Chassis assembly and fuel tank for generator set and method of assembling chassis assembly

Abstract

The invention relates to a chassis assembly for a generator set, a fuel tank and a method for assembling the chassis assembly. A chassis assembly for a generator set includes a frame. The frame includes a first side rail and a second side rail. The chassis assembly includes a fuel tank disposed between the first side rail and the second side rail. The fuel tank includes a top surface. The chassis assembly includes at least one cross member disposed at least partially in the fuel tank. The at least one cross member includes a top plate that is flush with or below a top surface of the fuel tank. The at least one cross member includes a sidewall extending from the top plate. The sidewall is disposed in the fuel tank and defines an opening for fluid flow through.

Description

Technical Field

[0001] The present disclosure relates to a chassis assembly and a fuel tank for a generator set and a method of assembling a chassis assembly for a generator set. Background Art

[0002] Generator sets (also referred to as "gensets") can be used for physical power production in a variety of applications (e.g., standby / backup power applications, etc.). Generator sets typically include an engine and an electrical generator coupled to the engine. The engine is configured to drive the generator, which in turn can generate electricity. The engine and generator can be disposed on a structural support system or chassis assembly that provides support for the generator set. Summary of the invention

[0003] One embodiment of the present disclosure relates to a chassis assembly for a generator set. The chassis assembly includes a frame. The frame includes a first side rail and a second side rail. The chassis assembly includes a fuel tank disposed between the first side rail and the second side rail. The fuel tank includes a top surface. The chassis assembly includes at least one cross member at least partially disposed in the fuel tank. The at least one cross member includes a top plate that is flush with or below the top surface of the fuel tank. At least one cross member includes a side wall extending from the top plate. The side wall is disposed in the fuel tank and defines an opening for fluid to flow through.

[0004] One embodiment of the present disclosure is directed to a chassis assembly wherein a first side rail is positioned distally from a second side rail and at least one cross member extends between and is coupled to the first side rail and the second side rail.

[0005] One embodiment of the present disclosure is directed to a chassis assembly wherein the side wall includes a top edge and a bottom edge. The top edge is coupled to or integral with the top plate, and the bottom edge is spaced from the top plate. The opening is positioned closer to the top edge than to the bottom edge.

[0006] One embodiment of the present disclosure is directed to a chassis assembly wherein at least one cross member defines a passage within the fuel tank, and the opening is a vent for air to escape from the passage.

[0007] One embodiment of the present disclosure is directed to a chassis assembly wherein at least one cross member includes a plurality of openings disposed along a length of the at least one cross member and adjacent to a top plate of the at least one cross member.

[0008] One embodiment of the present disclosure is directed to a chassis assembly wherein at least one cross member includes a pocket extending from a top plate of the cross member into a channel. The pocket is configured to receive a protrusion of an external component. The pocket is configured to reduce leakage of fuel from a fuel tank.

[0009] One embodiment of the present disclosure is directed to a chassis assembly that also includes an antivibration mount. The antivibration mount includes a protrusion for being disposed in a recess of at least one cross member.

[0010] One embodiment of the present disclosure relates to a chassis assembly, wherein at least one cross member includes a plurality of cross members at least partially disposed in a fuel tank. The plurality of cross members includes a first cross member and a second cross member. The first cross member is configured to support an engine, and the second cross member is configured to support an alternator.

[0011] One embodiment of the present disclosure is directed to a chassis assembly, wherein the plurality of cross members include a plurality of top plates, and wherein the top surface includes a plurality of panels. The plurality of panels are sealably coupled to the plurality of top plates to reduce leakage of fuel from a fuel tank via the top surface.

[0012] One embodiment of the present disclosure relates to a chassis assembly, wherein at least one cross member includes a plurality of cross members. The plurality of cross members include a first cross member and a second cross member. The first cross member is at least partially disposed in a fuel tank, and the second cross member is disposed outside the fuel tank. A top plate of the first cross member is a portion of a top surface of the fuel tank.

[0013] One embodiment of the present disclosure relates to a chassis assembly, wherein the sidewall is a first sidewall, and wherein at least one cross member further comprises a second sidewall. The top plate, the first sidewall, and the second sidewall define a channel. The opening is configured to allow fluid to flow therethrough to reduce the formation of air pockets within the channel.

[0014] One embodiment of the present disclosure is directed to a chassis assembly wherein a top surface includes a top plate and a panel coupled to the top plate.

[0015] One embodiment of the present disclosure relates to a method of assembling a chassis assembly for a generator set. The chassis assembly includes at least one cross member. The method includes positioning at least a portion of the at least one cross member in a fuel tank. The at least one cross member includes a top plate that forms a portion of a top surface of the fuel tank. The at least one cross member includes a side wall that extends from the top plate to define at least a portion of a channel. The side wall defines an opening for fluid to flow through. The at least one cross member includes a recess that extends from the top plate into the channel. The method includes inserting the side wall into the fuel tank. The method includes coupling the cross member to a first side rail and a second side rail. The fuel tank is disposed between the first side rail and the second side rail.

[0016] One embodiment of the present disclosure is directed to the method, wherein the top surface includes a panel. The method further includes sealably coupling the panel to a top plate of at least one cross member, disposing the panel and the top plate between a first side rail and a second side rail, and coupling the panel and the top plate to the first side rail and the second side rail.

[0017] One embodiment of the present disclosure is directed to the method, further comprising coupling a recess to the top plate. The recess is configured to receive a protrusion of the external component.

[0018] One embodiment of the present disclosure is directed to the method, further comprising coupling the outer component with the at least one cross member via the recess.

[0019] One embodiment of the present disclosure is directed to the method, wherein the recess is provided with a coupling mechanism configured to engage with a protrusion of an external component, and the external component is an anti-vibration mount.

[0020] One embodiment of the present disclosure is directed to the method, further comprising positioning an opening in the side wall adjacent to a top plate of at least one cross member.

[0021] One embodiment of the present disclosure is directed to the method, wherein the top surface includes a panel, and the at least one cross member includes a first cross member and a second cross member. The method also includes partially disposing the first cross member in the fuel tank so that the top plate is flush with the panel. The method also includes disposing the second cross member outside the fuel tank. The method also includes coupling the top plate to the panel to generate the top surface.

[0022] One embodiment of the present disclosure relates to a fuel tank for a generator set. The fuel tank includes a top surface. The top surface includes a top plate of a panel and a cross member, and the top plate is connected to the panel. The cross member includes a top plate. The cross member includes a first side wall extending from a first edge of the top plate. The cross member includes a second side wall extending from a second edge of the top plate. The first side wall and the second side wall extend from the top plate in the same direction. The first side wall has a first opening, and the second side wall has a second opening. The first side wall, the first opening, the second side wall, and the second opening are arranged in the fuel tank.

[0023] One embodiment of the present disclosure is directed to a fuel tank, wherein a top surface includes a plurality of panels, the plurality of panels including the panels. The top surface includes a plurality of top plates of a plurality of cross members, the plurality of top plates including the top plates of the cross members. At least one of the plurality of panels is disposed between the plurality of top plates. The plurality of panels are sealably coupled to the plurality of top plates to generate a top surface of the fuel tank.

[0024] These and other features, together with their organization and manner of operation, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.This summary is intended to be illustrative only and is not to be construed as limiting. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The foregoing features and other features of the present disclosure will become more fully apparent from the following description and the appended claims when read in conjunction with the accompanying drawings. It should be understood that these drawings depict only several embodiments according to the present disclosure and therefore should not be considered to limit the scope of the present disclosure, which will be described with additional specific description and details through the use of the accompanying drawings.

[0026] Figure 1 is a perspective view of a chassis assembly according to an example embodiment.

[0027] Figure 2 yes Figure 1 A top view of the chassis assembly.

[0028] Figure 3 yes Figure 1 Bottom perspective view of the cross member of the chassis assembly.

[0029] Figure 4 yes Figure 3 Top view of the cross member.

[0030] Figure 5 yes Figure 3 Front view of the cross member.

[0031] Figure 6 is along Figure 2 The line AA sees Figure 1 A cross-sectional view of a portion of a chassis assembly.

[0032] Figure 7 is a flow chart of a method of assembling a chassis assembly according to an example embodiment.

[0033] In the following detailed description, reference is made to the accompanying drawings. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It should be readily understood that the aspects of the present disclosure generally described herein and shown in the accompanying drawings may be arranged, substituted, combined, and designed in a variety of different configurations, all of which are expressly contemplated and constitute a part of the present disclosure. DETAILED DESCRIPTION

[0034] The following is a more detailed description of various concepts and implementations of systems and methods related to hybrid electric powertrain systems without the use of expensive and hard-to-find equipment. Before turning to the drawings that show certain exemplary embodiments in detail, it should be understood that the disclosure is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terminology used herein is for descriptive purposes only and should not be considered limiting.

[0035] According to various example embodiments, the systems and methods disclosed herein relate to a chassis assembly. The chassis assembly may be configured to support a generator set ("genset") and to accommodate or define a fuel tank configured to store fuel for powering the generator set. The chassis assembly includes a pair of side rails, and the fuel tank is disposed between the side rails. The chassis assembly includes at least one cross member extending between the side rails to provide additional support for the generator set. At least one cross member is at least partially disposed in the fuel tank. Therefore, the cross member does not add additional height to the chassis assembly. The absence of additional height can maintain a lower center of gravity of the generator set and allow the fuel tank to occupy more space between the side rails. Therefore, the storage capacity of the fuel tank can be increased without increasing the footprint of the chassis assembly.

[0036] At least one cross member includes a top plate that forms part of the top surface of the fuel tank or is coupled to the top surface of the fuel tank. For example, at least one cross member can be completely immersed in the fuel tank so that the top plate abuts against the inner surface of the top surface of the fuel tank. Alternatively, at least one cross member can be partially immersed so that the top plate forms part of the top surface and the side walls of the cross member are arranged in the fuel tank. In the case where the top plate forms part of the top surface, the top surface can include the top plate and other panels that can be sealably coupled together (e.g., welded) to reduce fuel leakage. In particular, fuel can be prevented from leaving the fuel tank via the top surface.

[0037] The side wall of the cross member may include at least one opening to allow fluid to flow therethrough. For example, the top plate and the side wall of the cross member may form a channel in the fuel tank. When fuel fills the fuel tank, air pockets may form in the channel. The opening allows air in the channel to escape the channel to allow the fuel to fill the channel. The opening may be disposed proximate to the top plate of the cross member to minimize the amount of air trapped in the channel and maximize storage space for the fuel. Thus, the formation of air pockets may be reduced.

[0038] The top plate of at least one cross member may include at least one recess. The recess may be configured to couple an external component (e.g., an anti-vibration mount) to the at least one cross member. The recess may be sealably coupled (e.g., welded) to the top plate to prevent fuel from exiting the fuel tank via an interface between the top plate and the recess. The recess may extend into the channel of the cross member and into the fuel tank.

[0039] refer to Figure 1 and Figure 2, perspective and top views of a chassis assembly 100 for a generator set (“genset”) are shown according to an example embodiment. The chassis assembly 100 is a structural support system configured to support the generator set. For example, the generator set can be disposed on the chassis assembly 100. The chassis assembly 100 includes a frame 105. The frame 105 includes at least one side member, shown as a side rail 110. The side rail 110 can extend the length of the chassis assembly 100. The frame 105 can include at least one end member 115. The end member 115 can extend the width of the chassis assembly 100.

[0040] The frame 105 may include a first side rail 110 and a second side rail 110. An end member 115 may extend between the first side rail 110 and the second side rail 110. For example, the first side rail 110 may be located away from the second side rail 110. For example, the first side rail 110 may be parallel to and spaced apart from the second side rail 110. A first end of the end member 115 may be coupled to the first side rail 110, and a second end of the end member 115 may be coupled to the second side rail 110. The end member 115 may be coupled to the side rail 110 at an end of the side rail 110. The frame 105 may include a plurality of end members 115. For example, the frame 105 may include a first or front end member 115 and a second or rear end member 115. The front end member 115 and the rear end member 115 may extend between the first side rail 110 and the second side rail 110. The front end member 115 may be coupled to the front end of the side rail 110 , and the rear end member 115 may be coupled to the rear end of the side rail 110 .

[0041] The frame 105 can define a cavity 120. For example, two end members 115 coupled to and disposed between the two side rails 110 can define the cavity 120. As described in more detail herein, at least a portion of the cavity 120 can be used as a fuel tank 125. The fuel tank 125 is disposed between the first side rail 110 and the second side rail 110. The fuel tank 125 can store fuel to power a generator set supported by the chassis assembly 100. The fuel tank 125 can extend along at least a portion of the frame 105. The side rails 110 can be sides of the fuel tank 125.

[0042] The chassis assembly 100 includes at least one structural support member, shown as a cross member 130. The cross member 130 can be configured to provide additional support for the generator set. For example, the cross member 130 can distribute the load from the generator set to the side rails 110. The cross member 130 is at least partially disposed in the fuel tank 125 of the chassis assembly 100. The cross member 130 can extend between the side rails 110 and be coupled to the side rails 110. For example, a first end of the cross member 130 can be coupled to the first side rail 110, and a second end of the cross member 130 can be coupled to the second side rail 110. In some embodiments, the ends of the cross member 130 are welded to the side rails 110. The chassis assembly 100 can include a plurality of cross members 130. For example, the chassis assembly 100 can include two, three, four, or more cross members 130. In some embodiments, different cross members 130 can support different components of the generator set. For example, first cross member 130 may be configured to support a first component of a generator set (eg, an engine), and second cross member 130 may be configured to support a second component of the generator set (eg, a generator or alternator).

[0043] The chassis assembly 100 includes a top surface 135. The top surface 135 can be configured to support a generator set. For example, the generator set can be disposed on the top surface 135 of the chassis assembly 100. The top surface 135 can be the top of the fuel tank 125. The top surface 135 can extend between the first side rail 110 and the second side rail 110. The top surface 135 can include at least one panel 140. The panel 140 can be a flat and thin piece of material (e.g., a metal plate) to generate at least a portion of the top surface 135. The top surface 135 can include a plurality of panels 140. The panels 140 can be coupled together to form the top surface 135. For example, the panels 140 can be welded together.

[0044] In some embodiments, the top surface 135 may also include a portion of the cross member 130. For example, as described in more detail herein, a top portion of the cross member 130 may form a portion of the top surface 135. In such embodiments, the panel 140 may be coupled to the top portion of the cross member 130 to form the top surface 135. For example, the panel 140 may be welded to the cross member 130. In some embodiments, the top surface 135 may include a plurality of panels 140 and a plurality of portions of the cross members 130. At least one panel 140 may be disposed between each cross member 130. The panel 140 and the cross member 130 may be sealably coupled together (e.g., welded together) to form the top surface 135.

[0045] The chassis assembly 100 may include at least one other structural support member, shown as an outer cross member 145. The outer cross member 145 may be disposed outside of the fuel tank 125. The outer cross member 145 may be the same as or different from the cross member 130. For example, the size, shape, number and type of openings, or other features of the outer cross member 145 may be the same as or different from the cross member 130.

[0046] refer to Figure 3 and Figure 4 , a bottom perspective view and a top view of a cross member 130 according to an example embodiment are shown. The cross member 130 has a top portion, shown as a top plate 305. The cross member 130 has at least one side wall 310 extending from the top plate 305. In some embodiments, the cross member 130 can be curved. For example, the cross member 130 can have a C-shape. For example, the cross member 130 can have a first side wall 310 extending from a first edge of the top plate 305 and a second side wall 310 extending from a second edge of the top plate 305. The side wall 310 can be coupled to the top plate 305 or be integral (e.g., integral) with the top plate 305. For example, the side wall 310 and the top plate 305 can be formed by a single component, wherein the side wall 310 is bent to extend in the same direction from the top plate 305 to form a C-shape.

[0047] The side wall 310 may have a first edge (shown as a top edge 315) and a second edge (shown as a bottom edge 320). The top edge 315 may be an edge of the side wall 310 that is coupled to or integral with (e.g., transitions into) the top plate 305. The bottom edge 320 may be an edge of the side wall 310 that is opposite the top edge 315 and spaced from the top plate 305. The cross member 130 may include a transition portion 325. The transition portion 325 may be disposed between the top plate 305 and the side wall 310. For example, the transition portion 325 may be a curved portion that transitions the top plate 305 into the side wall 310. The transition portion 325 may be a joint or a coupling mechanism that couples the side wall 310 to the top plate 305.

[0048] In some embodiments, all cross members 130 may have the same configuration (e.g., C-shaped). In some embodiments, cross members 130 may have different configurations or shapes. For example, a first cross member 130 may have a first shape, and a second cross member 130 may have a second shape. For example, a first cross member 130 may have a C-shape. A second cross member 130 may have a top hat shape (e.g., flanges extending away from each other from the free edges of the two side walls 310). The shape of the cross members 130 may be based on the amount of load that the cross members 130 are to support. For example, a cross member 130 having a first shape may be configured to support a greater load than a cross member 130 having a second shape.

[0049] The cross member 130 can define a channel 330. The channel 330 can be defined by the top plate 305, the first side wall 310, and the second side wall 310. The channel 330 can extend the length of the cross member 130.

[0050] The cross member 130 includes at least one opening 335. The opening 335 can extend through the cross member 130 to connect the channel 330 with the ambient fluid outside the cross member 130. The opening 335 can be a vent for a fluid (e.g., air) to leave the channel 330. For example, the opening 335 can be configured for a fluid to flow through. The opening 335 can be of any shape or size. For example, the opening 335 can be circular or square, or can have an elongated shape, etc. The side wall 310 of the cross member 130 defines at least one opening 335. The opening 335 can extend through the side wall 310. The opening 335 can be positioned closer to the top edge 315 of the side wall 310 than to the bottom edge 320. In some embodiments, the opening 335 is positioned as close to the top plate 305 as possible. For example, the opening 335 can be positioned at the top edge 315 of the side wall 310. The opening 335 can be located in the transition portion 325 of the cross member 130.

[0051] The cross member 130 can include a plurality of openings 335. For example, the plurality of openings 335 can be disposed along the length of the cross member 130. The plurality of openings 335 can be disposed along the side wall 310 of the cross member 130. A first opening or a first plurality of openings 335 can be disposed on the first side wall 310, and a second opening 335 or a second plurality of openings 335 can be disposed on the second side wall 310. The openings 335 can be disposed adjacent to the top plate 305 of the cross member 130.

[0052] The cross member 130 may include at least one recess 340. The recess 340 may be configured to receive a protrusion of an external component. For example, the recess 340 may be a protrusion extending from the top plate 305 of the cross member 130 into the channel 330. The recess 340 may be configured to receive a protrusion from an external component. For example, the recess 340 may define a cavity configured to receive a protrusion. The depth of the recess 340 may be based on the length of the protrusion to be set in the recess 340. The recess 340 may be a closed recess 340. For example, the cavity defined by the recess 340 may not be exposed to the channel 330 to prevent any fluid or material in the channel from entering the recess 340. The recess 340 may be coupled to the top plate 305 of the cross member 130. For example, the recess 340 may be welded or bonded to the top plate 305, or otherwise fixed to the top plate 305. The recess 340 may be coupled to the top plate 305 such that fluid or material from within the channel 330 cannot exit the channel 330 via an interface between the recess 340 and the top plate 305 .

[0053] The cross member 130 may have a plurality of pockets 340. The number of pockets 340 may be based on the number of external components to be coupled to or disposed on the cross member 130. The pockets 340 may be disposed along the top plate 305 of the cross member 130.

[0054] Reference now Figure 5 , shows a front view of the cross member 130 according to an example embodiment. The pocket 340 may extend into the channel 330 of the cross member 130. The pocket 340 may extend perpendicular to the top plate 305. In some embodiments, the chassis assembly 100 may include an external component 505. The external component 505 may be, for example, an anti-vibration mount. The external component 505 may include at least one protrusion 510 configured to be disposed in the pocket 340. The pocket 340 may be configured to receive the protrusion 510 of the external component 505. The size and shape of the pocket 340 may be based on the size and shape of the protrusion 510 to be received. The pocket 340 may be configured to couple the external component 505 with the cross member 130. For example, the pocket 340 may include a coupling mechanism 515. The coupling mechanism 515 may be configured to interface with the protrusion 510 of the external component 505. In some embodiments, the coupling mechanism 515 may be a thread configured to interface with a corresponding thread of the protrusion 510. The coupling mechanism 515 may be any type of mechanism configured to interface with the protrusion 510 of the outer component 505 and couple the outer component 505 with the cross member 130 .

[0055] refer to Figure 6 , shows a cross-sectional view of a portion of a chassis assembly 100 according to an example embodiment, as taken along Figure 1 1. The fuel tank 125 may be formed within the cavity 120 of the chassis assembly 100. For example, the fuel tank 125 has a top surface 135. The top surface 135 of the fuel tank 125 is the top surface 135 of the chassis assembly 100. The side rails 110 of the chassis assembly 100 may be the sides of the fuel tank 125. The chassis assembly 100 may have additional structural members or tank walls 605 that define the shape of the fuel tank 125 within the cavity 120.

[0056] The chassis assembly 100 includes at least one cross member 130 at least partially disposed in the fuel tank 125. Disposing the cross member 130 in the fuel tank 125 can increase the capacity of the fuel tank 125 while reducing the overall height. Therefore, the center of gravity of the generator set disposed on the chassis assembly 100 can be reduced relative to the center of gravity when the cross member 130 is in a raised position. For example, the side wall 310 of the cross member 130 can be disposed in the fuel tank 125. The top plate 305 of the cross member 130 is disposed flush with or below the top surface 135. For example, in some embodiments, the top plate 305 of the cross member 130 can form a portion of the top surface 135 of the fuel tank 125. For example, the panel 140 of the top surface 135 can be sealably coupled with the top plate 305 of the cross member 130 to produce the top surface 135. In some embodiments, the top surface 135 can include only the panel 140, wherein the top plate 305 is disposed below the top surface 135 in the fuel tank 125. Top plate 305 may still be coupled to panel 140 , but to an inner surface of panel 140 .

[0057] According to an exemplary embodiment, the fuel tank 125 includes a top surface 135. The top surface 135 includes the panel 140 and a top plate 305 of the cross member 130. The top plate 305 is coupled to the panel 140. The cross member 130 includes the top plate 305. The cross member 130 includes a first side wall 310 extending from a first edge of the top plate 305 and a second side wall 310 extending from a second edge of the top plate 305. The first side wall 310 and the second side wall 310 extend from the top plate 305 in the same direction. The first side wall 310 has a first opening 335, and the second side wall 310 has a second opening 335. The first side wall 310, the first opening 335, the second side wall 310, and the second opening 335 are disposed in the fuel tank 125.

[0058] In some embodiments, the top surface 135 includes a plurality of panels 140 and a plurality of roof panels 305 of the plurality of cross members 130. At least one of the plurality of panels 140 may be disposed between the plurality of roof panels 305. The plurality of panels 140 may be sealably coupled with the plurality of roof panels 305 to form the top surface 135 of the fuel tank 125.

[0059] The chassis assembly 100 may include a plurality of cross members 130 including a plurality of top panels 305. The top surface 135 of the fuel tank 125 may include a plurality of panels 140 coupled to the plurality of top panels 305. The panels 140 may be sealably coupled to the top panels 305 to prevent fuel from leaking out of the fuel tank 125 via the top surface 135.

[0060] The sidewall 310 is disposed in the fuel tank 125 so that the cross member 130 can define a passage 330 within the fuel tank 125. The opening 335 of the cross member 130 can be disposed on the sidewall 310 of the cross member 130 so that the opening 335 is disposed in the fuel tank 125. The opening 335 can be disposed as close to the top plate 305 or the top surface 135 as possible. For example, when fuel fills the fuel tank 125, the fuel can begin to fill the passage 330 of the cross member 130. When the fuel fills the passage 330, the opening 335 can provide a path for air to escape from the passage 330. The opening 335 can allow fluid to flow therethrough to reduce or prevent the formation of air pockets within the passage 330. In addition, the opening 335 can allow the fuel to fill the passage 330 to create additional available space for fuel, thereby increasing the fuel capacity of the fuel tank 125.

[0061] The recess 340 of the cross member 130 may be disposed in the fuel tank 125. The recess may be configured to reduce leakage of fuel from the fuel tank 125. For example, the recess 340 may be a closed recess 340 to prevent leakage from the fuel tank 125 via an interface between the recess 340 and the top plate 305 of the cross member 130. In some embodiments, the recess 340 may be welded to the top plate 305 to reduce leakage of fuel from the fuel tank 125. In particular, the recess 340 may be welded to the top plate.

[0062] The chassis assembly 100 may include a plurality of cross members 130. The plurality of cross members 130 may be at least partially disposed within the fuel tank 125. For example, Figure 4 As shown, the first cross member 130 may be disposed at a first location in the fuel tank 125, and the second cross member 130 may be disposed at a second location in the fuel tank 125. The top plate 305 of the first cross member 130 and the top plate 305 of the second cross member 130 may be part of the top surface 135 of the fuel tank 125. Any number of cross members 130 may be at least partially disposed within the fuel tank 125.

[0063] In some embodiments, the chassis assembly 100 may include at least one external cross member 145. In some embodiments, the external cross member 145 disposed outside the fuel tank 125 may be different from the cross member 130 disposed in the fuel tank 125. For example, the cross member 130 may have a C-shape, have at least one recess 340, and have at least one opening 335. The external cross member 145 may have a top hat shape, and may not have the recess 340 or the opening 335, or may have only one of the recess 340 or the opening 335. In some embodiments, the external cross member 145 may be the same as the cross member 130.

[0064] refer to Figure 7, a method 700 of assembling a chassis assembly 100 for a generator set is shown, wherein the chassis assembly 100 includes at least one cross member 130, according to an example embodiment. The method 700 includes positioning at least a portion of the at least one cross member 130 in a fuel tank 125 (step 705). The fuel tank 125 has a top surface 135. The cross member 130 includes a top plate 305 disposed flush with or below the top surface 135 of the fuel tank 125. The cross member includes a side wall 310 extending from the top plate 305. The side wall 310 includes at least one opening 335 for fluid flow therethrough.

[0065] In some embodiments, step 705 may include sealably coupling a panel 140 of a top surface 135 of the fuel tank 125 with a top plate 305 of the cross member 130. The panel 140 and the top plate 305 may be disposed between the first side rail 110 and the second side rail 110.

[0066] In some embodiments, the method 700 may include coupling the pocket 340 to the top plate 305 of the cross member 130. For example, the pocket 340 may be welded or bonded to the top plate 305, or otherwise secured to the top plate 305. The pocket 340 may extend from the top plate 305 into the channel 330 defined by the cross member 130. The pocket 340 may be configured to receive the protrusion 510 of the outer component 505 to couple the outer component 505 with the cross member 130. For example, the method 700 may include coupling the outer component 505 with the cross member 130 via the pocket 340. The pocket 340 may be provided with a coupling mechanism 515 configured to interface with the protrusion 510 of the outer component 505. In some embodiments, the outer component 505 may be an anti-vibration mount.

[0067] In some embodiments, the method 700 includes positioning the opening 335 of the side wall 310 of the cross member 130 adjacent to the top plate 305 of the cross member 130 .

[0068] The method 700 includes inserting 710 the sidewall 310 of at least one cross member 130 into the fuel tank 125. In some embodiments, the cross member 130 may include a plurality of sidewalls 310. Each sidewall 130 may be disposed in the fuel tank 125.

[0069] The method 700 includes coupling at least one cross member 130 to the first side rail 110 and the second side rail 110 (step 715). In some embodiments, step 715 may include coupling the cross member 130 to the first side rail 110 and the second side rail 110. For example, the cross member 130 may be welded, bonded, or otherwise secured to the first side rail 110 and the second side rail 110. In some embodiments, the panel 140 and the top panel 305 may be coupled to the first side rail 110 and the second side rail 110.

[0070] In some embodiments, method 700 may include providing a plurality of cross members 130, including a first cross member 130 and a second cross member. First cross member 130 may be at least partially disposed in fuel tank 125 such that top plate 305 of first cross member 130 is flush with panel 140 of top surface 135 of fuel tank 125. Top plate 305 may be coupled with panel 140 to create top surface 135 of fuel tank 125. Second cross member 130 may be disposed outside of fuel tank 125.

[0071] As used herein, the terms "approximately," "about," "substantially," and similar terms are intended to have a broad meaning consistent with the ordinary and acceptable usage by those of ordinary skill in the art to which the subject matter of the present disclosure belongs. Those skilled in the art who review the present disclosure should understand that these terms are intended to allow description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the present disclosure as described in the appended claims.

[0072] It should be noted that the term "exemplary" and variations thereof as used herein to describe various embodiments are intended to indicate that such embodiments are possible examples, representations or illustrations of possible embodiments (and such terms are not intended to imply that such embodiments are necessarily unusual or best examples).

[0073] As used herein, the term "connection" and its variations mean the direct or indirect connection of two components to each other. Such a connection can be static (e.g., permanent or fixed) or movable (e.g., removable or releasable). Such a connection can be achieved by directly connecting two components to each other, connecting two components to each other using one or more separate intermediate components, or connecting two components to each other using an intermediate component that is integrally formed as a single entity with one of the two components. If "connection" or its variations are modified by additional terms (e.g., direct connection), the general definition of "connection" provided above is modified by the simple language meaning of the additional terms (e.g., "direct connection" refers to the connection of two components without any separate intermediate components), resulting in a narrower definition than the general definition of "connection" provided above. This connection can be mechanical, electrical or fluid. For example, circuit A can be "connected" to circuit B in a communicative manner, which can mean that circuit A communicates directly with circuit B (i.e., without a medium) or indirectly with circuit B (e.g., through one or more mediums).

[0074] References herein to element positions (e.g., "top," "bottom," "upper," "lower") are only used to describe the orientation of various elements in the drawings. It should be noted that, according to other exemplary embodiments, the orientation of different elements may be different, and such variations are intended to be covered by the present disclosure.

[0075] It is important to note that the construction and arrangement of the chassis assembly 100 as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Although only one example of an element from one embodiment that may be incorporated or utilized in another embodiment is described above, it should be understood that other elements of the various embodiments may be incorporated or utilized with any other embodiment disclosed herein.

Claims

1. A chassis assembly for a generator set, comprising: a frame, the frame comprising a first sidebar and a second sidebar; a fuel tank disposed between the first side rail and the second side rail, the fuel tank comprising a top surface; and at least one cross member, the at least one cross member being at least partially disposed in the fuel tank, the at least one cross member comprising: a top plate, the top plate being arranged to be flush with or lower than the top surface of the fuel tank; and A side wall extends from the top plate, the side wall being disposed in the fuel tank and defining an opening for fluid to flow therethrough.

2. The chassis assembly according to claim 1, wherein: The first side rail is positioned distally from the second side rail, and the at least one cross member extends between and is coupled to the first side rail and the second side rail.

3. The chassis assembly according to claim 1, wherein: The side wall includes a top edge coupled to or integral with the top panel and a bottom edge spaced apart from the top panel, the opening being positioned closer to the top edge than to the bottom edge.

4. The chassis assembly according to claim 1, wherein: The at least one cross member defines a passage within the fuel tank, and the opening is a vent for air to exit the passage.

5. The chassis assembly according to claim 1, wherein: The at least one cross member includes a plurality of openings disposed along a length of the at least one cross member and adjacent the top plate of the at least one cross member.

6. The chassis assembly according to claim 4, wherein: The at least one cross member includes a pocket extending from the top plate of the cross member into the channel, the pocket being configured to receive a protrusion of an outer component, the pocket being configured to reduce leakage of fuel from the fuel tank.

7. The chassis assembly of claim 6, further comprising an anti-vibration mount including said projection for positioning in said recess of said at least one cross member.

8. The chassis assembly of claim 1, wherein: The at least one cross member includes a plurality of cross members at least partially disposed in the fuel tank, the plurality of cross members including a first cross member configured to support an engine and a second cross member configured to support an alternator.

9. The chassis assembly of claim 8, wherein: The plurality of cross members include a plurality of top plates; and The top surface includes a plurality of panels sealably coupled with the plurality of top panels to reduce leakage of fuel from the fuel tank via the top surface.

10. The chassis assembly of claim 1, wherein: The at least one cross member includes a plurality of cross members including a first cross member at least partially disposed in the fuel tank and a second cross member disposed outside the fuel tank, wherein the top plate of the first cross member is a portion of the top surface of the fuel tank.

11. The chassis assembly of claim 1, wherein: The sidewall is a first sidewall, wherein the at least one cross member further comprises a second sidewall, wherein the top plate, the first sidewall and the second sidewall define a channel, and the opening is configured to allow fluid to flow therethrough to reduce cavitation within the channel.

12. The chassis assembly of claim 1, wherein: The top surface includes the top plate and a panel coupled to the top plate.

13. A method of assembling a chassis assembly for a generator set, wherein: The chassis assembly includes at least one cross member, the method comprising: Positioning at least a portion of the at least one cross member in the fuel tank, the at least one cross member comprising: a top plate forming a portion of a top surface of the fuel tank; a side wall extending from the top plate to define at least a portion of the passage, the side wall defining an opening for fluid flow therethrough; and a recess extending from the top plate into the channel; and inserting the side wall into the fuel tank; and The at least one cross member is coupled to a first side rail and a second side rail, the fuel tank being disposed between the first side rail and the second side rail.

14. The method according to claim 13, wherein: The top surface includes a panel, the method further comprising: sealably coupling the face plate to the top plate of the at least one cross member; disposing the panel and the top panel between the first side rail and the second side rail; and The panel and the top panel are coupled to the first side rail and the second side rail.

15. The method according to claim 13, further comprising: The recess is coupled to the top plate, the recess being configured to receive a protrusion of an external component.

16. The method according to claim 15, further comprising: The outer component is coupled to the at least one cross-member via the recess.

17. The method of claim 15, wherein: The recess is provided with a coupling mechanism configured to engage with the protrusion of the outer component, and The external component is an anti-vibration mount.

18. The method according to claim 13, wherein: The top surface comprises a panel, and the at least one cross-member comprises a first cross-member and a second cross-member, the method further comprising: partially positioning the first cross member in the fuel tank so that the top plate is flush with the panel; disposing the second cross member outside the fuel tank; and The top plate is coupled to the face plate to create the top surface.

19. A fuel tank for a generator set, the fuel tank comprising: A top surface, the top surface comprising: Panels; and a top plate of a cross member, the top plate being coupled to the panel, wherein the cross member comprises: the top plate; a first side wall extending from a first edge of the top panel; and a second side wall, the second side wall extending from a second edge of the top plate, the first side wall and the second side wall extending from the top plate in the same direction; wherein the first side wall has a first opening, and the second side wall has a second opening; and The first side wall, the first opening, the second side wall and the second opening are arranged in the fuel tank.

20. The fuel tank according to claim 19, wherein The top surface comprises: a plurality of panels, the plurality of panels including the panel; and a plurality of top plates of a plurality of cross members, the plurality of top plates including the top plate of the cross member; wherein at least one of the plurality of panels is disposed between the plurality of top panels; and The plurality of panels are sealably coupled to the plurality of top panels to generate the top surface of the fuel tank.

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