As a clean source of energy, wind doesn’t depend on fossil fuels or pollute the planet. Wind turbines harness the kinetic energy found in wind and convert it into electrical energy. The technology dates back to 1887, when James Blyth, a Scottish academic, used a wind turbine to charge batteries that powered his holiday home. One of the essential components in modern turbines is the Falk gearbox, which a variety of stationary applications contain.
Types of Wind Turbines
Horizontal-Axis Wind Turbines
Horizontal-axis wind turbines are the types of turbines commonly seen on wind farms. They have an electrical generator and the main rotor shaft at the top of the tower. To be effective, the components must face into the wind with the help of a wind vane or a wind sensor and servomotor.
Many horizontal-axis wind turbines have Falk gearbox parts that help speed up the rate in which the blades rotate to drive an electrical generator. In general, the blades rotate at 10 to 22 revolutions per minute. Falk gearbox specialists install gearboxes to enhance the generator’s speed. While some turbines run at a constant speed, those with variable speed and a solid-state power converter that interfaces with the transmission system collect more energy.
Vertical-Axis Wind Turbines
In vertical-axis wind turbines, the main rotor shaft has a vertical arrangement. The design makes it so the turbine doesn’t have to face the wind, which is great for sites with variable wind directions or when the turbine is integrated into a building. Vertical designs are not as common as horizontal designs and produce less power.
Turbines with a vertical axis design can have the generator and Falk speed gearbox near the ground. To facilitate maintenance, there’s a direct drive from the rotor assembly to the gearbox on the ground.
There are a variety of vertical-axis wind turbines, including:
- Darrieus wind turbine: Resembling an eggbeater because of its curved blades, Darrieus turbines have a low starting torque.
- Girmill wind turbine: Girmill, or H-bar, turbines are a subtype of Darrieus turbines, but use straight blades instead of curved ones. It has a variable pitch, giving it a higher starting torque and a wide, flatter torque curve.
- Savonius wind turbine: Savonius are self-starting wind turbines that use two or more scoops. They convert the wind’s force into torque on a rotating shaft. Savonius turbine subtypes include twisted savonius and parallel turbines. Savonius turbines have long helical scoops that provide smooth torque, making them great for rooftop wind turbines and ships. Parallel turbines use the ground effect and are similar to centrifugal fans.
Role of Falk Gearboxes in Wind Turbines
A Falk speed gearbox increases a wind turbine’s rotational speed, converting low-speed rotations into high-speed rotations that generate electricity. Because of the loading and environmental conditions in which the Falk gears must operate, a wind turbine’s gearbox design may seem like a challenge.
Utility-scale wind turbines typically use three-stage gearboxes. The first stage is usually a planetary drive because of its high torque handling. The remaining two stages use helical gears. Falk gearbox specialists work with load cases—sensors on gearboxes measure over a period of time—because loads constantly change.
The torque from the turbine’s rotor creates power and applies large forces to the drivetrain. Therefore, it’s vital to ensure the gearbox can support the loads or that the drivetrain isolates the gearbox to prevent internal misalignments. When a gearbox fails, experts take the turbine offline and replace it, a project that can take up to several weeks to complete.
When you need Falk gearbox parts or fast, high-quality repairs, Mar-Dustrial makes the process of getting back up to speed quick and easy. Our inventory of thousands of new, hard-to-find, surplus and obsolete components, including couplings, will keep your turbine’s gearbox reducer humming. Our speedy repair services at our Falk-certified repair facility help you save on costs. Talk to one of our experienced Falk gearbox specialists at any time of the day, seven days a week, for all your gearbox needs.
Posted under Falk Gearboxes on Wednesday, March 7th, 2018