Generator Stator Casing Direct Mounting to Engine
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Solution Overview
Problem
Existing generator assemblies for engine-generators, particularly in combined heat and power devices, face inefficiencies due to bulky designs, maintenance requirements, and misalignment issues that lead to increased air gaps and reduced performance, as well as potential damage from centrifugal forces and vibrations.
Innovation Solution
A generator assembly with a stator casing directly mounted to the engine casing using pre-existing mounting points, eliminating the need for a flange, allowing the rotor-stator assembly to be closer to the engine, and featuring a rotor with a coupling formed from the same material as the electrical conductor for reduced size and weight, and asymmetric winding heads for improved magnetic field alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flange is used to mount the stator casing to the engine, then alignment accuracy is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent removes the intermediate flange component from the mounting system. The stator casing is mounted directly to the engine casing using pre-existing mounting points, eliminating the need for a separate flange while maintaining alignment accuracy through direct attachment.
Solution Approach 2:
The pre-existing mounting points on the engine casing are repurposed for mounting the stator casing, rather than requiring dedicated mounting points or a flange structure. This multi-functional use of existing features simplifies the overall design.
2Manufacturing precision
If the rotor is mounted on a shaft with bearings, then alignment is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent removes the shaft and bearings from the rotor mounting system. The rotor is mounted directly to the crankshaft output shaft using a coupling, eliminating intermediate components while maintaining the necessary mechanical connection and alignment.
Solution Approach 2:
The rotor mounting is merged directly with the crankshaft output shaft through a coupling, eliminating the separate shaft and bearing assembly. This integration reduces the number of parts while maintaining functional requirements.
3Manufacturing precision
If a flange is used for mounting, then alignment is improved, but the air gap increases
Solution Approach 1:
By removing the flange and mounting the stator casing directly to the engine casing, the overall length of the generator assembly is reduced. This brings the rotor closer to the stator, minimizing the air gap while maintaining alignment through direct mounting.
4Adaptability or versatility
If the rotor is separated from the mounting point by a shaft, then alignment flexibility is improved, but misalignment effects are magnified
Solution Approach 1:
The shaft that separated the rotor from the mounting point is removed. The rotor is mounted directly to the crankshaft, eliminating the leverage effect that would magnify misalignment. The coupling provides sufficient flexibility for alignment while minimizing misalignment effects.
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
This configuration reduces misalignment effects, enhances efficiency by minimizing the air gap, and simplifies manufacturing and assembly, while also allowing for effective heat dissipation through conductive couplings, leading to smoother operation and reduced maintenance costs.
Implementation Method 1
A generator, which uses relative motion of electrical and magnetic components to generate electricity
Implementation Method 2
allowing for effective heat dissipation through conductive couplings
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A generator assembly for an engine-generator device comprises: a rotor 3 having a coupling 7a; 7b for mounting the rotor 3 to the output shaft 8 of an engine 1; a stator 4; and a stator casing 5, wherein the stator casing 5 comprises a generally cylindrical hollow structure arranged to be mounted directly to the engine casing.