Couplings and overload protection for wind turbines
Powerful and durable
CD Couplings for Wind Turbines
Robust and easy to assemble
Overload Protection for Wind Turbines
Protects generator and gearbox
What is a wind turbine coupling?
Couplings for wind turbines are mechanical components that connect the drive train of a wind turbine and enable reliable transmission of rotary motion from the rotor shaft to the gear unit or directly to the generator. They perform an important role in the function and efficiency of wind turbines as they control motion and power transmission while handling certain mechanical challenges.
What is the importance of couplings in wind turbines?
As wind turbines are operated for many years in harsh environments (e.g. offshore wind farms), reliability and maintenance-free operation are particularly important. Couplings contribute significantly to reducing maintenance costs and increasing uptime by minimizing mechanical loads and protecting the drive train.
Couplings for wind turbines are therefore crucial components that contribute to the efficiency and durability of the turbines.
The Zero-Max wind turbine couplings offer several advantages specifically designed to meet the requirements of wind turbines. These couplings have been developed to increase the efficiency, reliability and durability of the wind turbine drive train.
In general, wind turbine couplings are exposed to extreme conditions and work in applications with high technical requirements. Frequently changing climatic conditions require products which operate at the highest technical level and enable high performance. Considering high, costly downtimes, Zero-Max offers unique and innovative coupling solutions for Wind turbine drivetrains. Couplings from Zero-Max are designed for a service life of more than 20 years and therefore exceed the average service life of standard solutions for the drive train.
The flexible wind turbine couplings, in combination with the high-performance composite material used, are a preferred coupling choice for new installations and retrofitting or replacement of turbine installations. The unique and patented “open arm” disk pack design promises maximum performance with proven reliability and results in maintenance-free operation.
The innovative “open arm” design offers the possibility of compensating misalignments, resulting reaction forces are minimized and thus significantly increase the life expectancy of the coupling.
All composite disc couplings are equipped with a high-performance composite material as the support material. The product design of the disk pack enables potential isolation, which is referred to as the electrically insulating properties of the coupling. This technical circumstance thus prevents leakage currents from being transmitted from the generator to the transmission. As a result of this approach to disk pack implementation, damage to the bearings or other add-on parts caused by existing leakage currents can be avoided.
Zero-Max wind turbine couplings and torque limiters are designed to resist external influencing factors. High requirements due to extreme temperatures (-57 °C to 121 °C), the effects of moisture or the use of chemicals can be solved by using Zero-Max wind turbine couplings. In conjunction with torque limiters, wind turbine couplings from Zero-Max offer an integrated solution for modern drive trains in the wind technology sector.
The intelligent design of the disc pack (“open arm”) minimizes reaction forces and reaction loads, but still offers a high torsional stiffness value for demanding requirements.
Summary of wind turbine couplings:
- Couplings and torque limiters available for many wind turbines
- Transmission of high torques (up to 200,000 Nm)
- Suitable for onshore and offshore turbines
- High misalignment capacity with low reaction forces/loads
- Very high fatigue strength/lifetime
- Low weight
- Easy installation or replacement
- Low life cycle costs (LLC)
- Corrosion resistance standard C4
- Use under the harshest conditions
- High resistance to environmental and ambient influences, e.g. temperature (-57 °C to 121 °C)
- Electrically insulating properties (electrical isolation)
- Direct replacement with existing couplings possible
| Turbine Manufacturer | Turbine Model | Coupling | Torque-Limiter* | Note** |
|---|---|---|---|---|
| Acconia/Nordex | AW-1500 | • | • | |
| NEG Micon/ Vestas | NM44/NM48 | • | ||
| NEG Micon/ Vestas | NM52/NM54 | • | ||
| Pioneer Wincon | P750/49 | • | • | |
| RRB Energy | PS600 | • | ||
| Siemens-Gamesa | G47 | • | ||
| Siemens-Gamesa | G5X | • | • | |
| Siemens-Gamesa | G8X/G9X | • | • | GEN2 & GEN3 |
| Siemens-Gamesa | G114 | • | • | 50 Hz Only |
| Unison | U88/U93 | • | • | |
| Unison | U113 | • | • | |
| Vestas | V47 | • |
Here are the main advantages offered by Zero-Max couplings:
1. Excellent shaft misalignment compensation
Zero-Max wind turbine couplings provide exceptionally good alignment of axial, radial and angular offsets between the connected components, such as the rotor shaft and the gearbox or generator. This is important because temperature variations, wind loads, and other factors can cause misalignments in the turbine that stress mechanical components. The couplings equalize these misalignments and reduce wear on bearings, gearboxes and other parts.
2. Shock and vibration damping
A major advantage of Zero-Max couplings is their ability to absorb and dampen vibrations and shocks. In wind turbines, changing wind conditions and sudden load changes cause strong vibrations and mechanical shocks. Zero-Max couplings absorb these forces, which protects the drivetrain and extends the service life of components such as the gearbox and generator.
3. Maintenance-free
Zero-Max couplings are designed for maintenance-free operation. This means that they can operate for long periods of time without regular lubrication or maintenance, which is particularly beneficial in offshore wind turbines where maintenance is expensive and difficult to perform. This feature reduces operating costs and increases the reliability of the system.
4. High torsional stiffness
Zero-Max couplings are known for their high torsional stiffness, which means that they transmit rotational movements with high precision. This property is particularly important to minimize losses during torque transmission and maximize the energy efficiency of the wind turbine.
5. Durability under extreme conditions
Zero-Max couplings are designed for use in harsh environments. They are robust enough to withstand extreme weather conditions such as strong winds, humidity and temperature variations. This resilience makes them particularly suitable for offshore and onshore wind farms where reliability and durability are crucial. They are also designed with an operating life of more than 20 years.
6. Protection of the drivetrain
Another major advantage is the protection of the drivetrain against damage caused by overloads or misalignments. The couplings act as a “buffer” between the mechanical components and ensure that unexpected stresses caused by gusts of wind or sudden load changes do not lead to damage to expensive and critical parts such as the gearbox or the generator.
7. Modular design and customizability
Zero-Max offers various sizes and configurations to meet the requirements of different types of wind turbines. The modular design makes it possible to adapt couplings specifically to the needs of different turbine models, optimizing wind turbine performance and efficiency.
Conclusion:
Zero-Max wind turbine couplings offer key advantages for use in wind turbines, particularly through their effective shaft misalignment properties, vibration and shock absorption, maintenance-free operation and durability in harsh environments. These features help maximize uptime and reduce maintenance costs, making them a valuable solution for modern wind turbines.
Let us advise you today.