One-Piece Generator Housing for Flexible Engine Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing engine-driven welding machine generator housings require complex multi-piece constructions and large die-cast engine adapters, limiting flexibility and compatibility with different engine brands and types, and complicating the attachment process.
Innovation Solution
A one-piece generator housing with an annular wall and support ring that encloses the stator and rotor assemblies, featuring cast-in bosses for attachment to engine adapters and a rotor flange with integral cooling fan blades, allowing for simpler and more versatile engine interface compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multi-piece housing construction is used, then the generator can be assembled with different components, but the device complexity increases and the manufacturing cost increases
Solution Approach 1:
The patent combines multiple housing pieces into a single integrated housing structure that encloses the generator assembly. This one-piece housing eliminates the need for separate front and rear housing sections, reducing assembly complexity while maintaining the ability to adapt to different engine types through standardized mounting interfaces.
Solution Approach 2:
The housing is designed with universal mounting features and standardized interfaces that allow it to work with various engine types and configurations. The single housing structure incorporates multiple functional elements including mounting bosses, cooling passages, and attachment points that provide versatility without requiring additional components.
2Adaptability or versatility
If large die-cast engine adapters are used, then the housing can be connected to the engine, but the device complexity increases and the adapter size increases
Solution Approach 1:
The patent integrates the engine adapter functionality directly into the housing structure itself, eliminating the need for separate large die-cast adapters. The housing incorporates mounting bosses and attachment features that directly interface with various engine types, reducing the overall adapter size and simplifying the connection system.
3Reliability
If the housing encloses approximately half of the stator and rotor assemblies, then the components are protected, but additional baffling is required and the housing complexity increases
Solution Approach 1:
The housing completely encloses the stator and rotor assemblies in a single integrated structure, eliminating the need for additional internal baffles or partitions. The one-piece construction provides full protection while simplifying the overall housing structure by combining what would otherwise require multiple separate components.
4Ease of operation
If rotors attach directly to the engine output shaft, then the connection is straightforward, but compatibility with different engine types is reduced
Solution Approach 1:
The housing incorporates universal mounting interfaces and standardized attachment points that can accommodate various engine types and output shaft configurations. This allows the generator assembly to be easily attached to different engines while maintaining compatibility across multiple engine platforms through the standardized housing interface.
Data Source
AI summary
A one-piece generator housing locates and secures the generator stator assembly, rotor bearings, and brush holder, and provides for attachment of the housing assembly to the engine interface. The disclosed one-piece housing completely encloses the stator and rotor assembly of the generator. An embodiment of the one-piece generator housing is applied to welding machine applications that use an in-line engine. With this type of engine, the power take-off (PTO) is normally the engine flywheel, and the variety of engine interfaces to which to mount the generator become more diverse. In an embodiment, the rotor has a flange with integral cooling fan blades that bolts to the flywheel. A shorter adapter is used in order to access the fasteners that attach the rotor shaft to the flywheel. The housing attaches to the adapter using cast-in bosses and bolts.