Generator Module Guiding Mechanisms for Fast Scalable Assembly
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Solution Overview
Problem
Existing generator sets are often custom-manufactured, leading to large and heavy units that are costly and difficult to transport and install, with long lead times and limited scalability, making it challenging to add capacity or respond to changing power needs.
Innovation Solution
A modular generator set system comprising a primary module and secondary modules, packaged in ISO containers, which allows for easy assembly and scalability by using attachment features, guiding elements, and automatic couplings to facilitate mechanical, electrical, and fluidic connections, reducing the need for skilled labor and simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If generator sets are custom-manufactured to meet specific power needs, then the power generation capacity can be precisely matched to demand, but the units become large and heavy, increasing transportation and installation costs and complexity
Solution Approach 1:
The generator set system is divided into multiple standardized modular units that can be independently manufactured and then assembled. Each module contains complete functional components (engine, generator, control systems), allowing the system to be scaled by simply adding or removing modules rather than custom-building entire systems.
Solution Approach 2:
The modular generator set uses standardized interfaces and universal connection mechanisms that allow the same module design to serve multiple power requirements. The standardized coupling systems enable modules to be configured in series or parallel arrangements, providing both voltage and capacity scaling from a single module design.
2Adaptability or versatility
If generator sets are custom-manufactured, then specific power requirements can be met, but lead times are extended and scalability is limited
Solution Approach 1:
Modular generator units are pre-manufactured and stocked in standardized configurations before being needed. This allows rapid deployment since the modules are already built and tested, requiring only assembly and connection at the installation site rather than custom manufacturing from scratch.
Solution Approach 2:
The system allows dynamic reconfiguration by adding or removing modules based on changing power requirements. The standardized coupling mechanisms enable quick reassembly of modules into different configurations, providing scalability and adaptability without lengthy remanufacturing processes.
3Power
If traditional generator sets are used, then sufficient power can be provided, but transportation and installation are costly and difficult
Solution Approach 1:
By segmenting the generator set into transportable modular units, each module can be moved using standard handling equipment. The modules are designed with standardized lifting points and coupling mechanisms that simplify loading, unloading, and assembly operations.
Solution Approach 2:
Standardized coupling mechanisms act as intermediaries between modules, providing simple and reliable connection points that reduce the skill level required for assembly. These coupling systems include aligned connection interfaces for electrical, fluid, and mechanical connections.
Data Source
AI summary
In general, techniques of this disclosure are directed to a modular generator set system. A generator set system may comprise a primary module, which may include an engine, a generator coupled to the engine, a primary frame configured to support the engine and the generator, and a first guiding element. The generator set system may also include a secondary module, a secondary frame, and a second guiding element that is reciprocal to the first guiding element such that, during installation of the secondary module, the second guiding element is configured to interface with the first guiding element to align the secondary module for purposes of automatically electrically or fluidically coupling the primary module to the secondary module upon assembling the primary frame and the secondary frame.