An engine system having a gearbox assembly

Abstract

An engine system includes: a gearbox assembly including a housing having a plurality of interconnected gears disposed between an engine side of the housing and an alternator side of the housing; a rotatable engine coupler connected to the engine side of the housing, the engine coupler configured to engage a rotatable shaft of the engine; and a rotatable alternator coupler connected to the alternator side of the housing, the alternator coupler configured to engage a rotor of a first alternator. The housing is configured to be disposed between the engine and the first alternator. The engine coupler is configured to engage an engine resiliently mounted within a power system and the alternator coupler is configured to engage a first alternator rigidly mounted within the power system to transfer rotation of the shaft of the engine to rotation of the rotor of the first alternator.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 62 / 657,469, filed on April 13, 2018, and the entire disclosure of that application is incorporated herein by reference. Technical Field

[0003] The subject matter described herein relates to connections between an engine and other devices such as an alternator or generator. Background Art

[0004] Various power systems include an engine that consumes fuel to rotate a shaft. The shaft may be connected to an alternator or generator that converts the rotation of the engine shaft into an electric current. For example, some vehicles may include an engine coupled to an alternator to generate an electric current. The electric current is then used to power the engine that drives the vehicle.

[0005] The engine and alternator in the power system can be rigidly coupled to the platform or other frame of the power system. For example, the engine and alternator can be bolted or otherwise reliably connected to the platform so that the engine and alternator will not move relative to the platform.

[0006] The rigid mounting of the engine and alternator may cause problems if the engine is replaced. For example, a vehicle owner may wish to replace a rigidly mounted engine with a resiliently mounted engine that is capable of movement relative to the platform (e.g., to absorb vibrations). However, because the engine is capable of movement and the alternator is rigidly mounted, the resiliently mounted engine may not be able to connect with the rigidly mounted alternator. The shaft connection between the engine and alternator may be subject to vibrations, movement, etc., which may damage the engine and / or alternator or prevent the operation of the engine and / or alternator. Summary of the invention

[0007] In one embodiment, an engine system includes: a gearbox assembly including a housing having a plurality of interconnected gears disposed between an engine side of the housing and an alternator side of the housing; a rotatable engine coupler connected to the engine side of the housing, the engine coupler configured to engage a rotatable shaft of an engine; and a rotatable alternator coupler connected to the alternator side of the housing, the alternator coupler configured to engage a rotor of a first alternator. The housing is configured to be located between the engine and the first alternator. The engine coupler is configured to engage the engine resiliently mounted in the power system and the alternator coupler is configured to engage the first alternator rigidly mounted in the power system to convert rotation of the shaft of the engine into rotation of the rotor of the first alternator.

[0008] In one embodiment, an engine system includes a gearbox assembly including a housing having a plurality of interconnected gears arranged between an engine side of the housing and an alternator side of the housing. The housing is configured to be located between an engine and a first alternator of a power system. The engine system also includes a rotatable engine coupler connected to the engine side of the housing. The engine coupler is configured to engage a rotatable shaft of the engine. The engine system also includes a rotatable alternator coupler connected to the alternator side of the housing. The alternator coupler is configured to engage a rotor of the first alternator. The engine coupler is configured to engage the engine and the alternator coupler is configured to engage the first alternator to convert rotation of the shaft of the engine into rotation of the rotor of the first alternator. The engine system also includes an auxiliary rotatable shaft extending from the housing and configured to be interconnected with a rotor of one or more of an auxiliary alternator or an auxiliary generator, the auxiliary rotatable shaft being coupled to the engine coupler through the interconnected gears within the housing.

[0009] In one embodiment, a gearbox assembly includes a housing having a plurality of interconnected gears disposed between an engine side of the housing and an alternator side of the housing. The housing is configured to be located between an engine and a first alternator of a power system to convert rotation of a shaft of the engine into rotation of a rotor of the first alternator. The assembly also includes a closed-loop lubrication system fluidly coupled to an internal cavity located within the housing and configured to be fluidly coupled to a liquid lubrication circuit of the engine. The closed-loop lubrication system is configured to direct lubricant within the engine into the internal cavity of the housing and to direct the lubricant exiting the internal cavity back to the liquid lubrication circuit of the engine.

[0010] In one embodiment, the shaft assembly includes a rotatable engine coupler configured to connect to a gearbox assembly and to a rotatable shaft of an engine, and a rotatable alternator coupler configured to connect to the gearbox assembly and to a rotor of an alternator. The engine coupler and the alternator coupler are each configured to be inserted into a common rotatable socket in the gearbox assembly to convert rotation of the shaft of the engine into rotation of the rotor of the alternator. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The subject matter of the invention will be better understood from the following description of non-limiting embodiments, with reference to the accompanying drawings, in which:

[0012] Figure 1 An example of a power system is shown;

[0013] Figure 2 An example of an engine system on a power system is shown;

[0014] Figure 3 An engine system according to an embodiment of the inventive subject matter described herein is shown;

[0015] Figure 4 Shows Figure 3 A perspective view of a gearbox assembly and an auxiliary mounting bracket according to an embodiment of the present subject matter is shown;

[0016] Figure 5 Shows Figure 3 The gearbox assembly shown and Figure 4 A side view of the auxiliary mounting bracket shown in;

[0017] Figure 6 Shows Figure 3 Another perspective view of an embodiment of a gearbox assembly is shown;

[0018] Figure 7 Including according to an embodiment Figure 6A perspective view of the tensioning device shown;

[0019] Figure 8 A perspective view of a shaft assembly according to an embodiment of the inventive subject matter is shown;

[0020] Fig. 9 Shows Figure 8 Another perspective view of the shaft assembly shown;

[0021] Fig.10 An embodiment of the inventive subject matter described herein is shown. Figure 1 The alternator shown is coupled to Figure 8 a side view of the shaft assembly shown;

[0022] Fig.11 shows a cross-sectional view of a flexible coupling assembly according to an embodiment of the inventive subject matter;

[0023] Fig.12 shows a cross-sectional view of a flexible coupling assembly according to another embodiment of the inventive subject matter;

[0024] Fig.13 shows a perspective view of a closed loop lubrication system according to an embodiment of the inventive subject matter described herein;

[0025] Fig.14 Shows Fig.13 A perspective view of another portion of the closed-loop lubrication system shown;

[0026] Fig.15 A flow chart illustrating an embodiment of a method for replacing an engine of a power system;

[0027] Fig.16 Shows Fig.10 A perspective view of the insulating coupling shown;

[0028] Fig.17 Shows Fig.10 a front view of the insulating coupling shown; and

[0029] Fig.18 Shows Fig.10 A cross-sectional view of an insulating coupling is shown. DETAILED DESCRIPTION

[0030] One or more embodiments of the inventive subject matter described herein provide an engine system for coupling an engine to an alternator and optionally one or more other components. The system described herein can be used to assemble a power system using a new or different engine (e.g., relative to an engine previously used with the power system). The system can couple a resiliently mounted engine to a rigidly mounted component, such as a rigidly mounted alternator and / or air compressor.

[0031] Figure 1 An example of a power system 100 is shown. Figure 2 A known engine system 200 is shown on a power system 100. In the illustrated embodiment, the power system 100 is a vehicle, in particular a locomotive. Alternatively, the power system 100 may be another type of vehicle such as a car, a truck, a mining vehicle, another type of off-highway vehicle (e.g., a vehicle not designed or legally permitted to travel on public roads), a marine vessel, etc. Alternatively, the power system 100 may be a stationary system, such as a stationary power generation system.

[0032] The engine system 200 includes an engine 102 that consumes fuel to rotate an engine shaft. The rotating engine shaft is coupled to an alternator 104. (Unless otherwise specified, "alternator" and "generator" are used synonymously herein and generally refer to any electromechanical device that converts rotational mechanical motion into electrical energy, whether the electrical energy is AC or DC.) For example, the engine shaft can be connected to the rotor of the alternator 104. The alternator 104 generates current based on the rotation of the rotor caused by the engine 102 rotating the engine shaft. In the example shown, the power system also includes an air compressor 106, which is connected to the engine 102 through a compressor shaft 108. The engine 102 operates to rotate the compressor shaft 108, and the compressor shaft 108 provides power to the air compressor 106. Alternatively, the air compressor 106 can be another type of device that is powered by the rotation of the shaft 108 driven by the engine 102 or operates in other ways (for example, the system may include a multi-shaft drive device coupled to the engine).

[0033] The engine system 200 may be rigidly mounted to the power system 100. For example, the power system 100 may include a platform 110 to which some components of the engine system 200 are bolted, securely connected, or otherwise secured such that at least some components of the engine system 200 cannot move relative to the platform 110. Such rigid mounting may include bolting the housings of the alternator 104, the engine 102, and / or the air compressor 106 to the platform 110. Rigidly mounting these components to the same platform 110 can help ensure that the rotational motion generated by the engine 102 causes the rotor of the alternator 104 and the compressor shaft 108 connected to the compressor 106 to rotate, but may also not allow for the absorption of vibrations that occur during operation of the power system 100. These vibrations can damage or otherwise degrade components of the engine system 200.

[0034] One or more embodiments of the inventive subject matter described herein provide systems, assemblies, and methods that allow a resiliently mounted engine of a power system 100 to be operably connected to a rigidly mounted alternator 104 and / or a rigidly mounted air compressor 106. This can allow the resilient or flexible mounting of the engine to absorb vibrations and other relatively small movements of the engine while allowing the engine to rotate the shaft that powers the air compressor 106 and alternator 104.

[0035] Figure 3 An engine system 300 is shown in accordance with an embodiment of the inventive subject matter described herein. The engine system 300 includes an engine 302 that can be resiliently mounted to the platform 110 of the power system 100 in place of the engine 102. For example, an owner or operator of the power system 100 can remove the rigidly mounted engine 102 and replace the engine 102 with a resiliently mounted engine 302 while still coupling the engine 302 to the alternator 104 and / or the compressor 106. The engine 302 can be supported on the platform 110 by a number of resilient mounts 304. These resilient mounts 304 can include flexible bodies that not only maintain the engine in place on the platform 110, but also absorb relatively small vibrations that occur during operation of the engine 302. Alternatively, the engine 302 can be the original engine of the power system 100 rather than a replacement engine.

[0036] and Figure 1 and Figure 2 , the engine 302 may not be directly coupled to the alternator 104. For example, the engine 102 may be directly coupled to the rotor of the alternator 104 without intervening components between the shaft of the engine 102 and the rotor of the alternator 104. However, the engine 302 may be coupled to the rotor of the alternator 104 via a gearbox assembly 306. The gearbox assembly 306 of the engine system 300 enables the flexible mounted engine 302 to be coupled to the rigidly mounted alternator 104 without having to move, disassemble, or otherwise modify the alternator 104.

[0037] In the illustrated embodiment, the gearbox assembly 306 is also connected to an auxiliary alternator or auxiliary generator 308. As described below, the gearbox assembly 306 is capable of converting or transmitting the rotation of the engine shaft (coupled to the flywheel 310) into the rotation of the rotor 312 of the alternator 104, and optionally into the rotation of the rotor of the auxiliary alternator or auxiliary generator 308.

[0038] Figure 4 A perspective view of a gearbox assembly 306 and an auxiliary mounting bracket 400 is shown in accordance with an embodiment of the present subject matter. Figure 5 Shows Figure 4 A side view of the gearbox assembly 306 and the auxiliary mounting bracket 400 is shown. The gearbox assembly 306 includes an outer housing 402 having a plurality of gears 404 disposed within an interior cavity of the housing 402. The housing 402 extends from an engine side 406 to an opposite alternator side 408. The engine side 406 of the housing 402 faces the engine 302, while the alternator side 408 of the housing 402 faces the alternator 104. Due to size constraints within the power system 100, the housing 402 of the gearbox assembly 306 may be relatively thin in a direction extending from the engine 302 to the alternator 104.

[0039] The gearbox assembly 306 includes an engine coupler 410 that is connected to and / or extends from the engine side 406 of the housing 402. The engine coupler 410 is rotatable in that the engine coupler 410 is rotatable relative to the housing 402 about or around an axis of rotation 412. The housing 402 may be rigidly mounted to the platform 110 of the power system 100, while the engine coupler 410 is free to rotate about or around the axis 412. As described below, the engine coupler 410 is connected to the flywheel 310 of the engine 302. As described below, due to the connection between the engine coupler 410 and the flywheel 310, rotation of the flywheel 310 caused by displacing the shaft of the engine 302 causes the engine coupler 410 to rotate.

[0040] The gearbox assembly 306 also includes an alternator coupler 500 connected to and / or extending from the alternator side 408 of the housing 402. Like the engine coupler 410, the alternator coupler 500 is also rotatable relative to the housing 402. The alternator coupler 500 is configured to be directly or indirectly coupled to the rotor of the alternator 104. As described below, the gearbox assembly 306 interconnects the rotatable engine coupler 410 with the rotatable alternator coupler 500 so that rotation of the engine coupler 410 about or around the axis 412 is converted or transmitted to rotation of the alternator coupler 500 about or around the axis 412. The rotation of the alternator coupler 500 causes the rotation of the rotor within the alternator 104, thereby generating electric current.

[0041] In one embodiment, the alternator coupler 500 supports and radially locates the rotor in the alternator 104. The rotor of the alternator 104 can be a single bearing rotor supported by a bearing on the end of the alternator opposite the end of the alternator 104 to which the alternator coupler 500 is connected. This results in the rotor of the alternator 104 being similar to a cantilever beam, which needs to be supported by the alternator coupler 500 to center the rotor on or about the axis 412 and enable the rotor to rotate about or around the axis 412. The alternator coupler 500 can ensure that the rotor is radially centered on the axis 412.

[0042] The gearbox assembly 306 may also include an auxiliary shaft 414 extending from the alternator side 408 of the housing 402 of the gearbox assembly 306. The auxiliary shaft 414 may rotate about or around another axis of rotation 416. The internal gear 404 of the gearbox assembly 306 enables the rotatable engine coupler 410 to be interconnected to the rotatable auxiliary shaft 414 in the internal cavity of the gearbox assembly 306. The rotation of the engine coupler 410 caused by the engine 302 and the flywheel 310 is converted or transmitted to the rotation of the auxiliary shaft 414 through the gear 404.

[0043] In one embodiment, the size and / or shape of the internal gear 404 and the gearbox assembly 306 are configured to increase the rotational speed applied to the auxiliary shaft 414 by the rotation of the engine coupler 410. As an example, the gear 404 in the gearbox assembly 306 can increase the rotational speed of the engine coupler 410 to the faster rotational speed of the auxiliary shaft 414, such as by tripling the rotational speed. This will cause the auxiliary shaft 414 to rotate at a speed twice faster than the simultaneous or synchronous rotational speed of the engine coupler 410 (caused by the rotation of the engine shaft). Optionally, the gear 404 of the gearbox assembly 306 can increase or increase the rotational speed of the engine coupler 410 by another amount. Optionally, the gear 404 of the gearbox assembly 306 can reduce the rotational speed of the engine coupler 410 so that the engine coupler 410 rotates at a faster rotational speed than the auxiliary shaft 414. In another embodiment, the gear 404 and the gearbox assembly 306 may maintain the rotational speeds of the engine coupler 410 and the auxiliary shaft 414 to the same rotational speed.

[0044] The auxiliary shaft 414 rotates about or around the axis 416 to rotate the belt 418 of the gearbox assembly 306. The belt 418 is also connected to the auxiliary shaft 420 of the auxiliary alternator or auxiliary generator 308. The auxiliary shaft 420 of the auxiliary alternator or auxiliary generator 308 is coupled to the rotor inside the auxiliary alternator or auxiliary generator 308, so that the rotation of the auxiliary shaft 420 causes the rotation of the rotor within the auxiliary alternator or auxiliary generator 308, thereby generating additional electric current.

[0045] In operation, the engine coupler 410 is rotated by the engine rotating the flywheel 310 via the engine shaft. The rotation of the engine coupler 410 is converted to rotation of the alternator coupler 500 via the gearbox assembly 306. This rotation of the alternator coupler 500 also rotates the rotor of the alternator 104, thereby generating electric current. The gears 404 of the gearbox assembly 306 also transfer or convert the rotation of the engine coupler 410 to rotation of the auxiliary shaft 414. The rotation of the auxiliary shaft 414 also rotates the belt 418, which also rotates the auxiliary shaft 420. The rotation of the auxiliary shaft 420 also rotates the rotor within the auxiliary alternator or auxiliary generator 308, thereby generating additional electric current.

[0046] The mounting bracket 400 can be connected to the outer housing of the AC generator 104, such as Figure 3 As shown. The mounting bracket 400 is capable of supporting and positioning the auxiliary AC generator or auxiliary generator 308 and the auxiliary shaft 420. The mounting bracket 400 may include a plurality of pillow block bearings 422 that support and radially position the auxiliary shaft 420. The shown position or positioning of the bracket 400 is an example of a position where the bracket can be set. In another embodiment, the bracket 400 can be located at another position outside the AC generator 104. For example, the bracket 400 is shown at the ten o'clock position on the outer circumference around the outer surface of the AC generator 104. Optionally, the bracket 400 can be at another position, such as the twelve o'clock position, the two o'clock position, etc.

[0047] Figure 6 Another perspective view of an embodiment of a gearbox assembly 306 is shown with the Figure 4 The engine coupling 410 and Figure 5The alternator coupler 500 shown. The housing 402 of the gearbox assembly 306 may include a number of foot plates 600. These plates 600 may include holes 602, openings 602, etc. for bolts or other fasteners to be inserted to mount the gearbox assembly 306 to the platform 110 of the power system 100. As described above, the housing of the gearbox assembly 306 may be rigidly mounted to the platform 110 of the power system 100. Optionally, one or more flexible bodies (e.g., rubber sheets) may be disposed between the plates 600 of the gearbox assembly 306 and the platform 110 to absorb vibrations, movements, etc. of the gearbox assembly 306.

[0048] Figure 6 Also shown in FIG. 3 is a tensioner device 604 of the gearbox assembly 306 . Figure 7 4 includes a perspective view of a tensioning device 604 according to one embodiment of the tensioning device 604. The tensioning device 604 includes a rotatable or circular body 606 that engages the belt 418. Optionally, the body 606 can be rotatable or circular around or around the belt 418. Figure 7 The tensioning device 604 includes an arm 702 (in Figure 7 ), rod 704 (in Figure 7 706 ). For example, the rod 704 can slide in opposite directions 706, 708 in the arm 702. One or more fasteners 710 can be tightened to limit or prevent the movement of the rod 704 in the arm 702, and can be loosened to allow the movement of the rod 704 in the arm 702. The rod 704 is connected to the body 606 so that movement of the rod 704 along or in direction 706 also moves the body 606 in direction 706, and movement of the rod 704 along or in direction 708 also moves the body 606 in direction 708.

[0049] In operation, the position of the body 606 can be moved in either direction 706, 708 to change the tension in the belt 418. For example, the rod 704 and body 606 can be moved in the direction 706 to increase the tension in the belt 418 and make the belt 418 tighter on the auxiliary shaft 420, the auxiliary shaft 414, and the body 606. Conversely, the rod 704 and body 606 can be moved in the opposite direction 708 to reduce the tension in the belt 418 and loosen the belt 418 from the auxiliary shaft 420, the auxiliary shaft 414, and the body 606. The tensioning device 604 can be used to loosen the belt 418 to replace the belt 418 without disassembling other components of the engine system 300 and / or the gearbox assembly 306.

[0050] exist Figure 6Also shown in the figure is a rotatable receptacle 608 within the housing 402 of the gearbox assembly 306. The rotatable receptacle 608 can be a ring or other annular body (curved or having one or more flat surfaces as shown in the illustrated embodiment) that is within the housing 402 and rotates relative to the housing 402. For example, the rotatable receptacle 608 can rotate around or about the axis 412. The outer surface of the rotatable receptacle 608 located inside the housing 402 of the gearbox assembly 306 can include teeth, grooves, ridges, etc., which cooperate with the teeth, grooves, ridges, etc. of one or more interconnected gears 404 within the housing 402 of the gearbox assembly 306. In one embodiment, the rotation of the receptacle 608 can be converted into the rotation of the auxiliary shaft 414.

[0051] In the illustrated embodiment of the gearbox assembly 306, the socket 608 has internal grooves 610 separated by ridges along the inner surface of the socket 608. Alternatively, the socket 608 may not include the grooves 610 or may include other surface features. As described below, the surface features of the socket 608 (e.g., the grooves 610 in the illustrated embodiment) cooperate with corresponding surface features of the engine coupler 410 and / or the alternator coupler 500 so that rotation of the engine coupler 410 also rotates the alternator coupler.

[0052] Figure 8 A perspective view of a shaft assembly 800 is shown in accordance with an embodiment of the inventive subject matter. Fig. 9 Shows Figure 8 800. The shaft assembly 800 is comprised of a combination of the engine coupler 410 and the alternator coupler 500. The engine coupler 410 extends from an engine interface side or surface 802 to an opposite inner side or surface 804. The alternator coupler 500 extends from an alternator interface side or surface 806 to an opposite inner side or surface 808. The engine interface side 802 of the engine coupler 410 faces toward and is capable of interconnecting with the engine 302, while the alternator interface side 806 of the alternator coupler 500 faces toward and is capable of interconnecting with the alternator 104. The sides 804, 808 of the couplers 410, 500 face each other.

[0053] In one embodiment, the engine coupler 410 and the alternator coupler 500 are not fixed to each other. For example, the engine coupler 410 and the alternator coupler 500 can be separate components or bodies that are not connected, bonded, or otherwise fixed to each other. The engine coupler 410 can be at least partially inserted into the rotatable socket 608 (e.g., the rotatable socket 608 of the housing 402 of the gearbox assembly 306). Figure 6For example, the side 804 of the engine coupler 410 can pass through or through the engine side 406 of the housing 402 of the gearbox assembly 306 (eg, Figure 4 The alternator coupler 500 may also be at least partially inserted into the rotatable receptacle 608 of the housing 402 of the gearbox assembly 306. For example, the side 808 of the alternator coupler 500 may pass through or extend through the alternator side 408 of the housing 402 of the gearbox assembly 306 (e.g., Figure 4 ) is inserted into the rotatable socket 608.

[0054] The couplers 410, 500 may be inserted into the receptacle 608 of the housing 402 without the sides 804, 808 of the couplers 410, 500 abutting, touching, or otherwise engaging one another. There may be a space or air gap between the sides 804, 808 of the couplers 410, 500 within the receptacle 608. Alternatively, the sides 804, 808 of the couplers 410, 500 may abut, touch, or otherwise engage one another within the receptacle 608 such that there is no space or air gap between the sides 804, 808 of the couplers 410, 500.

[0055] The coupler 410, 500 can be inserted into the receptacle 608 of the gearbox assembly 306 to reduce the size of the gearbox assembly 306. The available space between the engine 302 and the alternator 104 may be limited and small. Inserting the coupler 410, 500 into the receptacle of the gearbox assembly 306 can reduce the maximum size of the gearbox assembly 306 in the direction extending from the engine 302 to the alternator 104.

[0056] The couplers 410, 500 each include a spline shaft 810, 812. The spline shafts 810, 812 extend from respective sides 804, 808 toward respective opposite sides 802, 806 of the couplers 410, 500. For example, the spline shaft 810 of the engine coupler 410 may include outwardly or radially projecting ridges or teeth 814 extending from the side 804 toward (but not all the way to) the engine interface side 802 of the engine coupler 410. The spline shaft 812 of the alternator coupler 500 may include outwardly or radially projecting ridges or teeth 814 extending from the side 808 toward (but not all the way to) the alternator interface side 806 of the alternator coupler 500.

[0057] The teeth or ridges 814 of the spline shafts 810, 812 are sized to engage with the slots 610 in the rotatable socket 608. For example, the width, height, and / or spacing of the teeth or ridges 814 may match the depth, length, and / or spacing of the slots 610 in the socket 608. The teeth or ridges 814 of the spline shafts 810, 812 engage with the slots 610 in the socket 608 so that rotation of the engine coupler 410 by the engine shaft also rotates the socket 608 in the housing 402 of the gearbox assembly 306. The rotation of the socket 608 also rotates the alternator coupler 500. The rotation of the alternator coupler 500 rotates the rotor of the alternator 104.

[0058] Fig.10 1 shows a side view of a shaft assembly 800 coupled with an alternator 104 according to an embodiment of the inventive subject matter described herein. Fig.10 The gearbox assembly 306 is not shown. The alternator coupler 500 includes a circular plate 1000 coupled to one end of the alternator 104. For example, the plate 1000 of the alternator coupler 500 can be connected to the rotor 312 of the alternator 104. The spline shafts 810, 812 of the alternator coupler 500 and the engine coupler 410 are arranged at Figure 6 8. In the illustrated embodiment, the ends of the spline shafts 810, 812 engage one another, but may alternatively be separated by an air or space gap, as described above.

[0059] In the illustrated embodiment, the circular plate 1000 of the alternator coupler 500 is rigidly coupled to the spline shaft 812 of the alternator coupler 500. Figure 6 Rotation of the grooved inner surface of the socket 608 in the illustrated gearbox assembly 306 causes the spline shaft 812 to rotate, also causing the circular plate 1000 of the alternator coupler 500 to rotate. This causes the rotor 312 of the alternator 104 to rotate to generate electrical current, as described herein.

[0060] The engine coupler 410 also includes an annular plate 1004 coupled to the splined shaft 810 of the engine coupler 410. In the illustrated embodiment, the plate 1004 of the engine coupler 410 is smaller than the plate 1000 of the alternator coupler 500. For example, the circumference, radius, diameter, surface area, etc. of the plate 1004 of the engine coupler 410 is smaller than the corresponding circumference, radius, diameter, surface area, etc. of the plate 1000 of the alternator coupler 500. The plate 1004 may also be rigidly coupled to the splined shaft 810 of the engine coupler 410 such that rotation of the plate 1004 caused by rotation of the engine shaft also causes the splined shaft 810 of the engine coupler 410 to rotate.

[0061] The flexible insulating coupling 1002 can be connected to the plate 1004 of the engine coupler 410. Fig.10 , Fig.16 shows a perspective view of an insulating coupling 1002, Fig.17 shows a front view of the insulating coupling 1002, Fig.18 A cross-sectional view of an insulating coupling 1002 is shown. The insulating coupling 1002 interconnects the flywheel 310 and the engine shaft to the engine coupler 410. The insulating coupling 1002 includes an annular plate 1004 coupled to a number of elongated flexible bodies 1006. These flexible bodies 1006 may be made of one or more dielectric materials to electrically insulate the flywheel 310 and the engine shaft from the engine coupler 410. For example, the elongated flexible bodies 1006 may be made of rubber or the like to prevent current within the flywheel 310 from being conducted to the engine coupler 410. Alternatively, the bodies 1006 may not be flexible and / or may be made of another material.

[0062] The elongated body 1006 may be flexible to absorb vibrations, translations, torsional changes, etc. within the flywheel 310. The elongated body 1006 extends between opposite ends 1602, 1604, wherein one end 1602 is rotatably mounted to or coupled to the plate 1004 of the engine coupler 410, and the opposite end 1604 is rotatably mounted to or coupled to the flywheel 310 of the engine 302. In the illustrated embodiment, the ends of the elongated body 1006 are connected to the annular plate 1004 of the engine coupler 410 at various locations along, at, or near the outer circumference of the annular plate 1004 on the side of the plate 1004 facing the engine 302.

[0063] The elongated bodies 1006 can be rotatably coupled to the plate 1004 so that each of the elongated bodies 1006 can be individually and / or separately rotated about or around a different axis of rotation 1008, each axis of rotation 1008 of the elongated bodies 1006 being parallel to the axis of rotation 412 and / or the central axis of the engine shaft. For example, a bolt or other fastener 1610 can be inserted into one end of the elongated body 1006 coupled to the annular plate 1004 of the engine coupler 410.

[0064] The opposite ends 1604 of each elongated body 1006 may include a similar coupling to the flywheel 310. For example, bolts or other fasteners 1608 may be inserted through holes or other openings on the opposite ends of the elongated bodies 1006 such that each elongated body 1006 is rotatably coupled to the flywheel 310. This other rotatable coupling of each elongated body 1006 enables rotation of the elongated body 1006 about or around another axis of rotation 1010.

[0065] Thus, the ends 1602, 1604 of each elongated body 1006 can be rotatably coupled to both the engine coupler 410 and the flywheel 310. When the engine 302 is running (e.g., the engine 302 rotates the flywheel 310 through the rotation of the engine shaft), the elongated body 1006 is in a tensioned state. For example, when the flywheel 310 rotates, the ends 1604 of the elongated body 1006 can be pulled by the flywheel 310. By rotating the ends 1604 by the flywheel 310, the opposite ends 1602 of the elongated body 1006 are pulled on the rotation path. When the ends 1602 of the elongated body 1006 are pulled along the rotation path, the plate 1004 is rotated, thereby rotating the coupler 410 (because the coupler 410 is connected to the plate 1004).

[0066] The multiple axes of rotation 1008, 1010 of each elongated body 1006 and the formation of the elongated body 1006 from an elastic material (e.g., rubber) can allow vibrations, translations, torsional changes, or other movements of the shaft of the resiliently mounted engine 302 to be absorbed by the elongated body 1006 and not hinder or interfere with the operation of the rigidly mounted gearbox assembly 306 and / or the rigidly mounted alternator 104. For example, the engine 302 and the corresponding shaft can vibrate vertically and horizontally in other linear directions, the shaft of the engine 302 can vibrate radially, and / or the like. These movements can be at least partially absorbed by the flexible insulating coupling 1002 interconnecting the resiliently mounted engine 302 with the rigidly mounted gearbox assembly 306.

[0067] Fig.11 A cross-sectional view of a flexible coupling assembly 1100 according to an embodiment of the inventive subject matter is shown. The flexible coupling assembly 1100 can be used to connect the shaft 108 to the engine 302 and the compressor 106. As described above, the engine 302 can be resiliently mounted while the compressor or other component 106 is rigidly mounted. Thus, similar to the combination of the engine 302 and the alternator 104, a flexible coupling can be provided between the engine 302 and the compressor 106 to ensure that vibrations, movements, torsional changes, etc. of the engine 302 do not interfere with or hinder the operation of the compressor 106.

[0068] The flexible coupling assembly 1100 includes an engine coupling assembly 1102 and an end coupling assembly 1104. Fig.11As shown, since the shaft 108 can be a rigid shaft made of one or more rigid materials, the assemblies 1102, 1104 are arranged on the opposite ends of the shaft. The engine coupling assembly 1102 can be at least partially arranged in the engine 302 or otherwise coupled to the engine 302. The engine coupling assembly 1102 can include one or more gears 1106 that connect the shaft 108 to the shaft of the engine 302. These gears 1106 can adjust or accommodate radial, angular and / or axial deviations between the shaft 108 and the engine 302.

[0069] The end coupling assembly 1104 includes a flywheel 1108 on the end of the shaft 108 opposite the engine coupling assembly 1102. A connector 1110 on the end coupling assembly 1104 can be connected to the compressor 106 to transfer the rotation of the shaft 108 to the compressor 106. The flywheel 1108 is arranged between the connector 1110 and the shaft 108. The flywheel 1108 can absorb changes in the rotation speed and / or momentum of the shaft 108 generated by the engine 302.

[0070] The end coupling assembly 1104 also includes a flexible disc coupling 1112. The flexible disc coupling 1112 can be made of one or more flexible materials, such as rubber. The flexible disc coupling 1112 can absorb vibrations, movements, torsional changes, etc. in the compressor shaft 108. The flexible disc coupling 1112 can allow the rigid compressor shaft 108 rigidly coupled to the resiliently mounted engine 302 by the engine coupling assembly 1102 to absorb vibrations, torsional changes, or other movements of the engine 302 and the compressor shaft 108, thereby allowing the rigidly mounted compressor 106 to be powered by the rotation of the compressor shaft 108.

[0071] Fig.12 A cross-sectional view of a flexible coupling assembly 1200 according to another embodiment of the subject matter of the present invention is shown. The flexible coupling assembly 1200 can be used to connect the shaft 108 to the engine 302 and the compressor 106. As described above, the engine 302 can be elastically mounted, while the compressor or other components are rigidly mounted. Therefore, similar to the combination of the engine 302 and the alternator 104, a flexible connection can be provided between the engine 302 and the compressor 106 to ensure that vibrations, movements, torsional changes, etc. of the engine 302 do not interfere with or hinder the operation of the compressor 106.

[0072] The flexible coupling assembly 1200 includes the above-mentioned end coupling assembly 1104 and the engine coupling assembly 1202. Fig.12As shown, the assemblies 1202, 1104 are arranged on opposite ends of the compressor shaft 108. The engine coupling assembly 1202 may be at least partially arranged within the engine 302 or otherwise coupled to the engine 302. Compared to the engine coupling assembly 1102, the engine coupling assembly 1202 may not be coupled to the shaft of the engine 302 through gears. The engine coupling assembly 1202 includes a flexible circular plate 1204 that connects the shaft of the engine 302 to the compressor shaft 108.

[0073] Similar to the flexible disc coupling 1112 of the end coupling assembly 1104, the flexplate 1204 can be made of one or more flexible materials capable of absorbing vibrations, movements, torsional changes, etc. on the compressor shaft 108. The flexplate 1204 can allow the rigid compressor shaft 108 to be rigidly coupled to the resiliently mounted engine 302 through the engine coupling assembly 1102 to absorb vibrations, torsional changes, or other movements of the engine 302 and the compressor shaft 108, thereby allowing the rigidly mounted compressor 106 to be powered by the rotation of the compressor shaft 108.

[0074] Fig.13 A perspective view of a closed loop lubrication system 1300 according to an embodiment of the inventive subject matter described herein is shown. The closed loop lubrication system 1300 circulates or recirculates lubricant in the engine through the lubrication circuit of the engine 302, into the internal cavity of the gearbox assembly 306, and back into the lubrication system circuit of the engine 302. The liquid lubrication circuit of the engine 302 includes conduits, chambers, flow directions, etc., which define the locations where the lubricant flows through different components of the engine 302 to lubricate the moving parts of the engine 302.

[0075] exist Fig.13 , only a portion of the rear end of the engine 302 is shown. The inlet conduit 1302 is fluidly coupled to one or more lumen conduits in the engine 302 where a lubricant, such as oil, is present. The conduit 1302 may also be connected to the outer housing 402 of the gearbox assembly 306 and may be fluidly coupled to the lumen of the gearbox assembly 306. The inlet conduit 1302 may be a hose or other fluid connector that can direct the lubricant in the engine 302 to flow out of the engine 302, through the conduit 1302, and into the lumen or cavity of the housing 402 of the gearbox assembly 306. In one embodiment, the inlet conduit 1302 is coupled to the engine 302 at a downstream location where the lubricant is filtered and / or cooled. This may allow the lubricant to be directed directly from the engine 302 into the gearbox assembly 306 without the need for additional filters and / or cooling systems to clean and cool the lubricant.

[0076] Lubricant flows from the engine 302 to the gearbox assembly 306 to lubricate the interconnected gears 404 and / or other moving parts within the gearbox assembly 306 . Fig.14 Shown in Fig.13 A perspective view of another portion of the closed-loop lubrication system 1300 is shown in FIG. Fig.13 As shown, an inlet conduit 1302 fluidly couples the lubrication circuit of the engine 302 with the top or upper portion of the housing 402 of the gearbox assembly 306. This can allow gravity to assist in distributing lubricant throughout the interior portion of the housing 402 of the gearbox assembly 306. Similarly, a bottom surface or portion of the housing 402 of the gearbox assembly 306 can include an outlet conduit 1400 coupled to the housing 402 and fluidly coupled to an interior cavity or chamber of the housing 402 of the gearbox assembly 306.

[0077] After flowing through or passing through the interior of the housing 402 of the gearbox assembly 306, the lubricant may flow out of the gearbox assembly 306 through the outlet conduit 1400. The lubricant may flow through the outlet conduit 1400 into a portion of the lubrication circuit of the engine 302, such as a lubricant reservoir 1402 of the lubrication circuit of the engine 302. The lubricant reservoir 1402 may store the lubricant until the lubricant is drawn from the reservoir 1402 and returned to the engine 302. In this way, the closed-loop lubrication system 1300 allows the lubricant within the engine 302 to be used to lubricate the moving parts of the gearbox assembly 306 without requiring an additional source of lubricant, requiring additional filters for cleaning the lubricant, and / or requiring additional cooling systems for reducing the temperature of the lubricant. The lubrication system 1300 allows the gearbox assembly 306 to draw only a portion of the lubricant within the engine 302 to the gearbox assembly 306. This may ensure that the engine 302 has sufficient lubricant to continue to operate safely, while also providing lubricant to assist the gearbox assembly 306 in operating smoothly.

[0078] Fig.15 A flow chart of one embodiment of a method 1500 for replacing an engine of a power system is shown. The method 1500 may be used to replace a rigidly mounted engine 102 in a power system 100 with a resiliently mounted engine 302 while absorbing or otherwise withstanding vibrations, torsional changes, or other movements of the resiliently mounted engine 302 relative to other rigidly mounted components such as the alternator 104 and the compressor 106.

[0079] At 1502, an existing or pre-existing engine in the power system is removed. For example, a rigidly mounted engine 102 may be separated from the power system 100, including separating the engine 102 from the platform 110, the alternator 104, and the compressor 106. At 1504, a replacement engine is installed into the power system. For example, a resiliently mounted engine 302 may be coupled to the platform 110 of the power system 100 using a resilient mount 304 that allows the engine 302 to make some minor movements relative to the platform 110.

[0080] At 1506, the engine coupler is connected to the shaft of the engine. For example, the flexible insulating coupling 1002 of the engine coupler 410 can be threaded or otherwise coupled to the shaft of the engine 302. At 1508, the engine coupler is inserted into a rotatable socket of the gearbox assembly. For example, the splined shaft 810 of the engine coupler 410 can be partially inserted into the slotted socket 608 of the gearbox assembly 306. The splined shaft 810 of the engine coupler 410 can be inserted into the socket 608 so that the end 804 of the splined shaft 810 is located within the socket 608 and between the engine side 406 of the housing 402 of the gearbox assembly and the alternator side 408 of the housing 402 of the gearbox assembly 306.

[0081] At 1510, the alternator coupler is connected to the rotor of the alternator. For example, the alternator coupler 500 may be bolted or otherwise connected to the rotor of the alternator 104. The side 806 of the alternator coupler 500 may be connected to the rotor of the alternator 104 such that rotation of the alternator coupler 500 also causes the rotor of the alternator 104 to rotate.

[0082] At 1512, the alternator coupler is inserted into the receptacle of the gearbox assembly. For example, the splined shaft 812 of the alternator coupler 500 may be inserted into the slotted receptacle 608 of the gearbox assembly 306. The splined shaft 812 may be inserted into the receptacle 608 such that an end 808 of the splined shaft 812 partially extends into the receptacle 608 and is disposed at a location between the alternator side 408 of the housing 402 of the gearbox assembly 306 and the engine side 406 of the housing 402 of the gearbox assembly 306. In an embodiment, the ends 804, 808 of the splined shafts 810, 812 of the engine coupler 410 and the alternator coupler 500 do not contact each other within the receptacle 608 and are separated from each other by an air gap or other spatial gap. Optionally, the ends 804 , 808 of the splined shafts 810 , 812 of the alternator coupler 500 and the engine coupler 410 may engage, abut, or otherwise contact each other within the receptacle 608 of the gearbox assembly 306 .

[0083] The order of executing operations 1506, 1508, 1510, and 1512 may be the same as in Fig.15 For example, before connecting the flexible insulating coupling 1002 of the engine coupler 410 to the shaft of the engine 302 and / or before connecting the side 806 of the alternator coupler 500 to the rotor of the alternator 104, the engine coupler 410 and / or the alternator coupler 500 may first be inserted into the receptacle 608 of the gearbox assembly 306.

[0084] At 1514, an auxiliary generator or auxiliary alternator is optionally mounted to the alternator of the power system. For example, the mounting bracket 400 can be connected to the outer surface of the alternator 104 at any of a number of different locations. The auxiliary alternator or auxiliary generator 308 can be held external to the alternator 104 by the mounting bracket.

[0085] At 1516, the auxiliary shaft of the gearbox assembly is optionally coupled to the rotor of the auxiliary generator or alternator. For example, the auxiliary shaft 420 of the gearbox assembly 306 can be coupled to the rotor of the auxiliary alternator or alternator 308. As described above, this can allow the rotation of the engine shaft to be converted to the rotation of the auxiliary shaft 420 and the rotor of the auxiliary alternator or alternator 308 through the internal gears 404 of the gearbox assembly 306. The gears 404 of the gearbox assembly 306 can increase the rotation speed of the engine shaft so that the rotation of the auxiliary shaft 420 is much faster than the rotation speed of the shaft of the engine 302.

[0086] At 1518, one or more flexible couplings are optionally coupled to the opposite ends of the engine shaft and the compressor shaft. For example, a flexible coupling 1112, such as a ring or other annular body, can be coupled to the end of the compressor shaft 108 at or near the compressor 106. The flexible coupling 1112 can absorb vibrations, torsional changes, or other movements of the shaft 108 and / or the engine 302 relative to the fixed compressor 106. Optionally, a flexplate 1204 can be connected to the end of the shaft 108 near the engine 302. The flexplate body 1204 can also absorb vibrations, torsional changes, and / or other movements of the engine 302 relative to the rigidly mounted compressor 106.

[0087] In one embodiment, an engine system includes a gearbox assembly including a housing having a plurality of interconnected gears disposed between an engine side of the housing and an alternator side of the housing; a rotatable engine coupler connected to the engine side of the housing, the engine coupler being configured to engage a rotatable shaft of the engine; and a rotatable alternator coupler connected to the alternator side of the housing, the alternator coupler being configured to engage a rotor of a first alternator. The housing is configured to be positioned between the engine and the first alternator. The engine coupler is configured to engage an engine resiliently mounted within the power system, and the alternator coupler is configured to engage a first alternator rigidly mounted within the power system to convert rotation of the shaft of the engine into rotation of the rotor of the first alternator.

[0088] In one embodiment, the engine system may be a locomotive engine system, or alternatively, may be an engine system for another type of vehicle or a stationary system.

[0089] Optionally, the engine is a replacement engine that replaces a previous engine of the powertrain.

[0090] Optionally, the alternator coupling and housing are configured to support and radially position a rotor of the alternator.

[0091] Optionally, the system further comprises an auxiliary rotatable shaft extending from the housing and configured to interconnect with a rotor of one or more of the auxiliary alternator or the auxiliary generator. The auxiliary rotatable shaft can be coupled to the engine coupler via interconnected gears within the housing.

[0092] Optionally, the auxiliary rotatable shaft extends from the housing at a position to couple with the rotor of one or more of the auxiliary alternator or auxiliary generators mounted on the first alternator.

[0093] Optionally, the interconnected gears within the housing are configured to increase the rotational speed of the engine coupling rotated by the shaft of the engine to a faster rotational speed that rotates the auxiliary rotatable shaft.

[0094] Optionally, the auxiliary rotatable shaft is configured to be interconnected with a rotor of one or more of the auxiliary alternator or auxiliary generators via a belt.

[0095] Optionally, the system further comprises a tensioning device configured to vary the tension in the belt.

[0096] Optionally, the system further comprises a mounting bracket configured to couple to the first AC generator and one or more of the auxiliary AC generator or auxiliary generators to support the auxiliary AC generator or one or more of the auxiliary generators on the first AC generator.

[0097] Optionally, the mounting bracket is further configured to support the auxiliary rotatable shaft and a bearing on which the auxiliary rotatable shaft rotates.

[0098] Optionally, the system further comprises an inlet conduit coupled to the housing and fluidly coupled to an inner cavity in the housing. The inlet conduit can be configured to be fluidly coupled to a liquid lubrication circuit of the engine. The inlet conduit can also be configured to direct lubricant within the liquid lubrication circuit of the engine into the inner cavity of the housing. The system can include an outlet conduit coupled to the housing and fluidly coupled to the inner cavity in the housing. The outlet conduit can be configured to be fluidly coupled to a lubricant reservoir of the liquid lubrication circuit of the engine. The outlet conduit can also be configured to direct lubricant within the inner cavity of the housing into a lubricant reservoir of the liquid lubrication circuit of the engine.

[0099] Optionally, the system further comprises a rotatable socket in the housing. The rotatable socket can be coupled with the interconnected gear of the housing and can be configured to interconnect with the shaft of the engine and with the rotor of the alternator to convert the rotation of the shaft of the engine into the rotation of the rotor of the alternator.

[0100] Optionally, the rotatable engine coupler includes an engine spline shaft configured to cooperate with a shaft of the engine and to be received in a rotatable socket in the housing. The rotatable alternator coupler may include an alternator spline shaft configured to cooperate with a rotor of the alternator and to be received in a rotatable socket in the housing.

[0101] Optionally, the rotatable socket has an internal groove shaped to mate with ridges on the outer surface of the engine spline shaft and the outer surface of the alternator spline shaft.

[0102] Optionally, the engine spline shaft and the alternator spline shaft do not abut each other in the rotatable sockets within the housing.

[0103] Optionally, the system further includes a flexible insulating coupling configured to interconnect the engine shaft and the rotatable engine coupler.

[0104] Optionally, the flexible insulating coupling includes a plurality of elongated flexible bodies arranged along the periphery of the rotatable engine coupler. Each elongated flexible body can be rotatably coupled to the rotatable engine coupler at a first end of the elongated flexible body, and is configured to be rotatably coupled to the shaft of the engine at an opposite second end of the elongated flexible body.

[0105] Optionally, the powered system is a vehicle.

[0106] Optionally, the system further includes a compressor shaft configured to be coupled to the air compressor and rotated by the engine to power the air compressor. The system may also include a flexible disc coupling configured to connect the compressor shaft to the engine. The flexible disc coupling may be configured to bend and absorb torsional changes in one or more of the compressor shaft, the shaft of the engine, or the rotor of the alternator.

[0107] Optionally, the system further comprises a flywheel coupled to the flexible disc coupling.The engine coupling, the alternator coupling, the gearbox assembly, the flexible disc coupling and the compressor shaft can be configured to bend and absorb torsional changes in one or more of the compressor shaft, the shaft of the engine or the rotor of the first alternator.

[0108] In one embodiment, the engine system includes a gearbox assembly including a housing having a plurality of interconnected gears arranged between an engine side of the housing and an alternator side of the housing. The housing is configured to be disposed between an engine and a first alternator of the power system. The engine system also includes a rotatable engine coupler connected to the engine side of the housing. The engine coupler is configured to engage a rotatable shaft of the engine. The engine system also includes a rotatable alternator coupler connected to the alternator side of the housing. The alternator coupler is configured to engage a rotor of the first alternator. The engine coupler is configured to engage the engine, and the alternator coupler is configured to engage the first alternator to convert the rotation of the shaft of the engine into the rotation of the rotor of the first alternator. The engine system also includes an auxiliary rotatable shaft extending from the housing, the auxiliary rotatable shaft being configured to interconnect with a rotor of one or more of the auxiliary alternator or the auxiliary generator, and the auxiliary rotatable shaft is coupled to the engine coupler through an interconnected gear in the housing.

[0109] Optionally, the engine is a replacement engine for the powertrain.

[0110] Optionally, the alternator coupling and housing are configured to support and radially position a rotor of the alternator.

[0111] Optionally, the interconnected gears within the housing are configured to increase the rotational speed of the engine coupling rotated by the engine shaft to a faster rotational speed that rotates the auxiliary rotatable shaft.

[0112] Optionally, the engine coupler is configured to engage an engine resiliently mounted within the power system, and the alternator coupler is configured to engage a first alternator rigidly mounted within the power system.

[0113] Optionally, the auxiliary rotatable shaft extends from the housing at a position to couple with the rotor of one or more of the auxiliary alternator or auxiliary generators mounted on the first alternator.

[0114] Optionally, the auxiliary rotatable shaft is configured to be interconnected with a rotor of one or more of the auxiliary alternator or auxiliary generators via a belt.

[0115] Optionally, the engine system further includes a tensioner configured to vary tension within the belt.

[0116] Optionally, the engine system further comprises a mounting bracket configured to couple to the first AC generator and to one or more of the auxiliary AC generator or auxiliary generators to support the auxiliary AC generator or one or more of the auxiliary generators on the first AC generator.

[0117] Optionally, the engine system further comprises an inlet conduit coupled to the housing and fluidly coupled to an inner cavity in the housing. The inlet conduit can be configured to be fluidly coupled to a liquid lubrication circuit of the engine. The inlet conduit can also be configured to guide lubricant in the liquid lubrication circuit of the engine into the inner cavity of the housing. The engine system can also comprise an outlet conduit coupled to the housing and fluidly coupled to an inner cavity in the housing. The outlet conduit can be configured to be fluidly coupled to a lubricant reservoir of the liquid lubrication circuit of the engine. The outlet conduit can also be configured to guide lubricant in the inner cavity of the housing into a lubricant reservoir of the liquid lubrication circuit of the engine.

[0118] Optionally, the engine system further comprises a rotatable socket in the housing. The rotatable socket can be coupled with an interconnection gear of the housing. The rotatable socket can be configured to interconnect with the engine shaft and the rotor of the alternator to transfer the rotation of the engine shaft to the rotation of the rotor of the alternator.

[0119] Optionally, the rotatable engine coupler includes an engine spline shaft configured to mate with the engine shaft and be received in a rotatable socket in the housing. The rotatable alternator coupler may include an alternator spline shaft configured to mate with a rotor of the alternator and be received in a rotatable socket in the housing.

[0120] Optionally, the rotatable socket has an internal groove shaped to mate with ridges on the outer surface of the engine spline shaft and the outer surface of the alternator spline shaft.

[0121] Optionally, the engine spline shaft and the alternator spline shaft do not abut in the rotatable sockets within the housing.

[0122] Optionally, the engine system further includes a flexible insulating coupling configured to interconnect the engine shaft and the rotatable engine coupler.

[0123] Optionally, the flexible insulating coupling includes a plurality of elongated flexible bodies arranged along the periphery of the rotatable engine coupler. Each elongated flexible body can be rotatably coupled to the rotatable engine coupler at a first end of the elongated flexible body, and is configured to be rotatably coupled to the shaft of the engine at an opposite second end of the elongated flexible body.

[0124] Optionally, the powered system is a vehicle.

[0125] Optionally, the powered system is a locomotive.

[0126] Optionally, the engine system further includes a compressor shaft configured to be coupled to the air compressor and rotated by the engine to power the air compressor. The engine system may further include a flexible disc coupling configured to connect the compressor shaft to the engine, wherein the flexible disc coupling is configured to bend and absorb torsional changes in one or more of the compressor shaft, the shaft of the engine, or the rotor of the first alternator.

[0127] Optionally, the engine system may further include a flywheel coupled to the flexible disc coupling. The engine coupling, the alternator coupling, the gearbox assembly, the flexible disc coupling, and the compressor shaft may be configured to flex and absorb torsional changes in one or more of the compressor shaft, the engine shaft, or the first alternator.

[0128] In one embodiment, a gearbox assembly includes a housing having a plurality of interconnected gears disposed between an engine side of the housing and an alternator side of the housing. The housing is configured to be disposed between an engine and a first alternator of a power system to convert rotation of an engine shaft into rotation of a rotor of the first alternator. The assembly also includes a closed-loop lubrication system fluidly coupled to an inner cavity inside the housing and configured to be fluidly coupled to a liquid lubrication circuit of the engine. The closed-loop lubrication system is configured to direct lubricant within the engine into the inner cavity of the housing and to direct lubricant exiting the inner cavity back to the liquid lubrication circuit of the engine.

[0129] Optionally, the closed-loop lubrication system includes an inlet conduit coupled to the housing and fluidly coupled to the housing interior. The inlet conduit can be configured to fluidly couple to a liquid lubrication circuit of the engine to guide lubricant in the liquid lubrication circuit of the engine into the interior of the housing.

[0130] Optionally, the closed-loop lubrication system includes an outlet conduit coupled to the housing and fluidly coupled to the housing interior cavity. The outlet conduit can be configured to be fluidly coupled to a lubricant reservoir of a liquid lubrication circuit of the engine to guide lubricant in the housing interior cavity to the lubricant reservoir of the liquid lubrication circuit of the engine.

[0131] Optionally, the housing is configured such that the engine coupled thereto is a replacement engine that replaces a previous engine in the powertrain.

[0132] Optionally, the housing is configured to be coupled to an engine elastically mounted in the power system and to a first AC generator rigidly mounted in the power system to transfer rotation of a shaft of the engine into rotation of a rotor of the first AC generator.

[0133] Optionally, the assembly further comprises a rotatable engine coupler connected to the engine side of the housing. The engine coupler may be configured to engage a rotatable shaft of the engine. The assembly may further comprise a rotatable alternator coupler connected to the alternator side of the housing. The alternator coupler may be configured to engage a rotor of the first alternator.

[0134] Optionally, the assembly further comprises an auxiliary rotatable shaft extending from the housing, the auxiliary rotatable shaft being configured to interconnect with a rotor of one or more of the auxiliary alternator or the auxiliary generator. The auxiliary rotatable shaft may be coupled to the engine coupler via interconnected gears within the housing.

[0135] Optionally, the auxiliary rotatable shaft extends from the housing at a position to couple with the rotor of one or more of the auxiliary alternator or auxiliary generators mounted on the first alternator.

[0136] Optionally, the auxiliary rotatable shaft is configured to be interconnected with a rotor of one or more of the auxiliary alternator or auxiliary generator via a belt.

[0137] Optionally, the assembly further comprises a tensioning device configured to vary the tension in the belt.

[0138] Optionally, the assembly further comprises a mounting bracket configured to couple to the first alternator and one or more of the auxiliary alternator or auxiliary generators to support the auxiliary alternator or one or more of the auxiliary generators on the first alternator.

[0139] Optionally, the assembly further comprises a rotatable socket in the housing. The rotatable socket may be coupled to an interconnected gear of the housing. The rotatable socket may be configured to interconnect with the engine shaft and the rotor of the alternator to transfer the rotation of the engine shaft to the rotation of the rotor of the alternator.

[0140] Optionally, the rotatable engine coupler includes an engine spline shaft configured to mate with a shaft of the engine and to be received in a rotatable socket in the housing. The rotatable alternator coupler may include an alternator spline shaft configured to mate with a rotor of the alternator and to be received in a rotatable socket in the housing.

[0141] Optionally, the rotatable socket has an internal groove shaped to mate with ridges on the outer surface of the engine spline shaft and the outer surface of the alternator spline shaft.

[0142] Optionally, the engine spline shaft and the alternator spline shaft do not abut in the rotatable sockets within the housing.

[0143] Optionally, the assembly further includes a flexible insulating coupling configured to interconnect the engine shaft and the rotatable engine coupler.

[0144] Optionally, the flexible insulating coupling includes a plurality of elongated flexible bodies arranged along the periphery of the rotatable engine coupler. Each elongated flexible body can be rotatably coupled to the rotatable engine coupler at a first end of the elongated flexible body, and is configured to be rotatably coupled to the shaft of the engine at an opposite second end of the elongated flexible body.

[0145] Optionally, the powered system is a vehicle, such as a locomotive.

[0146] In one embodiment, the shaft assembly includes a rotatable engine coupler configured to connect to the gearbox assembly and the rotatable shaft of the engine, and a rotatable alternator coupler configured to connect to the gearbox assembly and the rotor of the alternator. The engine coupler and the alternator coupler are each configured to be inserted into a common rotatable socket in the gearbox assembly to convert the rotation of the shaft of the engine into the rotation of the rotor of the alternator.

[0147] Optionally, the engine coupler includes a splined outer surface configured to mate with a grooved inner surface of a socket of the gearbox assembly.

[0148] Optionally, the alternator coupler includes a splined outer surface configured to mate with a grooved inner surface of a socket of the gearbox assembly.

[0149] Optionally, the engine coupler and the alternator coupler do not abut each other in a receptacle of the gearbox assembly.

[0150] Optionally, the assembly further includes a flexible insulating coupling connected to the engine coupling and configured to interconnect a shaft of the engine and the engine coupling.

[0151] Optionally, the flexible insulating coupling includes a plurality of elongated flexible bodies arranged along the periphery of the engine coupler. Each elongated flexible body can be rotatably coupled to the engine coupler at a first end of the elongated flexible body, and is configured to be rotatably coupled to the shaft of the engine at an opposite second end of the elongated flexible body.

[0152] Unless expressly stated to exclude otherwise, as used herein, an element or step listed in the singular and preceded by the word "a" should be understood not to exclude a plurality of said elements or steps. Furthermore, reference to "an embodiment" of the presently described subject matter is not intended to be interpreted as excluding the existence of additional embodiments that also include the recited features. Furthermore, unless expressly stated to the contrary, an embodiment that "comprises" or "includes" one or more elements having a particular property may include other such elements that do not have that property.

[0153] It should be understood that the above description is intended to be illustrative rather than restrictive. For example, the above embodiments (and / or aspects thereof) can be used in combination with each other. In addition, without departing from the scope thereof, the teachings of the subject matter set forth herein may be modified in several ways to adapt to specific situations or materials. Although the dimensions and types of materials described herein are intended to limit the parameters of the disclosed subject matter, they are not restrictive at all but exemplary embodiments. Upon reading the above description, many other embodiments will be apparent to those of ordinary skill in the art. Therefore, the scope of the subject matter described herein may be determined by reference to the appended claims and the full scope of equivalents granted to these claims. In the appended claims, the terms "including" and "in which" are used as the plain English equivalents of the terms "comprising" and "wherein". Moreover, in the following claims, the terms "first", "second" and "third" etc. are used merely as distinctions and are not intended to increase numerical requirements on these objects. Further, the limitations of the following claims are not written in a means-plus-function format and are not intended to be interpreted according to 35 U.S.C. §112 (f). Unless the claim limitation explicitly uses the phrase "means for..." followed by a recitation of function and no further structure.

[0154] This written description uses examples to disclose several embodiments of the subject matter described herein, including the best mode, and also to enable one of ordinary skill in the art to practice embodiments of the disclosed subject matter, including making and using devices or systems and performing methods. The patentable scope of the subject matter described herein is defined by the claims, and may include other examples that occur to one of ordinary skill in the art. Such other examples are intended to be included within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A vehicle engine system (200), comprising: a gearbox assembly (306) comprising a housing (402) having a plurality of interconnected gears (404) disposed between an engine side (406) of the housing (402) and an alternator side (408) of the housing (402); a rotatable engine coupler (410) extending from the engine side (406) of the housing (402), the engine coupler (410) being configured to engage a rotatable shaft of a replacement engine (302); and a rotatable alternator coupler (500) extending from the alternator side (408) of the housing (402), the alternator coupler (500) being configured to engage a rotor of a first alternator, wherein the housing (402) is configured to be disposed between and coupled to a plurality of different engines, the plurality of different engines including the replacement engine (302) that replaces a previous engine of the power system (100) and the first AC generator, The vehicle engine system further comprises a flexible insulating coupling (1002) configured to interconnect the shaft of the replacement engine (302) with the rotatable engine coupler (410); the flexible insulating coupling (1002) comprises an annular plate (1004) coupled to a plurality of elongated flexible bodies (1006), one end (1602) of the elongated flexible bodies (1006) being connected to the annular plate (1004) and the opposite end (1604) being connected to the flywheel (310) of the replacement engine (302) and being configured to be in a tensioned state when the replacement engine (302) rotates the flywheel (310); The engine coupler (410) is configured to engage the replacement engine (302) elastically mounted in the power system (100) and the AC generator coupler (500) is configured to engage the first AC generator rigidly mounted in the power system (100) to transfer the rotation of the shaft of the replacement engine (302) to the rotation of the rotor of the first AC generator; the engine coupler (410) is connected to the annular plate (1004).

2. The vehicle engine system (200) according to claim 1 further includes a rotatable auxiliary shaft (414) extending from the housing (402) and configured to be interconnected with a rotor of an auxiliary AC generator, the rotatable auxiliary shaft (414) being coupled to the engine coupler (410) via the interconnected gears (404) within the housing (402).

3. The vehicle engine system (200) according to claim 1, further comprising: an inlet conduit (1302) coupled to the housing (402) and fluidically coupled to an inner cavity in the housing (402), the inlet conduit (1302) being configured to be fluidically coupled to a liquid lubrication circuit of the engine (102), the inlet conduit (1302) being further configured to guide lubricant in the liquid lubrication circuit of the engine (102) into the inner cavity of the housing (402); and An outlet conduit (1400) is coupled to the housing (402) and is fluidly coupled to the inner cavity in the housing (402), the outlet conduit (1400) being configured to be fluidly coupled to a lubricant reservoir (1402) of the liquid lubrication circuit of the engine (102), and the outlet conduit (1400) being further configured to guide the lubricant in the inner cavity of the housing (402) into the lubricant reservoir (1402) of the liquid lubrication circuit of the engine (102).

4. The vehicle engine system (200) of claim 1, further comprising: A rotatable socket (608) within the housing (402), the rotatable socket (608) being coupled to the interconnected gear (404) of the housing (402), the rotatable socket (608) being configured to be interconnected with the shaft of the engine (102) and with the rotor of the AC generator (104) to transfer the rotation of the shaft of the engine (102) to the rotation of the rotor of the AC generator (104).

5. The vehicle engine system (200) of claim 2, wherein: The interconnected gears (404) within the housing (402) are configured to increase the rotational speed of the engine coupler (410) rotated by the shaft of the engine (102) to a faster rotational speed at which the rotatable auxiliary shaft (414) rotates.

6. The vehicle engine system (200) of claim 2, wherein: The rotatable auxiliary shaft (414) extends from the housing (402) at a location where it is coupled to the rotor of the auxiliary alternator mounted on the first alternator.

7. The vehicle engine system (200) of claim 2, wherein: The rotatable auxiliary shaft (414) is configured to be interconnected with the rotor of the auxiliary alternator via a belt (418).

8. The vehicle engine system (200) of claim 2, further comprising: A mounting bracket (400) is configured to be coupled to the first alternator and to the auxiliary alternator to support the auxiliary alternator on the first alternator.

9. The vehicle engine system (200) of claim 8, wherein: The mounting bracket (400) is also configured to support a rotatable auxiliary shaft (414) and a bearing on which the rotatable auxiliary shaft rotates.

10. The vehicle engine system (200) of claim 4, wherein: The rotatable engine coupler (410) includes an engine spline shaft and is configured to cooperate with the shaft of the engine and be received in a rotatable socket (608) in the housing (402), wherein the rotatable AC generator coupler (500) includes an AC generator spline shaft, and the AC generator spline shaft is configured to cooperate with the rotor of the AC generator and be received in a rotatable socket in the housing (402).

11. The vehicle engine system (200) of claim 10, wherein: The rotatable socket has an internal groove shaped to mate with ridges on the outer surface of the engine spline shaft and the outer surface of the alternator spline shaft.

12. The vehicle engine system (200) of claim 10, wherein: The engine spline shaft and the alternator spline shaft do not abut each other in the rotatable socket within the housing (402).

13. The vehicle engine system (200) of claim 1, wherein: The elongated flexible body (1006) is made of a dielectric material, and the elongated flexible body (1006) is configured to electrically insulate the flywheel (310) of the replacement engine (302) from the engine coupler (410).

14. The vehicle engine system (200) of claim 1, wherein: Each of the elongated flexible bodies (1006) is rotatable about an end relative to the annular plate (1004) and about an end relative to the flywheel (310) of the replacement engine (302).

15. A vehicle engine system (200), comprising: a gearbox assembly (306) comprising a housing (402) having a plurality of interconnected gears (404) disposed between an engine side (406) of the housing (402) and an alternator side (408) of the housing (402); a rotatable engine coupler (410) extending from the engine side (406) of the housing (402), the engine coupler (410) being configured to engage a rotatable shaft of a replacement engine (302); and a rotatable alternator coupler (500) extending from the alternator side (408) of the housing (402), the alternator coupler (500) being configured to engage a rotor of a first alternator, wherein the housing (402) is configured to be disposed between and coupled to a plurality of different engines, the plurality of different engines including the replacement engine (302) that replaces a previous engine of the power system (100) and the first AC generator, The vehicle engine system further comprises a flexible insulating coupling (1002) configured to interconnect the shaft of the replacement engine (302) with the rotatable engine coupler (410); the flexible insulating coupling (1002) comprises an annular plate (1004) coupled to a plurality of elongated flexible bodies (1006), one end (1602) of the elongated flexible bodies (1006) being connected to the annular plate (1004) and an opposite end (1604) being connected to a flywheel (310) of the replacement engine (302); wherein the elongated flexible body (1006) is rotatable about an end relative to the annular plate (1004) and an end relative to the flywheel (310) of the replacement engine (302), respectively; and Wherein, for each of the slender flexible bodies (1006), the end coupled to the annular plate (1004) revolves around a first axis, and the end coupled to the flywheel (310) of the replacement engine (302) revolves around a second axis, the multiple first axes and the multiple second axes of the multiple slender flexible bodies (1006) are different from each other, and the multiple first axes and the multiple second axes are all parallel to the third axis around which the engine coupler (410) rotates.

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