Requirement: Overload protection in extreme conditions
The safety coupling was to be integrated into the drive train between the wind turbine and transmission. The intention was to protect the succeeding components, like the generator, from torque overloads with a continuously adjustable torque limiter.
The main component of every wind power turbine is the generator. The generator along with all other components must withstand very great stresses and extreme temperature fluctuations. Since the important mechanical components of a wind turbine are located in the so-called Nacelle (located at the top of the tower), developing a connection shaft that can withstand all of the stresses the wind turbine is exposed to was a special challenge.
For this reason, the coupling specialists developed a compact, weight-optimized custom solution based on the ST1 product line. This ST1, in size 160, was present to a disengagement torque of 100 KNm and can be continuously adjusted between 50 and 110 KNm.
Coupling key data:
Weight: approx. 542.5 kg
Diameter: approx. 750 mm
Adjustment range: 50 kNm – 110 kNm
Disengagement torque: 100 kNm
Bore diameter D1: 230F7 with double keyway connection offset at 180°
Operating speed: approx. 580 rpm
Flange-connection coupling / generator with integrated rubber bolts
The safety coupling is a crucial element in ensuring the smooth operation of an assembly. It protects the mechanical system against overload damage, which not only causes expensive repairs, but can also result in a complete shutdown. In the case of wind power turbines, it is primarily the generator that is at risk. Therefore, every millisecond counts when disconnecting the driveline in the event of a fault.
In the event of a torque overload, the coupling must separate the connection between the wind turbine and transmission within a few milliseconds. When the set torque is exceeded, the safety coupling disengages and protects the entire system from mechanical damage and downtimes. Only after an inspection of the equipment and manual re-engagement of the torque limiter modules will the system become operational again. No special tools are required for re-starting the system. This can be done easily with the assistance of a rubber mallet or by using levels.
Safety first – that’s why precision and expert knowledge are required when it comes to safety couplings.