The present disclosure relates generally to enclosures for housing engines and generators.
Generator sets (also known as “gensets”) may be employed for physical power production in a variety of applications (e.g., standby/backup power applications, etc.). A genset typically includes an engine and an electric power generator coupled to the engine. The engine is structured to mechanically drive the generator which, in turn, can produce electricity. The engine and the generator may be housed within an enclosure that allows the genset to operate outdoors, and to tolerate environmental extremes of temperature, humidity, precipitation (e.g., rain, snow, ice, etc.), and other factors. In some instances, the enclosures are made from intermodal containers (e.g., ISO containers, cargo containers, shipping containers, etc.) that are sized to contain the entire genset and any auxiliary equipment that is needed to operate the genset (e.g., cooling equipment, etc.). However, because of the limited availability of different container sizes, the footprint of the entire genset system is typically larger than required. In other words, these containers may need to be oversized to ensure that the enclosure can accommodate the entire genset system. Additionally, the standard-sized intermodal containers cannot be easily modified to accommodate different cooling systems or auxiliary equipment that may be used with the genset.
One embodiment of the present disclosure relates to a genset enclosure. The genset enclosure includes a skid platform, a plurality of gusset members, a plurality of roof supports, a first plurality of sidewall panels, and a second plurality of sidewall panels. The gusset members are spaced at intervals along an outer perimeter of the skid platform and are coupled to the skid platform using fasteners. The gusset members are arranged in opposed pairs positioned on opposite lateral ends of the skid platform. Each gusset member defines a first portion extending upwardly from the skid platform normal to an upper surface of the skid platform and a second portion disposed at an upper end of the first portion and extending normal to the first portion and toward a centerline of the skid platform. The plurality of roof supports extends between at least one of the opposed pairs of gusset members and couples upper ends of the at least one opposed pair of gusset members. The plurality of roof supports and the plurality of gusset members together define a skeletal framework for the genset enclosure. The first plurality of sidewall panels is coupled to both the plurality of gusset members and the skid platform and extends upwardly from an outer perimeter of the skid platform normal to the upper surface of the skid platform. The first plurality of sidewall panels and the gusset members are positioned in alternating arrangement along the outer perimeter of the skid platform. The second plurality of sidewall panels is coupled to the plurality of roof supports. The first plurality of sidewall panels and the second plurality of sidewall panels together define an enclosed volume.
Another embodiment of the present disclosure relates to a method of making a genset enclosure. The method includes providing a skid platform; mounting a generator system to the skid platform; fastening a first plurality of sidewall panels to the plurality of gusset members and the skid platform; fastening a plurality of roof supports to the plurality of gusset members; between upper ends of laterally opposed pairs of the plurality of gusset members, to define a skeletal framework; and fastening a second plurality of sidewall panels to the plurality of roof supports to define an at least partially enclosed volume between the second plurality of sidewall panels and the skid platform.
Yet another embodiment of the present disclosure relates to a genset enclosure. The genset enclosure includes a skid platform subassembly, a plurality of gusset members, a plurality of roof supports, and a first and second plurality of sidewall panels. The plurality of gusset members are mountable to the skid platform subassembly. At least one of the plurality of gusset members includes a first portion, a second portion disposed at an end of the first portion and extending normal to the first portion, and a flange disposed on the second portion and extending normal to the first portion and the second portion. The plurality of roof supports are mountable to the plurality of gusset members. The first plurality of sidewall panels are mountable to the plurality of gusset members, and the second plurality of sidewall panels are mountable to the plurality of roof supports.
It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the subject matter disclosed herein.
The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several implementations in accordance with the disclosure and are therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.
Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.
Embodiments described herein relate generally to methods and devices for forming a genset enclosure. In particular, embodiments described herein relate generally to a field-erectable and modular genset enclosure that is assembled without the use of welding or other complex manufacturing operations. The genset enclosure may be assembled using removable mechanical fasteners that allow for modifications to the size and configuration of the genset enclosure after it has been assembled. The genset enclosure includes a plurality of inwardly facing “L” shaped gusset members that are arranged in pairs on opposing lateral ends of a platform. Upper ends of each pair of gusset members are connected by roof supports to define a skeletal framework above the platform. Walls of the enclosure are formed by panels that are applied to the gusset members and roof supports to enclose the space surrounded by the skeletal framework. In one embodiment, the gusset members are plates that are “sandwiched” between a pair of sidewall panels, to reduce the overall size and weight of the skeletal framework. Among other benefits, the enclosure may be at least partially assembled on site (in the field, at a location where the genset will be installed, etc.). For example, the gusset members, roof supports, and sidewall panels may be shipped as separate components and assembled on-site to customize the design of the genset enclosure based to its surroundings (e.g., based on where the enclosure is located, the position of the enclosure in relation to neighboring structures, etc.) and the needs of the end user.
The spacing between gusset members may be adjusted to accommodate access doors for the genset enclosure at any position along the perimeter of the genset enclosure. In one embodiment, the spacing between gusset members is equal to a width of an access door such that the door may be repositioned to any location along the perimeter (or the roof of the genset enclosure) without having to disassemble the skeletal framework. The size of the genset enclosure may be adjusted by extending the length of the platform and adding more gusset members and sidewall panels. The genset enclosure can therefore be readily modified to accommodate different engine gensets sizes/types and/or auxiliary equipment (e.g., cooling equipment, controls, etc.) within one common enclosure footprint. This construction also provides a more compact overall footprint because the size of the panels may be modified (and the spacing between adjacent gusset members) to reduce unused space within the enclosure. The amount of material required for the genset enclosure may therefore be less than intermodal container constructions that may be used to house gensets of similar size. Additionally, because of the modular construction of the genset enclosure, the enclosure can be quickly and easily disassembled into sections (e.g., segments including multiple interconnected pieces or individual components) to transport the enclosure between locations. The genset enclosure is also expandable to accommodate changes to the genset and/or additional auxiliary equipment.
In some embodiments, the enclosure segments and construction techniques are also employed to form the air intake and discharge portions of the enclosure. The various concepts introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the described concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.
Various numerical values herein are provided for reference purposes only. Unless otherwise indicated, all numbers expressing quantities of properties, parameters, conditions, and so forth, used in the specification and claims are to be understood as being modified in all instances by the term “approximately.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations. Any numerical parameter should at least be construed in light of the number reported significant digits and by applying ordinary rounding techniques. The term “approximately” when used before a numerical designation, e.g., a quantity and/or an amount including range, indicates approximations which may vary by (+) or (−) 10%, 5%, or 1%.
As will be understood by one of skill in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member.
The air driver 40 is structured to draw air (e.g., ventilation air, cooling air, etc.) from an environment surrounding the enclosure 100 through the enclosure 100 to cool the generator 30 and/or other internal components of the genset assembly 10. In at least one embodiment, the air driver 40 is a fan. In other embodiments, the air driver 40 includes a plurality of fans positioned at different locations within the enclosure 100. In some embodiment, the fan may be coupled to the engine 20 (e.g., to the engine driveshaft via a pulley, etc.) such that a speed of the fan is proportional to a speed of the engine 20. In other embodiments, the fan is driven separately from the engine 20 (e.g., via an electric fan motor, etc.).
The exhaust assembly 50 forms part of the engine 20 and is structured to direct exhaust gasses from the engine 20 out of the enclosure 100. The exhaust assembly 50 may include a plurality of mufflers 52 for attenuating noise produced by the engine 20. As shown in
The configuration and arrangement of the engine 20, generator 30, air driver 40, and exhaust assembly 50 shown in
Returning to
In some embodiments, the enclosure 100 may be disposed on the ground. In other embodiments, the enclosure 100 may be mounted on a fuel tank (not shown) that is disposed on the ground, or mounted on skids (not shown) that are disposed on the ground. In other embodiments, the enclosure 100 may be positioned on a rooftop above the ground or another suitable location.
The enclosure 100 is configured to provide air flow therethrough to cool components housed within the enclosure 100 and provide intake air for the engine 20 (see
Air enters the enclosure 100 in a radial direction through the air inlet 114, and is directed in a longitudinal direction through the enclosure 100. Air passes across the genset (e.g., the engine 20, the generator 30, etc.) and then is directed in at a vertical direction (e.g., upwardly at an approximately 90° angle relative to the longitudinal direction), and is discharged through the air outlet 116 in the container roof 106. Among other benefits, the air flow path provided by the design of the enclosure 100, when used with air deflection plates, has been found to significantly reduce the noise that is generated due to air flow through the enclosure 100. In some embodiments, the air inlet 114 and/or the air outlet 116 may include louvers 118 or other elements that allow air to enter the enclosure 100, while redirecting water (e.g., due to rainfall) away from the enclosure 100 and/or to predefined water drainage areas of the enclosure 100. In other embodiments, the air inlet 114 and the air outlet 116 may be provided in another location along the enclosure 100 (e.g., the first pair of container sidewalls 108 and/or the second pair of container sidewalls 110).
The genset enclosure 100 also includes a deflector assembly structured to redirect noise in the air multiple times within the enclosure 100 and near the air outlet 116 of the enclosure 100 to attenuate noise exported from the enclosure 100. As shown in
The deflector assemblies 202, 204 are positioned on opposite sides of the engine 20, the generator 30, and the air driver 40, so as to reflect and reduce noise produced by the engine 20, the generator 30, and the air driver 40. In some embodiments, a position (e.g., an angular position, a length, etc.) of the first deflector assembly 202 and the second deflector assembly 204 is adjustable within the enclosure 100 to reduce exported noise. Additional aspects of the structure of the first deflector assembly 202 and the second deflector assembly 204 may be found in U.S. Patent Application No. 62/944,943, filed Dec. 6, 2019, the entire disclosure of which is hereby incorporated by reference herein. As shown in
As shown in
As shown in
Referring now to
The method 400 starts by assembling a skid platform subassembly for the genset enclosure. At operation 402, a plurality of skid members 502 are fastened together to form a skid framework 501. As shown in
At 404, skid panels 508 are fastened to the skid framework 501 to form a skid platform 500. Operation 404 is depicted in
At 406, the generator system including the engine 20, the generator 30, and the air driver 40 is mounted to the skid platform 500. As shown in
At 408, a sidewall structure 600 of the enclosure 100 is formed to at least partially enclose the space above the skid platform 500. As shown in
Operation 408 may include positioning a lower end of each gusset member 602 between adjacent ones of the skid panels 508 such that a portion of the gusset members 602 are “sandwiched” or otherwise disposed between the skid panels 508. Operation 408 may include arranging the gusset members 602 in opposed pairs 603 positioned on opposite lateral ends 605 of the skid platform 500. In at least one embodiment, operation 408 includes orienting at least one gusset member such that (i) a first portion of the gusset member extends upwardly from the skid platform normal to an upper surface of the skid platform (e.g., arranging the first portion in substantially perpendicular orientation with respect to an upper surface of the skid platform), and (ii) a second portion of the gusset member, extending normal to the first portion, extends toward a centerline of the skid platform. Operation 408 may further include positioning the first plurality of sidewall panels 604 between the gusset members 602 such that each gusset member 602 is at least partially “sandwiched” or otherwise disposed between adjacent ones of the first plurality of sidewall panels 604. The gusset members 602 (and sidewall panels 604) may be spaced in equal intervals along the length of the skid platform 500. In another embodiment, the spacing between two or more gusset members 602 may be different from the remaining gusset members 602 (e.g., the gusset members 602 may be spaced at unequal intervals). Among other benefits, maintaining a consistent spacing between gusset members 602 allows for quick and easy repositioning of doors and sidewall panels to different portions of the enclosure 100.
Operation 408 may further include fastening a lower end of each of the gusset members 602 (e.g., a lower end of first portion 606) and the first plurality of sidewall panels 604 to the skid platform 500. For example, as shown in
At 410, a plurality of roof supports 700 are fastened to the gusset members 602 to stabilize the structural walls on each lateral end of the enclosure 100 and to support the container roof 106. Together, the roof supports 700 and the gusset members 602 form a skeletal framework 609 (see
In one embodiment, operation 410 further includes fastening or otherwise coupling the first deflector assembly 202 and the second deflector assembly 204 to a respective one of the plurality of roof supports 700 (see
At 412, a second plurality of sidewall panels 604′ are fastened to the roof supports 700 and/or to the upper edge of the first plurality of sidewall panels 604. In the embodiment of
In one embodiment, operation 412 may further include sealing at least one seam formed between adjacent ones of the first plurality of sidewall panels 604 and the second plurality of sidewall panels 604′. As shown in
In one embodiment, the method of making a genset enclosure 100 further includes assembling the air inlet assembly (e.g., air inlet portion 122) and the air outlet assembly (e.g., air outlet portion 124) onto a container roof 106 of the enclosure 100. For example,
In one embodiment, the method of making the genset enclosure 100 further includes constructing an end wall structure to enclose the longitudinal ends of the enclosure 100. The method may be the same as or similar to operation 408 of method 400 (see
In one embodiment, the method of making the genset enclosure 100 further includes applying acoustic dampening materials to interior surfaces of the enclosure 100. The acoustic dampening materials (e.g., acoustic material lining, etc.) may be structured to absorb and attenuate noise produced by the genset assembly 10 (see
In at least one embodiment, the genset assembly includes a kit of materials that can be delivered as individual components and assembled on-site to form the desired enclosure geometry. For example, the genset assembly may be a kit including a skid platform subassembly, a plurality of gusset members that are mountable to (e.g., configured to fasten to or otherwise couple to) the skid platform subassembly. The gusset members may each include a first portion and a second portion disposed at an end of the first portion and extending normal to the first portion. The gusset members may also include a flange disposed on the second portion and extending normal to both the first portion and the second portion (e.g., along a reference plane that is oriented normal to a first reference plane aligned with the first portion and a second reference plane aligned with the second portion). The kit may also include a plurality of roof supports having opposing ends that are configured to mount to the plurality of gusset members, and a first and second plurality of sidewall panels that are mountable to the plurality of gusset members and/or the plurality of roof supports. In some embodiments, at least one gusset member of the plurality of gusset members is part of a gusset member assembly (e.g., kit, etc.) that includes a plurality of angle brackets to fasten the gusset members to the skid platform subassembly and/or a respective one of the first plurality of sidewall panels.
It should be noted that the term “example” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).
As utilized herein, the term “substantially” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed (e.g., within plus or minus five percent of a given angle or other value) are considered to be within the scope of the invention as recited in the appended claims.
The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.
It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the embodiments described herein.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any embodiment or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular embodiments. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
This application claims the benefit of and priority to U.S. Provisional Application No. 63/085,463, filed Sep. 30, 2020, which is hereby incorporated by reference in its entirety.
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