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

A gear system for a wind turbine power system, comprising:

• a carrier comprising a first portion and a separate, second portion;
• a plurality of pin shafts extending from the first portion of the carrier, each of the plurality of pin shafts comprising a first end and a second end, the first ends integrally formed with the first portion of the carrier, the first and second portions arranged on opposing sides of the plurality of pin shafts and being spaced apart such that the first and second portions do not contact each other, the second portion of the carrier defining an end plate that is secured to the second ends of the plurality of pin shafts, the end plate comprising a plurality of shaft holes, each of the plurality of shaft holes configured to receive one of the plurality of pin shafts, the end plate defining a shape that comprises an annular base portion having an inner diameter and an outer diameter, the inner diameter defining a central aperture, the plurality of shaft holes being arranged circumferentially around the central aperture at an edge of the annular base portion, wherein outer diameters of each of the plurality of shaft holes extends beyond the outer diameter of the annular base portion;
• and
• a plurality of gears mounted to the plurality of pin shafts, each of the plurality of gears arranged so as to rotate around one of the plurality of pin shafts,
• wherein the gear system is oriented such that the first portion of the carrier is positioned on a rotor-side of the wind turbine power system and the second portion of the carrier is positioned on a generator-side of the wind turbine power system,
• wherein a design of the gear system is optimized based on one or more design variables input to a computer-implemented loads model of the gear system so as to minimize mass thereof, wherein the one or more design variables comprises at least one of the outer diameter of the first portion of the carrier, an inner diameter of each of the plurality of pin shafts, the outer diameters of each of the plurality of shaft holes, an outer diameter of the annular base portion, a thickness of the first portion of the carrier, a thickness of each of the plurality of shaft holes, or a thickness of the annular base portion.