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Wind power coupling with integrated safety brakes
Shaft couplings for the connection of gearboxes and generators in wind power plants normally consist of a shaft misalignment compensation coupling, a torque-limiting overload protection device and an integrated brake disk. Depending on the plant performance, the wind power module by mayr power transmission can also be delivered completely equipped with electromagnetic safety brakes.
- The wind power module transmits the torque between the gearbox and the generator backlash-free, compensates for shaft misalignments, has integrated disk brakes and an integrated overload protection against torque impacts. The electric insulation of the intermediate sleeve prevents bearing damage caused by leakage currents or lightning strokes. Furthermore, optimum installation and de-installation characteristics were taken into account during the construction.
Wind power plants place high demands on the connection coupling between the gearbox and the generator, especially if it is mounted elastically on rubber elements. Since running times of at least 20 years are specified, the existing torques must be transmitted safely while at the same time high shaft misalignments must be compensated for via flexible compression of the gearbox and the generator. Here it is important to reduce the application of high-maintenance components to a minimum. Unpermittedly high torques are caused by temporary torque impacts (short-circuit torques). A mechanical overload element must be integrated into the coupling pack to make sure that no damage is caused to the drive line. Furthermore, an electric insulation between the generator and the gearbox is required to prevent leakage currents and voltage breakdowns. The coupling unit is designed in modular form for optimum installation and deinstallation. This modular design allows optional integration of a brake disk adjusted to the system.
Normally, the coupling manufacturers provide a brake disk according to customer requirements. But the question is why only the brake disk and not the complete brake? At mayr power transmission, taking this into consideration was a logical consequence. After all, the company does not only have decades of experience with torque limiting clutches and shaft couplings, but also has more than 40 years of experience in the development, production and application of electromagnetic safety brakes.
In wind power plants, “main brake” (primary brake) means the rotor blade adjustment by means of a pitch drive. Ideally, the pitch adjustment reduces the rotor speed to zero before the calliper brakes, which are arranged on the fast-running side of the brake disk (secondary brake), engage and cause a system standstill. On emergency stop braking actions, however, the brakes already engage at a generator speed of approximately 500 rpm. In doing so, they must absorb very high friction work values. The organic friction linings normally used in spring applied, electromagnetic safety brakes do not withstand these loads for long. Here, special sinter linings, which feature substantially higher thermal stability, higher reliable surface pressures and lower wear values, have proven their worth.