Generator with integrated transport fixture

Abstract

A generator module includes a housing for attachment to an internal combustion engine, a stator fixedly disposed within the housing, and a rotor rotatable within the stator. The housing has a first tapered surface and a first through hole, and the rotor has a rotor support flange with a second tapered surface and a second threaded hole. The second threaded hole is configured to receive a threaded fastener that extends through the first through hole and is threaded into the second threaded hole to draw the rotor support flange toward the housing so that the second tapered surface is compressively secured against the first tapered surface.

Description

[0001] Cross-references to related applications This application claims the benefit of U.S. Nonprovisional Patent Application No. 18 / 619,868 (filed March 28, 2024), the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0002] This disclosure generally relates to a generator, and more specifically to a generator having an integrated transport fixture. Background Technology

[0003] Generator transport fixtures are known. An example is shown and described in commonly assigned U.S. Patent Publication No. 2024 / 0048032, entitled “GENERATOR ROTOR CENTERING JIG”, authored by Condo et al., the entire contents of which are incorporated herein by reference as if listed in their entirety. Summary of the Invention

[0004] The example implementation broadly includes a generator module comprising a housing for attachment to an internal combustion engine, a stator fixed within the housing, and a rotor rotatable within the stator. The housing includes a first tapered surface and a first through-hole, and the rotor includes a rotor support flange having a second tapered surface and a second threaded hole. The second threaded hole is used to receive a threaded fastener that extends through the first through-hole and is screwed into the second threaded hole to pull the rotor support flange toward the housing, thereby pressing and securing the second tapered surface against the first tapered surface.

[0005] In some example embodiments, the generator module further includes a drive flange for forming a drive connection with the crankshaft of the internal combustion engine, and the rotor further includes a drive hub secured to the drive flange by fasteners. In one example embodiment, the threaded fastener is mounted in the second threaded hole along a first axial direction, and the fastener for securing the drive hub to the drive flange is mounted along a second axial direction opposite to the first axial direction. In one example embodiment, the drive hub includes a locating boss for positioning the drive hub in the crankshaft.

[0006] In some example embodiments, the generator module further includes a bearing. The housing also includes a locating surface, and the bearing is disposed on the locating surface. In one example embodiment, the rotor support flange includes a cylindrical surface, and the bearing is disposed within the cylindrical surface. In one example embodiment, the bearing includes an inner ring, an outer ring, and a plurality of rolling elements disposed therebetween. The inner ring is mounted on the locating surface, and the rolling elements are axially slidable on the inner ring.

[0007] In one example embodiment, a seal is provided between the rotor support flange and the housing. In one example embodiment, the first tapered surface has a first notch aligned with the first through hole, and the second tapered surface has a second notch aligned with the second threaded hole. In one example embodiment, the first diameter of the first through hole is larger than the second diameter of the second threaded hole.

[0008] In some example embodiments, the threaded fastener is a bolt. In some example embodiments, the first through hole is a first threaded hole, and after the generator module is assembled to the internal combustion engine, the bolt is removed and a sealing plug is screwed into the first threaded hole. In one example embodiment, the sealing plug includes an O-ring for sealing with the housing.

[0009] In some example embodiments, the generator module includes the threaded fastener. The threaded fastener includes a first threaded segment extending through the first through-hole, a second threaded segment for screwing into the second threaded hole, and an annular segment separating the first threaded segment from the second threaded segment. In one example embodiment, the first threaded segment has a first diameter, the second threaded segment has a second diameter, and the annular segment has an annular diameter larger than either the first or the second diameter.

[0010] In one example embodiment, the threaded fastener further includes an internal hexagonal segment for inserting a tool to rotate the threaded fastener. In one example embodiment, the generator module further includes a nut mounted on the first threaded segment for securing the threaded fastener in the first through hole. In one example embodiment, the threaded fastener further includes an O-ring for sealing the annular segment with the housing. Attached Figure Description

[0011] Figure 1 An end view of a generator module according to an example implementation is shown.

[0012] Figure 2 Showing roughly along Figure 1 The sectional view taken from line 2-2 shows the threaded fastener installed in the transport position.

[0013] Figure 3 Showing roughly along Figure 1 The sectional view taken from line 2-2 shows the sealing plug installed in the working position.

[0014] Figure 4 Showing roughly along Figure 1 The sectional view taken from line 2-2 shows the threaded fastener installed in the transport position.

[0015] Figure 5 Showing roughly along Figure 1 The sectional view taken from line 2-2 shows the threaded fastener installed in the working position.

[0016] Figure 6 Show Figure 4 The circled area 6 is a magnified view of a portion of the image.

[0017] Figure 7 Show Figure 5 The circled area 7 is a magnified view of a portion of the image. Detailed Implementation

[0018] This document describes embodiments of the present disclosure. It should be understood that the same reference numerals appearing in different view figures denote the same or functionally similar structural elements. It should also be understood that the disclosed embodiments are merely examples, and other embodiments may take various different and alternative forms. The figures are not necessarily drawn to scale; some features may be exaggerated or reduced to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to employ these embodiments in various ways. As will be understood by those skilled in the art, various features shown and described with reference to any of the figures may be combined with features shown with reference to one or more other figures to produce embodiments not explicitly shown or described. The illustrated combinations of features provide representative embodiments for typical applications. However, various combinations and modifications of features conforming to the teachings of this disclosure may also be applied to specific applications or implementations.

[0019] The terminology used herein is for the purpose of describing particular aspects only and is not intended to limit the scope of this disclosure. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. While any methods, apparatus, or materials similar to or equivalent to those described herein may be used in the implementation or testing of this disclosure, exemplary methods, apparatus, and materials are described below.

[0020] The following descriptions are combined Figure 1-3 Made. Figure 1An end view of a generator module 100 according to an example embodiment is shown. Figure 2 Showing roughly along Figure 1 The sectional view taken from line 2-2 shows the installed threaded fastener 102. Figure 3 Showing roughly along Figure 1 The cross-sectional view taken by line 2-2 shows the installed sealing plug 104. The generator module 100 includes a housing 106 for attachment to an internal combustion engine (not shown). Specifically, the housing includes a mounting surface 108 having mounting holes 110 that align with mounting holes in the engine block (not shown) of the internal combustion engine to receive bolts, securing the two components together in a known manner. Other components of the generator module are also attached to other components of the internal combustion engine, as described in more detail below.

[0021] The housing 106 includes a tapered surface 112 and a through-hole 114. The module 100 also includes a stator 116 fixedly disposed within the housing, and a rotor 118 rotatable within the stator. When the rotor is driven by an internal combustion engine and rotates within the stator, the stator and rotor cooperate in a known manner to generate electricity. The rotor 118 includes a rotor support flange 120 having a tapered surface 122 and a threaded hole 124 for receiving a threaded fastener (e.g., threaded fastener 102). For example, as... Figure 2 As shown, the threaded fastener extends through the through hole 114 and is screwed into the threaded hole 124 to pull the rotor support flange toward the housing, causing the tapered surface 122 to be pressed against the tapered surface 112. In other words, as the fastener 102 is screwed into the rotor support flange, the flange in Figure 2 The device is pulled to the right, causing the two conical surfaces to contact each other. By securing these two components together, potential damage to the stator, rotor, and / or bearings can be limited during transport before the generator module is installed with the internal combustion engine. In other words, the module is in the transport position when the conical surfaces are tightly held together by the threaded fasteners.

[0022] The generator module 100 also includes a drive flange 128 for forming a drive connection with the crankshaft of the internal combustion engine. For example, the flange 128 may be secured radially outer portion to another component (not shown) bolted to the crankshaft. The rotor 118 also includes a drive hub 130 secured to the drive flange by fasteners 132. In other words, power from the crankshaft is transmitted via the drive flange to the rotor flange to rotate the rotor and generate electricity as described above. The electricity generated by the generator module can be used to charge the vehicle battery, power an electric motor to drive the vehicle, or drive other devices connected to the vehicle (e.g., power tools, welding machines, RV lights, and / or electrical appliances).

[0023] For example, such as Figure 2 As shown, threaded fastener 102 is mounted in threaded hole 124 along axial direction 134, and fastener 132 for securing the drive hub to drive flange is mounted along axial direction 136 opposite to axial direction 134. Drive hub 130 includes locating boss 138 for positioning the drive hub within the crankshaft. Locating boss 138 may be integrally formed from a single piece of material with the drive hub, or it may be a separate component fixed to the drive hub by press fitting, welding, adhesive, etc. The locating boss is configured to radially center the rotor relative to the crankshaft, such that when the module is bolted to the internal combustion engine, the rotor and stator are radially centered by the engine block and crankshaft, respectively, while within the internal combustion engine, the engine block and crankshaft are internally centered relative to each other.

[0024] The generator module 100 also includes a bearing 140. The housing 106 includes a locating surface 142, and the bearing is disposed on the locating surface. The locating surface 142 may be integrally formed with the housing from the same material, or for example, as... Figure 2 and Figure 3 As shown, it may be part of a separate component (e.g., oil pump 144) fixed to the wall 146 of the housing. The rotor support flange 120 includes a cylindrical surface 148, and a bearing 140 is disposed within said cylindrical surface. For example, the bearing 140 may engage one or both of surfaces 142 and 144 by press-fit or sliding fit. The bearing 140 includes an inner ring 150, an outer ring 152, and rolling elements 154 disposed therebetween. In the illustrated embodiment, the rolling elements 154 are cylindrical rollers, although other embodiments may have different rolling elements (e.g., balls). The inner ring is mounted on the locating surface, and the rolling elements are axially slidable on the inner ring. That is, in order to press the rotor support flange onto the housing when the fastener 102 is tightened as described above, for example, the rolling elements may slide along the inner ring from... Figure 2 The indicated travel position slides to Figure 3 The normal operating position is shown. The rotor support flange 120 is sealed to the housing 106 (e.g., at the oil pump 144) via a sealing ring 156, for example.

[0025] like Figure 3As best shown, tapered surface 112 includes a notch aligned with through hole 114, and tapered surface 122 includes a notch aligned with threaded hole 124. That is, tapered surfaces 112 and 122 do not form a complete ring, but rather have a gap region through which threaded fastener 102 passes. Other embodiments (not shown) may include, for example, a complete tapered ring with the threaded hole arranged radially inside or outside the ring. The diameter of through hole 114 is larger than the diameter of threaded hole 124, allowing the threaded fastener to pass through through hole 114 without threaded connection. That is, to expedite the assembly and disassembly of the threaded fastener with threaded hole 124, the fastener can be rapidly advanced until it engages with threaded hole 124. Other embodiments (e.g., using threaded fastener 202 described below) may have holes 114 and 124 with the same diameter.

[0026] exist Figure 2 In the illustrated embodiment, the threaded fastener 102 is a bolt. The through hole 114 is a threaded hole, and after the generator module is assembled into the internal combustion engine, the bolt is removed and the sealing plug 104 (see [link to documentation]) is closed. Figure 3 The screw is screwed into the threaded hole. The sealing plug 104 includes an O-ring 160 for sealing with the housing. That is, once the housing is bolted to the engine block and the rotor is assembled with the crankshaft, as described above, the rotor is positioned within the stator. Therefore, the bolts can be removed and replaced with the sealing plug to prevent lubricating and cooling oil inside the housing from leaking out through the through hole 114.

[0027] The following descriptions are combined Figure 4-6 Made. Figure 4 Showing roughly along Figure 1 The sectional view taken from line 2-2 shows the threaded fastener installed in the transport position. Figure 5 Showing roughly along Figure 1 The sectional view taken from line 2-2 shows the threaded fastener installed in the working position. Figure 6 Show Figure 4 The circled area 6 is a magnified view of a portion of the image. Figure 7 Show Figure 5 The circled area 7 is a magnified view of a portion of the image.

[0028] The generator module 200 includes a threaded fastener 202. The threaded fastener 202 includes a threaded segment 262 extending through a through-hole 114, a threaded segment 264 screwed into a threaded hole 124, and an annular segment 266 separating the threaded segment 262 from the threaded segment 264. For example, as... Figure 6 and Figure 7As shown in the best embodiment, the annular segment 266 has an annular diameter larger than that of the threaded segments 262 and 264. The generator module 200 also includes a nut 268 mounted on the threaded segment 262 for securing the threaded fastener in the through hole 114. The threaded fastener 202 also includes an internal hexagonal segment 270 for inserting a tool to rotate the threaded fastener, and an O-ring 272 for sealing the annular segment against the housing (see [link]). Figure 7 ).

[0029] During the assembly of generator module 200, the threaded fastener can first be installed in the rotor support flange 120 and slide through the through hole 114. To secure the module in the transport position, tighten the nut 268 to press it against the housing 106, thereby pulling the two conical surfaces together, similar to the tightening of fastener 102 described above in conjunction with generator module 100. Once installed with the internal combustion engine, the nut 268 can be loosened or removed, and the fastener 202 can be unscrewed from the threaded hole 124 using the internal hex socket 270. If necessary, the nut 268 can be reinstalled and tightened onto the housing to secure the threaded fastener in the working position, wherein the O-ring 272 is pressed against the housing to prevent fluid leakage, similar to the sealing plug 104 described above. For example, if the module must be removed from the internal combustion engine for maintenance purposes, loosen and / or remove nut 268, align holes 114 and 124 in the direction of rotation, screw threaded section 262 into threaded hole 124 using hexagonal socket 270, and tighten the nut to secure the module in the transport position.

[0030] While exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms covered by the claims. The language used in this specification is descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of this disclosure. As previously stated, features of various embodiments may be combined with each other to form other embodiments of this disclosure not expressly described or shown herein. While various embodiments may be described as offering advantages or better performance relative to other embodiments or prior art implementations in one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics may be compromised to achieve the desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, lifecycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Therefore, any embodiment described as less desirable relative to other embodiments or prior art implementations in one or more characteristics does not exceed the scope of this disclosure and may still be ideal for a particular application.

[0031] Explanation of reference numerals in the attached figures 100 Generator Module 102 Threaded Fasteners 104 Sealing Plug 106 Casing 108 Mounting surfaces (housing) 110 Mounting Hole (Housing) 112 Conical surface (first, shell) 114 Through-hole (First, shell) 116 Stator 118 rotor 120 Rotor Support Flange 122 Tapered surface (second, rotor support flange) 124 Threaded hole (second, rotor support flange) 128 Drive Flange 130 drive hub 132 Fasteners (drive flange to drive hub) 134 Axial (First) 136 Axial (Second) 138 Positioning boss 140 bearing 142 Positioning surface (shell) 144 Oil pump (housing) 146 Wall (Shell) 148 Cylindrical surface (rotor support flange) 150 Inner Ring (Bearing) 152 Outer ring (bearing) 154 Rolling elements (bearings) 156 Sealing Ring 160 O-ring (sealing plug) 200 Generator Module 202 Threaded Fasteners 262 First thread segment (threaded fastener) 264 Second thread segment (threaded fastener) 266 Annular segment (threaded fastener) 268 nuts 270 internal hexagonal head (threaded fastener) 272 O-rings (threaded fasteners).

Claims

1. A generator module, comprising: A housing for fixing to an internal combustion engine, the housing including: a first conical surface; and a first through hole; a stator fixedly disposed within the housing; and a rotor rotatable within the stator, the rotor including a rotor support flange having: a second conical surface; and a second threaded hole for receiving a threaded fastener that extends through the first through hole and is screwed into the second threaded hole to pull the rotor support flange toward the housing, thereby pressing and fixing the second conical surface onto the first conical surface.

2. The generator module according to claim 1 further includes a drive flange for forming a drive connection with the crankshaft of the internal combustion engine, and the rotor further includes a drive hub fixed to the drive flange by fasteners.

3. The generator module according to claim 2, wherein: The threaded fastener is installed in the second threaded hole along the first axial direction; and the fastener for fixing the drive hub to the drive flange is installed along the second axial direction opposite to the first axial direction.

4. The generator module of claim 2, wherein the drive hub includes a positioning boss for positioning the drive hub in the crankshaft.

5. The generator module according to claim 1 further includes a bearing, wherein: The housing also includes a positioning surface; and the bearing is disposed on the positioning surface.

6. The generator module according to claim 5, wherein: The rotor support flange includes a cylindrical surface; and the bearing is disposed within the cylindrical surface.

7. The generator module according to claim 5, wherein: The bearing includes an inner ring, an outer ring, and a plurality of rolling elements disposed therebetween; the inner ring is mounted on the positioning surface; and the rolling elements are capable of axial sliding on the inner ring.

8. The generator module according to claim 1, wherein a seal is provided between the rotor support flange and the housing.

9. The generator module according to claim 1, wherein: The first tapered surface has a first notch aligned with the first through hole; and the second tapered surface has a second notch aligned with the second threaded hole.

10. The generator module according to claim 1, wherein the first diameter of the first through hole is greater than the second diameter of the second threaded hole.

11. The generator module according to claim 1, wherein the threaded fastener is a bolt.

12. The generator module according to claim 11, wherein: The first through hole is a first threaded hole; and after the generator module is assembled to the internal combustion engine, the bolt is removed and the sealing plug is screwed into the first threaded hole.

13. The generator module of claim 12, wherein the sealing plug includes an O-ring for sealing with the housing.

14. The generator module according to claim 1, further comprising the threaded fastener, wherein the threaded fastener comprises: The first threaded segment extending through the first through hole; The second thread segment used for screwing into the second threaded hole; And an annular segment that separates the first threaded segment from the second threaded segment.

15. The generator module according to claim 14, wherein: The first threaded segment has a first diameter; the second threaded segment has a second diameter; and the annular segment has an annular diameter greater than the first diameter or the second diameter.

16. The generator module of claim 14, wherein the threaded fastener further comprises an internal hexagonal segment for inserting a tool to rotate the threaded fastener.

17. The generator module according to claim 14, further comprising a nut mounted on the first threaded section for securing the threaded fastener in the first through hole.

18. The generator module of claim 14, wherein the threaded fastener further comprises an O-ring for sealing the annular segment with the housing.

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