The present disclosure relates to enclosures for engines, generators, or generator sets. More particularly, the present disclosure relates to systems and methods for reducing noise emissions from a generator set.
It is desirable to reduce the noise emission of power generation components such as generator sets including an engine and a generator. Some systems designed to reduce noise emissions includes a secondary noise reducing enclosure and/or increased thickness barriers. Current solutions to reduce noise emissions add weight and cost, and increase the footprint of the generator set.
One embodiment relates to an apparatus that includes an intake defined by an intake aperture, an intake baffle, and an intake floor structured to couple to an intake portion of an enclosure roof, the intake extending along at least eighty percent (80%) of a width of the apparatus on a first side, an exhaust defined by an exhaust aperture, an exhaust baffle, and an exhaust floor structured to couple to an exhaust portion of the enclosure roof, the exhaust extending along at least eighty percent (80%) of the width of the apparatus on a second side opposite the first side, a partition panel isolating the intake from the exhaust, and an engagement mechanism structured to couple the apparatus to a generator set.
Another embodiment relates to a system that includes an enclosure defining an enclosure width and including a first enclosure wall extending the entire enclosure width, an enclosure intake wall that extends along at least eighty percent (80%) of the enclosure width, an enclosure intake cavity defined between the first enclosure wall and the enclosure intake wall, a second enclosure wall positioned on an opposite side of the enclosure from the first enclosure wall and extending the entire enclosure width, an enclosure exhaust wall that extends along at least eighty percent (80%) of the enclosure width, an enclosure exhaust cavity defined between the second enclosure wall and the enclosure exhaust wall, and a chamber defined between the enclosure intake wall and the enclosure exhaust wall. A modular canopy defines a canopy width that extends along at least eighty percent (80%) of the enclosure width, and including a canopy intake defined by an intake aperture, an intake baffle, and an intake floor structured to couple to the enclosure to provide fluid communication between the intake aperture and the enclosure intake cavity, the canopy intake extending along substantially the entire canopy width adjacent the first enclosure wall, a canopy exhaust defined by an exhaust aperture, an exhaust baffle, and an exhaust floor structured to couple to the enclosure to provide fluid communication between the exhaust aperture and the enclosure exhaust cavity, the canopy exhaust extending along substantially the entire canopy width adjacent the second enclosure wall, and a partition panel isolating the canopy intake from the canopy exhaust.
Another embodiment relates to a method that includes removing a roof of a generator set enclosure, coupling a modular canopy to the generator set enclosure, providing an intake flow path extending along at least eighty percent (80%) of a width of the generator set enclosure through the coupled modular canopy and the generator set enclosure, the intake flow path includes an intake aperture positioned in the modular canopy, an intake baffle positioned in the modular canopy, an intake floor positioned in the modular canopy, and an intake cavity positioned in the generator set enclosure. The method further includes providing an exhaust flow path extending along at least eighty percent (80%) of the width of the generator set enclosure through the coupled modular canopy and the generator set enclosure, the exhaust flow path includes an exhaust aperture positioned in the modular canopy, an exhaust baffle positioned in the modular canopy, an exhaust floor positioned in the modular canopy, and an exhaust cavity positioned in the generator set enclosure. The method further includes separating the intake flow path and the exhaust flow path with a partition panel.
These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.
Following below are more detailed descriptions of various concepts related to, and implementations of, methods, apparatuses, and systems for a low noise enclosure for a generator set. The various concepts introduced above and discussed in greater detail below may be implemented in any number of ways, as the concepts described are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.
Referring to the figures generally, the various embodiments disclosed herein relate to systems, apparatuses, and methods for a low noise enclosure for a generator set. The enclosure includes a modular canopy that provides a circuitous intake and exhaust path. The modular canopy includes air flow partitions that are formed from sheet metal as thin as two millimeters (2 mm) thick. Air filters, intake silencers, and noise deadening or barrier material can be attached to wall and partition surfaces to further reduce noise emissions. Additionally, lift hooks can be connected to the enclosure within recesses which can be sealed with covers to further reduce noise emission.
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An enclosure exhaust wall 86 extends the width of the enclosure 14 and defines an enclosure exhaust cavity 90 between an outer or front wall 94 and the enclosure exhaust wall 86. An enclosure exhaust aperture 98 is defined in the enclosure exhaust wall 86 and sized to receive an exhaust manifold, component, and/or filter 102. Although the filter 102 is shown as an independent component, those of skill in the art will recognize that the filter 102 can be moved, eliminated, or altered to meet the requirements of the engine 18 and components 22. In some constructions, an air exhaust manifold of the engine 18 is structured to engage or cooperate with the enclosure exhaust aperture 98 to expel exhaust gases. Additionally, a combination of engine exhaust and exhausting cooling air may exit the enclosure exhaust aperture 98 and enter the enclosure exhaust cavity 90. Further, additional aftertreatment components or mufflers may be positioned or mounted within the enclosure exhaust cavity 90, the second cavity 58, and/or external to the enclosure 14 and the modular canopy 26, as desired. In some embodiments, sound deadening material or insulation is adhered or otherwise attached to the surfaces of the enclosure exhaust cavity 90 and is selected to reduce noise while standing up to or inhibiting degradation in the high heat environment of the enclosure exhaust cavity 90 (i.e., the insulation used in the enclosure exhaust cavity 90 is heat resistant).
The modular canopy 26 is structured to couple to the enclosure 14 and includes a canopy roof 103, a first or canopy back wall 104, and a second or canopy front wall 105. A canopy intake aperture 106 is defined in the canopy back wall 104 and is sized to receive a canopy intake filter 110 to provide the intake 30. A canopy intake baffle 114 extends substantially horizontally from the canopy back wall 104 adjacent the canopy intake aperture 106. A canopy intake floor 118 is spaced from the canopy intake baffle 114 and defines a canopy intake exit aperture 122 sized to communicate with the enclosure intake cavity 70. In some embodiments, the canopy intake aperture 106, the canopy intake baffle 114, the canopy intake floor 118 and the canopy intake exit aperture 122 all extend substantially the entire width of the modular canopy 26.
A canopy exhaust aperture 126 is defined in the canopy front wall 105 and is sized to receive a canopy exhaust filter 130 to provide the exhaust 34. A canopy exhaust baffle 134 extends substantially horizontally from the canopy front wall 105 adjacent the canopy exhaust aperture 126. A canopy exhaust floor 138 is spaced from the canopy exhaust baffle 134 and defines a canopy exhaust entrance aperture 142 sized to communicate with the enclosure exhaust cavity 90. A partition panel 146 extends substantially the entire width of the modular canopy 26 and separates the intake 30 from the exhaust 34. The canopy exhaust aperture 126, the canopy exhaust baffle 134, the canopy exhaust floor 138, and the canopy exhaust entrance aperture 142 all extend substantially the entire width of the modular canopy 26.
When the modular canopy 26 is installed on the enclosure 14, the canopy back wall 104 sealingly engages the enclosure back wall 74, the canopy intake floor 118 sealingly engages the enclosure intake wall 66, the canopy exhaust floor 138 sealingly engages the enclosure exhaust wall 86, and the canopy front wall 105 sealingly engages the enclosure front wall 94. The intake 30 is provided from the canopy intake aperture 106, across the canopy intake baffle 114 to the partition panel 146, across the canopy intake floor 118 to the canopy intake exit aperture 122, into the enclosure intake cavity 70, and through the enclosure intake aperture 78 to the second chamber 58, the engine 18, and/or one or more components 22. The exhaust 34 is provided from the enclosure exhaust aperture 98 to the enclosure exhaust cavity 90, through the canopy exhaust entrance aperture 142, across the canopy exhaust floor 138 to the partition panel 146, across the canopy exhaust baffle 134, and out the canopy exhaust aperture 126. The partition panel 146 isolates the intake 30 from the exhaust 34.
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Acoustic barrier and/or absorbtive material may advantageously be added in strategic positions within the intake 30, the exhaust 34, and/or with the second chamber 58 to absorb and damp sound to further reduce noise emissions. In some embodiments, the acoustic barrier material is adhered or attached to surfaces of the canopy intake baffle 114, the canopy intake floor 118, the enclosure intake cavity 70, the second chamber 58, the enclosure exhaust cavity 90, the canopy exhaust floor 138, the canopy exhaust baffle 134, the partition 146, or any combination of locations. In some embodiments, more than one type of acoustic barrier material is used. For example, heat resistant acoustic barrier material may be installed within the enclosure exhaust cavity 90 where high heat may be a concern. In some embodiments, acoustic barrier material is bonded to all the surfaces within the modular canopy 26 to reduce noise emission from the intake 30 and the exhaust 34.
The low noise enclosure system reduces noise emissions to sixty-five A-weighted decibels (65 dB(A)) or less at one meter (1 m) and provides a low cost, and simple to implement solution. The modular canopy 26 can be retrofitted to existing enclosures and provide the noise emission reduction benefits.
Applicant has identified that noise quality affects the perceived loudness of noise emissions. In this case, noise quality is defined by a frequency or frequency range. The low noise enclosure system can be tuned to reduce undesirable frequencies or frequency ranges and improve the noise quality. The dimensions of the modular canopy 26 including the width of the canopy intake baffle 114 and the canopy exhaust baffle 134, the height of the partition panel 146, the size of the canopy intake aperture 106 and the canopy exhaust aperture 126, and other dimensional components can be altered in order to tune the system to avoid or reduce undesirable frequencies. Additionally, the modular canopy 26 can be constructed with relatively thin material. In some embodiments, the modular canopy includes a frame that is covered in sheet metal. In some embodiments, the sheet metal defines a 1.6 millimeter (1.6 mm) or greater thickness. In some embodiments, the sheet metal is about three millimeters (3 mm) thick. In some embodiments, the sheet metal is less than six millimeters (6 mm) thick. In some embodiments, a 10-16 gauge sheet metal is used. Both ferrous and non-ferrous metals and alloys may be suitable in addition to non-metallic materials such as fiberglass, molded plastic, and glass reinforced plastics.
No claim element herein is to be construed under the provisions of 35 U.S.C. § 112(f), unless the element is expressly recited using the phrase “means for.”
For the purpose of this disclosure, the term “coupled” means the joining or linking of two members directly or indirectly to one another. Such joining may be stationary or moveable in nature. For example, a propeller shaft of an engine “coupled” to a transmission represents a moveable coupling. Such joining may be achieved with the two members or the two members and any additional intermediate members.
The foregoing description of embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from this disclosure. The embodiments were chosen and described in order to explain the principals of the disclosure and its practical application to enable one skilled in the art to utilize the various embodiments and with various modifications as are suited to the particular use contemplated. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the embodiments without departing from the scope of the present disclosure as expressed in the appended claims.
Accordingly, the present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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