An air-cooled turbocharged diesel generator set

Abstract

The present invention discloses an air-cooled turbocharged diesel generator set, comprising a diesel engine, a turbocharger, and a generator. The turbine comprises a housing, turbine blades, and an intake valve, and the compressor comprises a compressor impeller. The turbine blades are disposed within the housing and are axially movably sleeved on a rotating shaft via a spline, and the compressor impeller is connected to one end of the rotating shaft. The drive device comprises a driver, a push rod, and a shift fork. The driver is connected to the shift fork and the intake valve via the push rod, and is configured to synchronously shift the turbine blades along the rotating shaft to a central position within the housing when the intake valve is pushed open. The present invention enables the turbine blades to increase their rotational speed smoothly, avoiding the impact on the diesel engine and generator caused by speed jumps when the turbine is turned on. This can extend the service life of the diesel engine and generator, and improve the stability of the generator set's output voltage.

Description

Technical Field

[0001] The present application relates to the technical field of diesel generators, and in particular to an air-cooled turbocharged diesel generator set. Background Art

[0002] The power generated by a diesel generator is directly proportional to the displacement of the diesel engine. The greater the power generated, the larger the diesel engine's displacement, resulting in a larger generator set. In the prior art, turbochargers are used to increase the power generated by diesel generators and control their size. These turbochargers compress more air into the diesel engine, thereby increasing the engine's power. The introduction of a turbocharger can increase the power of a diesel engine by approximately 20%. Because turbochargers operate at a high speed, exhaust gas is introduced into the turbocharger to propel the diesel engine only when the diesel engine's speed reaches a certain level. The inventors discovered that when a turbocharger is engaged, the diesel engine's output torque and speed increase instantaneously, causing a significant impact on the generator connected to the diesel engine. This not only shortens the generator's lifespan but also causes output voltage fluctuations, impacting user equipment. Summary of the Invention

[0003] In view of the above problems, the present application provides an air-cooled turbocharged diesel generator set, which is used to reduce the impact when the above-mentioned turbocharger is involved.

[0004] To achieve the above object, the inventor provides an air-cooled turbocharged diesel generator set, comprising a diesel engine, a turbocharger and a generator;

[0005] The turbocharger is used to increase the intake pressure of the diesel engine, and includes a turbine, a compressor, and a drive device; the turbine is connected to the exhaust pipe of the diesel engine, and the compressor is connected to the intake pipe of the diesel engine;

[0006] The turbine includes a housing, turbine blades, and an intake valve, and the compressor includes a compressor impeller; the turbine blades are disposed in the housing and are axially movably sleeved on a rotating shaft via splines, and the compressor impeller is connected to one end of the rotating shaft;

[0007] The driving device includes a driver, a push rod and a shift fork, and the outer edge of the turbine blade is provided with a contact portion that cooperates with the shift fork;

[0008] The driver is connected to the shift fork and the intake valve via the push rod, and is used to synchronously shift the turbine blades along the rotating shaft to a middle position of the housing when pushing the intake valve to open.

[0009] Furthermore, the driver is a proportional electric push rod, which is used to control the proportional and gradual opening of the intake valve and the proportional and gradual movement of the shift fork to the middle position of the housing, so that the rotation speed of the turbine blade increases smoothly.

[0010] Furthermore, a plurality of supporting bearings are provided in the middle of the rotating shaft, and a lubrication cavity is provided outside the supporting bearings, and the lubrication cavity is provided with an oil inlet and an oil outlet.

[0011] Furthermore, the support bearing is a full floating bearing.

[0012] Furthermore, it also includes an intercooler, and the air outlet of the compressor is connected to the air inlet pipe through the intercooler.

[0013] Furthermore, a fan is provided at the front end of the diesel engine, and the intercooler is located at the air outlet side of the fan.

[0014] Furthermore, the rated speed of the diesel engine is greater than or equal to 3000 rpm, and the output power is less than or equal to 18KW.

[0015] Furthermore, the push rod is a push rod with adjustable length.

[0016] Furthermore, the generator and the diesel engine are fixedly connected by bolts.

[0017] Furthermore, the turbocharger is arranged on the upper side of the diesel engine.

[0018] Different from the prior art, the above-mentioned technical solution of the air-cooled turbocharged diesel generator set includes a diesel engine, a turbocharger and a generator, wherein the turbocharger is used to increase the intake pressure of the diesel engine, thereby increasing the output power of the diesel engine. In this technical solution, a driving device is added to control the start of the turbine, wherein the driving device includes a driver, a push rod and a shift fork, and the driver is connected to the shift fork and the intake valve through the push rod, and is used to synchronously shift the turbine blades along the rotating shaft to the middle position of the housing when pushing the intake valve to open, so that the intake valve of the turbine can be slowly opened, and the turbine blades are slowly pushed by the push rod to the middle position in the turbine housing, so that the speed of the turbine blades can be increased smoothly, avoiding the impact of the speed jump on the diesel engine and the generator when the turbine is turned on, which can extend the service life of the diesel engine and the generator, and improve the stability of the output voltage of the generator set.

[0019] The above-mentioned records related to the content of the invention are only an overview of the technical solution of this application. In order to enable ordinary technicians in this field to understand the technical solution of this application more clearly, and then implement it according to the text of the specification and the contents recorded in the drawings, and to make the above-mentioned purposes and other purposes, features and advantages of this application easier to understand, the following is an explanation in combination with the specific implementation methods and drawings of this application. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The drawings are only used to illustrate the principles, implementation methods, applications, features and effects of the specific embodiments of the present invention and other related contents, and are not to be considered as limiting the present application.

[0021] In the drawings of the specification:

[0022] Figure 1 This is a schematic diagram of the three-dimensional structure of the air-cooled turbocharged diesel generator set described in the specific embodiment;

[0023] Figure 2 It is a side view of the air-cooled turbocharged diesel generator set described in the specific embodiment;

[0024] Figure 3 Schematic diagram of the three-dimensional structure of the turbocharger according to the specific embodiment;

[0025] Figure 4 is a side view of the turbocharger according to the specific embodiment;

[0026] Figure 5 Schematic diagram of the internal structure of the turbocharger described in the specific embodiment Figure 1 ;

[0027] Figure 6 Schematic diagram of the internal structure of the turbocharger described in the specific embodiment Figure 2 ;

[0028] The reference numerals in the above drawings are described as follows:

[0029] 1. Diesel engine; 11. Fan; 12. Starter motor;

[0030] 2. Generator;

[0031] 3. Turbocharger;

[0032] 31. Intake pipe; 32. Compressor; 33. Turbine; 34. Driver; 35. Push rod; 36. Shift fork; 37. Support bearing; 38. Lubrication chamber;

[0033] 321, air outlet; 322, compressor impeller; 331, exhaust gas inlet; 332, turbine blade; 333, contact part; 361, shift fork handle; 381, oil inlet; 382, oil outlet; DETAILED DESCRIPTION

[0034] In order to explain in detail the possible application scenarios, technical principles, specific solutions that can be implemented, and the purpose and effects of this application, the following is a detailed description of the specific embodiments listed in conjunction with the accompanying drawings. The embodiments described herein are only used to more clearly illustrate the technical solutions of this application and are therefore only examples and are not intended to limit the scope of protection of this application.

[0035] References to "embodiments" herein mean that the specific features, structures, or characteristics described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the word "embodiment" in various places in the specification does not necessarily refer to the same embodiment, nor does it particularly limit its independence or relevance to other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the various technical features mentioned in the embodiments can be combined in any manner to form a corresponding implementable technical solution.

[0036] Unless otherwise defined, the technical terms used herein have the same meanings as those generally understood by those skilled in the art to which this application belongs; the use of relevant terms herein is only for describing specific embodiments and is not intended to limit this application.

[0037] In the description of this application, the term "and / or" is used to describe a logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and both A and B exist. In addition, the character " / " in this document generally indicates that the objects before and after are in a logical "or" relationship.

[0038] In this application, terms such as "first" and "second" are merely used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual quantity, priority or sequence relationship between these entities or operations.

[0039] Without further limitations, in this application, the words "include", "comprise", "have" or other similar open-ended expressions used in sentences are intended to cover non-exclusive inclusion. These expressions do not exclude the presence of additional elements in the process, method or product that includes the elements, so that the process, method or product that includes a series of elements may include not only those defined elements, but also other elements that are not explicitly listed, or also include elements inherent to such process, method or product.

[0040] Consistent with the understanding in the Examination Guidelines, in this application, expressions such as "greater than," "less than," and "exceed" are understood to exclude the number itself; expressions such as "above," "below," and "within" are understood to include the number itself. In addition, in the description of the embodiments of this application, "multiple" means more than two (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise clearly and specifically limited.

[0041] In the description of the embodiments of the present application, the space-related expressions used, such as "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "vertical", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicate the orientation or position relationship based on the orientation or position relationship shown in the specific embodiments or drawings, and are only for the convenience of describing the specific embodiments of the present application or facilitating the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, it should not be understood as a limitation on the embodiments of the present application.

[0042] Unless otherwise expressly specified or limited, in the description of the embodiments of the present application, the terms "installed", "connected", "connected", "fixed", "set", etc. used should be understood in a broad sense. For example, the "connection" can be a fixed connection, a detachable connection, or an integrated setting; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two elements or the interaction relationship between two elements. For those skilled in the art of the present application, the specific meanings of the above terms in the embodiments of the present application can be understood according to the specific circumstances.

[0043] See also Figures 1 to 6 , this embodiment provides an air-cooled turbocharged diesel generator set. Figure 1 and Figure 2As shown, the air-cooled turbocharged diesel generator set includes a diesel engine 1, a turbocharger 3, and a generator 2. The turbocharger 3 is used to increase the intake pressure of the diesel engine 1, and includes a turbine 33, a compressor 32, and a drive device. The turbine 33 is connected to the exhaust pipe of the diesel engine 1, and the compressor 32 is connected to the intake pipe 31 of the diesel engine 1. The turbine 33 includes a housing, turbine blades 332, and an intake valve. The compressor 32 includes a compressor impeller 322. The turbine blades 332 are arranged in the housing and are axially movably sleeved on the rotating shaft through splines. The compressor impeller 322 is connected to one end of the rotating shaft. The drive device includes a driver 34, a push rod 35, and a shift fork 36. The outer edge of the turbine blade 332 is provided with a contact portion 333 that cooperates with the shift fork 36.

[0044] The driver 34 is connected to the shift fork 36 and the intake valve via the push rod 35 , and is used to synchronously shift the turbine blades 332 along the rotating shaft to the middle position of the housing when pushing the intake valve to open.

[0045] Among them, Figure 3 and Figure 4 The figure shows a schematic diagram of the turbocharger structure. The compressor is equipped with an air outlet 321 and an air outlet, and the turbine housing is provided with an exhaust gas inlet 331 and an exhaust gas outlet. The turbine and impeller are respectively installed in the turbine chamber and the turbocharger. Specifically, the turbine housing contains the turbine chamber, the turbine chamber's air inlet is connected to the exhaust manifold, and the exhaust port is connected to the exhaust pipe. The compressor's air inlet is connected to the air filter duct of the intake pipe, and the exhaust port is connected to the intake pipe leading to the intake manifold.

[0046] A turbocharger utilizes the energy of diesel engine exhaust gases to operate, with the turbocharger's centrifugal compressor providing compressed air as the charge for the diesel generator. In a turbocharger, the compressor impeller and turbine wheel are mounted on a common shaft, called a rotor, and rotate together. A turbocharger increases the intake air volume of the diesel generator by compressing air. It uses the inertial momentum of the diesel engine's exhaust gases to rotate the turbine blades within the turbine chamber. These, in turn, drive the coaxial compressor impeller, which pressurizes air delivered from the air filter duct and enters the diesel engine's cylinders. As the diesel engine speed increases, the exhaust gas velocity and turbine speed also increase, causing the compressor impeller to compress more air into the cylinders. The increased air pressure and density allow for the combustion of more fuel. By increasing the fuel flow and adjusting the engine speed, the engine's output power can be increased.

[0047] Preferably, the rated speed of the diesel engine 1 is greater than or equal to 3000 rpm, and the output power is less than or equal to 18KW.

[0048] Described diesel engine is provided with starting motor 12, and starting motor 12 is connected with the flywheel of diesel generator by belt.When air-cooled turbocharged diesel generator set starts, the crankshaft of flywheel is driven to rotate by starting motor 12, thereby starts diesel engine.

[0049] like Figure 1 and Figure 5 In this embodiment, the shift fork has a Y-shaped structure and includes a shift fork handle 361 and a fork body disposed at the end of the shift fork handle. The shift fork handle is connected to the push rod, thereby driving the shift fork to move axially along the rotating shaft. Specifically, the push rod is connected to the rotating shaft of the intake valve and pushes the intake valve to rotate open and close. The shift fork handle 361 is connected to the rotating shaft of the intake valve via a connecting rod, thereby driving the shift fork to move via the push rod and the rotating shaft. Therefore, through this embodiment, the push rod can simultaneously push the intake valve to open and the turbine blades to move toward the middle position of the housing, thereby allowing the exhaust gas from the diesel generator to gradually enter the turbine housing through the exhaust gas inlet 311 and simultaneously causing the turbine blades to gradually move toward the middle position of the housing, gradually approaching the exhaust gas inlet 311. This embodiment simultaneously controls the exhaust gas intake volume of the turbine and the position of the turbine blades and the exhaust gas inlet 311, thereby allowing the turbine speed to slowly increase during startup.

[0050] During operation, the diesel engine is first started by the starter motor 12. At this time, the intake valve is closed, the turbine has not yet started, and the turbine blades are not located in the turbine chamber facing the air inlet. As the diesel engine speed increases to a preset value (for example, 2000 rpm), the driver controls the push rod intake valve to gradually open at a certain speed and controls the turbine blades to move synchronously toward the position of the turbine chamber near the air inlet. As a result, the air intake volume of the turbine chamber increases gradually, and the turbine blades gradually approach the air inlet, so that the turbine speed can slowly increase during startup.

[0051] In this embodiment, an air-cooled turbocharged diesel generator set includes a diesel engine 1, a turbocharger 3, and a generator 2. The turbocharger 3 is used to increase the intake pressure of the diesel engine 1, thereby increasing its output power. While maintaining the same displacement, the intake density can be increased, allowing the diesel engine to inject more fuel, thereby increasing engine power. The addition of a turbocharger can increase the power and torque of a diesel engine by 20% to 30%. Conversely, while maintaining the same power output, the cylinder diameter of the diesel engine can be reduced, reducing its size and weight. A diesel engine equipped with a turbocharger can improve combustion efficiency and reduce the amount of harmful components such as particulate matter and nitrogen oxides in the engine exhaust. It is an essential feature for diesel engines to meet Euro II emission standards and above. Furthermore, a turbocharger improves fuel economy and reduces fuel consumption. Due to the improved combustion performance of a diesel engine equipped with a turbocharger, fuel savings of 3% to 5% can be achieved.

[0052] In addition, in this embodiment, a driving device is added to control the start of the turbine, wherein the driving device includes a driver 34, a push rod and a shift fork. The driver 34 is connected to the shift fork and the intake valve through the push rod, and is used to synchronously move the turbine blades 332 along the rotating shaft to the middle position of the housing when pushing the intake valve to open, so that the intake valve of the turbine can be slowly opened, and the turbine blades are slowly pushed by the push rod to the middle position in the turbine housing, so that the speed of the turbine blades can be increased smoothly, avoiding the impact of speed jumps on the diesel engine 1 and the generator 2 when the turbine is started, which can extend the service life of the diesel engine and the generator, and improve the stability of the output voltage of the generator set.

[0053] In some embodiments, the actuator 34 is a proportional electric push rod, which is used to control the proportional and gradual opening of the intake valve and the proportional and gradual movement of the shift fork 36 toward the center of the housing, thereby gradually increasing the rotation speed of the turbine blades 332. The proportional electric push rod includes a stepper motor, which drives the telescopic rod of the proportional electric push rod to extend and retract. The stepper motor generates a corresponding rotation angle based on input pulse information, thereby driving the telescopic rod to move a corresponding length.

[0054] In this embodiment, the proportional electric push rod can accurately control the movement speed and amount of the intake valve and turbine blades, and can control the intake valve and turbine blades to move at a fixed speed, so that the turbine can increase the speed according to the preset value.

[0055] In some embodiments, the push rod 35 is a push rod with adjustable length. Figure 4As shown, the push rod 35 includes a push rod body and an adjusting rod. The end of the push rod body is provided with an external bolt, and the end face of the adjusting rod is provided with a threaded hole adapted to the external bolt. By rotating the adjusting rod, the axial relative position of the adjusting rod and the push rod body can be adjusted, thereby adjusting the length of the entire push rod.

[0056] like Figure 6 As shown, in some embodiments, a plurality of support bearings 37 are disposed in the middle of the rotating shaft, and a lubrication cavity 38 is disposed outside the support bearings 37. The lubrication cavity 38 is provided with an oil inlet 381 and an oil outlet 382. The plurality of support bearings 37 are spaced apart in the middle of the rotating shaft, allowing the rotating shaft to rotate smoothly at high speed. The lubrication cavity 38 can be formed by enclosing a plurality of arc-shaped pieces. When the turbocharger is operating, lubricating oil enters the lubrication cavity 38 through the oil inlet 381 and flows out through the oil outlet 382. The lubricating oil in the lubrication cavity 38 not only provides lubrication to reduce the resistance of the support bearings, but also acts as a cooling agent to prevent damage to the turbine due to excessive temperature.

[0057] In some embodiments, the support bearing 37 is a fully floating bearing. These bearings lack a rotor. Instead, they fill two gaps with lubricating oil at a pressure of 0.25-0.4 MPa, allowing the floating bearing to rotate in the same direction as the rotor shaft within the oil film, at a speed significantly faster than the rotor shaft. Fully floating bearings only transmit torque and are not subject to any reaction forces or bending moments. In this embodiment, the use of fully floating bearings can further reduce the rotational resistance of the rotating shaft and its high-temperature resistance, thereby further extending the service life of the turbocharger.

[0058] In some embodiments, an intercooler is also included, and the air outlet of the compressor 32 is connected to the air intake pipe 31 through the intercooler. Since the temperature of the compressed gas is relatively high, this not only affects the charging efficiency, but also easily causes deflagration. Therefore, a device for lowering the intake air temperature must be installed. Therefore, in this embodiment, an intercooler, or an intermediate cooler, is provided between the turbocharger outlet and the intake pipe to cool the air entering the cylinder. The intercooler uses air cooling or water cooling, and the heat of the air is dissipated into the atmosphere through cooling, thereby reducing the intake air temperature. An intercooler with good performance can not only keep the compression ratio of the diesel engine at a high value without causing deflagration, but also reduce the temperature to increase the intake pressure, further improving the effective power of the engine. The structure of the intercooler is similar to that of a water tank radiator. It is equipped with many small pipes inside, which disperse the high-temperature and high-pressure air into many small pipes. Normal-temperature air flows through the outside of the pipes at high speed (some use circulating water cooling or cooling fans) to achieve the purpose of cooling (the temperature of the compressed air can be reduced from 150°C to about 50°C). While increasing the engine power output, it reduces the temperature of the engine compression starting point and the average temperature of the entire cycle, thereby reducing the engine's exhaust temperature, heat load and NOx emissions.

[0059] like Figure 1 and Figure 2 As shown, in some embodiments, a fan 11 is provided at the front end of the diesel engine 1, and the intercooler is located on the air outlet side of the fan 11. The fan 11 is located at the front end of the diesel engine's flywheel. When the diesel engine is operating, the flywheel drives the fan 11 to rotate at high speed, generating a large amount of airflow that blows toward the diesel engine body at the rear end, thereby reducing the surface temperature of the diesel engine and maintaining its operation within a stable temperature range.

[0060] In some embodiments, the generator 2 is fixedly connected to the diesel engine 1 via bolts. In this embodiment, the generator 2 comprises a housing, a stator, and a rotor disposed within the housing. The housing is fixedly connected to the rear end of the diesel engine via bolts, and the rotor is connected to the diesel engine's power output shaft. In this embodiment, the direct connection of the generator 2 to the diesel engine 1 results in a smaller generator set and higher transmission efficiency.

[0061] like Figure 1 and Figure 2 As shown, in some embodiments, the turbocharger is disposed on the upper side of the diesel engine 1. The turbocharger 3 is fixedly connected to the upper side of the diesel engine (i.e., the upper side) via a mounting bracket, so that a large amount of heat generated by the turbocharger during operation can be directly dissipated to the external space of the diesel engine by the action of the fan.

[0062] Finally, it should be noted that although the above embodiments have been described in the specification and drawings of this application, this does not limit the scope of patent protection of this application. All technical solutions generated by replacing or modifying equivalent structures or equivalent processes based on the essential concepts of this application using the contents recorded in the specification and drawings of this application, as well as directly or indirectly implementing the technical solutions of the above embodiments in other related technical fields, are included in the scope of patent protection of this application.

Claims

1. An air-cooled turbocharged diesel generator set, characterized in that: Includes diesel engine, turbocharger and generator; The turbocharger is used to increase the intake pressure of the diesel engine, and includes a turbine, a compressor, and a drive device; the turbine is connected to the exhaust pipe of the diesel engine, and the compressor is connected to the intake pipe of the diesel engine; The turbine includes a housing, turbine blades, and an intake valve, and the compressor includes a compressor impeller; the turbine blades are disposed in the housing and are axially movably sleeved on a rotating shaft via splines, and the compressor impeller is connected to one end of the rotating shaft; The driving device includes a driver, a push rod and a shift fork. The outer edge of the turbine blade is provided with a contact portion that cooperates with the shift fork. The shift fork is a Y-shaped structure, including a shift fork handle and a fork body provided at the end of the shift fork handle. The shift fork handle is connected to the push rod, and the push rod is connected to the rotating shaft of the intake valve. The driver is connected to the shift fork and the intake valve via the push rod, and is used to synchronously shift the turbine blades along the rotating shaft to a middle position of the housing when pushing the intake valve to open; The driver is a proportional electric push rod, which is used to control the proportional gradual opening of the intake valve and the proportional gradual movement of the shift fork toward the middle position of the housing, so that the rotation speed of the turbine blades increases smoothly when the turbine is started.

2. The air-cooled turbocharged diesel generator set according to claim 1, characterized in that: A plurality of supporting bearings are arranged in the middle of the rotating shaft, and a lubricating cavity is arranged outside the supporting bearings. The lubricating cavity is provided with an oil inlet and an oil outlet.

3. The air-cooled turbocharged diesel generator set according to claim 2, characterized in that: The support bearing is a fully floating bearing.

4. The air-cooled turbocharged diesel generator set according to claim 1, characterized in that: It also includes an intercooler, and the air outlet of the compressor is connected to the air inlet pipe through the intercooler.

5. The air-cooled turbocharged diesel generator set according to claim 4, characterized in that: A fan is provided at the front end of the diesel engine, and the intercooler is located at the air outlet side of the fan.

6. The air-cooled turbocharged diesel generator set according to claim 1, characterized in that: The rated speed of the diesel engine is greater than or equal to 3000 rpm, and the output power is less than or equal to 18KW.

7. The air-cooled turbocharged diesel generator set according to claim 1, characterized in that: The push rod is a push rod with adjustable length.

8. The air-cooled turbocharged diesel generator set according to claim 1, characterized in that: The generator is fixedly connected to the diesel engine via bolts.

9. The air-cooled turbocharged diesel generator set according to claim 1, characterized in that: The turbocharger is arranged on an upper side of the diesel engine.

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