General Electric Company

Advanced Innovative Solutions, LLC

Raed Zuhair Hasan

Aaron Wertz

John Paul Davis

Lawrence Keith Taliaferro, Jr

Ganesh Raut

Fulton Jose Lopez

Adam Daniel Minadeo

Priyangu Chunilal Patel

James Edward Cencula

Souvik Porel

Boobalan Ayyasamy

Kevin M Vandevoorde

Jacob Johannes Nies

Ian David Wilson

George Albert Goller

Edward Lee McGrath

Collin McKee Sheppard

Ryan Eric Vogel

Kevin Vandevoorde

Matteo Bellucci

Farong Zhu

Dhanushkodi Durai Mariappan

Haitham Hussein Bilal

Jeremy Charles Ridge

Hayden Patrick Mcgarity-Bashiri

Hayden McgarityBashiri

Martxel Ruiz Luisa

A method for manufacturing a gear assembly of a gearbox in a wind turbine includes providing a pin shaft of the gear assembly. The method also includes depositing material onto an exterior surface of the pin shaft of the gear assembly via an additive manufacturing process driven by a computer numerical control (CNC) device to form a bearing that circumferentially surrounds and adheres to the pin shaft. Further, the method includes providing a gear circumferentially around the bearing to form the gear assembly.

Additively manufactured journal bearing for a wind turbine gearbox

A gear system includes a carrier having a first portion and a separate, second portion and a plurality of pin shafts extending from the first portion of the carrier. Each of the plurality of pin shafts includes a first end and a second end. As such, the first ends are integrally formed with the first portion of the carrier. The first and second portions are arranged on opposing sides of the plurality of pin shafts and are spaced apart such that the first and second portions do not contact each other. Further, the second portion of the carrier defines an end plate that is secured to the second ends of the plurality of pin shafts. The gear system also includes a plurality of gears mounted to the plurality of pin shafts, with each of the plurality of gears arranged so as to rotate around one of the plurality of pin shafts.

Wind turbine gearbox carrier with integrated pin shafts and method of manufacturing same

A method for manufacturing a planet gear or a sun gear of a gearbox of a wind turbine includes forming a base of the planet gear via at least one of casting or forging. The base of the planet gear includes an inner circumferential surface and an outer circumferential surface. Therefore, at least one of the inner circumferential surface or the outer circumferential surface of the planet gear includes a plurality of net or near-net gear teeth. The method also includes applying a coating material to at least a portion of the base of the gear and at least a portion of the plurality of gear teeth of the gear via an additive manufacturing process so as to increase a hardness of the portions of the base and the plurality of gear teeth that includes the coating material.

Hybrid-additive gear for a wind turbine gearbox

A modular gearbox assembly for a wind turbine having improved up-tower serviceability includes a low-speed gear stage module, a separate, intermediate-speed gear stage module adjacent to the low-speed gear stage module, and a separate high-speed gear stage module adjacent to the intermediate-speed gear stage module. The gearbox assembly also includes a first flange removably connecting the intermediate and high-speed gear stage modules and a second flange removably connecting the intermediate and low-speed gear stage modules. Thus, the low-speed gear stage module converts a low-speed, high torque input from a rotor shaft of the wind turbine to a high-speed, low torque output for a generator of the wind turbine via the intermediate and high-speed gear stage modules. In addition, the first and second flanges allow for easy disassembly of the gear stage modules such that the various stages can be easily repaired, replaced, and/or inspected.

Modular gearbox for wind turbine

A method for manufacturing a pitch bearing or a yaw bearing for a wind turbine includes forming an outer race of the bearing of a base material. The method also includes forming an inner race of the bearing of the base material. Further, one of the inner race or the outer race defines a circumferential surface comprising a plurality of gear teeth. The method further includes arranging the inner race within the outer race. In addition, the method includes providing a plurality of roller elements between the outer and inner races. Moreover, the method includes applying a coating material to at least a portion of the plurality of gear teeth via an additive manufacturing process. The coating material is different than the base material. As such, the coating material provides at least one of increased hardness, strength, or durability to the base material.

Method for manufacturing a pitch bearing or a yaw bearing of a wind turbine via additive manufacturing

The present disclosure is directed to a gearbox assembly for a wind turbine. The gearbox assembly has a maximal installed width and a maximal transport width. The maximal installed width is greater than the maximal transport width. The gearbox assembly includes at least one torque arm coupled to opposing sides of the gearbox housing. Each of the torque arms includes a proximal end and a distal end. The proximal ends are removably coupled to the exterior surface of the gearbox such that the distance between the distal ends define the maximal installed width. The torque arms are coupled to at least one support element and to a bedplate of the wind turbine.

System and method for reducing the transport width of a gearbox for a wind turbine

The present disclosure is directed to a system for monitoring wear on a gearbox of a wind turbine. A controller of the system is configured to determine a torque exerted on a rotor shaft of the wind turbine or a generator shaft of the wind turbine based on measurement signals received from a first sensor of the system. The controller is also configured to determine an accumulated wear value for the gearbox based on the torque.

System and method for monitoring wear on a gearbox of a wind turbine

An integral ring gear and torque arm for a wind turbine gearbox and method of manufacturing same includes forming the ring gear and the associated gear housing as a single part using the same material, e.g., using a casting process. Further, the ring gear defines an inner circumferential surface having a plurality of gear teeth. Thus, the method also includes applying a coating material to the gear teeth of the ring gear via an additive manufacturing process, such as cold spraying, so as to increase a hardness of gear teeth.

Integral ring gear and torque arm for a wind turbine gearbox

A constant velocity (CV) joint system include a CV joint assembly with a first elongated ring pivotally attached to a second elongated ring via a first rotating housing and a second rotating housing, the first rotating housing and the second rotating housing being configured to rotate along a first axis; a third elongated ring pivotally attached to a fourth elongated ring via a third rotating housing and a fourth rotating housing, the third rotating housing and the fourth rotating housing being configured to rotate along a second axis; a first sliding support; and a second sliding support. The first sliding support includes a first elongated opening; and a second elongated opening, the first elongated opening extending in a direction relatively perpendicular to the second elongated opening. The second sliding support includes a third elongated opening and a fourth elongated opening, the third elongated opening extending in a direction relatively perpendicular to the fourth elongated opening.

Universal constant velocity joint system and method of use

A carrier and at least one pin shaft of a gearbox of a wind turbine and method of manufacturing same includes forming the carrier and the pin shaft(s) as a single part or separate components. Further, the method includes forming one or more voids in the pin shaft(s) and/or the carrier via additive manufacturing. As such, the void(s) is configured to increase flexibility of the pin shaft(s)/carrier so as to improve a load distribution thereof.

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Greenville, SC, United States of America

Raed Zuhair Hasan