Direct-Coupled Engine Generator Compressor System
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Solution Overview
Problem
Existing engine-driven generator and compressor systems for spray applications are inefficient due to the need for oversized generators to handle high start-up amps, resulting in increased cost, weight, and space consumption, as well as the requirement for separate compressor drive motors and heavy base plates, which complicates portability and alignment.
Innovation Solution
A direct coupled engine/generator and compressor system, where the engine's output shaft is directly connected to both the generator and compressor, eliminating the need for a separate compressor drive motor and heavy base plate, and allowing for synchronized operation at optimal speeds (1800 or 3600 rpm) to produce electricity and compressed air efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the generator is sized to accommodate the start-up amps of the compressor motor, then the generator can handle the start-up load, but the generator becomes oversized, increasing cost and weight
Solution Approach 1:
The patent combines the compressor motor and generator into a single integrated unit with a shared stator and rotor assembly. The compressor motor rotor serves as the generator rotor, eliminating the need for separate motors and reducing overall system weight while maintaining the ability to handle start-up loads through the integrated design
Solution Approach 2:
The integrated assembly serves dual functions: the same rotor and stator components function as both the compressor motor during compression cycles and the generator during power generation. This multi-functionality eliminates the need for oversized dedicated components for each function
2Ease of operation
If a separate compressor drive motor is used, then the compressor can be driven independently, but additional hardware and heavy base plates are required, complicating portability
Solution Approach 1:
The patent merges the compressor drive motor and generator into one integrated assembly where the compressor motor rotor is directly coupled to the generator rotor. This eliminates separate drive motors, base plates, and coupling apparatus, reducing component count and simplifying portability while maintaining independent compressor operation through the integrated motor-compressor unit
3Volume of moving object
If the engine and generator are directly coupled, then the system becomes more compact and efficient, but precise alignment and speed matching are required
Solution Approach 1:
The patent combines the engine, generator, and compressor into a single integrated assembly where all components share common mounting structures and alignment references. The generator and compressor are directly coupled to the engine crankshaft within the same housing, eliminating the need for separate alignment procedures and reducing manufacturing precision requirements compared to separate mounted components
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
This solution reduces the need for oversized generators, minimizes start-up amperage draw, eliminates the need for additional hardware, and provides a compact, efficient power system capable of stable voltage and continuous operation, enhancing portability and reducing operational stress on the engine and generator.
Implementation Method 1
The engine is a conventional internal combustion engine
Implementation Method 2
the output shaft of the engine is directly coupled to an input shaft to the generator
Implementation Method 3
A compressor is directly coupled to the output shaft of the generator or another output shaft of the engine
Data Source
AI summary
Disclosed is a generator compressor combination power system based upon an internal combustion engine directly coupled to a generator and a compressor assembly. The engine, generator and compressor each having an operating drive shaft all positioned along the same axis, the generator is used to produce electricity and the compressor is used to compress gas.