Patent Application
20240003287
The present disclosure relates generally to generator systems, and specifically to air handling systems for generator systems.
Mobile generator systems may be used to provide power in remote environments. Mobile generator systems typically use internal combustion engines as prime movers. These engines typically are limited in their output based on the ambient conditions including ambient air temperature. For example, when the ambient temperature is outside of an operational temperature range, the engine output may be derated such that output power is reduced. At extreme temperatures, the generator may be shut down entirely to avoid damaging the engine.
The present disclosure provides for a generator system. The generator system may include a generator and engine positioned within an enclosure. The generator system may include a heater core, the heater core positioned within the enclosure. The generator system may include a fan positioned to force air through the heater core into the enclosure. The generator system may include a coolant heater. The generator system may include a pump, the pump operatively coupled to the coolant heater and the heater core positioned to pump heated coolant from the coolant heater to the heater core.
The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
In some embodiments, generator system 10 may include a generator 18, which may be powered by an engine 20. Generator 18 and engine 20 may be positioned within an enclosure 16. Generator system 10 may also include power handling equipment. In some embodiments, generator system 10 may include a radiator system 22 positioned to, for example and without limitation, provide cooling when necessary for a coolant system of generator system 10 as further discussed herein below.
In some embodiments, generator system 10 may include an air intake heater treatment system 100. Air intake heater treatment system 100 may include components mounted to skid 12 and positioned within enclosure 16.
Referring now to
As shown in
In some embodiments, top brackets 115 may operate in conjunction with bottom brackets 109 to allow a predetermined, relatively small, amount of relative movement along all three axes (in three dimensions) between heater core 107 and skid 12, so as to protect heater core 107 from vibrations and shocks during transportation of generator system 10. By insulating heater core 107 from vibration and shock and allowing it to move independently, the risk of a coolant leak is reduced.
In some embodiments, air intake heater treatment system 100 may be used to heat the interior of enclosure 16 to within an operational temperature range for the operation of engine 20. Air may be drawn into enclosure 16 through louvers 101 (shown in
Air entering enclosure 16 via louvers 101 may flow through at least one heater core 107. Heater core 107 may be mounted within enclosure 16 such that air passing through enclosure 16 passes through heater core 107. Heater core 107 may be mounted vertically, horizontally, or at an angle. In some embodiments, heater core 107 may include one or more coolant tubes configured such that heated coolant passed through heater core 107 heats the air passing through heater core 107. In some embodiments, for example and without limitation, the coolant tubes may be formed from copper or another material having similar physical characteristics.
After passing through heater core 107, the heated air continues further into enclosure 16 such that the heated air flows around engine 20. If the temperature of the heated air is greater than the temperature of engine 20 the heated air will transfer heat to engine 20 so as to preheat or maintain the temperature of engine 20 within a desired temperature range. As air inside enclosure 16 may also serve as intake air for engine 20, heat may be transferred to engine via the air intake in addition to air surrounding the engine
Referring to
HTC 202 may include a radiator system 22, which in turn may include at least one motor 212, which drives at least one radiator fan 214, and at least one radiator 216. Motor 212 drives radiator fan 214, which blows air across radiator 216. HTC 202 may further include a pump 206, a coolant heater 119A, and a radiator valve 203A and may optionally be fluidly connected to engine 20 so as to pump fluid therethrough. In this way, HTC 202 may be used to warm fluid (water) in the engine jacket and thus the engine itself prior to startup.
LTC 204 may include a radiator valve 203B, pump 208, coolant heater 119B, heater core 107, and heater core valve 205, which may be fluidly connected by coolant lines 201. Fluid flow through LTC 204 may be controlled by radiator valves 203B and heater core valve 205. In some embodiments, LTC 204 may also be in fluid communication with engine 20. In these embodiments, fluid flowing through LTC 204 is used to warm the engine pre startup in addition to providing the heat to the coolant that is then extracted through the heater core to warm the enclosure.
In some embodiments, pump 208 and pump 206 may be replaced with a single pump that is in fluid communication with both HTC 202 and LTC 204; in such an embodiment, flow through the various portions of coolant system 200 may be controlled by valves 203A, 203B, and pump 206. Additional valves may be included in the system as desired.
When it is necessary to remove heat from engine 20 instead of warming it, coolant heaters 119A and 119B may be switched off and radiator system 22 may function to transfer heat from generator system 10 to the atmosphere by passing ambient air across radiators 216.
In some embodiments, HTC 202 and LTC 204 may be in fluid communication with each other or may share components. For example, in the embodiment shown in
In some embodiments, valves 203A, 203B, and heater core valve 205 may be controlled by a controller. In some embodiments, the controller may be the same controller that operates generator 18 and engine 20. In other embodiments, the controller may be separate from the controller that operates generator 18 and engine 20. In some embodiments, the controller may also control the operation of one or more of louvers 101, fans 103, fans 214, coolant heaters 119A, 119B, and radiator system 22.
Each coolant heater 119A, 119B may comprise a burner fueled with natural gas, diesel, or other fuel or may be electrically powered. By way of example, coolant heater, 119B, may be a 55K BTU unit. In other embodiments, an electrically powered coolant heater may be integral with a heater core. Each coolant heater 119A, 119B may include a integral pump, which may be used to pump fluid through HTC 202 and LTC 204, respectively.
When it is desired to operate generator system 10, the controller may determine the ambient temperature measured as the engine temperature, the temperature within enclosure 16, the intake air temperature of enclosure 16, or a combination thereof. Where the ambient temperature is within a predetermined operational temperature range for generator system 10, engine 20 may be started up without any preliminary steps. The controller may then operate fans 214, pump 206, and radiator system 22 as normal to maintain the desired operational temperature of engine 20 during operation thereof.
If the controller determines that the ambient temperature is below the predetermined operational temperature range, the controller may activate either HTC 202, LTC 204, or both. Thus, one or both coolant heaters 119A, 119B are turned on. One or both pumps 206, 208 may optionally be turned on. Heater core valve 205 may be opened such that heated coolant is provided to heater core 107. If desired, radiator valves 203A, 203B may be opened. Fans 103 may be turned on, such that air is pulled into enclosure 16 through heater core 107 and heated air flows across engine 20. In some embodiments, pumps 206, 208 may supply heated coolant fluid to engine 20 such that the coolant also provides heating to engine 20. In this manner, engine 20 may be brought to an operational temperature more quickly. Once the ambient temperature is within the predetermined operational temperature range, engine 20 may be engaged. Selection of whether to operate both coolant heaters or just one may depend on the rate at which it is desired to bring the engine to the target temperature.
The controller may then be used to maintain the operational temperature range. For example, at some point during the operation of generator system 10, the heat from engine 20 may be sufficient to heat the interior of enclosure 16, prompting the controller to disengage one or both coolant heaters 119A, 119B, pump 208, and fans 103. In some embodiments, pump 206 and fan 214 remain in operation, allowing the HTC 202 to dissipate heat generated by the engine via radiator 216.
Although described as a single heater core 107, in some embodiments, multiple heater cores 107 may be positioned within enclosure 16. In some embodiments, heater core 107 may fully engage the top, bottom, and sides of enclosure 16. In other embodiments, heater core 107 may be smaller. Although fans 103 are described as pulling air through heater core 107, in other embodiments, fans 103 may be positioned to push air through heater core 107.
The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.
This application is a nonprovisional application which claims priority from U.S. provisional application No. 63/357,220, filed Jun. 30, 2022, which is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63357220 | Jun 2022 | US |
