Generator Adaptor Angled Cross Members Stiffness
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Solution Overview
Problem
Existing adaptors for connecting generators to prime movers are costly and complex to manufacture, require a core in the casting process, have limited space for assembly, are heavy due to excess material, and generate significant fan noise.
Innovation Solution
The use of angled cross members between flange members reduces material usage while maintaining stiffness, allows for larger openings for assembly, eliminates the need for a core in casting, and minimizes fan noise by presenting a progressive cutting edge to fan blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If openings are provided in the adaptor to allow connection of rotating parts, then assembly is enabled, but the adaptor becomes difficult to cast and requires a core, increasing manufacturing cost and complexity
Solution Approach 1:
The adaptor is divided into multiple separate casting pieces that are subsequently joined together. This segmentation allows each piece to be cast without complex cores, while the final assembled adaptor provides the necessary openings for assembly operations.
2Ease of operation
If the size of openings is increased to provide more space for assembly, then assembly ease is improved, but the stiffness of the adaptor is reduced and the risk of casting defects increases
Solution Approach 1:
By segmenting the adaptor into multiple pieces with strategically placed openings, sufficient assembly space is provided without compromising the overall structural stiffness of the complete adaptor assembly.
3Strength
If a relatively large amount of material is used to achieve the required stiffness, then structural integrity is improved, but the adaptor becomes heavy and manufacturing cost increases
Solution Approach 1:
The adaptor is constructed from multiple separate casting pieces joined together, allowing material to be placed only where structurally necessary. This reduces overall material usage and weight while maintaining the required stiffness through strategic positioning of structural elements.
Solution Approach 2:
Different regions of the adaptor have different material thicknesses and densities optimized for their specific functional requirements. Critical load-bearing areas have sufficient material for stiffness, while non-critical areas use minimal material, reducing overall weight.
4Ease of operation
If openings are provided in the adaptor for assembly access, then assembly is enabled, but fan noise is increased due to air flow through openings
Solution Approach 1:
The adaptor is segmented into multiple pieces with openings positioned to provide assembly access while minimizing their alignment with fan air flow paths. This reduces the noise-generating effect of air passing through openings while maintaining necessary assembly capability.
Data Source
AI summary
An adaptor for connecting a generator to a prime mover. The adaptor includes a first flange member for connection to the prime mover, a second flange member for connection to the generator, and a plurality of angled cross members between the first and second flange members. By providing a plurality of angled cross members between the first and second members, the adaptor may use less material for a given stiffness.