WO2018174979A1

WO2018174979A1 - Seal carrier arrangement for large diameter bearing

Info

Publication number: WO2018174979A1
Application number: PCT/US2017/067859
Authority: WO
Inventors: Richard Borowski; Douglas R. LUCAS; Jennifer S. HYPES
Original assignee: The Timken Company
Priority date: 2017-03-24
Filing date: 2017-12-21
Publication date: 2018-09-27

Abstract

A bearing comprising an outer ring (34) having an annular, axially- extending projection (118) integrally formed as one piece with the outer ring; an inner ring (46,54); a plurality of rolling elements (62,66) positioned between the inner and outer rings; and a seal (82) disposed axially adjacent the outer ring and interposed between a distal end of the annular projection and a seal carrier (114) that is secured to the outer ring.

Description

SEAL CARRIER ARRANGEMENT FOR LARGE DIAMETER BEARING

BACKGROUND

[0001] The present invention relates to roller bearings, and more particularly to large diameter roller bearings (e.g., greater than one meter).

[0002] Large diameter roller bearings, such as double-row tapered roller bearings, are commonly used in wind turbines to support the rotor shaft. These bearings include seals for keeping the lubricant (e.g., grease or oil) in the bearing and contaminants out of the bearing.

SUMMARY

[0003] In one embodiment , the invention provides a bearing including an outer ring having an annular, axially-extending projection integrally formed as one piece with the outer ring. The bearing further includes an inner ring, a plurality of rolling elements positioned between the inner and outer rings, and a seal disposed axially adjacent the outer ring and interposed between a distal end of the annular projection and a seal carrier that is secured to the outer ring.

[0004] In another embodiment, the invention provides a bearing comprising an outer ring having first and second outer raceways; a first inner ring having a first inner raceway; a first plurality of rolling elements positioned between the first inner and outer raceways; a second inner ring having a second inner raceway; a second plurality of rolling elements positioned between the second inner and outer raceways; and a spacer ring between the first and second inner rings; wherein (i) the spacer ring includes oppositely -facing and axially -facing first and second annular channels sized and configured to receive axially inwardly -facing first and second annular projections on the respective first and second inner rings; or (ii) the spacer ring includes oppositely-facing and axially outwardly-extending first and second annular projections sized and configured to be received in axially inwardly -facing first and second annular channels in the respective first and second inner rings.

[0005] In one embodiment, the invention provides a bearing including an outer ring, an inner ring, a plurality of rolling elements positioned between the inner and outer rings, and a seal disposed axially adjacent the outer ring in a radially-inwardly facing channel of a seal carrier that is secured to the outer ring. A fastener extends at least partially through the seal carrier and is operable upon tightening to reduce a width of the channel to compress the seal therein.

[0006] In one embodiment, the invention provides a bearing including an outer ring having an annular, axially-extending projection integrally formed as one piece with the outer ring. The bearing further includes an inner ring, a plurality of rolling elements positioned between the inner and outer rings, and a seal interposed between a portion of the annular projection and an end ring that is secured to the annular projection.

[0007] In one embodiment, the invention provides a bearing including an outer ring, an inner ring, a plurality of rolling elements positioned between the inner and outer rings, and a seal disposed axially adjacent the outer ring in a radially-inwardly facing channel of a seal carrier that is secured to the outer ring.

[0008] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Fig. 1 illustrates a wind turbine incorporating a bearing embodying the invention.

[0010] Fig. 2 is a partial section view of a bearing embodying the invention.

[0011] Fig. 3 is an enlarged partial section view illustrating the seal carrier and seal arrangement of a bearing similar to that shown in Fig. 2.

[0012] Fig. 4 is an enlarged partial section view illustrating a seal carrier and seal arrangement of another embodiment

[0013] Figs. 5A-E illustrate different embodiments of the seal carrier.

[0014] Fig. 6 illustrates an alternative embodiment with a piloting arrangement for facilitating alignment and mounting of the seal carrier with the outer ring.

[0015] Fig. 7 is a partial section view of a bearing embodying the invention.

[0016] Fig. 8 is an enlarged partial section view illustrating the seal carrier and seal arrangement of the bearing shown in Fig. 7. [0017] Fig. 9 is an enlarged partial section view illustrating a seal carrier and seal arrangement of another embodiment

[0018] Figs. 10A-E illustrate different embodiments of the seal carrier.

[0019] Figs. 1 1 A and 1 IB are enlarged partial section views of yet another embodiment, the sections being taken through different angular locations.

[0020] Fig. 12 is a partial section view of a bearing embodying the invention.

[0021] Fig. 13 is an enlarged partial section view illustrating the seal arrangement of a bearing similar to that shown in Fig. 12.

[0022] Fig. 14 is an enlarged partial section view illustrating a seal arrangement of another embodiment.

[0023] Figs. 15A-E illustrate different embodiments of the end ring.

[0024] Fig. 16 is an enlarged partial section view illustrating a seal arrangement of yet another embodiment.

[0025] Fig. 17 is an enlarged partial section view illustrating a seal arrangement of another embodiment.

[0026] Fig. 18 is a partial section view of a bearing embodying the invention.

[0027] Fig.19 is an enlarged partial section view illustrating the seal carrier and seal arrangement of a bearing similar to that shown in Fig. 18.

[0028] Fig. 20 is an enlarged partial section view illustrating a seal carrier and seal arrangement of another embodiment

[0029] Figs. 21A-E illustrate different embodiments of the seal carrier. DETAILED DESCRIPTION

[0030] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

[0031] Fig. 1 illustrates a wind turbine 10 that can include one or more bearings 14 according to the present invention. The bearings 14 are tapered roller bearings that support a rotor shaft or main shaft 18 of the wind turbine 10. The wind turbine 10 also includes a gearbox 20 and a generator 22, which are ultimately driven by the rotation of the rotor blades 26. The bearings 14 are supported within a bearing housing 30. In some embodiments, the wind turbine 10 can include bearings, 214, 214', 214", 314, 314', 314", 314" ', 414, and/or 414' that are described below.

[0032] Fig. 2 illustrates the components of the bearings 14. The illustrated bearing 14 is a double-row tapered roller bearing having a one-piece outer ring 34 supported by the bearing housing 30. The outer ring 34 defines thereon first and second outer raceways 38, 42, respectively. The outer ring 34 has a diameter greater than one meter. A first inner ring 46 defines thereon a first inner raceway 50 in opposing relation to the first outer raceway 38. A second inner ring 54 defines thereon a second inner raceway 58 in opposing relation to the second outer raceway 42. The inner rings 46, 54 are coupled with the rotor shaft 18 for rotation therewith. A spacer ring 60 separates the inner rings 46, 54 and is operable to facilitate setting the preload of the bearing 14. Additional features of the spacer ring 60 will be discussed in further detail below. The outer ring 34, the inner rings 46, 54, and the spacer ring 60 may be one-piece rings, or may be segmented, multi-piece rings.

[0033] A first row of rolling elements 62 is positioned on the first outer raceway 38 and the first inner raceway 50, and a second row of rolling elements 66 is positioned on the second outer raceway 42 and the second inner raceway 58. The illustrated rolling elements 62, 66 are tapered rollers. A first cage 70 supports the rolling elements 62 and a second cage 74 supports the rolling elements 66. The cages 70, 74 can be one-piece cages or may be segmented, multi-piece cages. In the illustrated embodiment, the cages 70, 74 are of the type shown and described in U. S. Patent Nos. 9,039,289 and/or 8,926,190.

[0034] Each end of the bearing 14 includes a sealing arrangement operable to keep the lubricant (e.g., grease or oil) within the bearing 14 and contaminants out of the bearing 14. The sealing arrangements are substantially identical on each end, except for the fact that they are mirror images of one another. Referring now to Fig. 3, the first inner ring 46 includes a sealing surface 78 on which a two-piece seal 82 engages and slidably seals as the first inner ring 46 rotates. It should be noted that when used in a wind turbine 10, the inner rings 46, 54 will rotate while the outer ring 34 will remain stationary. However, the bearing 10 can alternatively be used in other applications in which the outer ring 34 would rotate while the inner rings 46, 54 remain fixed. The seal 82 is designed to seal during relative rotation of the inner and outer rings 46, 54, 34, regardless of which rings are actually moving. The illustrated seal or seal assembly 82 includes a primary seal 86 having a body portion 90 and a sealing lip portion 94. The sealing lip portion 94 is biased into engagement with the sealing surface 78 by a supplemental force exerted on the sealing lip portion 94 to energize the contact with the sealing surface 78. In the illustrated embodiment, a garter spring 98 is used to apply the supplemental force, however, in other embodiments, finger springs or other biasing features could be substituted. The seal assembly 82 further includes a secondary seal 102 having a body portion 106 and a sealing lip portion 110 that also engages the sealing surface 78. The secondary seal 102 is located axially outwardly of the primary seal 86. The seal assembly 82 is secured in place in the bearing 14 using a seal carrier 1 14. While the illustrated seal 82 is a two-piece seal, in other embodiments, the seal 82 could be a unitized, one-piece seal (see Fig. 4). In yet other embodiments, the primary seal 86 and/or the secondary seal 102 could each be formed as two pieces.

[0035] As shown in Fig. 3, the seal carrier 1 14 cooperates with an annular extension or projection 1 18 that is integrally formed as one piece with the outer ring 34 and that extends axially outwardly toward an axial end 122 of the first inner ring 46. In the illustrated embodiment, the annular projection 1 18 extends far enough axially to at least partially axially overlap the sealing surface 78, however, in other embodiments, the annular proj ection 1 18 may not overlap the sealing surface 78. While the illustrated annular projection 118 is shown as having distinct, axially-extending surfaces defining its inner and outer diameters, in other embodiments this need not be the case. For example, in some embodiments, the outer diameter of the outer ring 34 may be the same over the entire axial width of the outer ring 34. In other embodiments, the first raceway 38 might extend all the way to a distal end or axial end face of the outer ring 34. In either altemative, an entire, radially-outermost portion of the outer ring 34 overlaps or nearly overlaps the sealing surface 78 and is therefore the annular projection. [0036] The seal carrier 1 14 is secured via fasteners 126 to the annular projection 1 18 of the outer ring 34. Specifically, fasteners 126 are received in bores 130 in the seal carrier 1 14 and in threaded bores 134 in the distal end or axial end face 138 of the annular projection 1 18. The fasteners 126 are tightened to secure the seal carrier 1 14 to the annular projection 118. Referring again to Fig. 2, it can be seen that the bore 130 in the seal carrier 1 14 can also be provided with a counterbore such that the heads of the fasteners 126 can be recessed entirely within the seal carrier 114, as opposed to extending axially from the seal carrier 114 as shown in the embodiment illustrated in Fig. 3. In other embodiments, various features can be provided to assist in aligning or piloting the seal carrier 114 into its mounting position relative to the distal end 138 of the projection 118. Fig. 6 illustrates one such example in which the annular projection 1 18 has a stepped distal end 138. A shoulder 139 defines an outer diameter against which an inner diameter of the seal carrier 114 can abut to pilot the seal carrier 1 14 into the correct position against the distal end 138. One of skill in the art will understand that other piloting arrangements could also be used. For example, a shoulder of the distal end could provide an inner diameter against which an outer diameter of the seal carrier abuts. Alternatively, a channel or proj ection in the seal carrier could engage with a mating projection or channel in the distal end.

[0037] The seal carrier 114 includes a radially -extending, axially -inwardly facing surface 142 that cooperates with the distal end 138 of the annular projection 1 18 to secure the seal assembly 82 in position. In the illustrated embodiment, the distal end 138 is a radially- extending surface. Specifically, the body portions 90, 106 of the primary and secondary seals 86, 102 are interposed and sandwiched axially between the surface 142 and the distal end 138. Securing the seal carrier 1 14 to the annular projection 1 18 physically compresses the body portions 90, 106 axially to hold the seals 86 and 102 in place. Radially outer-most surfaces 90a and 106a of the body portions 90, 106 abut an axially-extending surface 146 of the seal carrier 1 14 that intersects with the radially-extending surface 142 to further constrain the seal assembly 82. The surfaces 142, 138 (and perhaps also the axially-extending surface 146) can be knurled, grooved, or otherwise textured to assist in gripping/holding the seal 82 therein. However, in other embodiments, the surfaces 142, 138, and 146 can also be smooth.

[0038] The seal carrier 114 can be a one-piece, continuous ring (see Fig. 5 A - shown without the bores 130), or alternatively can be a segmented ring with two or more segments being bolted or otherwise secured or held together about the first inner ring 46 in a manner that will connect the segments and prevent the leakage of lubricant while also preventing the ingress of contaminants (see Figs. 5B-E for exemplary segmented configurations - bores 130 shown only in Fig. 5B). Figs. 5B-E illustrate exemplary segmented configurations, however, other configurations are also contemplated. Fig. 5B illustrates two one-hundred-eighty degree segments. Fig. 5C illustrates two segments, with one segment being smaller than the other (e.g., one segment is ninety degrees and the other segment is two-hundred-seventy degrees). Fig. 5D illustrates three one-hundred-twenty degree segments. Fig. 5E illustrates four ninety degree segments. The seal carrier 1 14 can be made of metal (e.g., steel), or can alternatively be made of thermoplastics or other suitable rigid materials.

[0039] Fig. 4 illustrates an alternative embodiment of the bearing 14' in which like parts have been given like reference numbers with the prime (') indicator. The only difference between the bearing 14' and the bearing 14 described above is that the seal assembly is a one- piece design. More specifically, the primary and secondary seals are now integrated into a single seal 150 having a body portion 154, a first sealing lip portion 158, and a second sealing lip portion 162. The first sealing lip portion 158 is held into engagement with the sealing surface 78' by an optional garter spring 98' . As mentioned above, a supplemental force can be exerted on the sealing lip portion 158' to energize the contact with the sealing surface 78'. In the illustrated embodiment, the garter spring 98' is used to apply the supplemental force, however, in other embodiments, finger springs or other biasing features could be substituted. In this embodiment, the body portion 154 is again interposed and sandwiched axially between the surface 142' and the distal end 138' when the seal carrier 1 14' is secured to the annular projection 118' . Radially outer-most surface 154a of the body portion 154 abuts axially- extending surface 146' of the seal carrier 1 14' that intersects with the radially-extending surface 142' to further constrain the seal 150. The envelope defined between the surfaces 142', 146', and 138' has the same dimensions as the envelope defined between the surfaces 142, 146, and 138 such that the seal 150 could be easily interchanged with the seal 82, and vice-versa. While the illustrated seal 150 is one piece, it could be formed by co-molding techniques in which the body portion 154 could be molded from a stiffer material while the sealing lip portions 158, 162 could be molded from a more resilient material.

[0040] The illustrated seals 82 and 150 are generally provided as a continuous ring or as elongated strips to be inserted into the envelopes defined between the surfaces 142', 146', and 138' or the surfaces 142, 146, and 138. Once installed, if the seals 82 and 150 are in the form of elongated strips, the abutting ends of the elongated strips can be glued or otherwise secured together, or in other embodiments, may just be compressed together without using glue.

[0041] Referring again to Fig. 2, the illustrated spacer ring 60 has a generally I-shaped cross-section defined in part by oppositely-facing and axially-facing first and second annular channels 200 and 204 sized and configured to receive axially inwardly -facing first and second annular projections 208 and 212 on the respective first and second inner rings 46 and 54. The piloted engagement between the channels 200, 204 and the projections 208, 212 helps to maintain the concentricity of the inner rings 46, 54 thereby improving the performance of the bearing 14. As seen in Fig. 2, each of the first and second inner rings 46, 54 includes an O-ring 216 (or other seal) positioned in an annular groove in the projections 208, 212 to provide a seal between the respective inner rings 46, 54 and the spacer ring 60. In other embodiments, the O-rings 216 could be positioned in grooves in the channels 200, 204 of the spacer ring 60. Additionally, the arrangement of the annular channels and the annular projections could be reversed, such that the annular channels are formed in the inner rings 46, 54 and the annular projections extend from the spacer ring 60.

[0042] Fig. 7 illustrates the components of a bearing 214. The illustrated bearing 214 is a double-row tapered roller bearing having a one-piece outer ring 234 supported by the bearing housing 30. The outer ring 234 defines thereon first and second outer raceways 238, 242, respectively. The outer ring 234 has a diameter greater than one meter. A first inner ring 246 defines thereon a first inner raceway 250 in opposing relation to the first outer raceway 238. A second inner ring 254 defines thereon a second inner raceway 258 in opposing relation to the second outer raceway 242. The inner rings 246, 254 are coupled with the rotor shaft 218 for rotation therewith. A spacer ring 260 separates the inner rings 246, 254 and is operable to facilitate setting the preload of the bearing 214. Additional features of the spacer ring 260 will be discussed in further detail below. The outer ring 234, the inner rings 246, 254, and the spacer ring 260 may be one-piece rings, or may be segmented, multi-piece rings.

[0043] A first row of rolling elements 262 is positioned on the first outer raceway 238 and the first inner raceway 250, and a second row of rolling elements 266 is positioned on the second outer raceway 242 and the second inner raceway 258. The illustrated rolling elements 262, 266 are tapered rollers. A first cage 270 supports the rolling elements 262 and a second cage 274 supports the rolling elements 266. The cages 270, 274 can be one-piece cages or may be segmented, multi-piece cages. In the illustrated embodiment, the cages 270, 274 are of the type shown and described in U.S. Patent Nos. 9,039,289 and/or 8,926,190.

[0044] Each end of the bearing 214 includes a sealing arrangement operable to keep the lubricant (e.g., grease or oil) within the bearing 214 and contaminants out of the bearing 214. The sealing arrangements are substantially identical on each end, except for the fact that they are mirror images of one another. Referring now to Fig. 8, the first inner ring 246 includes a sealing surface 278 on which a two-piece seal 282 engages and slidably seals as the first inner ring 246 rotates. It should be noted that when used in a wind turbine 210, the inner rings 246, 254 will rotate while the outer ring 234 will remain stationary. However, the bearing 210 can alternatively be used in other applications in which the outer ring 234 would rotate while the inner rings 246, 254 remain fixed. The seal 282 is designed to seal during relative rotation of the inner and outer rings 246, 254, 234, regardless of which rings are actually moving. The illustrated seal or seal assembly 282 includes a primary seal 286 having a body portion 290 and a sealing lip portion 294. The sealing lip portion 294 is biased into engagement with the sealing surface 278 by a supplemental force exerted on the sealing lip portion 294 to energize the contact with the sealing surface 278. In the illustrated embodiment, a garter spring 298 is used to apply the supplemental force, however, in other embodiments, finger springs or other biasing features could be substituted. The seal assembly 282 further includes a secondary seal 2102 having a body portion 2106 and a sealing lip portion 21 10 that also engages the sealing surface 278. The secondary seal 2102 is located axially outwardly of the primary seal 286. The seal assembly 282 is secured in place in the bearing 214 using a seal carrier 21 14. While the illustrated seal 282 is a two-piece seal, in other embodiments, the seal 282 could be a unitized, one-piece seal (see Fig. 9). In yet other embodiments, the primary seal 286 and/or the secondary seal 2102 could each be formed as two pieces.

[0045] As shown in Fig. 8, the seal carrier 21 14 is secured via fasteners 2118 directly to a radially-extending surface or axial end face 2122 of the outer ring 234. Specifically, fasteners 21 18 are received in bores 2126 in the seal carrier 2114 and in threaded bores 2130 in the radially-extending surface 2122. The fasteners 2118 are tightened to secure the seal carrier 2114 to the outer ring 234. It can be seen that the bore 2126 in the seal carrier 21 14 can be provided with a counterbore such that the heads of the fasteners 21 18 can be recessed entirely within the seal carrier 21 14, as opposed to extending axially from the seal carrier 2114 as shown in the embodiment illustrated in Fig. 9. [0046] In the illustrated embodiment, when the seal carrier 21 14 is mounted on the outer ring 234, a portion of an outer diameter 2134 of the seal carrier 21 14 abuts an axially- extending annular surface 2138 of the outer ring 234 to assist with aligning and mounting the seal carrier 2114 (i.e., piloting) and to provide added support to the seal carrier 2114. In other embodiments, other piloting features, such as an abutment at the inner diameter of the seal carrier 2114 or mating projections and grooves in the surfaces 2122 and 2146 can be provided. An O-ring 2142 (or other seal) is positioned between the outer ring 234 and an end surface 2146 of the seal carrier 2114. In the illustrated embodiment, the O-ring 2142 is positioned in an annular groove 2150 formed in the radially-extending surface 2122 of the outer ring 234, but in other embodiments, the O-ring 2142 could be positioned in an annular groove formed in the end surface 2146 of the seal carrier 21 14.

[0047] The seal carrier 21 14 includes a radially-inwardly facing annular channel 2154 aligned with and spaced apart from the sealing surface 278 of the inner ring 246 for supporting the seal assembly 282. The channel 2154 has a first, radially inward portion 2158 that supports the seal assembly 282, and a second, radially outward portion 2162 operable to provide flexibility to the seal carrier 21 14 such that the radially inward portion 2158 of the channel 2154 can be selectively compressed and relaxed axially in order to secure or release the seal assembly 282 within the radially inward portion 2158 of the channel 2154.

[0048] More specifically, the radially inward portion 2158 is defined by two radially- extending surfaces 2166 and 2170 and an axially-extending surface 2174 that together constrain the body portions 290, 2106 of the seal 282. The illustrated radially outward portion 2162 of the channel 2154 is formed in the axially-extending surface 2174 and is generally V-shaped with converging walls 2178 and 2182. In other embodiments, the radially outward portion 162 of the channel 2154 can be generally U-shaped (see Figs. 1 1A and 11B) or any other configuration that will enable some deflection/compression of the channel 2154, as discussed below. The fasteners 1 18 extend through a portion of the radially outward channel portion 2162 such that tightening of the fasteners 21 18 will cause deflection in the channel 2154 that will reduce an axial width dimension of the radially inward channel portion 2158 and operate to compress the body portions 290, 2106 of the seal 282 within the radially inward channel portion 2158. Specifically, after the fasteners 21 18 secure the seal carrier 2114 to the outer ring 234, further tightening of the fasteners 2118 will draw the converging wall 2178 toward the converging wall 2182, and will likewise draw the radially - extending surface 2166 toward the radially-extending surface 2170. In this manner, the body portions 290, 2102 of the seal 282 will be compressed between the radially-extending surfaces 2166, 2170 to secure the seal 282 in the radially inward portion 2158 of the channel 2154. A relaxed or un-compressed width between the radially-extending surfaces 2166, 2170 can be the same as or even slightly larger than a combined width of the body portions 290, 2102 to make installation of the seal 282 into the radially inward channel portion 2158 easier than if the channel width were smaller than the combined width of the body portions 290, 2102. Should the seal 282 need to be removed and replaced, the fasteners 2118 can be loosened to relax the spacing between the radially-extending surfaces 2166, 2170, thereby making removal of the old seal 282 and replacement with a new seal 282 easy. The radially- extending surfaces 2166, 2170 (and perhaps also the axially-extending surface 2174) of the channel 2154 can be knurled, grooved, or otherwise textured to assist in gripping/holding the seal 282 therein. However, in other embodiments, the surfaces 2166, 2170, and 2174 can also be smooth.

[0049] As shown in Fig. 8, and on the left side of the bearing 214 in Fig. 7, an optional positive stop feature can be provided as part of the channel 2154 to limit the amount of deflection of the channel 2154, and therefore the compressive force applied to the seal 282. More specifically, the illustrated positive stop feature can take the form of an annular slot 2186 formed at the vertex or apex of the converging walls 2178, 2182 to define the radially- outermost end of the channel 2154. The illustrated slot 2186 is at least partially radially aligned with the bores 2126 in the seal carrier 2114 and defines a width or gap in the axial direction (e.g., 0.020 inches) such that once the opposing walls 2188, 2190 of the slot 2186 deflect that amount and into direct abutment with one another, further deflection of the channel 2154 is prevented. In this manner, the deflection of the radially-extending surfaces 2166, 2170, and the resulting compressive force applied to the seal 282, can be controlled and limited. In other embodiments, the slot 2186 need not be positioned at the vertex or apex of the converging walls 2178, 2182, but instead may be somewhere else relative to the channel 2154. Also, two or more separate slots may be used. In yet other embodiments, different techniques can be used for providing a positive stop feature, or as illustrated on the right side of Fig. 7 or in Fig. 9, some embodiments may not include any positive stop feature, but may instead rely upon the user to consider the appropriate amount of torque applied to the fasteners 2118. [0050] While the embodiment of Fig. 9 illustrates a truncated, radially inwardly- extending, finger-shaped projection 2192 adjacent and at least partly defining the radially- extending surface 2170, in other embodiments such as that shown in Figs. 7 and 8, a longer, radially-extending finger-shaped projection 2194 may be provided to extend further toward the sealing surface 278 adjacent the sealing lip portion 294 to improve sealing. In this way, a radial distance between the sealing surface 278 and the seal carrier 2114 is reduced adjacent the seal 282 to reduce the size of the aperture through which lubricant may pass axially before reaching the seal 282. The projections 2192 and 2194 are aligned with a portion of the sealing surface 278.

[0051] While the seal carrier 21 14 could be a one-piece, continuous ring (see Fig. 10A), in the illustrated embodiments, the seal carrier 21 14 is a segmented ring with two or more segments bolted or otherwise secured or held together about the first inner ring 246 in a manner that will connect the segments and prevent the leakage of lubricant while also preventing the ingress of contaminants. Figs. 7 and 8 illustrate a threaded bolt hole 2196 that would receive a fastener for securing two segments of the seal carrier 2114 together. Figs. 10B-E illustrate exemplary segmented configurations, however, other configurations are also contemplated. Fig. 10B illustrates two one-hundred-eighty degree segments. Fig. I OC illustrates two segments, with one segment being smaller than the other (e.g., one segment is ninety degrees and the other segment is two-hundred-seventy degrees). Fig. 10D illustrates three one-hundred-twenty degree segments. Fig. 10E illustrates four ninety degree segments. The seal carrier 2114 can be made of metal (e.g., steel), or can alternatively be made of thermoplastics or other suitable rigid materials.

[0052] Fig. 9 illustrates an alternative embodiment of the bearing 214' in which like parts have been given like reference numbers with the prime (') indicator. One difference between the bearing 214' and the bearing 214 described above is that the seal assembly is a one-piece design. More specifically, the primary and secondary seals are now integrated into a single seal 2198 having a body portion 2202, a first sealing lip portion 2206, and a second sealing lip portion 2210. The first sealing lip portion 2206 is held into engagement with the sealing surface 278' by an optional garter spring 298' . As mentioned above, a supplemental force can be exerted on the sealing lip portion 2158' to energize the contact with the sealing surface 278'. In the illustrated embodiment, the garter spring 298' is used to apply the supplemental force, however, in other embodiments, finger springs or other biasing features could be substituted. At least the radially inward portion 2158' of the channel 2154' has the same dimensions as the radially inward portion 2158 of the channel 2154 such that the seal 2198 could be easily interchanged with the seal 282, and vice-versa. While the illustrated seal 2198 is one piece, it could be formed by co-molding techniques in which the body portion 2202 could be molded from a stiff er material while the sealing lip portions 2206, 2210 could be molded from a more resilient material.

[0053] The illustrated seals 282 and 2198 are generally provided as a continuous ring or as elongated strips to be inserted into the radially inward portion 2158, 2158' of the channel 2154 2154' . Once installed, if the seals 282 and 2198 are in the form of elongated strips, the abutting ends of the elongated strips can be glued or otherwise secured together, or in other embodiments, may just be compressed together without using glue.

[0054] Another difference between the bearing 214' shown in Fig. 4 and the bearing 214 of Figs. 7 and 8 is the optional region of added material or added material thickness 2214 provided on the outer diameter 2134' of the seal carrier 21 14' in axial alignment with the channel 2154' . If the envelope of the bearing housing 30 permits, the added region of material thickness 2214 can be provided in an annular arrangement on the outer diameter 2134' of the seal carrier 21 14' to provide added strength and durability. The added material 2214 helps to accommodate the added stresses and compressive forces exerted on the seal carrier 2114' as a result of deforming the channel 2154' . While the illustrated region of added material 2214 is shown as having a generally truncated triangular cross-section, other geometries could be substituted as desired and/or as permitted by the envelope in the bearing housing 30. In other embodiments, like those shown in Figs. 7 and 8, no regions of added material may be necessary.

[0055] Figs. 1 1 A and 1 IB illustrate yet another embodiment of a bearing 214" that is similar to the bearing 214 except for the differences described below. Like parts have been given like reference numbers with the double prime (") indicator. Figs. 11 A and 1 IB are sectional views taken through different angular locations about the bearing 214". In the embodiment of Figs. 1 1A and 1 IB, the fasteners 21 18" (see Fig. 1 IB) are still used to secure the seal carrier 1 14" to the outer ring 234", but separate fasteners 2218 (see Fig. 1 1A) received in blind bores 2222 in the seal carrier 21 14" are provided for creating or releasing the deformation of the channel 2154". By having the separate fasteners 2218 to achieve the deformation of the channel 2154", the stress and load on the mounting fasteners 2118" can be reduced. Furthermore, in the embodiment of Figs. 11A and 1 1B, the annular slot 2186" extends across an entire diameter of the blind bores 2222 receiving the separate fasteners 2218, while the U-shaped radially outward portion 2162" of the channel 2154" is not aligned with the blind bores 2222. The slot 2186" operates in the same manner discussed above to act as a positive stop feature. In this embodiment, the seal 282" can first be installed and secured into the radially inward channel portion 2158 using the separate fasteners 2218. Then, the seal carrier 21 14" can be connected to the outer ring 234" using the mounting fasteners 21 18". Of course, if desired, the reverse order could be used with the seal carrier 21 14" first mounted to the outer ring 234", and then the seal 282" could be installed and compressed in the radially inward channel portion 2158" using the separate fasteners 2218.

[0056] In the embodiment of Figs. 1 1A and 1 IB, the outer diameter 2134" has a reduced diameter portion along a mid-section, but then includes a region of added material or increased thickness 2214" in axial alignment with the channel 2154". Just as described above, this region of added material or increased thickness 2214" provides added strength and durability to the seal carrier 2114". The outer diameter 2134" is then chamfered adjacent the head of the fasteners 21 18" and 2218 to further reduce material in the seal carrier 21 14".

[0057] Referring again to Fig. 7, the illustrated spacer ring 260 has a generally I-shaped cross-section defined in part by oppositely-facing and axially-facing first and second annular channels 2226 and 2230 sized and configured to receive axially inwardly -facing first and second annular projections 2234 and 2238 on the respective first and second inner rings 246 and 254. The piloted engagement between the channels 2226, 2230 and the projections 2234, 2238 helps to maintain the concentricity of the inner rings 246, 254 thereby improving the performance of the bearing 214. As seen in Fig. 7, each of the first and second inner rings 246, 254 includes an O-ring 2242 (or other seal) positioned in an annular groove in the projections 2234, 2238 to provide a seal between the respective inner rings 246, 254 and the spacer ring 260. In other embodiments, the O-rings 2242 could be positioned in grooves in the channels 2226, 2230 of the spacer ring 260. Additionally, the arrangement of the annular channels and the annular projections could be reversed, such that the annular channels are formed in the inner rings 246, 254 and the annular proj ections extend from the spacer ring 260.

[0058] Fig. 12 illustrates the components of a bearing 314. The illustrated bearing 314 is a double-row tapered roller bearing having a one-piece outer ring 334 supported by the bearing housing 30. The outer ring 334 defines thereon first and second outer raceways 338, 342, respectively. The outer ring 334 has a diameter greater than one meter. A first inner ring 346 defines thereon a first inner raceway 350 in opposing relation to the first outer raceway 338. A second inner ring 354 defines thereon a second inner raceway 358 in opposing relation to the second outer raceway 342. The inner rings 346, 354 are coupled with the rotor shaft 318 for rotation therewith. A spacer ring 360 separates the inner rings 346, 354 and is operable to facilitate setting the preload of the bearing 314. Additional features of the spacer ring 360 will be discussed in further detail below. The outer ring 334, the inner rings 346, 354, and the spacer ring 360 may be one-piece rings, or may be segmented, multi-piece rings.

[0059] A first row of rolling elements 362 is positioned on the first outer raceway 338 and the first inner raceway 350, and a second row of rolling elements 366 is positioned on the second outer raceway 342 and the second inner raceway 358. The illustrated rolling elements 362, 366 are tapered rollers. A first cage 370 supports the rolling elements 362 and a second cage 374 supports the rolling elements 366. The cages 370, 374 can be one-piece cages or may be segmented, multi-piece cages. In the illustrated embodiment, the cages 370, 374 are of the type shown and described in U.S. Patent Nos. 9,039,289 and/or 8,926,190.

[0060] Each end of the bearing 314 includes a sealing arrangement operable to keep the lubricant (e.g., grease or oil) within the bearing 314 and contaminants out of the bearing 314. The sealing arrangements are substantially identical on each end, except for the fact that they are mirror images of one another. Referring now to Fig. 13, the first inner ring 346 includes a sealing surface 378 on which a two-piece seal 382 engages and slidably seals as the first inner ring 346 rotates. It should be noted that when used in a wind turbine 310, the inner rings 346, 354 will rotate while the outer ring 334 will remain stationary. However, the bearing 310 can alternatively be used in other applications in which the outer ring 334 would rotate while the inner rings 346, 354 remain fixed. The seal 382 is designed to seal during relative rotation of the inner and outer rings 346, 354, 334, regardless of which rings are actually moving. The illustrated seal or seal assembly 382 includes a primary seal 386 having a body portion 390 and a sealing lip portion 394. The sealing lip portion 394 is biased into engagement with the sealing surface 378 by a supplemental force exerted on the sealing lip portion 394 to energize the contact with the sealing surface 378. In the illustrated embodiment, a garter spring 398 is used to apply the supplemental force, however, in other embodiments, finger springs or other biasing features could be substituted. The seal assembly 382 further includes a secondary seal 3102 having a body portion 3106 and a sealing lip portion 31 10 that also engages the sealing surface 378. The secondary seal 3102 is located axially outwardly of the primary seal 386. The seal assembly 382 is secured in place in the bearing 314 using an end ring 31 14. While the illustrated seal 382 is a two-piece seal, in other embodiments, the seal 382 could be a unitized, one-piece seal (see Fig. 14). In yet other embodiments, the primary seal 386 and/or the secondary seal 3102 could each be formed as two pieces.

[0061] As shown in Fig. 13, the end ring 31 14 cooperates with an annular extension or projection 31 18 that is integrally formed as one piece with the outer ring 334 and that extends axially outwardly toward an axial end 3122 of the first inner ring 346. In the illustrated embodiment, the annular projection 3118 extends far enough axially to at least partially axially overlap the sealing surface 378. While the illustrated annular proj ection 3118 is shown as having distinct, axially-extending surfaces defining its inner and outer diameters, in other embodiments this need not be the case. For example, in some embodiments, the outer diameter of the outer ring 334 may be the same over the entire axial width of the outer ring 334. In other embodiments, the first raceway 338 might extend all the way to a distal end or axial end face of the outer ring 334. In either alternative, an entire, radially-outermost portion of the outer ring 334 overlaps or nearly overlaps the sealing surface 378 and is therefore the annular projection.

[0062] The end ring 31 14 is secured via fasteners 3126 to the annular projection 3118 of the outer ring 334. Specifically, fasteners 3126 are received in bores 3130 in the end ring 31 14 and in threaded bores 3134 in the distal end or axial end face 3138 of the annular proj ection 3118. The fasteners 3126 are tightened to secure the end ring 31 14 to the annular projection 31 18. In some embodiments, the bore 3130 in the end ring 3114 can also be provided with a counterbore such that the heads of the fasteners 3126 can be recessed partly or entirely within the end ring 3114, as opposed to extending axially from the end ring 31 14 as shown in the embodiment illustrated in Fig. 13. In other embodiments, various features can be provided to assist in aligning or piloting the end ring 31 14 into its mounting position relative to the distal end 3138 of the projection 3118. For example, a shoulder of the distal end 3138 could provide an inner diameter against which an outer diameter of the end ring 31 14 abuts. Alternatively, a channel or projection in the end ring could engage with a mating projection or channel in the distal end. One of skill in the art will understand that other piloting arrangements could also be used.

[0063] The end ring 31 14 includes a radially-extending, axially-outwardly facing surface or end face 3140 and a radially-extending, axi ally -inwardly facing surface or end face 3142 that, in the illustrated embodiment, is parallel with the end face 3140. The axially-inwardly- facing end face 3142 cooperates with the annular projection 31 18 to secure the seal assembly 382 in position. In the illustrated embodiment, the body portions 390, 3106 of the primary and secondary seals 386, 3102 are interposed and sandwiched axially between the end face 3142 of the end ring 3114 and a radially-extending surface or shoulder 3146 of the annular projection 31 18. Securing the end ring 31 14 to the annular projection 31 18 physically compresses the body portions 390, 3106 axially to hold the seals 386 and 3102 in place. Radially outer-most surfaces 390a and 3106a of the body portions 390, 3106 abut an axially- extending surface 3148 of the annular projection 3118 that intersects with the radially- extending surface 3146 to further constrain the seal assembly 382. Together, the radially- extending surface 3146 of the annular projection 3118 and the axially-extending surface 3148 of the annular projection 3118 define an annular groove in a radially inner surface of the annular projection 3118 that receives the seal 382. The surface 3146, a portion of the end face 3142 (and perhaps also the axially-extending surface 3148) can be knurled, grooved, or otherwise textured to assist in gripping/holding the seal 82 therein. However, in other embodiments, the surfaces 3142, 3146, and 3148 can also be smooth.

[0064] While not shown in the embodiment of Fig. 13, the embodiment shown in Fig. 12 includes a radially-extending finger-shaped projection 3149 that extends further toward the sealing surface 378 than a remainder of the annular projection 3118 adjacent the sealing lip portion 394 to improve sealing. In this way, a radial distance between the sealing surface 378 and the annular proj ection 3118 is reduced adjacent the seal 382 to reduce the size of the aperture through which lubricant may pass axially before reaching the seal 382. The projection 3149 is aligned with a portion of the sealing surface 378. In the illustrated embodiment, the projection 3149 extends radially inwardly of the body portion 390 of the primary seal 386 and thereby helps to retain the primary seal 386.

[0065] The end ring 31 14 can be a one-piece, continuous ring (see Fig. 15 A - shown without the bores 3130), or alternatively can be a segmented ring with two or more segments that can be separately bolted or otherwise secured onto the annular projection 3118 (see Figs. 15B-E for exemplary segmented configurations - bores 3130 not shown). Figs. 15B-E illustrate exemplary segmented configurations, however, other configurations are also contemplated. Fig. 15B illustrates two one-hundred-eighty degree segments. Fig. 15C illustrates eight forty -five degree segments. Fig. 15D illustrates three one-hundred-twenty degree segments. Fig. 15E illustrates four ninety degree segments. The end ring 31 14 can be made of metal (e.g., steel), or can alternatively be made of thermoplastics or other suitable rigid materials.

[0066] Fig. 14 illustrates an alternative embodiment of the bearing 314' in which like parts have been given like reference numbers with the prime (') indicator. The only difference between the bearing 314' and the bearing 314 described above is that the seal assembly is a one-piece design. More specifically, the primary and secondary seals are now integrated into a single seal 3150 having a body portion 3154, a first sealing lip portion 3158, and a second sealing lip portion 3162. The first sealing lip portion 3158 is held into engagement with the sealing surface 378' by an optional garter spring 398'. As mentioned above, a supplemental force can be exerted on the sealing lip portion 3158' to energize the contact with the sealing surface 378' . In the illustrated embodiment, the garter spring 398' is used to apply the supplemental force, however, in other embodiments, finger springs or other biasing features could be substituted. In this embodiment, the body portion 3154 is again interposed and sandwiched axially between the end face 3142' of the end ring 31 14' and the radially-extending surface 3146' of the annular projection 3118' when the end ring 3114' is secured to the annular projection 31 18' . Radially outer- most surface 3154a of the body portion 3154 abuts axially-extending surface 3148' of the annular projection 31 18' that intersects with the radially-extending surface 3146' to further constrain the seal 3150. The envelope defined between the surfaces 3142', 3146', and 3148' has the same dimensions as the envelope defined between the surfaces 3142, 3146, and 3148 such that the seal 3150 could be easily interchanged with the seal 382, and vice-versa. While the illustrated seal 3150 is one piece, it could be formed by co-molding techniques in which the body portion 3154 could be molded from a suffer material while the sealing lip portions 3158, 3162 could be molded from a more resilient material.

[0067] The illustrated seals 382 and 3150 are generally provided as a continuous ring or as elongated strips to be inserted into the envelopes defined between the surfaces 3142', 3146', and 3148' or the surfaces 3142, 3146, and 3148. Once installed, if the seals 382 and 3150 are in the form of elongated strips, the abutting ends of the elongated strips can be glued or otherwise secured together, or in other embodiments, may just be compressed together without using glue.

[0068] Referring again to Fig. 12, the illustrated spacer ring 360 has a generally I-shaped cross-section defined in part by oppositely-facing and axially-facing first and second annular channels 3200 and 3204 sized and configured to receive axially inwardly -facing first and second annular projections 3208 and 3212 on the respective first and second inner rings 346 and 354. The piloted engagement between the channels 3200, 3204 and the projections 3208, 3212 helps to maintain the concentricity of the inner rings 346, 354 thereby improving the performance of the bearing 314. As seen in Fig. 12, each of the first and second inner rings 346, 354 includes an O-ring 3216 (or other seal) positioned in an annular groove in the projections 3208, 3212 to provide a seal between the respective inner rings 346, 354 and the spacer ring 360. In other embodiments, the O-rings 3216 could be positioned in grooves in the channels 3200, 3204 of the spacer ring 360. Additionally, the arrangement of the annular channels and the annular projections could be reversed, such that the annular channels are formed in the inner rings 346, 354 and the annular proj ections extend from the spacer ring 360.

[0069] Fig. 16 illustrates another alternative embodiment of the bearing 314"' in which like parts have been given like reference numbers with the prime (") indicator. The only difference between the bearing 314"' and the bearings 314, 314' described above is that the end ring 31 14" and the annular projection 31 18" are modified slightly in how they capture and retain the seal 382". More specifically, the end ring 31 14" includes an annular undercut 3250 formed by a radially-extending wall portion 3254 and an axially-extending wall portion 3258. The body portions 390", 3106" of the primary and secondary seals 386", 3102" are interposed and sandwiched axially between the radially-extending wall portion 3254 of the end ring 3114" and the radially-extending surface or shoulder 3146" of the annular projection 3118". Securing the end ring 3114" to the annular projection 31 18" physically compresses the body portions 390", 3106" axially to hold the seals 386" and 3102" in place. Radially outer-most surfaces 390a" and 3106a" of the body portions 390", 3106" abut the axially- extending surface 3148" of the annular projection 31 18" and the axially-extending wall portion 3258 to further constrain the seal assembly 382. The surface 3146", the wall portion 3254 (and perhaps also the axially-extending surface 3148" and the wall portion 3258) can be knurled, grooved, or otherwise textured to assist in gripping/holding the seal 382" therein. However, in other embodiments, the surfaces 3254, 3258, 3146", and 3148" can also be smooth.

[0070] In the illustrated embodiment, the undercut 3250 has an axial width sized to receive substantially the entire width of the body portion 3106" of the secondary seal 3102" therein, however, in other embodiments the width of the undercut 3250 can vary to retain more or less of the width of the seal 382". For example, the undercut 3250 might receive only a portion of the secondary seal 3102", or may receive the entire secondary seal 3102" plus a portion of the primary seal 386".

[0071] Fig. 17 illustrates a variation of the embodiment shown in Fig. 16. Fig. 17 illustrates a bearing 314'" in which like parts have been given like reference numbers with the triple prime ("') indicator. The only difference between the bearing 314"' and the bearing 314" described above is that the end ring 31 14"' includes a piloting feature in the form of a shoulder 3262 that abuts a shoulder 3266 of the annular projection 31 18"'. In the illustrated embodiment, the shoulder 3262 defines an outer diameter surface that engages with an inner diameter surface defined by the shoulder 3266. This arrangement helps to achieve concentric positioning of the axially-extending surface 3148"' and the axially-extending wall portion 3258, and therefore the concentricity of the seals 386"', 3102"'. In other embodiments, this arrangement could be reversed with the shoulder of the end ring 31 14"' defining the inner diameter surface and the shoulder of the annular projection 31 18"' defining the outer diameter surface. In yet other embodiments, other combinations of channels, projections, and shoulders could be used to provide the piloting arrangement that facilitates the concentricity of the seals 386"', 3102"'.

[0072] Fig. 18 illustrates the components of a bearing 414. The illustrated bearing 414 is a double-row tapered roller bearing having a one-piece outer ring 434 supported by the bearing housing 30. The outer ring 434 defines thereon first and second outer raceways 438, 442, respectively. The outer ring 434 has a diameter greater than one meter. A first inner ring 446 defines thereon a first inner raceway 450 in opposing relation to the first outer raceway 438. A second inner ring 454 defines thereon a second inner raceway 458 in opposing relation to the second outer raceway 442. The inner rings 446, 454 are coupled with the rotor shaft 418 for rotation therewith. A spacer ring 460 separates the inner rings 446, 454 and is operable to facilitate setting the preload of the bearing 414. Additional features of the spacer ring 460 will be discussed in further detail below. The outer ring 434, the inner rings 446, 454, and the spacer ring 460 may be one-piece rings, or may be segmented, multi-piece rings.

[0073] A first row of rolling elements 462 is positioned on the first outer raceway 438 and the first inner raceway 450, and a second row of rolling elements 466 is positioned on the second outer raceway 442 and the second inner raceway 458. The illustrated rolling elements 462, 466 are tapered rollers. A first cage 470 supports the rolling elements 462 and a second cage 474 supports the rolling elements 466. The cages 470, 474 can be one-piece cages or may be segmented, multi-piece cages. In the illustrated embodiment, the cages 470, 474 are of the type shown and described in U.S. Patent Nos. 9,039,289 and/or 8,926,190.

[0074] Each end of the bearing 414 includes a sealing arrangement operable to keep the lubricant (e.g., grease or oil) within the bearing 414 and contaminants out of the bearing 414. The sealing arrangements are substantially identical on each end, except for the fact that they are mirror images of one another. Referring now to Fig. 19, the first inner ring 446 includes a sealing surface 478 on which a two-piece seal 482 engages and slidably seals as the first inner ring 446 rotates. It should be noted that when used in a wind turbine 410, the inner rings 446, 454 will rotate while the outer ring 434 will remain stationary. However, the bearing 410 can alternatively be used in other applications in which the outer ring 434 would rotate while the inner rings 446, 454 remain fixed. The seal 482 is designed to seal during relative rotation of the inner and outer rings 446, 454, 434, regardless of which rings are actually moving. The illustrated seal or seal assembly 482 includes a primary seal 486 having a body portion 490 and a sealing lip portion 494. The sealing lip portion 494 is biased into engagement with the sealing surface 478 by a supplemental force exerted on the sealing lip portion 494 to energize the contact with the sealing surface 478. In the illustrated embodiment, a garter spring 498 is used to apply the supplemental force, however, in other embodiments, finger springs or other biasing features could be substituted. The seal assembly 482 further includes a secondary seal 4102 having a body portion 4106 and a sealing lip portion 41 10 that also engages the sealing surface 478. The secondary seal 4102 is located axially outwardly of the primary seal 486. The seal assembly 482 is secured in place in the bearing 414 using a seal carrier 41 14. While the illustrated seal 482 is a two-piece seal, in other embodiments, the seal 482 could be a unitized, one-piece seal (see Fig. 20). In yet other embodiments, the primary seal 486 and/or the secondary seal 4102 could each be formed as two pieces. [0075] As shown in Fig. 19, the seal carrier 4114 is secured via fasteners 4118 directly to a radially-extending surface or axial end face 4122 of the outer ring 434. Specifically, fasteners 4118 are received in bores 4126 in the seal carrier 4114 and in threaded bores 4130 in the radially-extending surface 4122. The fasteners 4118 are tightened to secure the seal carrier 4114 to the outer ring 434. Referring again to Fig. 18, it can be seen that the bore 4126 in the seal carrier 4114 can also be provided with a counterbore such that the heads of the fasteners 4118 can be recessed entirely within the seal carrier 4114, as opposed to extending axially from the seal carrier 4114 as shown in the embodiment illustrated in Fig. 19.

[0076] In the illustrated embodiment, when the seal carrier 4114 is mounted on the outer ring 434, a portion of an outer diameter 4134 of the seal carrier 4114 abuts an axially- extending annular surface 4138 of the outer ring 434 to assist with aligning and mounting the seal carrier 4114 (i.e., piloting) and to provide added support to the seal carrier 4114. In other embodiments, other piloting features, such as an abutment at the inner diameter of the seal carrier 4114 or mating projections and grooves in the surfaces 4122 and 4146 can be provided. An O-ring 4142 (or other seal) is positioned between the outer ring 434 and an end surface 4146 of the seal carrier 4114. In the illustrated embodiment, the O-ring 4142 is positioned in an annular groove 4150 formed in the radially-extending surface 4122 of the outer ring 434, but in other embodiments, the O-ring 4142 could be positioned in an annular groove formed in the end surface 4146 of the seal carrier 4114.

[0077] The seal carrier 4114 includes a radially-inwardly facing annular channel 4154 aligned with and spaced apart from the sealing surface 478 of the inner ring 446 for supporting the seal assembly 482. The channel 4154 has a width W that is slightly smaller than a combined width of the body portions 490, 4106 of the primary and secondary seals 486, 4102 such that the channel 4154 compresses and secures the seal assembly 482 therein when the seal assembly 482 is installed in the channel 4154. The body portions 490, 4106 of the seal 482 are constrained between two radially-extending surfaces defining the channel 4154 and an axially-extending surface defining the channel 4154. The radially-extending surfaces (and perhaps also the axially-extending surface) of the channel 4154 can be knurled, grooved, or otherwise textured to assist in gripping/holding the seal 482 therein. However, in other embodiments, the surfaces can also be smooth. While the embodiment of Fig. 19 illustrates a truncated, radially inwardly -extending, finger-shaped projection 4158 adjacent and at least partly defining the axially inward end of the channel 4154, in other embodiments such as that shown in Fig. 18, a longer, radially-extending finger-shaped projection 4162 may be provided to extend further toward the sealing surface 478 adjacent the sealing lip portion 494 to improve sealing. In this way, a radial distance between the sealing surface 478 and the seal carrier 4114 is reduced adjacent the seal 482 to reduce the size of the aperture through which lubricant may pass axially before reaching the seal 482. The projections 4158 and 4162 are aligned with a portion of the sealing surface 478. An axially outward surface of the projections 4158, 4162 at least partly defines an axially inward surface of the channel 4154.

[0078] While the seal carrier 41 14 could be a one-piece, continuous ring (see Fig. 21 A), in the illustrated embodiments, the seal carrier 41 14 is a segmented ring with two or more segments bolted or otherwise secured or held together about the first inner ring 446 in a manner that will connect the segments and prevent the leakage of lubricant while also preventing the ingress of contaminants. Figs. 18 and 19 illustrate a threaded bolt hole 4166 that would receive a fastener for securing two segments of the seal carrier 4114 together. Figs. 21B-E illustrate exemplary segmented configurations, however, other configurations are also contemplated. Fig. 21 B illustrates two one-hundred-eighty degree segments. Fig. 21C illustrates two segments, with one segment being smaller than the other (e.g., one segment is ninety degrees and the other segment is two-hundred-seventy degrees). Fig. 21D illustrates three one-hundred-twenty degree segments. Fig. 21E illustrates four ninety degree segments. The seal carrier 4114 can be made of metal (e.g., steel), or can alternatively be made of thermoplastics or other suitable rigid materials.

[0079] Fig. 20 illustrates an alternative embodiment of the bearing 414' in which like parts have been given like reference numbers with the prime (') indicator. The only difference between the bearing 414' and the bearing 414 described above is that the seal assembly is a one-piece design. More specifically, the primary and secondary seals are now integrated into a single seal 4170 having a body portion 4174, a first sealing lip portion 4178, and a second sealing lip portion 4182. The first sealing lip portion 4178 is held into engagement with the sealing surface 478' by an optional garter spring 498'. As mentioned above, a supplemental force can be exerted on the sealing lip portion 4178' to energize the contact with the sealing surface 478' . In the illustrated embodiment, the garter spring 498' is used to apply the supplemental force, however, in other embodiments, finger springs or other biasing features could be substituted. In this embodiment, the body portion 4174 is again slightly wider in its uncompressed state than the width W of the channel 4154' such that the channel 4154' compresses and secures the seal 4170 therein when the seal 4170 is installed in the channel 4154' . The channels 4154, 4154' have the same widths W such that the seal 4170 could be easily interchanged with the seal 482, and vice-versa. While the illustrated seal 4170 is one piece, it could be formed by co-molding techniques in which the body portion 4174 could be molded from a suffer material while the sealing lip portions 4178, 4182 could be molded from a more resilient material.

[0080] The illustrated seals 482 and 4170 are generally provided as a continuous ring or as elongated strips to be inserted into the channels 4154, 4154' . Once installed, if the seals 482 and 4170 are in the form of elongated strips, the abutting ends of the elongated strips can be glued or otherwise secured together, or in other embodiments, may just be compressed together without using glue. Various techniques can be used to install the seals 482 and 4170 into the channels 4154, 4154' . With respect to the seal 482, the primary and secondary seal body portions 490 and 4106 can be held and compressed together to install the primary and secondary seals 486, 4102 simultaneously. Alternatively, the primary seal 486 could be inserted into the channel 4154 first and held in place while the body portion 4106 of the secondary seal 4102 could be forced into the channel 4154, causing compression of one or both of the body portions 490 and 4106. For the seal 4170, the body portion 4174 could be compressed to install it into the channel 4154' .

[0081] Referring again to Fig. 18, the illustrated spacer ring 460 has a generally I-shaped cross-section defined in part by oppositely-facing and axially-facing first and second annular channels 4200 and 4204 sized and configured to receive axially inwardly-facing first and second annular projections 4208 and 4212 on the respective first and second inner rings 446 and 454. The piloted engagement between the channels 4200, 4204 and the projections 4208, 4212 helps to maintain the concentricity of the inner rings 446, 454 thereby improving the performance of the bearing 414. As seen in Fig. 18, each of the first and second inner rings 446, 454 includes an O-ring 4216 (or other seal) positioned in an annular groove in the projections 4208, 4212 to provide a seal between the respective inner rings 446, 454 and the spacer ring 460. In other embodiments, the O-rings 4216 could be positioned in grooves in the channels 4200, 4204 of the spacer ring 460. Additionally, the arrangement of the annular channels and the annular projections could be reversed, such that the annular channels are formed in the inner rings 446, 454 and the annular proj ections extend from the spacer ring 460.

[0082] Various features and advantages of the invention are set forth in the following claims.

Claims

What is claimed is:

1. A bearing comprising:

an outer ring having an annular, axially-extending projection integrally formed as one piece with the outer ring;

an inner ring;

a plurality of rolling elements positioned between the inner and outer rings; and a seal disposed axially adjacent the outer ring and interposed between a distal end of the annular projection and a seal carrier that is secured to the outer ring.

2. The bearing of claim 1 , wherein the seal carrier is fastened to the distal end of the annular projection.

3. The bearing of claim 1 , wherein the seal is a two-piece seal having a primary seal and a secondary seal.

4. The bearing of claim 1, wherein the seal is a one-piece seal.

5. The bearing of claim 1 , wherein the seal carrier is a one-piece, continuous ring.

6. The bearing of claim 1 , wherein the seal carrier is a segmented ring with two or more segments.

7. The bearing of claim 1 , wherein the seal is compressed axially between the seal carrier and the distal end of the annular projection when the seal carrier is secured to the outer ring.

8. The bearing of claim 1 , wherein the inner ring includes a sealing surface that the seal engages, and wherein the annular projection axially overlaps with the sealing surface.

9. The bearing of claim 1 , wherein the inner ring includes a sealing surface that the seal engages, and wherein the annular projection does not axially overlap with the sealing surface.

10. The bearing of claim 1 , wherein the seal is constrained between a radially-extending surface of the seal carrier, an axially-extending surface of the seal carrier, and the distal end of the annular projection.

11. The bearing of claim 10, wherein the distal end is a radially-extending surface.

12. The bearing of claim 1, wherein the inner ring is coupled to a main shaft of a wind turbine.

13. A bearing comprising:

an outer ring having first and second outer raceways;

a first inner ring having a first inner raceway;

a first plurality of rolling elements positioned between the first inner and outer raceways;

a second inner ring having a second inner raceway;

a second plurality of rolling elements positioned between the second inner and outer raceways; and

a spacer ring between the first and second inner rings;

wherein

i) the spacer ring includes oppositely -facing and axially -facing first and second annular channels sized and configured to receive axially inwardly -facing first and second annular projections on the respective first and second inner rings; or

ii) the spacer ring includes oppositely -facing and axially outwardly- extending first and second annular projections sized and configured to be received in axially inwardly -facing first and second annular channels in the respective first and second inner rings.

14. A bearing comprising:

an outer ring;

an inner ring;

a plurality of rolling elements positioned between the inner and outer rings; and a seal disposed axially adjacent the outer ring in a radially -inwardly facing channel of a seal carrier that is secured to the outer ring; and

a fastener extending at least partially through the seal carrier, and operable upon tightening to reduce a width of the channel to compress the seal therein.

15. The bearing of claim 14, wherein the channel includes a radially inward portion in which the seal is retained, and a radially outward portion having opposing walls; and wherein the fastener passes at least partly through the radially outward portion of the channel.

16. The bearing of claim 15, further comprising a positive stop feature in the channel to limit the reduction of width to the channel.

17. The bearing of claim 16, wherein the positive stop feature is a slot at a radially- outermost end of the channel.

18. The bearing of claim 15, wherein the radially outward portion is V-shaped or U- shaped.

19. The bearing of claim 14, wherein the fastener also connects the seal carrier to the outer ring.

20. The bearing of claim 14, wherein the fastener is positioned in a blind bore in the seal carrier.

21. The bearing of claim 14, wherein the seal carrier is fastened to a radially-extending surface of the outer ring.

22. The bearing of claim 21, wherein an outer diameter of the seal carrier abuts an axially-extending annular surface of the outer ring.

23. The bearing of claim 14, wherein the seal is a two-piece seal having a primary seal and a secondary seal.

24. The bearing of claim 14, wherein the seal is a one-piece seal.

25. The bearing of claim 14, wherein the seal carrier is a one-piece, continuous ring.

26. The bearing of claim 14, wherein the seal carrier is a segmented ring with two or more segments.

27. The bearing of claim 14, wherein the inner ring includes a sealing surface that the seal engages, and wherein the seal carrier includes a radially inwardly-extending, finger-shaped projection aligned with a portion of the sealing surface and adjacent the seal.

28. The bearing of claim 27, wherein an axially outward surface of the projection at least partly defines an axially inward surface of the channel.

29. The bearing of claim 14, wherein the seal is constrained between two radially- extending surfaces defining the channel and an axially-extending surface defining the channel.

30. The bearing of claim 14, wherein the inner ring is coupled to a main shaft of a wind turbine.

31. The bearing of claim 14, further comprising a second seal positioned at an interface between the outer ring and the seal carrier.

32. The bearing of claim 14, wherein the channel has a relaxed or un-compressed width that is the same as or larger than a width of a body portion of the seal.

33. The bearing of claim 14, further comprising an area of increased material thickness on the seal carrier at a location axially aligned with the channel.

34. A bearing comprising:

an inner ring;

a plurality of rolling elements positioned between the inner and outer rings; and a seal interposed between a portion of the annular projection and an end ring that is secured to the annular projection.

35. The bearing of claim 34, wherein the end ring is fastened to a distal end of the annular projection.

36. The bearing of claim 34, wherein the seal is a two-piece seal having a primary seal and a secondary seal.

37. The bearing of claim 34, wherein the seal is a one-piece seal.

38. The bearing of claim 34, wherein the end ring is a one-piece, continuous ring.

39. The bearing of claim 34, wherein the end ring is a segmented ring with two or more segments.

40. The bearing of claim 34, wherein the seal is compressed axially between the end ring and the annular projection when the end ring is secured to the outer ring.

41. The bearing of claim 34, wherein the inner ring includes a sealing surface that the seal engages, and wherein the annular projection axially overlaps with the sealing surface.

42. The bearing of claim 34, wherein the seal is constrained between a radially-extending surface of the annular projection, an axially-extending surface of the annular projection, and an end face of the end ring.

43. The bearing of claim 42, wherein the radially-extending surface of the annular projection and the axially-extending surface of the annular projection together define an annular groove in a radially inner surface of the annular projection.

44. The bearing of claim 34, wherein the seal is constrained between a radially-extending surface of the annular projection, an axially-extending surface of the annular projection, an axially-extending wall portion of the end ring, and a radially-extending wall portion of the end ring.

45. The bearing of claim 34, wherein the end ring and the annular projection include piloting features to facilitate alignment of the end ring with the annular projection.

46. The bearing of claim 34, wherein the end ring includes an annular undercut that receives at least a portion of the seal.

47. The bearing of claim 34, where the end ring includes a plurality of apertures extending therethrough for receiving fasteners that secure the end ring to the annular projection.

48. The bearing of Claim 34, wherein the inner ring is coupled to a main shaft of a wind turbine.

49. The bearing of Claim 34, wherein the end ring has an axially inner end face that abuts the seal and the outer end face.

50. The bearing of Claim 49, wherein the inner and outer end faces are parallel.

51. The nearing of Claim 49, wherein the end ring includes a plurality of apertures extending between the inner and outer end faces for receiving fasteners that secure the end ring to the annular projection.

52. A bearing comprising:

an outer ring;

an inner ring;

a plurality of rolling elements positioned between the inner and outer rings; and a seal disposed axially adjacent the outer ring in a radially -inwardly facing channel of a seal carrier that is secured to the outer ring.

53. The bearing of claim 52, wherein the seal carrier is fastened to a radially-extending surface of the outer ring.

54. The bearing of claim 53, wherein an outer diameter of the seal carrier abuts an axially-extending annular surface of the outer ring.

55. The bearing of claim 52, wherein the seal is a two-piece seal having a primary seal and a secondary seal.

56. The bearing of claim 52, wherein the seal is a one-piece seal.

57. The bearing of claim 52, wherein the seal carrier is a one-piece, continuous ring.

58. The bearing of claim 52, wherein the seal carrier is a segmented ring with two or more segments.

60. The bearing of claim 52, wherein the seal is compressed axially within the channel when installed in the channel.

61. The bearing of claim 52, wherein the inner ring includes a sealing surface that the seal engages, and wherein the seal carrier includes a radially inwardly-extending, finger-shaped projection aligned with a portion of the sealing surface and adjacent the seal.

62. The bearing of claim 60, wherein an axially outward surface of the projection at least partly defines an axially inward surface of the channel.

63. The bearing of claim 52, wherein the seal is constrained between two radially- extending surfaces defining the channel and an axially-extending surface defining the channel.

64. The bearing of claim 52, wherein the inner ring is coupled to a main shaft of a wind turbine.

65. The bearing of claim 52, further comprising a second seal positioned at an interface between the outer ring and the seal carrier.

66. The bearing of claim 52, wherein the channel has a width W, and wherein the width W is smaller than an un-compressed width of a body portion of the seal.