Torque Converter Power Take-Off Generator for Transport Refrigeration
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Solution Overview
Problem
Existing power generation systems for vehicles, such as transport refrigeration systems, are complex and inefficient, requiring numerous components like prop-shafts, flexible joints, and clutches to transfer mechanical power from the engine bay to the TRS, which increases complexity and reduces power density.
Innovation Solution
A power generation assembly comprising a torque converter, a power take-off device directly coupled to a permanent magnet generator, eliminating the need for intervening components like prop-shafts and geared arrangements, with a high aspect ratio rotor to achieve compactness and efficiency, generating at least 8 kW of power at 500 rpm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a long prop-shaft and gearbox or belt and pulley system is used to transfer mechanical power from the engine bay to the generator, then the generator can be positioned remotely, but the device complexity increases significantly
Solution Approach 1:
The invention extracts and eliminates the intermediate mechanical transfer components (prop-shaft, gearbox, belt and pulley system) from the power transmission path. By directly coupling the generator rotor to the power take-off device, the system removes unnecessary intermediary elements while maintaining the essential power transfer function, thereby reducing complexity without sacrificing positioning flexibility
Solution Approach 2:
The invention merges the power take-off device and generator rotor into a directly coupled integrated assembly. This consolidation eliminates the need for separate mechanical transfer components and reduces the number of moving parts, achieving both simplified device complexity and maintained adaptability in generator positioning
2Power
If a relatively large diameter generator is used to provide sufficient electrical power, then the power output is adequate, but the device complexity and space requirements increase
Solution Approach 1:
The invention changes the operational parameters of the generator by directly coupling it to the power take-off device, which provides optimized rotational speed and torque characteristics. This direct coupling allows the generator to achieve sufficient power output with a more compact design, eliminating the need for large diameter generators that would be required in indirect coupling arrangements
Solution Approach 2:
The invention replaces the complex mechanical transmission system (gearbox or belt and pulley) with a direct mechanical coupling between the power take-off device and generator rotor. This substitution eliminates the need for intermediate mechanical components and allows for a more compact generator design while maintaining adequate power output
3Adaptability or versatility
If numerous components like bearings, flexible joints, and couplings are used in the power transfer system, then the system can accommodate misalignment and movement, but the device complexity and potential failure points increase
Solution Approach 1:
The invention extracts and removes the intermediate mechanical components (flexible joints, couplings, bearings) from the power transmission path. By implementing direct coupling between the power take-off device and generator rotor, the system eliminates these intermediary elements that were previously needed to accommodate misalignment and movement
Solution Approach 2:
The directly coupled generator assembly is designed to perform multiple functions simultaneously: power transfer, misalignment accommodation, and vibration damping, all within a single integrated structure. This multi-functionality eliminates the need for separate specialized components while maintaining the ability to handle operational variations
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 solution provides a compact, high-power-density generator that simplifies the power generation system, reduces complexity, and achieves sufficient power output for transport refrigeration systems without the need for additional mechanical transfer components, while allowing for direct power delivery to the TRS.
Implementation Method 1
a permanent magnet generator having a rotor directly coupled to the power take-off device for power generation
Data Source
AI summary
There is disclosed a power generation assembly (300) for powering a transport refrigeration system (TRS) (52) of a vehicle (10), the power generation assembly (300) comprising: a torque converter (402) having an engine side input (404) and a transmission side output (406); a power take-off device (302) coupled to the engine side input (404) of the torque converter (402), the power take-off device (302) having a rotary output; a permanent magnet generator (304) having a rotor (420) directly coupled to the power take-off device (302) for power generation; wherein the power generation assembly (300) is configured to be housed in an engine bay (210) of a vehicle (10), and is configured to generate at least 8 kW of power when the engine side input (404) has a rotational speed of 500 rpm.