Patents by Inventor Raed Zuhair Hasan
Raed Zuhair Hasan has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11865621Abstract: 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.Type: GrantFiled: June 25, 2019Date of Patent: January 9, 2024Assignee: General Electric CompanyInventors: Hayden McgarityBashiri, Aaron Wertz, Kevin M. Vandevoorde, Raed Zuhair Hasan, Priyangu C. Patel, John P. Davis, Ganesh Raut
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Patent number: 11773963Abstract: 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.Type: GrantFiled: June 29, 2020Date of Patent: October 3, 2023Assignee: General Electric CompanyInventors: Collin McKee Sheppard, Fulton Jose Lopez, Raed Zuhair Hasan, Dhanushkodi Durai Mariappan, Ryan Eric Vogel
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Patent number: 11660671Abstract: 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.Type: GrantFiled: June 21, 2019Date of Patent: May 30, 2023Assignee: General Electric CompanyInventors: Aaron Wertz, Raed Zuhair Hasan, Adam Daniel Minadeo, Souvik Porel, Ganesh Raut, Jeremy Charles Ridge
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Patent number: 11536361Abstract: 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.Type: GrantFiled: March 8, 2018Date of Patent: December 27, 2022Assignee: General Electric CompanyInventors: Raed Zuhair Hasan, Ian David Wilson, Lawrence Keith Taliaferro, Boobalan Ayyasamy
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Patent number: 11333200Abstract: 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.Type: GrantFiled: June 20, 2019Date of Patent: May 17, 2022Assignee: General Electric CompanyInventors: Raed Zuhair Hasan, Adam Daniel Minadeo, John P. Davis, Aaron Wertz, Ganesh Raut, Souvik Porel
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Patent number: 11255313Abstract: 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.Type: GrantFiled: March 26, 2020Date of Patent: February 22, 2022Assignee: General Electric CompanyInventors: Aaron Joseph Wertz, Boobalan Ayyasamy, Hayden Patrick Mcgarity-Bashiri, Martxel Ruiz Luisa, Raed Zuhair Hasan, Fulton Jose Lopez
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Publication number: 20210404548Abstract: 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.Type: ApplicationFiled: June 29, 2020Publication date: December 30, 2021Inventors: Collin McKee Sheppard, Fulton Jose Lopez, Raed Zuhair Hasan, Dhanushkodi Durai Mariappan, Ryan Eric Vogel
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Publication number: 20210270358Abstract: 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.Type: ApplicationFiled: June 25, 2019Publication date: September 2, 2021Inventors: Hayden McgarityBashiri, Aaron Wertz, Kevin M. Vandevoorde, Raed Zuhair Hasan, Priyangu C. Patel, John P. Davis, Ganesh Raut
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Publication number: 20210254667Abstract: 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.Type: ApplicationFiled: June 20, 2019Publication date: August 19, 2021Inventors: Raed Zuhair Hasan, Adam Daniel Minadeo, John P. Davis, Aaron Wertz, Ganesh Raut, Souvik Porel
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Publication number: 20210123418Abstract: 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.Type: ApplicationFiled: June 21, 2019Publication date: April 29, 2021Inventors: Aaron Wertz, Raed Zuhair Hasan, Adam Daniel Minadeo, Souvik Porel, Ganesh Raut, Jeremy Charles Ridge
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Patent number: 10935001Abstract: 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.Type: GrantFiled: November 2, 2017Date of Patent: March 2, 2021Assignee: General Electric CompanyInventors: Raed Zuhair Hasan, Farong Zhu, Lawrence Keith Taliaferro, Jr., Priyangu Chunilal Patel, James Edward Cencula, Edward Lee McGrath
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Publication number: 20200309098Abstract: 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.Type: ApplicationFiled: March 26, 2020Publication date: October 1, 2020Inventors: Aaron Joseph Wertz, Boobalan Ayyasamy, Hayden Patrick Mcgarity-Bashiri, Martxel Ruiz Luisa, Raed Zuhair Hasan, Fulton Jose Lopez
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Publication number: 20200032851Abstract: This system and method is directed to A joint system comprising: a rings system having: a first pair of rings pivotally attached to each other by a first set of rotating housings, the first set of rotating housings being configured to rotate along a first axis and a second pair of rings pivotally attached to each other by a second set of rotating housings, the second set of rotating housings being configured to rotate along a second axis; a first sliding support subassembly configured to slidingly receive a first ring from the rings system; and a second sliding support subassembly configured to slidingly receive a second ring from the rings system; a primary gears system carried by and having a first and second primary gear wherein the first primary gear and the second primary gear are rotatably attached to a central connecting support.Type: ApplicationFiled: October 3, 2019Publication date: January 30, 2020Applicant: Advanced Innovative Solutions, LLCInventors: Haitham Hussein Bilal, Raed Zuhair Hasan
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Patent number: 10495210Abstract: 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.Type: GrantFiled: November 9, 2017Date of Patent: December 3, 2019Assignee: General Electric CompanyInventors: Raed Zuhair Hasan, Kevin M. Vandevoorde, Lawrence Keith Taliaferro, Jr., George Albert Goller, James Edward Cencula
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Patent number: 10473162Abstract: 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.Type: GrantFiled: July 12, 2016Date of Patent: November 12, 2019Assignee: Advanced Innovative Solutions, LLCInventors: Haitham Hussein Bilal, Raed Zuhair Hasan
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Publication number: 20190277393Abstract: 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.Type: ApplicationFiled: March 8, 2018Publication date: September 12, 2019Inventors: Raed Zuhair Hasan, Ian David Wilson, Lawrence Keith Taliaferro, Boobalan Ayyasamy
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Patent number: 10330174Abstract: 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.Type: GrantFiled: November 9, 2017Date of Patent: June 25, 2019Assignee: General Electric CompanyInventors: Jacob Johannes Nies, Matteo Bellucci, Kevin M. Vandevoorde, Raed Zuhair Hasan, John P. Davis, Aaron Joseph Wertz
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Publication number: 20190136962Abstract: 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.Type: ApplicationFiled: November 9, 2017Publication date: May 9, 2019Inventors: Raed Zuhair Hasan, Kevin M. Vandevoorde, Lawrence Keith Taliaferro, JR., George Albert Goller, James Edward Cencula
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Publication number: 20190136945Abstract: 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.Type: ApplicationFiled: November 9, 2017Publication date: May 9, 2019Inventors: Jacob Johannes Nies, Matteo Bellucci, Kevin M. Vandevoorde, Raed Zuhair Hasan, John P. Davis, Aaron Joseph Wertz
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Publication number: 20190128243Abstract: 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.Type: ApplicationFiled: November 2, 2017Publication date: May 2, 2019Inventors: Raed Zuhair Hasan, Farong Zhu, Lawrence Keith Taliaferro, JR., Priyangu Chunilal Patel, James Edward Cencula, Edward Lee McGrath