Patent Application
20100071584
The present disclosure relates generally to a power module for a locomotive and, more particularly, to a roof structure for the power module.
Mobile machines are known to include a power system for generating power. For example, a power system may include one or more electric motors, a generator unit, and a power-transfer system for transferring power from the generator unit to the one or more electric motors. It is known for the generator unit to include an engine for driving a generator. Often, the generator unit is housed within an enclosure to protect the generator unit from environmental elements. The enclosure is likely to trap a large amount of heat created by the generator unit, which may be dissipated via one or more cooling devices to maintain the generator unit operating conditions at an acceptable level. For example, it is known for a generator unit to include a radiator, a cooling fan, and/or other cooling devices for dissipating the heat within the enclosure.
In a generator unit mounted on a locomotive, it is known to house the generator unit within an enclosure and to cool the generator unit with one or more cooling devices. For example, it is known to employ a cooling passage located in walls of the enclosure. It is also known to circulate cooling air over the generator unit with a cooling fan.
Under some circumstances, locomotive power systems may discharge cooling air out of a top portion of the enclosure. For example, a portion of the power system enclosure may be covered with a wire mesh-type material. While the wire mesh-type material may allow cooling air to escape the enclosure and prevent large debris from entering the power system enclosure of the locomotive, environmental elements, such as precipitation (e.g., rain, snow, ice) and other debris, may penetrate the wire mesh-type material and contact the generator unit, thereby causing damage or otherwise reducing the life and efficiency of the generator unit.
One example of a roof structure providing ventilation is described in U.S. Pat. No. 4,609,126 to Janda (“the '126 patent”). The '126 patent discloses a venting cap for an enclosure used in an outdoor environment. The venting cap includes an inner roof panel and an outer roof panel. The outer roof panel includes a single outer aperture that is centrally positioned and offset from a plurality of inner apertures formed on the inner roof panel. Since the outer aperture is offset from the inner apertures, the venting cap may reduce the likelihood of precipitation passing through inner apertures into the apparatus housing. Further, an interior of the enclosure may be ventilated with cool air entering from an opening in the bottom of the enclosure and hot air may be vented through the outer aperture.
Although the venting cap of the '126 patent may alleviate some of the problems associated with cooling an enclosure, other problems may persist. The venting cap of '126 may not provide sufficient ventilation to remove heat generated by a power system, such as a locomotive power module. Additionally, the venting cap of the '126 patent may not be well suited for permitting operators to service the equipment housed within the enclosure by, for example, walking on the outer roof panel.
In one aspect, the present disclosure is directed to a roof structure for a power module of a locomotive. The roof structure may include an upper roof layer and at least a portion of the upper roof layer may include a first set of cooling passages. The roof structure may further include a lower roof layer at least partially positioned below the upper roof layer and at least a portion of the lower roof layer may include a second set of cooling passages. Each of the cooling passages of the first set of cooling passages may not overlap a cooling passage of second set of cooling passages.
In another aspect, the present disclosure is directed to a method of cooling a power module for a locomotive. The method may include allowing a flow of cooling air to pass through at least a portion of at least one of the plurality of walls. The method may further include directing the flow of cooling air over at least a portion of the power module. The method may also include expelling the flow of cooling air through the roof structure, such that the flow of cooling air passes through a lower roof layer via a first set of cooling passages and through an upper roof layer via a second set of cooling passages. The method may additionally include collecting a majority of environmental elements that pass through the second set of cooling passages, such that the majority of environmental elements may be prevented from passing through the roof structure into the power module.
As shown in
Frame 26 may include various structural elements including a base structure 36, vertical supports 38, and a top structure 40 (shown in
Power module 14 may be removably fastened to platform 12 via one or more fasteners (not shown). That is, frame 26 may fasten to platform 12 with any number or configuration of fasteners sufficient to securely fasten power module 14 to platform 12. In an exemplary embodiment, base structure 36 of frame 26 may fasten to platform 12 at four mounting locations (not shown), with each mounting location including a pair of fastening bolts (not shown).
Enclosure 20 may be removably fastened to frame 26, for example, along fastening rail 49 via walls 22 (not shown). It is contemplated that fastening rail 49 may be mounted on base structure 36 and include a plurality of holes 50 for receiving fasteners (not shown) to secure one or more of walls 22 of enclosure 20 to frame 26. Roof structure 24 may attach to one or more walls 22 (
Roof structure 24 may include a first end 52 spaced from and opposite to a second end 54. Roof structure 24 may also include a first side 56 spaced from and opposite to a second side 58. Roof structure 24 may include a substantially horizontal portion 60 that extends from first end 52 to second end 54, and positioned substantially midway between first side 56 and second side 58. Roof structure 24 may also include a first angled portion 62 extending from horizontal portion 60 to first side 56 and a second angled portion 64 extending from horizontal portion 60 to second side 58.
Roof structure 24 may also include a plurality of removable roof sections. For example roof structure 24 may include a first end roof section 66, a central roof section 68, and second end roof section 70, wherein each of roof sections 66, 68, 70 may be separately removable from enclosure 20 to provide access to power module 14. Roof sections 66, 68, 70 may individually fasten to walls 22 of enclosure 20 and/or frame 26 by one or more fasteners (not shown). First end roof section 66 may substantially cover first end 52 of power module 14. Central roof section 68 may substantially cover a central portion of power module 14. Second end roof section 70 may substantially cover second end 54 of power module 14. As shown in
One or more of roof sections 66, 68, 70 may include a plurality of cooling pathways 72. It is contemplated that cooling pathways 72 may help move heat generated by generator set 28 away from power module 14. For example, first end roof section 66 and central roof section 68 may each include a plurality of cooling pathways 72 substantially evenly spaced thereon and passing therethrough. Air passing through a cooling pathway 72 is shown, for example, in
In some situations, it may not be desirable to include cooling pathways 72 in one or more roof sections 66, 68, 70. For example, second end roof section 70 may include a solid surface 71. That is, second end roof section 70 and, more particularly, solid surface 71, may not include cooling pathways 72. Second end roof section 70 may not include cooling pathways 72 because excessive heat may not be generated in the space below second end roof section 70 and/or one or more components (e.g., rectifier) positioned in the space beneath second end roof section 70 may be sensitive and require greater protection from environmental elements than other components (e.g., engine 30) of generator set 28. While second end roof section 70 is shown with solid surface 71, it is contemplated than any one of roof sections 66, 68, 70 may include a solid surface. Further, it is contemplated that solid surface 71 may be implemented to cover roof sections with cooling pathways 72, for example, during abnormal environmental conditions (e.g., heavy precipitation). For example, one or more solid surfaces 71 may slide from a first roof section (e.g., second end roof section 70) to cover first end roof section 66 and second end roof section. Alternatively, solid section 71 may be moveable to change the section of roof structure 24 that includes uncovered cooling pathways 72.
A barrier wall 73 (identified in
As previously noted, enclosure 20 may include one or more wall access passages 25. Enclosure 20 may also include one or more roof access passages to permit access to elements therein, such as for example, components of power module 14. For example, as shown in
As shown in
As best shown in
As best shown in the cross-sectional view of
Upper roof layer 90 may form a portion of the plurality of cooling pathways 72 including, for example, upper cooling passages 100. Likewise, lower roof layer 92 may form a portion of the plurality of cooling pathways 72 and may include, for example, lower cooling passages 102. Upper and lower cooling passages 100, 102 may be any shape or size sufficient to dissipate heat generated by generator set 28. For example, upper and lower cooling passages 100, 102 may substantially circular or oval in shape. Upper and lower cooling passages 100, 102 may be shaped similarly to one another or may differ from one another in shape and/or size. Upper and lower cooling passages 100, 102 may be oriented on roof structure 24 in any configuration that permits heat to escape from enclosure 20 and blocks or otherwise limits precipitation or debris from entering power module 14. In an exemplary embodiment, upper and lower cooling passages 100, 102 may each be configured in a grid-like orientation with upper and lower cooling passages 100, 102 arranged in columns and rows. Further, cooling passages 100, 102 may be substantially, evenly spaced over first end roof section 66 and central roof section 68. Alternatively, upper and lower roof layers 90, 92 may include cooling pathways defined as louvers (not shown).
It is contemplated that the alignment of upper cooling passages 100 relative to lower cooling passages 102 may be staggered or offset, for example, along a vertical direction (i.e., substantially perpendicular to horizontal portion 60). That is, upper cooling passages 100 may be offset from lower cooling passages 102 in a direction along longitudinal axis 18. Further, it is contemplated that the configuration of upper cooling passages 100 may be offset from lower cooling passages 102 in a direction transverse to longitudinal axis 18. In other words, upper roof layer 90 may include an upper roof surface 104 that is positioned above each of lower cooling passages 102 to cover lower cooling passages 102. Further, lower roof layer 92 may include upper roof surface 98 that extends directly beneath each of upper cooling passages 100. Therefore, precipitation or debris that may penetrate upper roof layer 90 through upper cooling passages 100 may be collected on upper roof surface 98 of lower roof layer 92 without passing through lower roof layer 92.
Each of the roof sections 66, 68, 70 that contain cooling pathways 72 may include cooling pathways 72 with different sizes, shapes, and/or configurations as compared to another one of roof sections 66, 68, 70. Although, first end roof section 66 and central roof section 68 are shown to have substantially the same configuration of upper and lower cooling passages 100, 102, it is contemplated that the size, shape, and/or configuration of upper and lower cooling passages 100, 102 may differ based on, for example, balancing the cooling needs and the environmental protection needs of each component (e.g., engine 30 and generator 32) of generator set 28.
As shown in
Upper roof layer 90 and lower roof layer 92 may include similar cross sections, wherein each roof layer 90, 92 may include horizontal portion 60 extending between first and second angled portions 62, 64. Therefore, the distance between upper roof layer 90 and lower roof layer 92 may remain substantially constant throughout the space defined between roof layers 90, 92. Further, precipitation or debris collected on upper roof surfaces 98, 104, may be guided from roof structure 24 via downward slope surfaces of upper and lower roof layers 90, 92 (e.g., first and second angled portions 62, 64). The liquid portion of the environmental elements that may penetrate upper cooling passages 100 and collect on upper roof surface 98 may be guided by first and second angled portions 62, 64 towards a first set of drain passages 108 adjacent each of first and second sides 56, 58, such that precipitation or debris may be drained from the space defined between upper roof layer 90 and lower roof layer 92.
Roof structure 24 may include a second set of drain passages 110 positioned along a first end wall 112 on first end 52 of roof structure 24. Drain passages 110 on first end wall 112 may be positioned along a roofline formed by lower roof layer 92, such that precipitation or debris, especially the liquid portion, collected on upper roof surface 98 may drain from the space defined between upper roof layer 90 and lower roof layer 92. Roof structure 24 may also include a second end wall 114 on second end 54. Since second end roof section 70 may not include cooling pathways 72, second end wall 114 may not include drain passages 110. However, in some situations, such as when second end roof section 70 includes cooling pathways 72, second end wall 114 may include drain passages 110. In addition to permitting draining of precipitation or debris, drain passages 108, 110 may also serve as additional cooling pathways 72, similar to cooling passages 100, 102, for permitting heat from generator set 28 to be expelled from power module 14.
As best shown in
The enclosure of the power module may be applicable to any power system that may be subjected to environmental elements. The disclosed enclosure for housing the power module may include a roof structure that permits dissipation of heat and blocks or otherwise limits precipitation or debris from penetrating into the power module. The operation of roof structure 24 of enclosure 20 will now be described.
Roof structure 24 may include a multilayer configuration including cooling pathways 72 to facilitate dissipation of heat generated by power module 14. In addition to allowing heat to escape enclosure 20, cooling pathways 72 may also provide ingress for cooler ambient air. For example, a flow of cooling air may enter enclosure 20 through one or more wall access passages 25. The flow of cooling air may be directed by one or more cooling devices (e.g., cooling fans) toward generator set 28 to dissipate heat from within enclosure 20. A majority of the cooling air received into enclosure 20 through one or more wall access passages 25 may be expelled from enclosure 20 through roof structure 24. Alternatively or additionally, ambient air may enter enclosure 20 through cooling pathways 72 in roof structure 24. Air entering enclosure 20 may exit via cooling pathways 72 of roof structure 24. Air may also exist via wall access passages 25, however, as most exiting air will be heated, it is likely that it will rise and exit enclosure 20 via cooling pathways 72 in roof structure 24. Thus, for example, cooling air may enter enclosure 20 of power module 14 through wall access passages 25, pass over generator set 28 (i.e., cooling generator set 28) and heat the air. The heated air may exit power module 14 through roof structure 24.
While cooling passages 100, 102 may provide an exit for air (see, e.g., arrow 118 representing air exiting enclosure 20 in
Roof structure 24 may also include various features for servicing power module 14. For example, an operator may access exhaust stack 78 via exhaust access passage 74 and access the hydraulic reservoir vent (not shown) via hydraulic reservoir vent access passage 76. Further, an operator may open frame access doors 84 to reveal frame lifting eyes 86 (
The disclosed roof structure 24 may increase heat dissipation and limit environmental element penetration through roof structure 24 with the use of the multilayer roof design including offset cooling passages 100, 102. Further, roof structure 24 may increase the versatility of lifting and/or moving one or more portions of power module 14 via the plurality of sets of lifting eyes 86, 88, 89.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed power module without departing from the scope of the disclosure. Other embodiments of the power module will be apparent to those skilled in the art from consideration of the specification and practice of the system 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 and their equivalents.
