Automatic Module Couplings for Scalable Generator Set Assembly
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Solution Overview
Problem
Custom-manufactured generator sets are large, heavy, and costly to transport and install, with long lead times and limited scalability, making them inefficient for on-demand power needs and site expansions.
Innovation Solution
A modular power generation system comprising a primary module and secondary modules, packaged in ISO shipping containers, allowing for easy assembly and scalability by automatically coupling electrical and fluidic connections, guided by attachment features and guiding elements, reducing the need for skilled labor and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If custom-manufactured generator sets are used, then power generation capacity is achieved, but transportation cost increases
Solution Approach 1:
The generator set system is divided into multiple modular units that can be manufactured separately and transported independently. Each module contains standardized components (engine, generator, control systems) that can be assembled in various configurations to meet different power requirements, reducing transportation costs compared to moving single large custom-built units.
Solution Approach 2:
The modular generator set employs universal interfaces and standardized mounting configurations that allow the same basic modules to serve multiple functions and be deployed in different power generation scenarios. This universality enables efficient transportation of standardized modules rather than custom-built units for each specific application.
2Power
If custom-manufactured generator sets are used, then power generation capacity is achieved, but installation time increases
Solution Approach 1:
By segmenting the generator set into standardized modular units with pre-assembled subsystems, the installation process becomes a matter of connecting predefined modules rather than assembling custom-built units on-site. This significantly reduces installation time while maintaining the required power generation capacity.
Solution Approach 2:
Critical assembly tasks are performed in advance during module manufacturing, including pre-assembly of engine-generator sets, pre-wiring of electrical connections, and pre-positioning of mounting hardware. These preliminary actions eliminate time-consuming on-site assembly operations and reduce overall installation time.
3Power
If custom-manufactured generator sets are used, then specific power needs are met, but scalability is limited
Solution Approach 1:
The system is segmented into standardized modular units that can be easily added, removed, or reconfigured to match changing power requirements. This segmentation enables scalable deployment from small single-module installations to large multi-module systems without requiring custom manufacturing for each size increment.
Solution Approach 2:
Universal interfaces and standardized mounting configurations allow the same modular components to be used across different system sizes and configurations. This universality provides scalability by enabling the same basic modules to be deployed in various arrangements to meet different power needs.
4Ease of operation
If automated coupling mechanisms are added, then assembly simplicity is improved, but device complexity increases
Solution Approach 1:
The coupling mechanism is designed to automatically perform alignment and connection functions when modules are brought into proximity. The self-aligning features and automated coupling reduce the need for manual intervention and complex positioning operations, simplifying assembly despite the added complexity of the automated mechanisms.
Data Source
AI summary
In general, a generator set system may include a primary module including: an engine; a generator coupled to the engine and configured to convert mechanical energy of the engine to electrical energy; a primary frame configured to support the engine and the generator; and a first coupling. The generator set system also may include a secondary module including a secondary module including: at least one of a heat recovery module, an exhaust module, a cooling system module, a fuel system module, a solar power module, a battery module, an electrical system module, an air intake module, or an air outlet module; a secondary frame; and a second coupling. The first coupling and the second coupling are configured to automatically electrically or fluidically couple the primary module to the secondary module upon assembling the primary frame and the secondary frame.