AU2019240735B2

AU2019240735B2 - Generator assembly

Info

Publication number: AU2019240735B2
Application number: AU2019240735A
Authority: AU
Inventors: Mark Vincent Keogh
Original assignee: LAA Industries Pty Ltd
Current assignee: LAA Industries Pty Ltd
Priority date: 2014-09-09
Filing date: 2019-10-07
Publication date: 2020-12-03
Anticipated expiration: 2035-09-08
Also published as: AU2015224409A1; AU2019240735A1

Abstract

A generator assembly 20 is housed within a 40 foot shipping container 100. The shipping container 100 is a purpose built structure and has configuration and construction certification, which allows it to be transported fully as a sea container. The shipping container 100 comprises a bottom wall 102, a top wall 104, a side wall 106, an opposite side wall 108, a first end wall 110, a second end wall 112 and an internal space 114. Components of the generator assembly 20 are disposed within the internal space 114. The present invention relates to a layout of the components of the generator assembly 20 within the housing container 100 which provides specific advantages compared to existing layouts for installation and maintenance. The layout is designed to operate at high temperatures of 45°C to 50°C ambient temperature in contrast to OEM manufactured generator sets that are built to a 28°C ambient ISO condition. The generator assembly 20 in the embodiment is rated to produce 2000 KVA of power Prime rating. 1/7 LO{) S2 v. ~ to' FIGURE 1

Description

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FIGURE 1

GENERATOR ASSEMBLY

Field of the Invention

[1] The present invention relates to a generator assembly.

Background of the Invention

[2] The present invention seeks to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[3] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the Invention

[4] According to a first aspect, the present invention provides a generator assembly comprising:

a housing comprising a bottom wall, side walls, a first end wall, a second end wall, and a top wall defining an internal space;

generator components disposed within the internal space comprising an engine coupled to an alternator for generating electrical energy, an engine silencer assembly, and an engine cooling assembly;

wherein one or more of the side walls comprise apertures for entry of air into the internal space and the top wall comprises apertures for exit of air for the engine silencer assembly and the engine cooling assembly,

the cooling assembly comprising radiators disposed adjacent and extending along opposing side walls of the housing, and at least one radiator cooling fan disposed to extend adjacent and across the top wall and between the radiators, and

wherein the side walls comprise louver doors extending across the engine cooling assembly which allow fresh air flow across the radiators, the louver doors being pivotably openable to allow access into the engine cooling assembly for service and maintenance, and hot air can then be discharged via the radiator fans upwardly from the top wall.

[5] In one embodiment, the housing is formed as a shipping container.

[6] In another embodiment, the top wall comprises exit apertures for the engine silencer assembly and the engine cooling assembly.

[7] In another embodiment, the side walls comprise a front wall, a rear wall, a first end wall, and a second end wall.

[8] In another embodiment, the internal space comprises an engine compartment, a silencer assembly compartment, and an engine cooling assembly compartment.

[9] In another embodiment, the generator assembly further comprises one or more air filters disposed adjacent the top wall of the housing.

[10] In another embodiment, the generator assembly further comprises respective air intake tubes extending from the air filters to the engine intake, the air intake tubes at least partially extending adjacent the top wall.

[11] In another embodiment, the generator assembly further comprises a fuel tank and an oil tank, both the fuel tank and the oil tank comprising a respective sight glass disposed adjacent a wall of the housing.

[12] In another embodiment, the generator assembly further comprises a battery tray configured as a step platform.

[13] In another embodiment, the silencer assembly outlet is directed towards an aperture in the top wall.

[14] In another embodiment, the cooling assembly comprises radiators disposed adjacent and extending partly along side walls of the housing.

[15] In another embodiment, the radiators are disposed along opposing side walls of the housing

[16] In another embodiment, the cooling assembly comprises at least one fuel cooler radiator.

[17] In another embodiment, the cooling assembly comprises at least one radiator cooling fan disposed to extend adjacent and across the top wall, and between the radiators.

[18] In another embodiment, the top wall comprises panels having apertures for the silencer assembly and the cooling assembly.

[19] In another embodiment, the side walls comprise louver doors.

[20] In another embodiment, the front wall comprises a respective door for each compartment.

[21] In another embodiment, the rear wall comprises a respective door for each compartment.

[22] In another embodiment, the end walls comprise a respective door.

[23] In another embodiment, the doors are louver doors.

[24] In another embodiment, the side walls comprise socket fittings connected to components for servicing and maintenance of the components

[25] Other aspects of the invention are also disclosed.

Brief Description of the Drawings

[26] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings in which:

[27] Fig. 1 is an isometric projection of a generator assembly in accordance with a preferred embodiment of the present invention, with cover panels of the generator assembly not shown for illustration purposes;

[28] Fig. 2 is an opposite isometric projection of the generator assembly of Figure 1;

[29] Fig. 3 is a top view of the generator assembly of Figure 1 with the cover panels shown;

[30] Fig. 4 is a side view of the generator assembly of Figure 3;

[31] Fig. 5 is an opposite side view of the generator assembly of Figure 3;

[32] Fig. 6 shows (a) first end view and (b) second end view of the generator assembly of Figure 3;

[33] Fig. 7 is a front cross-section of a generator assembly in accordance with a second preferred embodiment of the present invention;

[34] Fig. 8 is a mid-cross-section view of the generator assembly of Figure 7;

[35] Fig. 9 shows (a) first end cross-section view and (b) second end cross-section view of the generator assembly of Figure 7;

[36] Fig. 10 is a top view of the generator assembly of Figure 7;

[37] Fig. 11 shows (a) front view, (b) rear view, (c) second end view and (d) first end view of the generator assembly of Figure 7.

Description of Embodiments

[38] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

[39] Figures 1 to 6 show a generator assembly 20 in accordance with a first preferred embodiment of the present invention. The generator assembly 20 is housed within a 40 foot shipping container 100. The shipping container 100 is a purpose built structure and has configuration and construction certification, which allows it to be transported fully as a sea container.

[40] The shipping container 100 is a hollow rectangular prism housing comprising a bottom wall 102, a top wall 104, a side wall 106, an opposite side wall 108, a first end wall 110, a second end wall 112 and an internal space 114. Components of the generator assembly 20 are disposed within the internal space 114.

[41] The generator assembly 20 comprises a combination of an engine (typically a diesel engine) coupled to an electric generator (often an alternator) to generate electrical energy. The packaged combination is referred to as a "generating set" or a "genset". Generating sets are used in places without connection to the power grid or as emergency power-supply if the grid fails. The present invention relates to a layout of the components of the generator assembly 20 within the housing container 100 which provides specific advantages compared to existing layouts for installation and maintenance. The layout is designed to operate at high temperatures of 45°C to 50°C ambient temperature in contrast to OEM manufactured generator sets that are built to a 28°C ambient ISO condition. The generator assembly 20 in the embodiment is rated to produce 2000 KVA of power Prime rating.

[42] Referring initially to Figures 1 and 2, the generator assembly 20 comprises an engine 22, an alternator 24, air filters 26, fuel tank 28, a silencer assembly 30, and an engine cooling assembly 32.

[43] The silencer assembly 30 is disposed adjacent the engine 22 towards the first end wall 110 side thereof, with the engine cooling assembly 32 disposed between the silencer assembly 30 and the first end wall 110. A first divider wall 140 is disposed between the engine 22 and the silencer assembly 30. A second divider wall 142 is disposed between the silencer assembly 30 and the engine cooling assembly 32. An engine compartment 173 is defined between the second end wall 112 and the first divider wall 140, a silencer assembly compartment 175 is defined between the first and second divider walls 140 and 142, and an engine cooling assembly compartment 177 is defined between the second divider wall 142 and the first end wall 110.

[44] Components in the engine compartment 173 will be first described. The engine 22 is disposed at a central portion of the housing 100, which in the embodiment is a Cummins QSK60-G4 engine. It is to be understood that other suitable prime movers can also be used. The engine 22 is coupled to the alternator 24, and both are mounted above a skid 25. The set of air filters 26 are disposed above the alternator 24. The air filters 26 are mounted to a bracket 27 which extends between the front and rear walls of the housing 100 and adjacent the top wall 104. Respective air intake tubes 42 extend from the air filters 26 to the engine intake. The air intake tubes 42 at least partially extend adjacent the top wall 104.

[45] The fuel tank 28 is a hollow rectangular prism tank and is mounted to the bottom wall 102 and adjacent the second end wall 112. The fuel tank 28 is a 1150 L fuel tank and comprises a sight glass 44 for monitoring the level of fluid therein. The sight glass 44 is adjacent and faces the opposite side wall 108.

[46] The generator assembly 20 also comprises an oil tank 46 which is mounted to an oil tank mounting skid 48 adjacent the fuel tank 28. The skid 48 mounts the oil tank 46 at an elevated level above the bottom wall 102. The oil tank 46 comprises an oil sight glass 50 and a hand pump 52 for filling, which both face the side wall 106.

[47] The generator assembly 20 further comprises a battery tray 54 mounted to the bottom wall 102 and adjacent the oil tank mounting skid 48. The battery tray 54 extends across from the side wall 106 to the opposite side wall 108, and also functions as a platform for maintenance personnel for servicing the air filters 26. The generator assembly 20 further comprises a battery isolator 62 and distribution box and battery charger 64 disposed adjacent to the side wall 106. Light fittings 82, being LED light fittings, are mounted to the top wall 104 for the area above the oil tank 46 and fuel tank 28.

[48] Below the engine 22 and adjacent the side wall 106 are disposed a coolant heater 68 and a hand pump 70 for oil evacuation. The coolant heater 68 is mounted onto a mounting plate and extends across to adjacent the opposite side wall 108. Below the engine 22 and adjacent the opposite side wall 108 are disposed an engine control unit (ECU) box 84 and a fuel filter 86 (a Racor filter) mounted onto a mounting plate. The ECU box 84 also provides customer interface terminals. Light fittings 92 are mounted to the front and rear walls 106 and 108 adjacent the top wall 104, for lighting this section.

[49] The silencer assembly 30 comprises a silencer (muffler) 120 mounted to a mounting plate 121. Exhaust pipes 122 extend from the engine 22 to the silencer 120. The silencer assembly 30 includes an outlet covered by a pivotable silencer rain cap 124.

[50] The cooling assembly 32 comprises four radiators 150, two of which are disposed adjacent and extending partly along the side wall 106, and two of which extend adjacent and partly along the opposite side wall 108. Also extending adjacent and partly along the opposite side wall 108 are two fuel cooler radiators 152. The cooling assembly 32 further includes two radiator cooling fans 154 which are disposed to extend adjacent and across the top wall 104, and between the sets of radiators 150 and 152. Light fittings 156 are provided for lighting this section. The cooling assembly 32 further includes gauges 158 mounted adjacent the junction between the side wall 106 and the top wall 104.

[51] Referring to Figures 3 to 6, the housing 100 of the generator assembly 20 comprises a number of features which provide installation, servicing and maintenance advantages. The configuration is designed to operate at temperatures of up to 50°C ambient and has a noise level of 80 DBA at 1 meter (no load free field condition) due to the configuration and layout of the assembly.

[52] The top wall 104 comprises a first top plate 170 adjacent the first end 110 which covers the engine cooling assembly compartment 177. The radiator cooling fans 154 are installed in the first top plate 170, and the first top plate 170 further comprises water filling aperture points 171 for the radiators. The top wall 104 further comprises a second top plate 172 which covers the silencer assembly compartment 175. The second top plate 172 comprises mesh panels and an aperture for discharge of hot air from the silencer 120. The top wall 104 further comprises a generally solid third top plate 174 which covers the engine compartment 173. The third top plate 174 comprises two central detachable container roof sections 179 for engine assembly and installation. Roof hand grips 181 are also provided for access.

[53] The side wall 106 comprises louver doors 184 extending across the engine cooling assembly 177. The louver doors 184 allow fresh air flow into the engine cooling assembly 177 across the radiators 150. The louver doors 184 are also pivotably openable to allow access into the engine cooling assembly 177 for service and maintenance. The louver doors 184 comprise openings for the gauges 158.

[54] The side wall 106 further includes a silencer compartment door 186 for silencer service. The side wall 106 further comprises four doors 190 and an access cover 192 for providing access to the engine compartment and the components thereof, such as the oil sight glass 50, hand pump 52, distribution box 64 and for installation and servicing of the engine fans. Light fittings 194 are provided across the side wall 106, as well as socket fittings 196, being socket fitting 196a for fuel drain, socket fitting 196b for bunding drain, socket fitting 196c for fuel tank fill, socket fitting 196d for bunding drain, socket fitting 196e for tank drain and socket fitting 196e for oil drain. The side wall 106 further includes an earthing point 198 and an emergency stop button 200 at a central portion thereof. Sections of the side wall 106 adjacent the doors 190 are provided as louver sections to allow fresh air into the engine compartment 173.

[55] The opposite side wall 108 is similar to the side wall 106 and comprises louver doors 204 extending across the engine cooling assembly 177. The louver doors 204 allow fresh air flow into the engine cooling assembly 177 across the radiators 150 and 152. The louver doors 204 are also pivotably openable to allow access into the engine cooling assembly 177 for service and maintenance.

[56] The opposite side wall 108 also further includes a silencer compartment door 206 for silencer installation and service. The opposite side wall 108 further comprises two doors 210 for providing access to the engine compartment and the components thereof, and a control panel box 212 which provides access to the ECU box 84. Light fittings 214 are provided across the opposite side wall 108, as well as socket fittings 216, being spare socket fittings. The opposite side wall 108 further includes an earthing point 218 and an emergency stop button 220 at a central portion thereof. Adjacent the second end wall 112, the opposite side wall 108 includes a window 222 for the fuel tank sight glass 44, and a manual external fuel filler box 224. Sections of the opposite side wall 108 adjacent the control panel box 212 are provided as louver sections to allow fresh air into the engine compartment 173.

[57] The first end wall 110 comprises a panel door 230 which is pivotably openable to provide access to the engine cooling assembly compartment 177. The panel door 230 can also be modified to be louver doors. The first end wall 110 further includes two drain sockets 232 and two spare sockets 234.

[58] The second end wall 112 similarly comprises a panel door 238 which is pivotably openable to provide access to the engine compartment 173. The panel door 238 comprises louver sections to allow fresh air intake.

[59] Referring to Figures 3 to 5, in use, fresh air (as indicated by arrows 240) can enter through the doors 184 and 204 for the radiators in the engine cooling assembly compartment 177. Fresh air (as indicated by arrows 242) can also enter through the doors 252 and the louver sections of the front and rear walls 106 and 108 and into the engine compartment 173. Hot air can then be discharged via the silencer exhaust outlet and the radiator fans 154 as indicated by arrows 244 upwardly from the top wall. It can be seen that fresh air generally enters the housing via the side and end walls and exits via the top wall. This assists in providing a consistent stream of cooling air into the housing.

[60] The housing 100 is a shipping container having container corners 101 and provides the various structural advantages of a shipping container, such as rigidity, stackability and ease of handling, transport and shipping due to its standard size and the container corners 101. The housing 100 is a purpose built housing which is certified to be transported as a shipping container, in contrast to other OEM manufactured generator sets which are only modified shipping containers.

[61] The present invention thus provides a layout and access doors at which components of the generator assembly 20 can be easily accessed and serviced. The housing 100 also provides various external features which allows checking, servicing and/or maintenance to be performed without having to open any of the access doors.

[62] Figures 7 to 11 show a generator assembly 320 in accordance with a second preferred embodiment of the present invention. The generator assembly 320 has similar components as the generator assembly 20, and similar parts are referred to with similar reference numerals. The generator assembly 320 is housed within a 20 foot shipping container 400. The generator assembly 320 in the embodiment is rated to produce 1250 KVA of power.

[63] The shipping container 400 is a hollow rectangular prism housing comprising a bottom wall 102, a top wall 104, a side wall 106, an opposite side wall 108, a first end wall 110, a second end wall 112 and an internal space 114. Components of the generator assembly 20 are disposed within the internal space 114.

[64] The generator assembly 320 comprises an engine 22, an alternator 24, air filters 26, fuel tank 28, a silencer assembly 30, and an engine cooling assembly 32.

[65] The engine 22 is disposed at a central portion of the housing 100. The engine 22 is coupled to the alternator 24, and both are mounted above a skid 25. The set of air filters 26 are disposed above the alternator 24 and below the silencer assembly 30 the air filters being connected to apertures 29 formed in the top wall 104. Respective air intake tubes 42 extend from the air filters 26 to the engine intake. The fuel tank 28 is mounted to the bottom wall 102 and close to the first end wall 110.

[66] The silencer assembly 30 comprises a silencer (muffler) 120 mounted to a silencer housing 121. Exhaust pipes 122 extend from the engine 22 to the silencers 120.

[67] The cooling assembly 32 comprises a remote radiator 150 disposed adjacent and extending across the first end wall 110. The cooling assembly 32 further includes two radiator cooling fans 154 which are disposed to extend adjacent and across the top wall 104, and adjacent the radiator 150. The use of a remote radiator provides advantages for the purpose of the assembly.

[68] The housing 100 of the generator assembly 320 comprises a number of features which provide installation, servicing and maintenance advantages. The configuration and layout of the components of the generator assembly allow operation of the generator assembly in ambient temperatures of up to 50°C.

[69] The radiator cooling fans 154 are installed in the top wall 104, and the top wall further comprises louver openings 169.

[70] The side wall 106 comprises louver panels 184, access doors 190 and a control panel box 212 for providing access to the internal space 114. Light fittings 194 are provided across the side wall 106, as well as socket fittings 196. The side wall 106 further includes an emergency stop button 200 at a central portion thereof and a manual external fuel filler box 224.

[71] The opposite side wall 108 is similar to the side wall 106 and comprises louver panels and four access doors 210 for providing access to the internal space 114. Light fittings 214 are provided across the opposite side wall 108, as well as socket fittings 216. The opposite side wall 108 further includes an emergency stop button 220 at a central portion thereof. Sections of the opposite side wall 108 are provided as louver sections to allow fresh air into the internalspace 114.

[72] The first end wall 110 comprises a panel door 230 which is pivotably openable. The second end wall 112 comprises two panel doors 238 which is pivotably openable to provide access.

[73] The present generator assemblies have been designed to operate at temperatures of up to 50°C ambient temperature. They are also designed to be mobilised quickly worldwide to provide power in isolated areas and areas that require reliable power. the components that make up the units are modular and can be used across a range of generator configurations.

[74] A feature of the preferred embodiments is that all of the major components of the generator assemblies are designed to allow drop in and final connection assembly substantially without interference from other components, thus providing quicker assembly of the generator assembly.

[75] Drop in and connect components include:

• Roof fans 154

• Engine compartment fans

• Radiators 150

• main CB cabinet complete with termination buss bars for outgoing feeders

• Main control panel 212

• Fuel tank 28

• Engine/Alt assembly 22/24

• Exhaust system 30

[76] The layout of the generator assemblies, which places these components adjacent an openable wall of the housing, provides the drop in and final connection feature.

[77] Whilst preferred embodiments of the present invention have been described, it will be apparent to skilled persons that modifications can be made to the embodiments described.

Claims

Claims The claims defining the invention are as follows:

1. A generator assembly comprising:

wherein one or more of the side walls comprise apertures for entry of air into the internal space and the top wall comprises apertures for exit of airforthe engine silencer assembly and the engine cooling assembly,

2. The generator assembly of claim 1 wherein the housing is formed as a shipping container.

3. The generator assembly of claim 1 wherein the internal space comprises an engine compartment, a silencer assembly compartment, and an engine cooling assembly compartment.

4. The generator assembly of claim 1 further comprising one or more air filters disposed adjacent the top wall of the housing.

5. The generator assembly of claim 4 further comprising respective air intake tubes extending from the air filters to the engine intake, the air intake tubes at least partially extending adjacent the top wall.

6. The generator assembly of claim 1 further comprising a fuel tank and an oil tank, both the fuel tank and the oil tank comprising a respective sight glass disposed adjacent a wall of the housing.

7. The generator assembly of claim 1 further comprising a battery tray configured as a step platform.

8. The generator assembly of claim 1 wherein the silencer assembly outlet is directed towards an aperture in the top wall.

9. The generator assembly of claim 1 wherein the cooling assembly comprises at least one fuel cooler radiator.

10. The generator assembly of claim 1 wherein the top wall comprises panels having apertures for the silencer assembly and the cooling assembly.

11. The generator assembly of claim 3 wherein the side walls comprises a respective door for each compartment.

12. The generator assembly of claim 1 wherein the end walls comprise a respective door.

13. The generator assembly of any one of claims 11 to 12 wherein the doors are louver doors.

14. The generator assembly of claim 1 wherein the side walls comprise socket fittings connected to components for servicing and maintenance of the components.