Close Coupled Generator Adapter Torque Transfer
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Solution Overview
Problem
Existing generator set designs face challenges in efficiently transferring torque between the prime mover and generator, leading to excessive weight and cost due to oversized mounts and skids, and are prone to vibration-induced mechanical failures from unsuitable adapters.
Innovation Solution
A close coupled adapter with a cylindrical sidewall and specific aperture patterns is used to mechanically connect the prime mover and generator, providing torsional stiffness while allowing access for fastener insertion and alignment, thereby reducing weight and vibration issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional mounting methods with separate feet and bolts are used to attach prime mover and generator to skid, then ease of assembly is improved, but weight and structural complexity increase due to oversized mounts and skids
Solution Approach 1:
The adapter merges the mounting functions for both the prime mover and generator into a single integrated component. The adapter body combines front and rear mounting surfaces with aperture patterns that serve dual purposes: structural connection and fastener access, eliminating the need for separate feet and reducing overall mounting structure weight.
Solution Approach 2:
The adapter serves multiple functions simultaneously: it acts as a structural connector between prime mover and generator, provides mounting surfaces for both components, enables fastener insertion through integrated apertures, and maintains alignment during assembly. This multi-functionality replaces traditional separate mounting elements.
2Ease of manufacture
If traditional mounting methods with separate feet and bolts are used to attach prime mover and generator to skid, then ease of assembly is improved, but device complexity increases due to multiple mounting components
Solution Approach 1:
The adapter consolidates multiple mounting components into a single integrated part. Instead of separate feet, brackets, and alignment fixtures, the adapter body combines all mounting surfaces and fastening features into one component that attaches to the skid and supports both prime mover and generator.
Solution Approach 2:
The adapter performs multiple mounting functions simultaneously: providing attachment surfaces for prime mover and generator, enabling fastener insertion through integrated apertures, maintaining component alignment, and transferring mechanical loads. This reduces the number of separate parts needed.
3Strength
If adapter with limited aperture access is used to connect prime mover and generator, then structural integrity is improved, but ease of operation deteriorates due to difficulty in fastener insertion and alignment
Solution Approach 1:
The adapter features localized aperture patterns with varying geometries optimized for specific functions: triangular apertures provide structural reinforcement while enabling fastener insertion, oval apertures allow tool access for alignment, and circular apertures accommodate different fastener types. Each aperture shape is tailored to its specific operational requirement.
Solution Approach 2:
The adapter body is segmented with multiple aperture types distributed across its surface. This segmentation allows different regions of the adapter to serve different purposes: some apertures optimized for strength, others for access, and others for alignment, all while maintaining overall structural integrity.
4Ease of operation
If adapter with triangular and oval aperture patterns is used to connect prime mover and generator, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The adapter incorporates locally optimized aperture patterns where triangular apertures are positioned for structural reinforcement zones and oval apertures are placed for fastener access zones. This local quality differentiation allows standard manufacturing tolerances to be applied to each aperture type based on its specific functional requirements.
Solution Approach 2:
The adapter design includes preliminary alignment features such as tapered bore sections and positioning surfaces that guide the armature shaft and crankshaft into correct alignment before final fastening. This preliminary action reduces the precision required during the final assembly operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The close coupled adapter effectively transfers torque, reduces weight and cost by optimizing mount and skid design, and enhances assembly efficiency while maintaining structural integrity and vibration resistance.
Implementation Method 1
The close coupled adapter effectively transfers torque
Implementation Method 2
providing torsional stiffness while allowing access for fastener insertion and alignment
Implementation Method 3
enhances assembly efficiency while maintaining structural integrity and vibration resistance
Data Source
AI summary
An adapter is used to couple a prime mover body to a housing of a generator. The adapter has openings that allow an armature of the generator to be attached to the flywheel of the prime mover. The adapter provides a torque coupling between the prime mover and the generator so that the attachments of the prime mover and generator to the skid, as well as the skid itself, can be reduced in size and weight because they no longer need to oppose the prime mover-generator torque load. A thickness of the adapter and a pattern of the openings in the body of the adapter are selected to move any natural resonance frequencies of the adapter outside an operating frequency of the prime mover.