Generator Set Variable Pulley Transmission for Low Load Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional generator systems employing direct drive transmissions are inefficient and noisy during low load operation due to fixed engine speeds, and while inverter-based systems can address this, they are complex and expensive.
Innovation Solution
A generator system incorporating a continuously variable transmission (CVT) pulley system and a governor that adjusts engine speed in response to load, allowing the alternator to operate at variable speeds while maintaining a constant rotor speed, thereby optimizing engine efficiency and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a direct drive transmission is used to couple the engine to the alternator, then the system structure is simple, but the engine speed is fixed and the system is inefficient and noisy during low load operation
Solution Approach 1:
The patent applies a continuously variable transmission (CVT) system with variable diameter pulleys that allow dynamic adjustment of the transmission ratio. The drive pulley and driven pulley can change their effective diameters continuously, enabling the engine speed to vary dynamically while maintaining alternator speed, thus improving efficiency during low load operation without requiring a complex fixed-speed direct drive system
Solution Approach 2:
The invention changes the physical parameter of pulley diameter from fixed to variable. The CVT system allows the effective diameter of the drive and driven pulleys to change continuously based on load conditions, which enables the transmission ratio to be adjusted and optimizes system efficiency across different operating conditions while maintaining a relatively simple mechanical structure
2Device complexity
If a direct drive transmission is used to couple the engine to the alternator, then the transmission system is simple, but the system generates excessive noise during low load operation
Solution Approach 1:
The CVT system enables dynamic speed adjustment of the engine based on load conditions. During low load operation, the engine can operate at lower speeds through the variable transmission ratio, which significantly reduces mechanical noise and vibration while maintaining a simple mechanical transmission structure without requiring complex noise control mechanisms
3Loss of energy
If an inverter is used to allow the engine to operate at speeds proportionate to power demand, then fuel economy is improved, but the system becomes complex and expensive
Solution Approach 1:
The patent replaces the electronic inverter system with a mechanical continuously variable transmission system. The CVT uses variable diameter pulleys and a belt to achieve continuous speed variation mechanically, eliminating the need for complex electronic inverters, rectifiers, and control circuits while still enabling the engine to operate at speeds proportionate to power demand, thus improving fuel economy with a simpler and more cost-effective mechanical solution
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 system achieves improved efficiency, reduced noise, lower emissions, and better fuel economy by dynamically adjusting engine speed based on load, providing a steady power supply and extending engine life.
Implementation Method 1
A belt is configured to engage the drive pulley and the driven pulley
Implementation Method 2
The governor adjusts the engine throttle to control the speed of the engine in response to a speed of the rotor shaft
Implementation Method 3
The driven pulley is configured to open and close to change a diameter of the belt disposed between the third sheave and the fourth sheave in response to a load on the generator
Data Source
AI summary
A generator system includes a prime mover having a drive shaft and a throttle, a driven member having a rotor disposed on a rotor shaft, and a continuously variable transmission pulley system. The transmission pulley system includes a drive pulley coupled to the drive shaft and having a variable drive pulley effective diameter. A driven pulley coupled to the rotor shaft has a variable driven pulley effective diameter responsive to varying torque on the rotor shaft. A belt configured to engage the drive pulley and the driven pulley has a belt tension, wherein the drive pulley effective diameter varies in response to the belt tension.