore, the brake disc may comprise a number of radial segments. If the brake disc is divided into radial segments it is possible to exchange a large brake disc in an easy way. 
     The inventive generator comprises an inventive brake system as previously described. The inventive generator has the same advantages as the inventive brake system. 
     Generally, the generator may have an air gap, which is located between stator elements and rotor elements of the generator. The rotor elements contain permanent magnets for example, while the stator elements contain stacked laminate plates, which support at least one winding of the stator coil. 
     The air gap should be relatively small to ensure a high efficiency of the generator. Thus the air gap should stay in a range of only a few millimeters. For generators, like direct drive or directly driven generators, this is very difficult due to their size. Direct drive generators show a diameter of several meters. 
     Rotor elements and stator elements are typically arranged opposite to each other, thus the air gap has to ensure that they do not come into contact while the generator is at operation. Thus the air gap should be very small to ensure the efficiency of the generator on the one hand while a certain width of the air gap is needed to prevent mechanical damages. 
     Especially for a direct drive generator it is difficult to keep the air gap in a range of only a few millimeters. This requires therefore very rigid, massive and heavy support structures for the stator elements and for the rotor elements. 
     The air gap of a generator can be determined by tolerances of the permanent magnets, which are part of the rotor, by tolerances of the stacked laminate-plates, which are part of the stator, and/or by tolerances of the coil-windings, which are part of the stator-coil. Also other elements of the generator contribute to the dimensions of the air gap. The air gap may be designed in a way that the elements of the rotor and of the stator do not get in contact, while the rotor rotates around its dedicated rotational axis. 
     The inventive generator may comprise a rotor and a stator. Advantageously, the distance in radial direction (radial distance) between the brake disc and the frictional member is less than the distance in radial direction (radial distance) between the rotor and the stator. The frictional member can be the brake calliper or the brake calliper system or part of the brake calliper system, for instance a bracket. For example, the radial distance between the brake disc and the frictional member can be between 1 mm and 5 mm, preferably between 2 mm and 4 mm. The radial distance between the rotor and the stator can be between 4 mm and 10 mm, preferably between 5 mm and 7 mm. 
     If the radial distance between the brake disc and the frictional member is less than the radial distance between the rotor and the stator, the brake disc would hit the frictional member, for example the bracket of the brake calliper system, before the stator hits the rotor. This prevents damages to the generator and increases the safety of the system. The radial distance between rotor and stator is also called air gap. The generator may be part of a direct drive wind turbine with a unilateral bearing. The generator may comprises an unsupported end, which is the opposite end of where the bearing is located. By means of the inventive generator the air gap at the unsupported end can be maintained within the narrow tolerances. 
     The inventive wind turbine comprises an inventive brake system and/or an inventive generator as previously described. The inventive wind turbine has the same advantageous as the inventive brake system and/or an inventive generator. Preferably the inventive wind turbine may be a direct drive wind turbine. Moreover, the inventive wind turbine may comprise an outer rotor configuration. 
     The inventive wind turbine may comprise a nacelle, a hub and a generator. The generator may be located inside the nacelle or between the nacelle and the hub. The brake system may be connected to the generator and/or to the hub. For example, the brake system may be an integrated part of the generator and/or an integrated part of the hub. 
     The generator may comprises a near side facing the hub and a far side opposite to the hub. Preferably the brake system and/or the lock system may be located at the far side opposite to the hub. 
     Since the inventive brake system may be more or less an integrated part of the generator it does not take up extra space inside the nacelle. Moreover, entrance through the generator, especially through the stator, is possible, which is a great advantage. This provides easy access to the hub. Moreover, easy access to the parts of the brake system, especially if the brake system is located at the far side of the generator opposite to the hub, is provided. This allows for easier maintenance and service. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features, properties and advantageous of the present invention will become clear from the following description of an embodiment in conjunction with the accompanying drawings. All features are advantageous alone or in combination with each other. 
         FIG. 1  schematically shows a wind turbine. 
         FIG. 2  schematically shows part of an inventive generator with an inventive brake system in a sectional view. 
         FIG. 3  schematically shows a front view of an inventive brake system. 
         FIG. 4  schematically shows part of the inventive brake system in a sectional view along IV-IV of  FIG. 3 . 
         FIG. 5  schematically shows part of the rotor lock system of the inventive brake system in a sectional view along V-V. 
         FIG. 6  schematically shows the rotor lock system of  FIG. 5  in a locked position. 
         FIG. 7  schematically shows part of an inventive wind turbine. 
     
    
    
     DETAILED DESCRIPTION OF INVENTION 
     An embodiment of the present invention will now be described with reference to  FIGS. 1 to 7 .  FIG. 1  schematically shows a wind turbine  1 . The wind turbine  1  comprises a tower  2 , a nacelle  3  and a hub  4 . The nacelle  3  is located on top of the tower  2 . The hub  4  comprises a number of wind turbine blades  5 . The hub  4  is mounted to the nacelle  3 . Moreover, the hub  4  is pivot-mounted such that it is able to rotate about a rotation axis  9 . A generator  6  is located inside the nacelle  3 . The wind turbine  1  is a direct drive wind turbine. The generator  6  comprises a near side  19  facing the hub  4  and a far side  20  opposite to the hub  4 . 
       FIG. 2  schematically shows part of a generator  6  with an outer rotor configuration in a sectional view. The generator  6  comprises a stator assembly  7  and a rotor assembly  8 . The stator assembly  7  comprises a stationary shaft  10  which is located close to the rotation axis  9 . The rotor assembly  8  comprises an outer rotor portion  11  which is located radially outward of the stator assembly  7 . The rotor assembly  8  further comprises a brake disc  12 . The brake disc  12  may be part of the outer rotor portion  11  or it may be connected to the outer rotor portion  11 . The brake disc  12  extends radially inward from the outer portion  11  to the rotation axis  9 . The outer portion  11  of the rotor assembly  8  and the brake disc  12  are pivot-mounted about the rotation axis  9 . 
     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 radial distance  22  between the brake disc  12  and the brake calliper system  13  is less than the radial distance  23  (air gap) between the outer rotor portion  11  and the stator assembly  7 . Advantageously, radial distance  22  is between 1 mm and 5 mm, preferably between 2 mm and 4 mm. Preferably, the air gap  23  has a width between 4 mm and 10 mm, advantageously between 5 mm and 7 mm. 
       FIG. 3  schematically shows a front view of the inventive brake system of the generator  6 . Elements which correspond to elements of the previously described Figures are designated with the same reference numerals and will not be described again in detail. The brake disc  12  comprises an inner surface  21 . The inner surface  21  of the brake disc  12  comprises a number of recesses  15 . Preferably the recesses  15  are radially and/or symmetrically spaced in the inner surface  21 . 
     Generally, the brake disc  12  can be divided into radial segments  12   a ,  12   b  and  12   c . The brake disc  12  can also be divided into any other number of radial segments. This makes it possible to exchange a large brake disc  12  easily. 
     The brake system further comprises a number of central mounted flanges  14 , in the present embodiment three central mounted flanges  14 . The flanges  14  are mounted to the stationary shaft  10 . The flanges  14  are staggered about an angle of 120° regarding the circumference of the stationary shaft  10 . Alternatively any other number of the flanges  14  is possible. Preferably the flanges  14  are arranged around the circumference of the stationary shaft  10  such that adjacent flanges have an equal distance to each other. 
     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 flange  14  or is located inside of a lock casing. The lock casing can be connected to the flange  14 . Alternatively, the brake system can comprise separate flanges for housing the pistons or for being connected with at least one lock casing of the rotor lock system  17  and separate 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 . Preferably, the rotor lock system  17  comprises an automatic actuator. The automatic actuator may be configured for actuating the rotor lock. Especially, the rotor lock system  17  may comprise an automatic actuator for pushing the pistons  16  into the corresponding recesses  15 . Preferably the actuator comprises hydraulic or electrical means, for instance a hydraulic cylinder. Instead of recesses also holes can be present in the brake disc  12  and instead of pistons also pins may be used. 
     Instead of the described rotor lock system  17  comprising a number of pistons  16  also a lock system comprising an interlock, a snap-in lock, a block, an arrest, a barricade or a similar means may be used. 
       FIG. 4  schematically shows part of the inventive brake system in a sectional view along IV-IV of  FIG. 3 . In  FIG. 4  two brake callipers  13 A and  13 B are located each on one side of the brake disc  12  opposite to each other. The two brake callipers  13 A and  13 B are connected to the central mounted flange  14 . The flange  14  is connected to the stationary shaft  10 . In  FIG. 4  the brake disc is integrated part of the outer rotor portion  11 . Alternatively, the brake disc  12  may be a separate element which is mounted to the outer rotor portion  11 . For example, the brake disc  12  can be fastened to a flange of a rotor support, for instance by bolts or screws. 
     The actuation force for actuating the brake callipers  13 A and  13 B is designated by an error  18 . When the brake callipers  13 A and  13 B are actuated, they frictionally engage a portion of the brake disc  12 . 
     The wind turbine  1  may comprise a bed frame or a support structure of the stator. In this case the brake calliper system  13  can be mounted directly to the bed frame of the wind turbine  1  or to the support structure of the stator. 
       FIGS. 5 and 6  schematically show part of the inventive brake system in a sectional view along V-V of  FIG. 3 . In the present embodiment the rotor lock system  17  is integrated into the brake system.  FIG. 5  schematically shows the rotor lock system in an unlocked state.  FIG. 6  shows the rotor lock system in a locked state. In  FIG. 5  the piston  16  is completely located inside of the flange  14  or inside of another component of the rotor lock system  17 , for example a lock casing. In  FIG. 6  the piston  16  is pushed into a corresponding recess  15  of the brake disc  12 . In this position the rotor is locked in a parking position. The piston  16  can be pushed into the corresponding recess  15  of the brake disc  12  by hydraulic or electrical means. 
     Preferably the inventive brake system is located at the far side  20  of the generator  6  opposite to the hub  4 . This allows for an easy access to the brake system and the integrated rotor lock system, especially for maintenance and service. Alternatively, the inventive brake system may be located at the hub. For example, the inventive brake system may directly be connected to the hub. 
       FIG. 7  schematically shows part of an inventive wind turbine  301 . It comprises a typical and well known “one-bearing” arrangement. A wind turbine  301  comprises a direct drive generator  302 , which is arranged on the upwind side of a tower  303  of the wind turbine  301 . 
     A tower flange  304  is arranged on the top of the tower  303 . A bedplate  305  is attached to the tower flange  304 . The wind turbine  401  comprises a yaw system—not shown here—which is used to turn the bedplate  305  of the wind turbine  301  around the axis  300 . 
     The wind turbine  301  comprises a stationary shaft  306 , while the shaft  306  has a centre axis  200 . The rear side of the stationary shaft  306  is attached to a retaining arrangement  307 . On the front side of the stationary shaft  306  a stator arrangement  308  of the direct drive generator  302  is arranged. The stator arrangement  308  comprises a stator support structure  309  and a lamination stack  310 . The lamination stack  310  supports windings  311 . 
     The stator support structure  309  comprises two support elements  312  for a two side support of the lamination stack  310 . The support elements  312  are ring-shaped. They are attached to the outside of the stationary shaft  306 . A hollow cylindrical support element  313  is attached to the outer ends of the ring-shaped support elements  312 . The hollow cylindrical support element  313  carries the ring-shaped lamination stack  310  and the windings  311 . 
     A rotor arrangement  314  is arranged around the stator arrangement  308 . The rotor arrangement  314  comprises a front endplate  315  and a cylinder element  317 . The front endplate  315  is ring-shaped, while the cylinder element  317  is hollow. 
     The cylinder element  317  comprises a plurality of permanent magnets  318 , which are mounted on the inside of the hollow cylinder element  317 . The permanent magnets  318  are arranged opposite to the lamination stack  310  and the supported windings. An air gap  319  with a width of approximately 6 mm is located between the permanent magnets  318  and the lamination stack  310 . Preferably, the air gap  319  has a width between 4 mm and 10 mm, advantageously between 5 mm and 7 mm. A brake disc  12  is connected to the cylinder element  317  of the rotor. A brake calliper system  13  is connected to the stationary shaft  306 . The radial distance  22  between the brake calliper system  13  and the brake disc  12  is less than the air gap  319 . Advantageously, radial distance  22  is between 1 mm and 5 mm, preferably between 2 mm and 4 mm. 
     The front endplate  315  is arranged on the stationary shaft  306  via a bearing  320 . The bearing  320  is capable to transform axial loads in both directions of the centre axis A. An appropriate bearing is disclosed in DE 201 16 649 U1 for example. 
     The stationary part  321  of the bearing  320  is attached to the stationary shaft  306 . The rotating part  322  of the bearing  320  is connected to a mounting ring  323 . The front endplate  315  as well as the hub  324  are attached to the mounting ring  323 . The hub  324  comprises mounting devices  325  for wind turbine rotor blades—not shown here. 
     The air gap  319  shown here is uniform to achieve a constant distance between the elements of the rotor and the elements of the stator. The one bearing design is very attractive due to its easy design.