Patent Application
20140346780
The present disclosure is directed to a connection assembly and, more particularly, a connection assembly for a power system.
Power systems often include engines operatively connected to one or more generators (e.g., an alternator). The generator(s) convert mechanical energy into electricity, which may be stored and subsequently used to provide power to another part of the power system (e.g., a traction motor). For example, a crankshaft of an engine may be rotatably connected to a rotor of a generator that creates electricity through rotation within a stator. In some power system applications, it may be desirable to replace the engine currently in-use with another engine, such as an engine that is more efficient, produces lower emissions, etc. However, the replacement engine may not be readily connectable with the existing generator components. Modifications may be necessary to connect the replacement engine with the existing generator.
One example of a generator connected to an engine is disclosed in U.S. Patent Application Publication 2010/0295005 of Wolff et al. (“the '625 publication”). In particular, the '625 publication discloses a power system including an electrical converting device and a “repowered” portion including a replacement internal combustion engine. The repowered portion further includes a gearbox and a pair of connecting structures that operatively connect an output member of the internal combustion engine to the gearbox and the gearbox to an input member of the electrical converting device. The engine output member thereby drives the electrical converting device input member through the gearbox and connecting structures. A separate support is rigidly mounted to a support frame to provide support to a driven end of the electrical converting device.
While the '625 publication discloses a modified connection between an engine and a generator, it may be less that optimal. In particular, the use of two connecting structures and a gearbox to connect the engine to the generator may be bulky, especially considering the limited amount of space available in a typical power system application. Similarly, use of a separate support mounted to the support frame may be impractical for applications in which there is limited space between the engine and the generator. In addition, the input shaft of the generator may not be readily connectable to a connecting structure.
The present disclosure is directed to overcoming one or more of the problems set forth above and/or other problems of the prior art.
In one aspect, the present disclosure is directed to a connection assembly for a power system. The connection assembly may include a housing configured to be connected to a stationary portion of a generator and a bearing operatively connected to the housing. The connection assembly may also include a shaft supported by the bearing and configured to be connected to a rotor of the generator. The connection assembly may additionally include an adapter coupled to the housing and configured to be connected to an engine. The shaft may extend through an opening in the housing and an opening in the adapter to connect with a crankshaft of the engine.
In another aspect, the present disclosure is directed to a shaft extension for a connection assembly. The shaft extension may include a connection plate configured to be connected to a connection surface on an existing generator. The shaft extension may also include a shaft extending from the connection plate and configured to connect to a securing member on an engine. The shaft extension may be configured to support a bearing to convert the existing generator from a single-bearing generator to a dual-bearing generator
In another aspect, the present disclosure is directed to a method of connecting components of a power system. The method may include connecting a shaft to a rotor of a generator and connecting a housing to a stationary portion of the generator such that the shaft extends through an opening in the housing. The method may also include supporting the shaft with a bearing connected to the housing. The method may additionally include moving the engine to align an axis defined by a securing member with an axis defined by the shaft.
Connection assembly 16 may include components configured to provide support and maintain alignment between engine 12 and generator 14. These components may include, among other things, a housing 22 connected to generator 14, and an adapter 24 connected to a flywheel housing 64 of engine 12. In an exemplary embodiment, connection assembly 16 may be a retrofit assembly configured to secure a generator 14, originally connected to another engine, to a replacement engine 12.
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In an exemplary embodiment, shaft extension 18 and bearing assembly 19 may be components added to an existing generator 14 to convert generator 14 from a single-bearing generator to a dual-bearing generator. For example, the rotor of generator 14 may be supported by an original bearing (not shown) provided on a non-connection end of generator 14 (i.e., end of generator 14 distal to engine 12). Connection assembly 16 may provide bearing assembly 19, including a bearing 20, as the additional bearing on a connection end of generator 14 (i.e., end of generator 14 proximal to engine 12) for further supporting rotational components of power system 10, specifically shaft extension 18. While bearing 20 is described herein as a ball bearing, it should be understood that bearing 20 could be another type of bearing, such as a journal bearing, magnetic bearing, or any other type of bearing known in the art.
Bearing assembly 19 may include bearing 20, a bearing housing 32, a cover 42, a cap 52, and a gasket 54. Bearing 20 may be supported on shaft 26 of shaft extension 18 and held in bearing housing 32. Bearing housing 32 may include an outer surface 34, a first protrusion 36, a second protrusion 38 on a side opposite first protrusion 36, and a through bore 40. Bearing 20 may be sized to fit within bearing housing 32. For example, bearing 20 may be a circular ball-bearing case with an outer diameter configured to fit in through bore 40 of bearing housing 32 and an inner diameter sized to receive shaft 26. Cover 42 may be secured to bearing housing 32 to close off one side of through bore 40. Cap 52 and gasket 54 may be placed on the other side of through bore 40 to seal bearing 20 within bearing housing 32. Cover 42, cap 52, and gasket 54 may each include openings through which shaft 26 may extend.
Bearing housing 32 may be secured to housing 22 to connect bearing assembly 19 to generator 14. In an exemplary embodiment, housing 22 may be an original housing associated with an engine previously connected to generator 14. For example, housing 22 may be a flywheel housing originally associated with the replaced engine. Housing 22 may include a circular opening 44, an exterior surface 46, and a rim portion 50. First protrusion 36 of bearing housing 32 may be configured to extend into circular opening 44 in housing 22 to guide attachment of bearing housing 32 to housing 22. Fasteners (e.g., bolts) may extend through holes in an exterior surface 46 of housing 22 and holes in outer surface 34 of bearing housing 32 to secure the components together. Housing 22 may be secured to a stationary portion of generator 14 by fasteners extending through holes in an outer edge 48 of generator 14 and rim portion 50 of housing 22. While fasteners inserted through corresponding holes are described as connection members throughout this disclosure, it should be understood that other types of fastening means, such as gluing, welding, etc., may be used. With housing 22 and bearing housing 32 attached to generator 14, shaft 26 may extend through circular opening 44, through bore 40, and bearing 20.
Adapter 24 may be provided to secure housing 22 to engine 12. Adapter 24 may include an attachment member 56 configured to be secured to housing 22, and an extension portion 60 configured to be secured to engine 12. Attachment member 56 may include a plurality of holes configured to be aligned with holes in exterior surface 46 of housing 22 for receiving fasteners therethrough. Second protrusion 38 of bearing housing 32 may be configured to extend into circular opening 58 to guide attachment of attachment member 56 to exterior surface 46 of housing 22. Extension portion 60 may include a circular rim 62 configured to be secured to engine 12, such as to an edge of flywheel housing 64.
Components of engine 12 may be configured to fit within an opening defined by extension portion 60. For example, flywheel components 68 may be configured to fit within extension portion 60 to allow a securing member 70 to be secured on an end of shaft 26 of shaft extension 18, which extends through an opening defined by attachment member 56 of adapter 24. In an exemplary embodiment, securing member 70 may be a pressure-fit cap that is secured to an end of shaft 26 of shaft extension 18 for transferring torque from the flywheel of engine 12 to shaft 26. Securing member 70 may be secured to the flywheel of engine 12, either directly or indirectly, such that rotation of the flywheel results in corresponding rotation of securing member 70. The flywheel may be connected to the crankshaft of engine 12 such that rotation of the crankshaft results in rotation of the flywheel, which is transferred to the shaft extension 18 and eventually to the rotor of generator 14. In this way, connection assembly 16 may be utilized to transfer torque and rotatably drive the rotor of generator 14. Bearing 20 may provide support to connection assembly 16 to help prevent orbiting and/or vibrating that may damage components of power system 10 and prevent efficient transfer of energy.
The disclosed connection assembly 16 may be applicable to any power system 10 in which torque is transferred from one component to another. The connection assembly 16 may be particularly beneficial when utilized to connect a power source (e.g., engine 12) to a generator/alternator (e.g., generator 14). Further, connection assembly 16 may be applicable to introduce an additional bearing 20 to support rotational components. For example, the disclosed connection assembly 16 may be utilized to convert a single-bearing generator into a dual-bearing generator. An exemplary process for converting such a generator is described below.
An existing power system 10 may include an existing engine (not shown) operatively connected to generator 14. The existing engine may be replaced with engine 12 to update power system 10 by including a power source that, for example, is more efficient, has higher power, produces lower emissions, etc. It may be beneficial to continue to use generator 14 as part of power system 10 to, for example, reduce the number of parts to be replaced, reduce costs of updating power system 10, etc.
In an exemplary disclosed embodiment, generator 14 may be a locomotive alternator supported by a single bearing at the far end of generator 14 and connected to the existing engine by housing 22. For example, housing 22 may be a flywheel housing of the existing engine. In replacing the existing engine with the new engine 12, flywheel housing 64 may be incompatible for direct connection to generator 14. Connection assembly 16 may be implemented to accommodate an operative connection between the crankshaft/flywheel of the new engine 12 and the rotor of the existing generator 14.
After the existing engine has been separated from power system 10, generator 14 may be modified to accommodate connection to the new engine 12. First, shaft extension 18 may be attached to connection surface 30 of the rotor of generator 14. The connection between connector 28 and connection surface 30 may be adjusted to prevent orbiting and/or vibrating of shaft 26 as it rotates with the rotor. For example, a shimming process may be used to incrementally adjust the connector 28 (e.g., adjust the alignment of connector 28 with respect to connection surface 30, the tension placed on connector 28 by the fasteners, etc.) until proper alignment (i.e., rotation with orbiting and/or vibrating below a threshold level) is achieved.
After shaft extension 18 has been secured to the rotor, housing 22 may be reattached to generator 14. For example, outer edge 48 of generator 14 may be secured to rim portion 50 of housing 22 by fasteners extending though aligned holes. With housing 22 secured to generator 14, shaft extension 18 may be enclosed by generator 14 and housing 22, except for shaft 26 extending out of circular opening 44 in exterior surface 46 of housing 22.
Bearing 20 and bearing housing 32 may be secured to housing 22 to provide further support to shaft 26 of shaft extension 18. Bearing 20 may be secured within bearing housing 32, which can be completed before or after bearing housing 32 is secured to housing 22 and/or adapter 24. Bearing 20 may be secured in through bore 40 of bearing housing 32 by cover 42 on one side (e.g., side proximal engine 12) and by cap 52 and gasket 54 on the opposite side (e.g., side proximal generator 14).
Either before or after housing 22 is secured to generator 14, bearing housing 32 may be secured to housing 22. First protrusion 36 may be inserted into opening 44 to guide attachment of bearing housing 32 to housing 22. With first protrusion 36 inserted into opening 44, fasteners may be inserted through holes in outer surface 34 of bearing housing 32 and exterior surface 46 of housing 22. With bearing housing 32 attached to housing 22 and housing 22 attached to generator 14, shaft 26 of shaft extension 18 may extend through circular opening 44 and through bore 40 such that bearing 20 supports shaft 26. Shaft 26 may be configured to extend beyond cover 42 when these components are in place.
Next, adapter 24 may be attached to housing 22. Second protrusion 38 of bearing housing 32 may be inserted into opening 58 to guide attachment of adapter 24 to housing 22. With second protrusion 38 inserted into opening 58, fasteners may be inserted through holes in attachment member 56 of adapter 24 and exterior surface 46 of housing 22. With adapter 24 attached to housing 22, shaft 26 may extend through opening 58 into extension portion 60.
With adapter 24 set in place, replacement engine 12 may be supported by common base 72 and moved into position for operative connection to generator 14. Engine 12 may be placed on common base 72 with flywheel housing 64 of engine 12 generally arranged such that an axis through a center of the securing member 70 is generally aligned with an axis through a center of shaft 26. An adjustment process may be utilized to adjust the position of engine 12 to refine the alignment of these axes, such that securing member 70 can be secured to an end of shaft 26 and circular rim 62 can be secured to flywheel housing 64. For example, common base 72 may be incrementally adjusted in one or more directions (e.g., up or down and/or side to side) to adjust the position of engine 12. Since generator 14 is supported by base feet 74, which are not attached to common base 72, movement of common base 72 may result in movement of engine 12 relative to generator 14, allowing for gradual alignment.
After securing member 70 has been generally aligned with shaft 26, engine 12 may be moved toward generator 14 until securing member 70 is secured on an end of shaft 26. Thereafter, adapter 24 may be attached to flywheel housing 64, such as by placing fasteners through aligned holes in circular rim 62 and an outer edge portion of flywheel housing 64. After all components are connected, engine 12 may be arranged to transfer rotational energy from the crankshaft to the rotor of generator 14. After initial operations (e.g., test runs), additional adjustment of the position of engine 12 may be necessary to achieve sufficient alignment of shaft 26 with the rotating members of engine 12. If necessary, proper alignment may be accomplished by additional incremental movement of common base 72.
With all components in place and sufficiently aligned, power system 10 may be operated. Power production (e.g., from combustion events in cylinders of engine 12) may result in rotation of the crankshaft of engine 12, which may cause the flywheel within flywheel housing 64 to rotate. Rotation of the flywheel may produce corresponding rotation of securing member 70, which may transfer torque to shaft 26 of shaft extension 18. Bearing 20 may support shaft 26 as the transferred torque causes shaft extension 18 to rotate and thus may help prevent shaft 26 from orbiting and/or vibrating beyond an allowable degree. Rotation of connector 28 of shaft extension 18 may cause rotation of fan 31 and the rotor of generator 14. Rotation of the rotor within a stator of generator 14 may convert the mechanical rotational energy into electricity, which may be stored and transferred to another component of power system 10, such as a traction motor for driving traction devices.
Since the replacement engine 12 may produce higher power and torque than the replaced engine, the dual-bearing arrangement provided by bearing 20 (when combined with the original far-end bearing) may be necessary to support rotation of the relevant components of power system 10. For example, the dual-bearing arrangement may prevent orbiting and/or vibrating that may cause damage to or inefficient operation of engine 12, generator 14, and/or connection assembly 16. Further, use of shaft extension 18 and adapter 24 may allow for housing 22 to be repurposed from a flywheel housing to a connection member that supports bearing housing 32 and bearing 20. In addition, the arrangement of common base 72 may allow for simpler alignment of rotational components by allowing engine 12 to easily be moved relative to generator 14.
It will be apparent to those skilled in the art that various modifications and variations can be made to the connection assembly of the present disclosure without departing from the scope of the disclosure. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims.
