Adapter for rotating an electric machine

Abstract

An adapter for connecting a rotary electric machine to a prime mover is disclosed. The adapter comprises a first portion (52) arranged to surround the fan and a second portion (54) arranged to provide access to a rotating component for connecting the rotating electrical machine to the prime mover. The first portion provides appropriate air diffusion characteristics for the fan, while the second portion provides appropriate apertures for access to the rotating assembly. This may help improve the rate of airflow from the fan while providing access to the rotating assembly.

Description

[0001] The present invention relates to an adaptor for connecting a rotating electrical machine to a prime mover, and in particular to an adaptor that helps improve airflow through the machine and facilitates connection of the machine to the prime mover.

[0002] The power generation system generally includes a prime mover connected to a rotating electrical machine. For example, a generator set may include an internal combustion engine, such as a diesel engine, that is coupled to a generator (alternator). The engine is used to drive a generator to generate output power. This is achieved by mechanically connecting the rotating parts of both the engine and the generator. The engine and the generator are generally mounted on a pedestal. An adapter may be used to connect the non-rotating parts of both the generator and the engine, such as a generator frame and a flywheel housing. An adapter may convert a set of connections on the generator into another set of connections on the prime mover. Using an adapter helps prevent relative movement between the engine and the generator.

[0003] Many rotating electrical machines, particularly those of larger design, require some form of cooling. This can be achieved by providing a fan that causes airflow through the machine. The fan can be mounted on the machine shaft inside the adapter. An air outlet is provided in the adapter to provide an outlet path for the airflow. The air outlet can also provide access for the operator to connect the rotating parts of both the engine and the generator during assembly.

[0004] International patent application number WO 2017 / 158322 A1 (the subject matter of which is incorporated herein by reference) discloses an adapter having a plurality of air outlets and a plurality of walls arranged to provide an increase in the cross-sectional area of ​​the air flow toward the air outlets. The walls can provide a gradual decrease in the air flow velocity by a steady expansion of the air flow cross section, which can help increase the air flow rate through the machine.

[0005] International patent application number WO 2019 / 243829 A1 (the subject matter of which is incorporated herein by reference) discloses an adapter having a rear member, a front member, and a plurality of wedge-shaped cross members. The cross members can act as diffusers for airflow from a fan, thereby facilitating good airflow and thermal performance while being efficient from a structural and cost perspective.

[0006] The adapters disclosed in WO 2017 / 158322 A1 and WO 2019 / 243829 A1 can help improve airflow through the machine. However, in existing adapter designs, the adapter must also provide access to the drive coupling to connect the machine to the prime mover. It has been found that this actually sacrifices some of the air diffusion capacity of the adapter. This in turn may lead to a reduction in heat dissipation.

[0007] Therefore, it is desirable to increase the airflow rate through the machine by improving the air diffusion characteristics of the adapter while at the same time allowing access to the rotating assembly.

[0008] According to one aspect of the present invention, there is provided an adapter for connecting a rotating electrical machine to a prime mover, the adapter comprising:

[0009] a first portion, the first portion being configured to surround the fan; and

[0010] A second portion is configured to provide access to a rotating assembly for connecting the rotating electrical machine to the prime mover.

[0011] The present invention can provide the following advantages: by dividing the adapter into a first portion arranged to surround the fan, and a second portion arranged to provide access to the rotating assembly to connect the machine to the prime mover, the first portion can provide the appropriate air diffusion characteristics for the fan, while the second portion can provide appropriate openings to access the rotating assembly. This can help improve the airflow rate from the fan while providing access to the rotating assembly.

[0012] Preferably, the first part is arranged to be connected to a rotating electrical machine and the second part is arranged to be connected to a prime mover. For example, the first part may be arranged to be connected to a housing or frame of a machine and the second part may be arranged to be connected to a non-rotating part of the prime mover, such as a flywheel housing.

[0013] The fan may be, for example, a fan mounted on the shaft of the rotating electrical machine. The fan is preferably arranged to draw cooling air through the machine. The rotating assembly may be, for example, a coupling disc and may be arranged to be connected to a rotating assembly of the prime mover, such as a flywheel, or to another rotating assembly, such as a shaft. The rotating assembly may be connected to the prime mover, for example, using bolts or using any other appropriate fasteners.

[0014] Preferably, the first part and the second part are adjacent to each other in the axial direction, and preferably abut each other.Thus, the first part and the second part can be combined to form a physical connection between the machine and the prime mover, for example between the machine housing and the flywheel housing.

[0015] The second portion is preferably arranged to space the first portion axially from the prime mover. This can allow the second portion to provide space for accessing the interior of the adapter when the rotary electric machine is connected to the prime mover, while allowing the first portion to provide appropriate air dispersion characteristics for the fan.

[0016] The second part may include a front member and a plurality of cross members, which connect the front member to the first part. The front member may, for example, be in the form of an annular disk. The front member may be arranged to be connected to a non-rotating part of the prime mover, such as a flywheel housing. The cross member may extend axially between the front member and the first part. This may allow the second part to space the first part axially from the prime mover. The cross member may, for example, have a T-shaped or U-shaped cross section or any other appropriate shape.

[0017] Preferably, an access window is defined between two adjacent cross members in the circumferential direction. The access window may allow access to a rotating component, such as a coupling disc, for connecting the machine to the prime mover. Preferably, the access window is arranged to allow insertion and rotation of a tool for connecting the rotating electrical machine to the prime mover. For example, the access window may allow insertion and rotation of a wrench to tighten bolts connecting the coupling disc to the engine flywheel and / or bolts connecting the adapter to the flywheel housing. The access window may be larger in the circumferential direction than in the axial direction so as to allow rotation of the tool while minimizing the axial width of the second portion.

[0018] The first portion is preferably arranged to allow cooling air to leave the machine.Thus, the first portion may comprise a plurality of outlet paths for airflow from the fan.

[0019] The first part can, for example, act as a diffuser, that is, it can act to ensure that air moves from an area of ​​higher concentration to an area of ​​lower concentration. For example, the first part can be arranged to provide a stable expansion of the air flow cross section in the direction of the air flow through the adapter. This can provide a gradual reduction in air velocity, which can help convert part of the dynamic pressure into additional static pressure. For a given fan input power, this in turn can help increase the total amount of cooling air passing through the machine.

[0020] The adapter may include a middle member, which may be in the form of an annular disk, for example. The middle member may act as a wall to at least partially separate the first and second parts of the adapter. For example, the middle member may help guide airflow from the fan in a radially outward direction and / or at least partially prevent airflow from the fan from entering the second part. The middle member may be provided as part of the first part and / or part of the second part of the adapter, or as a separate component.

[0021] The first part may include: a rear member and a plurality of vanes extending axially outward from the rear member. For example, the first part may include a rear member, a middle member and / or a plurality of vanes connecting the middle member to the rear member. Alternatively, the middle member may be arranged on the second part. The middle member and / or the rear member may be annular. For example, the middle member and / or the rear member may take the form of an annular disk. The vanes may function to physically connect the middle member to the rear member. Therefore, the vanes may function to ensure the physical rigidity of the adapter while also providing air diffusion properties. The vanes may, for example, be flat, wedge-shaped, aerofoil-shaped, or any other appropriate shape. The outlet path may be limited between adjacent vanes to allow airflow to leave the machine.

[0022] The blades may be at a (non-zero) angle with respect to a radial direction through the adapter. Thus, when viewed axially, a centerline through the blade (e.g., a line equidistant from the two side surfaces of the blade and / or a line passing from the radially inward edge of the blade through the center of the blade) may be angled with respect to the radial direction. For example, the blades may be at an angle approximately equal to the angle at which the airflow leaves the fan. This may help ensure that the blades minimally obstruct the airflow.

[0023] Where the second portion comprises a front member and a plurality of cross members, the number of blades may be greater than the number of cross members. This may allow the second portion to provide a sufficiently large access window in the circumferential direction to allow the machine to be connected to the prime mover whilst allowing the number of blades to be optimised for airflow.

[0024] Preferably, the width of the second portion in the axial direction is smaller than the width of the first portion. This may allow a reduced number of cross members to be used in the second portion, thereby allowing an access window of a desired size to be provided. In particular, a relatively large access window in the circumferential direction may be provided, which may allow a wrench to be rotated when tightening a bolt.

[0025] The blades are preferably substantially the same width in the axial direction as the width of the fan. This can help to improve the ability of the fan to draw cooling air by avoiding or reducing axial gaps or clearances adjacent to the fan blades.

[0026] The fan may also include a back plate, in which case the middle member may be substantially aligned with the back plate in an axial direction. For example, the middle member may be located radially outward of the back plate. This may help ensure smooth airflow through the fan, which may help cooling.

[0027] In one embodiment, the first part and the second part are integrally formed. For example, the first part and the second part may be molded as a single component, or may be manufactured in any other manner (eg, fabrication).

[0028] In another embodiment, the first part and the second part are manufactured as separate components. In this case, the second part can be removably connected to the first part. This can allow different types of second parts to be used with the same type of first part. Therefore, the adapter can be configured so that multiple different types of second parts can be connected to the first part. For example, the second part can be replaceable to match different flywheel housing connections, rather than replacing the entire adapter. Moreover, the second part can be replaced with a bearing support part. This can allow a single-bearing machine and a dual-bearing machine to share the same first part.

[0029] In some embodiments, the axial width of the second portion can be relatively small. This can allow a larger window to be provided in the circumferential direction, which can facilitate assembly. However, in some cases, the relatively small axial width of the second portion may limit hand access. Therefore, in some embodiments, a section of the adapter is removable to provide improved access.

[0030] The adapter may thus include at least one section that is removable to improve access to the rotating assembly to connect the rotating electrical machine to the prime mover. The removable section may, for example, include at least a portion of the front member, middle member or blade, or any other portion, or any combination thereof.

[0031] In another embodiment, the adapter further comprises at least one removable cover, and at least one removable cover comprises blades. The blades may be arranged at a position on the cover corresponding to an area of ​​the first portion that does not have blades. The blades on the cover may have a shape that is the same or similar to at least one of the blades on the first portion. Thus, for example, the first portion may have a "missing" blade to improve access, and the aerodynamic properties of the "missing" blade may be reintroduced as part of the removable cover. This may allow the adapter to have similar aerodynamic performance to an adapter that does not have missing blades.

[0032] As described above, the first part may be arranged to be connected to the housing of the machine. Thus, the first part may include suitable connections (such as bolt holes) for connecting the adapter to the machine housing. Alternatively, the machine housing and the first part may be provided as a single component. The single component may be, for example, a manufactured component. Thus, the first part may be integral with the machine housing.

[0033] According to another aspect of the present invention, a rotating electrical machine is provided, the rotating electrical machine comprising an adapter in any of the above forms. The rotating electrical machine may comprise: a rotor, a stator, a housing, a shaft, a fan mounted on the shaft, and / or a coupling disc for connecting the machine to a prime mover.

[0034] According to another aspect of the present invention, there is provided a generator set, which includes: an engine, a generator, and an adapter in any of the above forms.

[0035] A corresponding method may also be provided. Therefore, according to another aspect of the present invention, there is provided a method of connecting a rotating electrical machine to a prime mover using an adapter, the adapter comprising a first part and a second part, the method comprising the following steps:

[0036] connecting the adapter to the rotating motor such that the first portion surrounds the fan; and

[0037] The second section provides access to the rotating assembly to connect the rotating motor to the prime mover.

[0038] Features of one aspect of the invention may be provided with any other aspect. Apparatus features may be provided with method aspects, and vice versa.

[0039] As used herein, unless the context dictates otherwise, terms such as "axially," "radially," and "circumferentially" are generally defined with reference to the rotating axis of the electric machine.

[0040] Preferred features of the present invention are described below purely by way of example with reference to the accompanying drawings, in which:

[0041] Figure 1 A generator set is schematically shown;

[0042] Figure 2 shows a portion of a generator prior to assembly to an engine;

[0043] Figure 3 A previously considered adapter design is shown;

[0044] Figure 4 An adapter in an embodiment of the present invention is shown;

[0045] Figure 5 Shows Figure 4 a cross-sectional view of a portion of an adapter;

[0046] FIG. 6A to FIG. 6C An axial cross section through the diffuser portion of the adapter is shown;

[0047] Figure 7 shows a diffuser portion of an adapter in one embodiment;

[0048] Figure 8 A shows the connection to Figure 7 a spacer portion of a diffuser portion;

[0049] Figure 8 B shows the connection to Figure 7 a bearing support portion of a diffuser portion;

[0050] Fig. 9 An adapter in another embodiment of the present invention is shown;

[0051] Fig.10 shows the generator through the Fig. 9 a cross-sectional view of a portion of an adapter;

[0052] Fig.11 A and Fig.11 B shows an adapter in another embodiment of the present invention;

[0053] Fig.12 A and Fig.12 B illustrates Fig.11 How the diffuser sections of A and 11B may be used with the bearing support section;

[0054] Fig.13 An adapter in another embodiment of the present invention is shown;

[0055] Fig.14 Shows Fig.13 a portion of the adapter having the removable section removed;

[0056] Fig.15 The removable section is shown in more detail;

[0057] Fig.16 An adapter in another embodiment of the present invention is shown;

[0058] Fig.17 Shows Fig.16 the portion of the adapter from which the removable blade section is removed;

[0059] Fig.18 and Fig.19 showing front and rear views of a removable blade section;

[0060] Fig. 20 An adapter in another embodiment of the present invention is shown;

[0061] Fig.21 Shows Fig. 20 the portion of the adapter from which the removable blade section is removed;

[0062] Fig. 22 The removable blade section is shown in more detail;

[0063] Fig.23 shows a portion of an adapter in another embodiment of the present invention;

[0064] Fig.24 shows a generator frame and a diffuser portion of an adapter in another embodiment; and

[0065] Fig.25 The generator frame and diffuser sections and spacer sections are shown.

[0066] Figure 1 A generator set comprising an engine 10 coupled to a generator (AC generator) 12 is schematically shown. The engine 10 is typically an internal combustion engine, such as a gasoline engine or a diesel engine. The generator 12 can be any type of generator (such as a synchronous generator with an excitation coil or a permanent magnet), and is typically housed in a generator frame. The engine 10 and the generator 12 are both mounted on a base frame 14. The crankshaft (not shown) of the engine is mechanically connected to the rotor (not shown) of the generator. In operation, the mechanical energy generated by the engine 10 is transferred to the generator 12 to generate an electrical output.

[0067] exist Figure 1 In the arrangement of FIG. 1 , the engine 10 includes a flywheel located in a flywheel housing 16. An adapter 18 is used to connect the engine 10 to the generator 12. Typically, the adapter is connected between the flywheel housing and the generator frame. The adapter 18 helps prevent relative movement between the engine and the generator. Openings 20 are provided in the adapter that provide an exit path for airflow through the generator. The openings 20 also allow the operator to connect the rotating part once the generator has been aligned with the engine.

[0068] Figure 2 A portion of the generator is shown before assembly to the engine. Figure 2 , the generator 12 includes a rotor and a stator (not shown) inside a generator frame 22. The generator frame is connected to an adapter 18, which is used to connect the generator to the flywheel housing. The generator also includes a fan 26 and a coupling disc 28 mounted on a generator shaft 24. The fan 26 is located inside the adapter 18. An opening 20 in the adapter provides an exit path for airflow. During assembly, the generator 12 and the adapter 18 are aligned with the engine. The opening 20 in the adapter allows an operator to access the coupling disc 28, such as Figure 2 This allows the operator to bolt the coupling disc 28 to the engine flywheel. A socket wrench can be inserted through the opening 20 to tighten the bolts.

[0069] Figure 3 A previously considered adapter design is shown. Figure 3, the adapter 30 includes: a front wall 32, a rear wall 34, and a plurality of blades 36. The front wall 32 is configured to connect the adapter to the flywheel housing, and the rear wall 34 is configured to connect the adapter to the generator frame. The blades 36 provide a physical connection between the front wall 32 and the rear wall 34, and thus act to ensure the physical rigidity of the adapter. The rear wall 34 has a mating surface 38, which has a plurality of bolt holes 40 that connect the adapter to the generator frame. The front wall also has a mating surface and a plurality of bolt holes that connect the adapter to the flywheel housing. The adapter 30 is configured to accommodate the fan 26, and the blades 36 are located at spaced positions around the outside of the fan. The blades 36 can act as a diffuser and can help reduce wake blockage, thereby helping the fan to draw cooling air through the machine.

[0070] exist Figure 3 In the arrangement, a large gap or window is left between some of the blades 36 in the circumferential direction. The window is used to provide access to the coupling disk to allow the bolts to be inserted and tightened. Moreover, the width of the blade 36 in the axial direction is greater than the width of the fan. This leaves an axial gap between the fan 26 and the front wall 32 to allow a wrench to be inserted between the fan and the coupling disk. These features allow access to the coupling disk. However, it has been found that they can reduce the diffusion characteristics of the adapter, resulting in a reduction in air flow rate. In particular, the number of blades and their spacing may not be optimal for good air diffusion capabilities. Moreover, the axial gap between the fan and the front wall may create a gap, resulting in a loss of kinetic energy and a reduction in air flow rate. In addition, a relatively high-strength grille may be required to cover the window to prevent ingress, which may further hinder airflow.

[0071] Figure 4 An adapter in an embodiment of the present invention is shown. The adapter in this embodiment is designed to connect a generator housing to an engine flywheel housing. Figure 4 , the adapter 50 is generally cylindrical and is divided into two parts: a diffuser part 52 and a spacer part 54. The diffuser part 52 and the spacer part 54 are adjacent to each other in the axial direction. The diffuser part 52 is designed to be connected to the generator housing, and the spacer part 54 is designed to be connected to the engine flywheel housing. The dividing line between the diffuser part 52 and the spacer part 54 is in a plane orthogonal to the rotation axis of the generator.

[0072] The diffuser portion 52 of the adapter 50 is arranged to surround the fan 26 mounted on the generator shaft 24. The diffuser portion 52 includes: a middle wall 56, a rear wall 58, and a plurality of blades 60. The middle wall 56 and the rear wall 58 are in the form of annular disks that are substantially concentric but spaced apart in the axial direction. The rear wall 58 includes a curved annular surface 59 that helps to ensure smooth airflow from the generator to the fan 26. The rear wall 58 also includes a mating surface 62 that docks with the generator housing and a plurality of bolt holes 64 for connecting the adapter 50 to the generator housing. The middle wall 56 is connected to the spacer portion 54 of the adapter 50. The blades 60 provide a physical connection between the middle wall 56 and the rear wall 58. Therefore, the blades 60 connect the middle wall 56 and the rear wall 58 and space them apart in the axial direction. The blades 60 are spaced apart circumferentially around the outside of the fan 26 and around the adapter. The blades 60 are designed to maximize airflow while retaining the inherent structural benefits of the cylindrical adapter.

[0073] exist Figure 4 In the arrangement of the blades 60, the width in the axial direction is substantially equal to the width of the fan 26. Therefore, the diffuser portion 52 of the adapter 50 is sized so that it accommodates the fan 26 but does not extend significantly beyond the fan in the axial direction. The middle wall 56 is substantially aligned with the rear plate of the fan 26 in the axial direction.

[0074] The spacer portion 54 of the adapter 50 is configured to axially space the diffuser portion 52 from the flywheel housing and provide access to a coupling disc (not shown) for connecting the shaft 24 to the engine flywheel. The spacer portion 54 includes a front wall 66 and a plurality of cross members 68. The front wall 66 is in the form of an annular disc that is substantially concentric with the diffuser portion 52 of the adapter but axially spaced from the diffuser portion. The front wall 66 includes a plurality of bolt holes 70 for connecting the adapter 50 to the flywheel housing. The number and location of the bolt holes 70 may be controlled according to standard requirements such as SAE (Society of Automotive Engineers) standards, or any other appropriate configuration may be employed.

[0075] The cross members 68 are disposed at circumferentially spaced locations around the spacer portion 54 of the adapter. The cross members 68 extend axially between the front wall 66 of the spacer portion 54 and the middle wall 56 of the diffuser portion 52. Thus, the cross members 68 connect the front wall 66 with the diffuser portion 54 of the adapter and space them axially apart. In the illustrated arrangement, the cross members 68 have a T-shaped cross section when viewed in the axial direction. This can help provide physical rigidity while minimizing weight and material volume.

[0076] exist Figure 4In the arrangement, the spacing between the cross members 68 in the circumferential direction is selected to be large enough to provide hand access to the coupling disk while providing the necessary structural rigidity. Therefore, the cross members 68 define an access window 72 that provides access to the coupling disk. Since the spacer portion 54 of the adapter does not surround the fan, the cross members do not need to provide air diffusion properties. Therefore, the cross members can be further spaced apart from each other and configured for structural rigidity rather than air diffusion. On the other hand, the spacing between the blades 60 of the diffuser portion 52 of the adapter is selected to optimize their air diffusion properties. Therefore, the spacing between the blades 60 in the circumferential direction is less than the spacing between the cross members 68. This can allow the number of blades 60 and their size, shape and angle to be selected to optimize the air diffusion function and provide structural rigidity while still allowing access to the coupling disk.

[0077] Figure 5 Shows Figure 4 A cross-sectional view of a portion of the adapter. Figure 5 , it can be seen that the width of the blades 60 in the axial direction is substantially the same as the width of the fan 26. Moreover, the middle wall 56 is substantially aligned with the rear plate 74 of the fan 26 in the axial direction and is positioned radially outside the rear plate. This allows the airflow to be smoothly guided through the fan, through the gaps between the blades 60 to the atmosphere through the rear plate 74 and the middle wall 56. Therefore, this arrangement avoids the need for an axial gap between the fan 26 and the middle wall 56, which helps to improve airflow.

[0078] from Figure 5 It can also be seen that the width of the spacer portion 54 in the axial direction is relatively small compared to the overall size of the adapter. This can allow the number and / or size of the cross members 68 to be reduced, thereby increasing the size of the access window 72 in the circumferential direction. This can allow an access window 72 of sufficient size to be provided to facilitate connecting the generator to the engine. In particular, the size of the access window 72 in the circumferential direction is sufficient to allow a wrench to be inserted through the window and rotated through an angle sufficient to allow the bolts to be tightened. This can allow the access window to tighten the bolts connecting the coupling disc to the engine flywheel and / or connecting the adapter to the flywheel housing. The size of the window in the axial direction is sufficient to allow a wrench to be inserted into the window, but it does not need to allow any significant movement of the wrench in the axial direction. Therefore, the size of the window in the axial direction can be smaller than the size in the circumferential direction.

[0079] Figure 4 and Figure 5The arrangement may allow a sufficient number of blades to ensure that good diffusion characteristics are provided while providing a window for accessing the coupling disk. In particular, the number of blades 60 is greater than the number of cross members 68, which may contribute to the air diffusion characteristics of the diffuser portion 52. Moreover, an uneven distribution of the blades that may harm the diffusion characteristics may be avoided. The width of the blades in the axial direction may be substantially the same as the width of the fan. This may help to avoid a gap between the fan and the rear of the adapter, which would otherwise result in a loss of kinetic energy and thereby reduce the fan's ability to draw cooling air. Moreover, the grille covering the fan may be lighter than would otherwise be the case, thereby further improving the airflow.

[0080] FIG. 6A to FIG. 6C Shows Figure 4 and Figure 5 An axial cross section of the adapter 50 through the diffuser portion 52; reference FIG. 6A to FIG. 6C , the diffuser portion 52 includes a center wall 56 and a plurality of vanes 60 circumferentially spaced about the center wall.

[0081] exist Fig. 6A In the configuration of , the blade 60 is in the form of a flat plate. This can be advantageous for manufacturing compared to other blade designs, although it may not provide the most ideal airflow.

[0082] exist Figure 6B In the configuration, the blades 60 are wedge-shaped, having a triangular cross-section. The wedge-shaped design provides a narrow edge for the airflow while having a width at the outer circumference of the adapter to ensure sufficient strength and rigidity. The wedge-shaped design can also allow the distance between adjacent blades to increase as the distance outward through the adapter increases. This can provide a gradual decrease in air velocity and minimize turbulence and energy losses, thereby converting a portion of the dynamic pressure into additional static pressure rise through a steady expansion of the airflow cross-section. Therefore, the wedge-shaped design can help improve airflow by improving air diffusion characteristics and reducing wake blockage while ensuring sufficient structural strength.

[0083] exist Figure 6C In the configuration of , the blades 60 have an airfoil (wing (airfoil)) shape. The advantage of the airfoil design can be that it provides a narrow edge for airflow, while also allowing the cross member to have a thinner, more aerodynamically efficient shape than some other designs, and thus can help to further improve air diffusion characteristics. Therefore, the airfoil design can help provide optimal airflow characteristics, although this is at the cost of increased complexity.

[0084] exist FIG. 6A to FIG. 6CIn the arrangement of the blades 60, the blades are angled about the radial direction. Typically, the angle is selected to be approximately the same as the angle at which the airflow leaves the fan. The width of the blades and the number of blades are selected to ensure sufficient physical strength while minimizing any obstruction to the airflow.

[0085] It should be realized that FIG. 6A to FIG. 6C The blade designs are given as examples only, and other blade configurations may be used instead or in addition. For example, the blades may take any of the forms disclosed in WO 2019 / 243829A1, the subject matter of which is incorporated herein by reference. Typically, the number, size, shape, and angle of the blades are selected to provide the desired air diffusion characteristics while ensuring adequate structural support and ease of manufacture.

[0086] exist Figure 4 In the arrangement of Figure 6, the spacer portion 54 of the adapter can be attached to the diffuser portion 52 in any appropriate manner, for example, by bolting or by welding. Alternatively, the adapter including the diffuser portion 52 and the spacer portion 54 can be manufactured (e.g., cast, machined and / or fabricated) as a single piece. In another possible arrangement, the diffuser portion can be manufactured (e.g., assembled) as part of the frame. This will make the frame and the diffuser a single part. The entire adapter (including the diffuser portion and the spacer portion) can also be manufactured as part of the frame. In any arrangement, the adapter can be made, for example, of a metal such as a ferrous metal or an aluminum-based alloy, or any other appropriate material.

[0087] Where the spacer portion 54 of the adapter is manufactured separately from the diffuser portion 52, different types of spacer portions 54 may share the same diffuser portion 52. For example, a plurality of differently sized spacer portions 54 may be provided to allow the adapter 50 to be connected to a range of different prime movers while using the same diffuser portion 52. Differently sized spacer portions 54 may, for example, allow connection to different SAE sizes. Alternatively or in addition, single bearing machines and dual bearing machines may share the same diffuser portion.

[0088] exist Figure 4 In the arrangement of Figure 6, the middle wall 56 is provided as part of the diffuser portion of the adapter. However, in an alternative arrangement, all or part of the middle wall may be provided as part of the spacer portion of the adapter.

[0089] Figure 7 The diffuser portion of the adapter is shown in one embodiment. Figure 7 The diffuser portion 52 includes a middle wall 56, a rear wall 58, and a plurality of blades 60, which may be of the type described above with reference to Figure 4to the form discussed in relation to FIG. 6 .

[0090] Figure 8 A shows the connection to Figure 7 The diffuser section of the spacer part. Figure 8 A, the spacer portion 54 includes a front wall 66 and a plurality of cross members 68, which may be substantially in the form discussed above. The front wall 66 includes a plurality of bolt holes 70 for connecting the adapter 50 to the flywheel housing. The number and location of the bolt holes 70 may be controlled in accordance with standard requirements such as the SAE standard. A plurality of different forms of the spacer portion 54 may be provided to connect the adapter to a plurality of different flywheel housings while using, for example, Figure 7 The same diffuser section 52 is shown. This can reduce manufacturing costs by allowing different adapters to share the same diffuser section.

[0091] Figure 8 B shows the Figure 7 The bearing support portion of the diffuser section. Figure 8 The bearing support part of B is designed to support the bearing in a two-bearing machine. Figure 8 B, the bearing support portion 76 includes a front wall 78 and a bearing support 80. The bearing support 80 is used to support the bearing housing. The diffuser portion 52 and the bearing support portion 76 combination acts as a bracket for use with a dual-bearing generator, where one end of the generator shaft is supported by a bearing held by the bracket rather than using an engine bearing. This can allow a single-bearing machine and a dual-bearing machine to share the same diffuser portion, thereby reducing manufacturing costs.

[0092] exist Figure 8 In the arrangement of B, the front wall 78 in the bearing support part 76 includes a plurality of bolt holes 82. The bolt holes 82 can be used to connect a separate adapter to the bearing support part. The adapter can be used to connect the bracket to the prime mover. If necessary, the adapter and the bearing support part 76 and / or the diffuser part can be arranged as a single component. Alternatively, the generator and the engine can be mounted on the pedestal without using an adapter to connect the bearing support part to the engine.

[0093] Refer to above Figures 4 to 8 The described arrangement may provide some or all of the following benefits:

[0094] • Thermal benefits to the stator and rotor by improving airflow through the machine.

[0095] Flexibility to replace spacer sections to match different SAE connections instead of replacing the entire adapter.

[0096] • Interference with the engine can be avoided by designing the spacer portion to be smaller than would otherwise be possible.

[0097] Single bearing machines and dual bearing machines can share the same diffuser section.

[0098] • Stronger supports allow the use of grids with higher porosity and weaker structures.

[0099] Smaller fans can be used to achieve the same heat level.

[0100] The reduction in air turbulence across the diffuser reduces noise.

[0101] It can also improve machine efficiency (reduce windage losses).

[0102] Fig. 9 FIG. 2 shows an adapter in another embodiment of the present invention. Fig. 9 , the adapter 90 is generally cylindrical and is divided into two parts: a diffuser portion 92 and a spacer portion 94. The diffuser portion 92 is designed to be connected to the generator housing, and the spacer portion 94 is designed to be connected to the engine flywheel housing. The diffuser portion 92 is arranged to surround the fan 26 mounted on the generator shaft 24. In a manner similar to the diffuser portion described above, the diffuser portion 92 includes: a middle wall 96, a rear wall 98, and a plurality of blades 100. The spacer portion 94 includes a front wall 102 and a plurality of cross members 104. The cross members 104 are arranged at positions spaced circumferentially around the spacer portion 94 of the adapter. The cross members 104 define an access window 106 that provides access to the coupling disk.

[0103] exist Fig. 9 In the adapter 90 of FIG. 1 , the diffuser portion 92 and the spacer portion 94 are integrally formed. This can be achieved, for example, by casting the adapter 90 as a single piece. The cross member 104 extends axially between the front wall 102 and the middle wall 96. In this embodiment, the cross member 104 has a U-shaped cross section when viewed in the axial direction.

[0104] Fig.10 shows the generator through the Fig. 9 A cross-sectional view of a portion of the adapter. Fig.10 , the generator includes a rotor and a stator (not shown) inside a generator frame 22. The generator also includes a generator shaft 24. A fan 26 is mounted on the shaft 24 via a fan hub 108. A coupling disc 28 is mounted on the shaft 24 via a coupling disc hub 110. The coupling disc 28 is connected to the hub 110 using bolts 112. An adapter 90 is connected to the generator frame 22. The fan 26 is inside a diffuser portion 92 of the adapter 90.

[0105] exist Fig.10 100 is substantially the same width as the fan 26 in the axial direction. Moreover, the middle wall 96 is substantially aligned with the rear plate 74 of the fan 26 in the axial direction, and the middle wall 96 is positioned radially outside the rear plate 74. This enables the airflow to be smoothly directed through the diffuser portion 92 of the adapter through the rear plate 74 and the middle wall 96, through the gaps between the blades 100 to the atmosphere. Access to the coupling disk 28 is provided by an access window 106 in the spacer portion 94 of the adapter 90.

[0106] Fig.11 A and Fig.11 B shows an adapter in another embodiment of the present invention. Fig.11 A, adapter 120 is generally cylindrical and is divided into two parts: diffuser part 122 and spacer part 124. Fig. 9 and Fig.10 In a similar manner to the diffuser portion of FIG. 1 , the diffuser portion 122 includes a middle wall, a rear wall, and a plurality of blades. Fig. 9 and Fig.10 In a similar manner to the spacer portion of , the spacer portion 124 includes a front wall and a plurality of U-shaped cross members. Fig.11 A and Fig.11 In the embodiment of FIG. 1B, the diffuser portion 122 and the spacer portion 124 are manufactured as separate components. The spacer portion 124 is connected to the diffuser portion 122 using a plurality of bolts 118. The bolts 118 pass through holes 126 in the cross member. The diffuser portion 122 includes a plurality of bolt holes 128 for receiving the bolts 118. Fig.11 B shows an adapter having a spacer portion 124 connected to a diffuser portion 122 .

[0107] For example, if you want to connect the generator to an engine with a different SAE interface, Fig.11 A and Fig.11 The arrangement of B may allow for removal and replacement of the spacer portion 124. Alternatively or additionally, the bearing support portion may be connected to the diffuser portion in a manner similar to that described above. Fig.11 A and Fig.11 B shows a spacer portion having a U-shaped cross member, but it will be appreciated that a T-shaped cross member or any other suitable shape of cross member could be used instead or as well.

[0108] Fig.12 A and Fig.12 B illustrates Fig.11 A and Fig.11How the diffuser section of B can be used with the bearing support section. Fig.12 A, a bearing support portion 130 is provided for connection to the diffuser portion 122. The bearing support portion 130 is designed to support the bearing housing. The diffuser portion 122 and the bearing support portion 130 combination act as a bracket for use with a dual-bearing generator. This can allow single-bearing machines and dual-bearing machines to share the same diffuser portion, thereby reducing manufacturing costs.

[0109] The above arrangement can allow the adapter to act as a diffuser for the airflow from the fan and provide access to the coupling disc at the same time. Since the spacer portion is relatively narrow in the axial direction, it does not need to be as strong, so a larger gap can be left between the cross members. However, in some situations, the relatively small axial narrow width of the spacer portion can limit access.

[0110] In other embodiments of the present invention, a section of the adapter is removable to provide improved access.

[0111] Fig.13 FIG. 2 shows an adapter in another embodiment of the present invention. Fig.13 , the adapter includes two parts: a diffuser portion 132 and a spacer portion 134. In the illustrated arrangement, the diffuser portion 132 and the spacer portion 134 are a single piece. However, the diffuser portion and the spacer portion may also be separate components connected together in any of the above-described ways.

[0112] exist Fig.13 In the embodiment, the diffuser portion 132 includes a middle wall 136, a rear wall 138, and a plurality of blades 140 in a manner similar to the diffuser portion described above. Figures 4 to 8 In a similar manner to the spacer portion of FIG. 1 , the spacer portion 134 includes a front wall 142 and a plurality of T-shaped cross members 144. However, in this embodiment, the front wall 142 includes a plurality of removable sections 146. The removable sections 146 are attached to the front wall 142 using a plurality of screws 148.

[0113] In use, the removable section 146 can be removed from the adapter by loosening the screws 148. This can allow improved access to the coupling disc when the generator is being attached to the engine. The removable section 146 can then be reattached to the front wall 142 using the screws 148.

[0114] The removable section 146 may be, for example, a molded metal or sheet metal component, or made using any other suitable material and / or manufacturing method. Self-locking or "snap-fit" features may also be used in addition to (or instead of) the screws 148. Although in Fig.13Six removable segments are shown in FIG, but any suitable number of removable segments may be provided, having any suitable dimensions and disposed in any suitable locations.

[0115] Fig.14 Shows Fig.13 The portion of the adapter with the removable section removed. Fig.14 , it can be seen that the front wall 142 of the adapter includes a window 150. The window 150 extends circumferentially in the area between the two cross members 144. The window 150 also extends radially inwardly from the outer edge of the front wall 142. However, the window 150 only extends partially through the front wall 142 in the radial direction, leaving an inner ring 152 of the front wall. This helps to ensure that structural rigidity is maintained. Screw holes 154 are circumferentially arranged on either side of the window 150 to receive screws 148. The window 150 helps hand access to the coupling disc during assembly of the generator to the engine.

[0116] Fig.15 One of the removable sections is shown in more detail. Fig.15 , the removable section 146 is generally arcuate and has a hole 156 at each end for receiving a screw 148. In this embodiment, the removable section 146 has a step 158 to help locate it when it is assembled to the adapter. The step 158 is designed to engage with the side of the front wall 142 that forms the window 150. Alternatively or additionally, this feature can be achieved using a locating pin or any other similar feature.

[0117] Fig.16 FIG. 2 shows an adapter in another embodiment of the present invention. Fig.16 , in a similar manner to the above adapter, the adapter is divided into two parts: a diffuser part 162 and a spacer part 164. The diffuser part 162 includes: a middle wall 166, a rear wall 168 and a plurality of blades 170. The spacer part 164 includes a front wall 172 and a plurality of T-shaped cross members 174.

[0118] In this embodiment, the adapter includes a plurality of removable blade segments 176. Each of the removable blade segments 176 replaces a portion of the middle wall 166 and a portion of the blade 170. The removable blade segments 176 are attached to the middle wall 166 using a plurality of screws 178. The removable blade segments 176 can be, for example, molded plastic, molded metal, sheet metal components, or made using any other suitable material and / or manufacturing method.

[0119] In use, the removable blade segment 176 can be removed from the adapter by loosening the screw 178. This can allow improved access to the coupling disc when the generator is being attached to the engine. The removable blade segment 176 can then be reattached to the midwall 166 using the screw 178. If desired, a self-locking or "snap-fit" feature can also be used as well as (or instead of) the screw 178.

[0120] Fig.17 Shows Fig.16 The adapter has a portion of the removable blade section removed. Fig.17 , it can be seen that the adapter includes a window 180 that replaces part of the middle wall 166 and part of the blade 170. The distance that the window 180 extends circumferentially is approximately equal to the distance between two adjacent blades in the circumferential direction. Two screw holes 182 are provided in the middle wall 166, one screw hole is provided circumferentially on each side of the window 180 to receive the screw 178. A groove 184 is provided on the inner surface of the rear wall 168 to assist in the positioning of the removable blade segment 176. The window 180 helps the hand access the coupling disk during the assembly of the generator to the engine.

[0121] Fig.18 and Fig.19 The front and rear views of one of the removable blade sections are shown in more detail. Fig.18 and Fig.19 , the removable blade segment 176 includes a wall member 186 designed to replace a portion of the middle wall 166 and two blade members 188, 190 designed to replace portions of two blades 170. The wall member 186 is generally arc-shaped and includes a tab with a hole 192 at each end of the tab for receiving a screw 178. The first blade member 188 replaces a large portion of one of the blades except for one end of the blade located radially inward of the adjacent blade on one side. The second blade member 190 replaces a portion of the adjacent blade located radially inward of the first blade member 188 on the other side. Since the blades 170 partially overlap each other in the circumferential direction, this arrangement allows a section of the blade 170 and the middle wall 166 to be removed to improve hand access during assembly.

[0122] Fig. 20 An adapter in another embodiment of the present invention is shown. Fig. 20 The adapter is similar to Fig.16 However, in this embodiment, each removable blade segment comprises a complete blade. Fig. 20, the adapter includes: a middle wall 166, a rear wall 168, a plurality of blades 170, a front wall 172, a plurality of T-shaped cross members 174, and a plurality of removable blade sections 194. Each of the removable blade sections 194 replaces a portion of the middle wall 166 and one of the blades 170. The removable blade section 196 is attached to the middle wall 166 using a plurality of screws 178.

[0123] Fig.21 Shows Fig. 20 The adapter has a portion of the removable blade section removed. Fig.21 , it can be seen that the adapter includes a window 196 that replaces part of the middle wall 166 and one of the blades 170. The window 196 extends circumferentially through the portion of the middle wall 166 where the blade is located. The window 196 also extends radially inward from the outer edge of the middle wall 166. However, the window 196 only partially extends through the middle wall 166 in the radial direction, leaving an inner ring of the middle wall. This helps to ensure that structural rigidity is maintained. Two screw holes 182 are provided in the middle wall 166, one screw hole circumferentially on each side of the window 196 to receive the screws 178. A groove 184 is provided on the inner surface of the rear wall 168 to assist in positioning the removable blade section 194. The window 196 helps hand access to the coupling disc during assembly of the generator to the engine.

[0124] Fig. 22 Shown in more detail Fig. 20 One of the removable blade sections. Fig. 22 , the removable blade section 194 includes a wall member 198 designed to replace a portion of the middle wall 166 and a blade member 200 designed to replace one of the blades 170. The wall member 198 includes a tab having a hole 202 at each end of the tab for receiving the screw 178.

[0125] Fig.23 FIG. 2 shows a portion of an adapter in another embodiment of the present invention. In this embodiment, the adapter includes a diffuser portion and a spacer portion, which can basically take any of the forms described above. Fig.23 , the diffuser portion of the adapter includes a rear wall 168 and a plurality of vanes 170. A plurality of shrouds 204, 206 are provided that extend circumferentially around the outside of the adapter. Each shroud has a plurality of holes to allow air to exit the adapter while providing ingress protection. The removable shroud may be press-fit into the adapter and / or attached in any other manner (such as using bolts, snaps, or a "click together" feature, etc.).

[0126] exist Fig.23In the arrangement, some of the blades are "missing" from the diffuser portion of the adapter. Thus, gaps are provided between some of the blades in the circumferential direction where blades would otherwise be. The "missing" blades may allow improved access to the interior of the adapter, thereby facilitating assembly and / or maintenance of the generator set. Two different types of shrouds are used. A first type of shroud 204 is disposed radially outwardly of one or more blades 170. A second type of shroud 206 includes blades 208 that replace the "missing" blades on the adapter.

[0127] During assembly, the removable covers 204, 206 may be removed to allow access to the coupling discs. The "missing" blades may allow improved access to the interior of the adapter, thereby facilitating assembly and / or repair of the generator set. By including the "missing" blades on the removable covers 206, the aerodynamic performance of the adapter may be maintained.

[0128] It should be appreciated that, if desired, other parts of the adapter may be removable to improve hand access, either instead of or in addition to those described above. Moreover, different types of removable parts may be used together on the same adapter.

[0129] Fig.24 A generator frame and a diffuser portion of an adapter in another embodiment are shown. In this embodiment, the diffuser portion of the adapter and the generator frame are provided as a single component.

[0130] Reference Fig.24 , the generator frame 210 is in the form of a cylindrical shell, which is configured to accommodate a generator (not shown). The diffuser portion 212 of the adapter is integral with the generator frame 210. The diffuser portion of the adapter includes a rear wall 214 and a plurality of blades 216. The rear wall is in the form of an annular disk at the drive end of the generator frame 210. The blades 216 are wedge-shaped blades extending axially outward from the rear wall 214. In this embodiment, the diffuser portion of the adapter does not include an intermediate wall, which is instead provided on a spacer portion (not shown). The axially outward (front) face of each blade 216 is designed to dock with the intermediate wall on the spacer portion. The blade 216 has a locating feature 218 for locating the spacer portion. Bolt holes 220 are provided in the blades 216 so as to connect the spacer portion to the diffuser portion. The combined generator frame and the diffuser portion of the adapter can be manufactured using any suitable technology, such as manufacturing (e.g., steel manufacturing).

[0131] As in the previous embodiment, Fig.24In the arrangement of the adapter, the diffuser portion of the adapter is sized so that it accommodates the fan but does not extend significantly beyond the fan in the axial direction. The spacer portion of the adapter is arranged to axially space the diffuser portion from the flywheel housing and provide access to the coupling disc for connecting the shaft to the engine flywheel.

[0132] exist Fig.24 In the illustrated arrangement, the locating features 218 on the blade 216 are machined spigots. However, other types of locating features, such as locating pins, may alternatively or also be used to align the spacer portion with the blade.

[0133] Fig.25 The diffuser and spacer sections of the generator frame and adapter are shown. Fig.25 In this embodiment, the intermediate wall 222 is attached to the vanes in the diffuser section 212. The spacer section 224 is then attached to the intermediate wall 222. Different sized spacer sections may be used to allow the adapter to be connected to a range of different prime movers.

[0134] If desired, any of the adapter designs described herein may be used to provide a combined diffuser section and generator frame assembly.

[0135] Embodiments of the invention are described by way of example only, and modifications in detail will be apparent to the skilled person. For example, the cross members, blades, and other components of the adapter may have sizes, orientations, and quantities different from those shown. In any of these embodiments, all or part of the middle wall may be provided as part of the spacer portion of the adapter. Features of one embodiment may be used with any of the other embodiments. Detailed other modifications will be apparent to the skilled person within the scope of the claims.

Claims

1. An adapter for connecting a rotating electrical machine to a prime mover, the adapter comprising: a first portion, the first portion being configured to surround the fan; as well as A second portion is configured to provide access to a rotating assembly to connect the rotating electrical machine to the prime mover.

2. The adapter according to claim 1, wherein: The first portion is configured to be connected to the rotating electrical machine, and the second portion is configured to be connected to the prime mover.

3. The adapter according to claim 1 or 2, wherein: The first portion and the second portion are adjacent to each other in an axial direction.

4. An adapter according to any one of the preceding claims, wherein: The first portion and the second portion in combination are configured to provide a physical connection between the rotating electrical machine and the prime mover.

5. An adapter according to any one of the preceding claims, wherein: The second portion is arranged such that the first portion is axially spaced apart from the prime mover.

6. An adapter according to any one of the preceding claims, wherein: The second portion includes a front member and a plurality of cross members connecting the front member to the first portion.

7. The adapter according to claim 6, wherein: An access window is defined between two adjacent cross members in the circumferential direction.

8. The adapter according to claim 7, wherein: The access window is configured to allow insertion and rotation of a tool for connecting the rotary electric machine to the prime mover.

9. The adapter according to claim 7 or 8, wherein: The access window is larger in the circumferential direction than in the axial direction.

10. An adaptor according to any one of the preceding claims, wherein: The first portion includes a plurality of exit paths for airflow from the fan.

11. An adaptor according to any one of the preceding claims, wherein: The first portion is arranged to provide a stable expansion of the air flow cross section.

12. An adaptor according to any one of the preceding claims, wherein: The first portion includes a rear member, a middle member, and a plurality of blades connecting the middle member to the rear member.

13. The adapter according to claim 12, wherein: The rear member and / or the middle member are annular.

14. The adapter according to claim 12 or 13, wherein: The blades are flat, wedge-shaped or airfoil-shaped and are preferably angled with respect to the radial direction.

15. An adaptor according to any one of claims 12 to 14 when dependent on claim 6, wherein The number of blades is greater than the number of cross members.

16. The adapter according to any one of claims 12 to 15, wherein: A width of the second portion in the axial direction is smaller than a width of the first portion.

17. The adapter according to any one of claims 12 to 16, wherein: The width of the blade in the axial direction is substantially the same as the width of the fan.

18. The adapter according to any one of claims 12 to 17, wherein: The fan includes a rear plate, and the middle member is substantially aligned with the rear plate in an axial direction.

19. An adaptor according to any one of the preceding claims, wherein: The second portion is removably connected to the first portion.

20. The adapter according to claim 19, wherein: The adapter is arranged to enable a plurality of second parts of different types to be connected to the first part.

21. An adaptor according to any preceding claim, comprising at least one removable section which can be removed to improve access to the rotating assembly for connecting the rotating electrical machine to the prime mover.

22. The adapter according to claim 21, wherein: The removable section includes at least a portion of at least one of: a front member, a middle member, and a blade.

23. The adapter of any one of the preceding claims, further comprising at least one removable cover, wherein: At least one removable cover includes blades.

24. A rotating electric machine comprising an adapter according to any one of the preceding claims.

25. A method of connecting a rotating electrical machine to a prime mover using an adapter, the adapter comprising a first portion and a second portion, the method comprising the steps of: connecting the adapter to the rotating motor so that the first portion surrounds the fan; as well as A rotating assembly is accessed through the second portion to connect the rotating electrical machine to the prime mover.

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