Flexible Drivetrain Coupling for Mobile Generator Alignment
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Solution Overview
Problem
Mobile generators face challenges with alignment and weight imbalance due to conventional drivetrains, requiring frequent and time-consuming realignment during transportation, especially in remote locations like oil and gas sites, and are impractical for large generators with heavy components.
Innovation Solution
A flexible drivetrain using universal joints and isolated rubber supports allows for greater misalignment tolerance and customizable component orientation, enabling separate mounting and transportation of engine and alternator without precise realignment, and improving weight balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional drivetrain with rigid coupling is used to connect the engine and alternator, then the alignment precision can be maintained during stationary operation, but the device becomes difficult to transport and requires time-consuming realignment when moved
Solution Approach 1:
The patent changes the flexibility parameter of the drivetrain coupling from rigid to flexible, allowing the coupling to accommodate alignment variations while maintaining torque transmission. This enables the generator to be transported without realignment while still operating within acceptable precision tolerances.
Solution Approach 2:
The patent introduces a dynamic flexible coupling that can adapt its configuration during operation to maintain proper alignment between engine and alternator even when the generator is moved to different locations, eliminating the need for manual realignment.
2Productivity
If the engine and alternator are unitized on a common foundation with tight alignment tolerances, then the drivetrain performance is optimized, but the weight distribution becomes unbalanced making transportation difficult
Solution Approach 1:
The patent segments the drivetrain components into separately mountable units connected by a flexible coupling, allowing independent positioning of the engine and alternator to achieve better weight balance while maintaining drivetrain performance through the flexible connection.
3Adaptability or versatility
If a gearbox is added to change the electrical output frequency from 50 Hz to 60 Hz, then the frequency requirement is met, but the alignment complexity and realignment time increase significantly
Solution Approach 1:
The patent uses the flexible coupling to accommodate the additional angular and positional variations introduced by the gearbox, maintaining proper alignment across all three components (engine, gearbox, alternator) without requiring time-consuming realignment procedures.
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 flexible drivetrain simplifies and accelerates the deployment of mobile generators by allowing greater misalignment freedom, reducing realignment time and weight imbalance issues, enhancing operational efficiency and safety.
Implementation Method 1
These mounting techniques include rubber supports intended to minimize shock and vibration
Implementation Method 2
A flexible drivetrain may comprise a universal joint, allowing an additional degree of freedom for the connection
Data Source
AI summary
A mobile generator includes an engine and an alternator separately mounted on a substantially planar mounting surface, with a flexible drivetrain configured to transmit torque from the engine to the alternator. The flexible drivetrain, which may comprise a universal joint, allows the mobile generator to be transported without the need for re-alignment between the engine and alternator after the generator has reached its destination.