GB2539699B

GB2539699B - An air intake system routed within the base of the engine and generator assembly it supplies

Info

Publication number: GB2539699B
Application number: GB1511214.7A
Authority: GB
Inventors: Stellwagen Karl; H Luft Markus; Ante Jonjic; W Vormstein Holger
Original assignee: Caterpillar Energy Solutions GmbH
Current assignee: Caterpillar Energy Solutions GmbH
Priority date: 2015-06-25
Filing date: 2015-06-25
Publication date: 2019-08-28
Anticipated expiration: 2035-06-25
Also published as: GB2539699A; GB201511214D0

Description

AN AIR INTAKE SYSTEM ROUTED WITHIN THE BASE OF THE ENGINE AND GENERATOR ASSEMBLY IT SUPPLIES

Technical Field [0001] The present disclosure relates generally to a generator system. More specifically, the present disclosure relates to an efficiently assembled and integrated air intake system for the generator system.

Background [0002] Various generator systems include engines, such as gas engines, which are commonly known to employ an air intake system to supply a compressed combustible mixture to an intake manifold of an engine. The generator system generally includes a turbocharger and an aftercooler mounted on a base frame of the engine. The turbocharger includes a turbine end and a compressor end. As is customarily known, the turbocharger receives and compresses a combustible mixture. The aftercooler is disposed downstream of the compressor end of the turbocharger. The aftercooler receives the compressed combustible mixture from the compressor end of the turbocharger. The aftercooler then cools the compressed air fuel-mixture and supplies the cooler compressed combustible mixture to the intake manifold of the engine, via a known charge distribution system.

In conventional intake systems, the base frame and/or the engine may be provided with appropriate tubes and pipes for delivery of intake air to the engine. Due to packaging constraints, such arrangements, which may contain a number of air intake tubes or pipes, may increase the complexity and bulkiness of conventional intake systems. In addition, to service the engine, the tubes and the pipes may be required to be removed, prior to the associated service procedure. This makes engine service a cumbersome task. Moreover, this arrangement may require more space and need additional structural components for supporting the tubes and pipes. Hence, there is a need for an intake system that limits the number of air intake tubes, to reduce the manufacturing cost and provide efficient serviceability.

Summary of the Invention [0004] Various aspects of the present disclosure are directed towards air intake system for an engine and a generator module. The engine includes a turbocharger. The air intake system includes a base frame assembly, at least one conduit, and a supply conduit. The base frame assembly is sized to extend along a length of the engine and the generator module. The base frame assembly spans a width of the engine and the generator module. The engine and the generator module are mounted to the base frame assembly. The at least one conduit includes an inlet and an outlet. The at least one conduit is enclosed within the base frame assembly and extends substantially along the length of an edge portion of the base frame assembly. The supply conduit is positioned between the at least one conduit and the turbocharger. The supply conduit is in fluid communication with the at least one conduit and the turbocharger. The supply conduit includes a first portion and a second portion. The first portion is coupled to the outlet of the at least one conduit. The second portion is coupled to the turbocharger.

Brief Description of the Drawings [0005] FIG. lisa schematic of an exemplary generator system that illustrates an engine and a generator module of the generator system, in accordance with the concepts of the present disclosure; [0006] FIG. 2 is a schematic of the exemplary generator system of FIG. 1, illustrating a sectional view of an air intake system of the engine of the generator system, in accordance with the concepts of the present disclosure; [0007] FIG. 3 is a pictorial view of the air intake system of FIG. 2, illustrating a portion of the base frame assembly sectioned, a conduit, and a supply conduit, in accordance with the concepts of the present disclosure; and [0008] FIG. 4 is an exploded view of the supply conduit of FIG. 3, depicted in conjunction with a portion of the conduit of FIG. 3.

Detailed Description [0009] Referring to FIG. 1, there is shown a generator system 10 that is adapted to produce electrical power to run one or more electrically operated machines (not shown). The generator system 10 may be a stationary unit, although mobile units may be envisioned. The electrically operated machine (not shown) may include electrical drives, industrial drive motor, or electrically operated cranes, and varied applications associated with construction machinery.

[0010] The generator system 10 may be installed in an operating location via a plurality of stationing leg members 12. The generator system 10 commonly includes an internal combustion engine 14, a generator module 16, and an air intake system 18. For ease in reference, the internal combustion engine 14 will be referred to as the engine 14, interchangeably hereinafter. The generator system 10 may also include a fuel intake system (not shown) for supply of fuel to mix with the air to form the combustible mixture.

[0011] The engine 14 may be a gaseous fuel engine that includes one or more cylinders (not shown), a turbocharger 20, and an aftercooler 22. The cylinders (not shown) include a combustion chamber where the compressed combustible mixture is combusted to produce mechanical power. The engine 14 is drivingly coupled to the generator module 16. This is enabled by use of a crankshaft (not shown) of the engine 14 that is engaged to a rotor shaft (not shown) of the generator module 16 via an adapter assembly (not shown). The generator module 16 is adapted to receive mechanical power from the engine 14, convert the mechanical power into electrical energy, and supply the electrical energy to the electrically operated machine (not shown).

[0012] The turbocharger 20 includes a mixture inlet 24, compressor side (not shown), a mixture outlet 26, and a turbine side (not shown). The compressor side (not shown) and the turbine side (not shown) are mechanically coupled to each other. The turbocharger 20 may be a positive displacement air-compressor such that the turbine side (not shown) of the turbocharger 20 utilizes a portion of kinetic energy from exhaust gases, transmitted to the compressor side (not shown) of the turbocharger 20 to compress the combustible mixture. The compressor side (not shown) is located downstream of the mixture inlet 24 and is in fluid communication with the mixture inlet 24. The compressor side (not shown) is located upstream of the mixture outlet 26 and hence, is in fluid communication with the mixture outlet 26. Further, the mixture inlet 24 is in fluid communication with the air intake system 18 and the fuel intake system (not shown). The mixture outlet 26 is in fluid communication with the aftercooler 22. The combustible mixture from the air intake system 18 is compressed and pumped by the turbocharger 20, and supplied to the aftercooler 22.

[0013] The aftercooler 22 is fluidly connected to the turbocharger 20 via the mixture outlet 26, as noted. The aftercooler 22 is disposed downstream to the turbocharger 20 in the mixture flow direction, depicted by flow arrow 28. In that manner, the aftercooler 22 is adapted to receive the hot compressed combustible mixture from the compressor side (not shown) of the turbocharger 20. The aftercooler 22 may include a number of cooling chambers (not shown) adapted to cool the inflow of the compressed combustible mixture, to improve operational efficiency of the engine 14. The depicted assembly of the turbocharger 20 with the aftercooler 22 is exemplary in nature.

[0014] Referring to FIGS. 1 and 2, the air intake system 18 supplies the cooler compressed combustible mixture to the cylinders (not shown), via the turbocharger 20 and the aftercooler 22. In further detail, the air intake system 18 facilitates intake of the air into the generator system 10. Downstream, this supply of air is enriched with fuel. A resulting supply of combustible mixture is directed towards an inlet of compressor side (not shown) of the turbocharger 20, since there exists fluid communication of the air intake system 18 with the turbocharger 20. As a result, a compressed combustible mixture is formed which is delivered to each cylinder (not shown) via the aftercooler 22. The air intake system 18 of the engine 14 includes a base frame assembly 30, a conduit 32, and a supply conduit 34.

[0015] The base frame assembly 30 is of such a size that it extends along a length of the engine 14 and the generator module 16. Further, the base frame assembly 30 is also structured to span a width ‘W of the engine 14 and the generator module 16. Such a configuration helps mounting of the engine 14 and the generator module 16 to the base frame assembly 30. The base frame assembly 30 includes a first wing 36 and a second wing 38, which are connected via a base portion 40. Each of the first wing 36 and the second wing 38 includes a hollow enclosure 42.

[0016] The first wing 36 of the base frame assembly 30 includes a first end face 44, a second end face 46, a bottom edge 48, a top edge 50, and one or more ribs 52. FIG. 3 shows a schematic of the structure of the first wing 36 of the base frame assembly 30. The first end face 44 is exposed to an ambient environment 54. The bottom edge 48 portion is defined between the first end face 44 (FIG. 1) and the second end face 46. The bottom edge 48 is proximal to the stationing leg members 12 of the generator system 10. Similarly, the top edge 50 is defined between the first end face 44 (FIG. 1) and the second end face 46. The top edge 50 extends substantially parallely to the bottom edge 48. The top edge 50 is structured with appropriate width and length to mount onto the engine 14 (FIG. 1) and the generator module 16 (FIG. 1). Further, the first wing 36 of the base frame assembly 30 also includes the ribs 52, which are housed inside the hollow enclosure 42 of the base frame assembly 30. The ribs 52 are generally vertical members attached between the top edge 50 and the bottom edge 48. This arrangement provides rigidity and robustness to a structure to the base frame assembly 30. Each rib 52 includes multiple holes 56, and each hole 56 is similar in dimension to the other. In an embodiment, the second wing 38 (FIG. 1) is similar to the first wing 36, in structure and arrangement. When deployed along the length of the base frame assembly 30, the holes 56 facilitate formation of a co-axially deployed passage, or the conduit 32 that extends from the first end face 44 (FIG. 1) to the second end face 46. The first wing 36 and second wing 38 (FIG. 1) may be made up of a single rectangular channel or multiple rectangular channels welded together, as customarily known in the art.

[0017] The conduit 32 is housed in the first wing 36 of the base frame assembly 30. The conduit 32 is a hollow and cylindrical member. The conduit 32 is enclosed in the base frame assembly 30 and is substantially extended along a length of the bottom edge 48 of the base frame assembly 30, that is, between the first end face 44 and the second end face 46. The conduit 32 is disposed adjacent to the bottom edge 48 and is aligned nearly parallel to the bottom edge 48. The conduit 32 is held in position in the first wing 36, by placement in the one or more holes 56 of the ribs 52. The dimension of the one or more holes 56 is determined by the diameter of the conduit 32. The conduit 32 may be a single tube, or multiple cylindrical pieces welded together. The conduit 32 may be manufactured by extrusion or rolling, and may be welded along the seam, as ordinarily known in the art.

[0018] The conduit 32 includes an inlet 58 (FIG. 1) and an outlet 60. The inlet 58 (FIG. 1) is positioned at the first end face 44 of the base frame assembly 30. The inlet 58 (FIG. 1) is exposed to the external environment, to facilitate entry of air as shown by arrow 62 (FIG. 1). The outlet 60 is positioned at the second end face 46. Referring to FIG. 3 and FIG. 4, the outlet 60 is attached to the supply conduit 34, via a first sealing member 64, which is commonly known in the art. In an embodiment, there may be more than one first sealing member for attachment of the outlet 60 with the supply conduit 34. The air, which enters in the conduit 32 via the inlet 58, flows to the supply conduit 34 via the outlet 60, as depicted by arrow 66 (FIG. 1). In an embodiment, an auxiliary conduit may be positioned in the second wing 38, to meet the air intake demands of the generator system 10. In another embodiment, the conduit 32 and the supply conduit 34 may be joined via bolted joint flanges.

[0019] The supply conduit 34 is positioned between the conduit 32 and the turbocharger 20. In the present embodiment, the supply conduit 34 includes a first portion 68, an intermediate portion 70, and a second portion 72. The conduit 32 is fluidly connected to the first portion 68, which in turn, is in fluid communication with the intermediate portion 70. The intermediate portion 70 is fluidly connected to the second portion 72.

[0020] Referring to FIG. 4, an arrangement between the conduit 32 and the supply conduit 34 may be better understood. Moreover, the depiction shows an exploded view of the supply conduit 34 in relation to an associated extension from the conduit 32 and the air intake system 18. The conduit 32 is attached to the first portion 68, which is elbow-shaped in structure and includes a first end 74 and a second end 76. The first end 74 is fluidly connected to the outlet 60 of the conduit 32. Connection between the first end 74 and the outlet 60 is secured via the first sealing member 64, as mentioned above. The first portion 68 is in fluid communication with the intermediate portion 70, via the second end 76.

[0021] The intermediate portion 70 is frustoconical in shape. The intermediate portion 70 includes a first end 78, a second end 80, and a fuel inlet 82. The first end 78 is fluidly connected to the second end 76 of the first portion 68. A second sealing member 84 secures the connection between the first end 78 of the first portion 68 and the second end 76 of the intermediate portion 70. The fuel inlet 82 disposed in a lateral wall 86, is defined between the first end 78 and the second end 80. The fuel inlet 82 is further connected to the fuel intake system (not shown). The intermediate portion 70 is in fluid communication with the second portion 72, via the second end 80.

[0022] The second portion 72 is elbow-shaped in structure and includes a first end 88 and a second end 90. The first end 88 of the second portion 72 is attached to the second end 80 of the intermediate portion 70. The first end 88 and the second end 80 are secured together via a third sealing member 92. The second end 90 is fluidly connected to the mixture inlet 24 (FIG. 1) of the turbocharger 20 (FIG. 1). This establishes fluid communication between the second portion 72 of the supply conduit 34 and the turbocharger 20 (FIG. 1). The supply conduit 34, in conjunction with the fuel inlet 82, is able to supply the combustible mixture to the turbocharger 20 (FIG. 1), via the mixture inlet 24. In an embodiment, the structure, shape, and dimensions of the first portion 68, the intermediate portion 70, and/or the second portion 72 may vary for different designs and configurations, without departing from the scope of the present disclosure. In another embodiment, the first portion 68, the intermediate portion 70, and/or the second portion 72 may be formed as a single piece casting, or may be joined together by bolted flange type joint, or welded together.

Industrial Applicability [0023] In operation, the air intake system 18 is operational when ambient air enters the conduit 32, via the inlet 58. The conduit 32 is in fluid communication with the supply conduit 34 and delivers ambient air to the supply conduit 34, via the outlet 60. Ambient air, which enters the supply conduit 34, mixes with the fuel that entered the supply conduit 34, via the fuel inlet 82. This results in formation of the combustible mixture in the supply conduit 34. Simultaneously, the exhaust gases from the engine 14 are routed and delivered to the turbine side (not shown) of the turbocharger 20. As the exhaust gases pass through the turbine side (not shown) of the turbocharger 20, the compressor side (not shown) of the turbocharger 20 is operated and the combustible mixture is sucked from the supply conduit 34 of the air intake system 18 into the turbocharger 20. Thereafter, the turbocharger 20 compresses the combustible mixture and supplies the compressed combustible mixture to the aftercooler 22 in the mixture flow direction (depicted by flow arrow 28). While the compressed combustible mixture flows through the aftercooler 22, the compressed combustible mixture is cooled and directed to the one or more cylinders (not shown) of the engine 14. [0024] The proposed air intake system 18 includes the conduit 32, which is enclosed in the base frame assembly 30. Hence, this reduces the space taken by pipes and conduits of the generator system 10. The proposed air intake system 18 also provides for easy servicing of the generator system 10, with no need for removal of pipes, like in existing generator systems. Since the inlet of the air intake system 18 is towards the rear side of generator module 16, the air entered is colder in temperature, which otherwise would have been hot, if taken from engine surroundings. Therefore, in comparison to the existing air intake systems, the disclosed air intake system 18 is not cumbersome and requires less effort to assemble.

Claims

Claims What is claimed is:
1. An air intake system for an engine and a generator module, the engine including a turbocharger, the air intake system comprising: a base frame assembly being sized to extend along a length of the engine and the generator module and span a width of the engine and the generator module, wherein the engine and the generator module being mounted to the base frame assembly; at least one conduit including an inlet and an outlet, the at least one conduit being enclosed within the base frame assembly and the at least one conduit extending along substantially the length of an edge of the base frame assembly; and a supply conduit positioned between the at least one conduit and the turbocharger, the supply conduit having a first portion coupled to the outlet of the at least one conduit and a second portion coupled to the turbocharger, wherein the supply conduit is in fluid communication with the at least one conduit and the turbocharger.