Power generating system

• US 20070158946A1
• Filed: 01/06/2006
• Published: 07/12/2007
• Est. Priority Date: 01/06/2006
• Status: Active Grant

• Current Assignee: Aerodyne Corporation
• Original Assignee: Aerodyne Corporation
• Inventors: Woodroffe, Jaime, Annen, Kurt, Agnese, Michael, Stickler, David
• Granted Patent: US 7,485,977 B2
• Time in Patent Office: Days
• US Class Current: 290/1.R
• CPC Class Codes: F02B 2075/025 two
• CPC Class Codes: F02B 71/04 Adaptations of such engines for special use; Combinations of such engines with apparatus driven thereby
• CPC Class Codes: H02K 35/04 with moving coil systems and stationary magnets
• CPC Class Codes: H02K 7/1884 structurally associated with free piston engines

Abstract

This invention overcomes the disadvantages of the prior art by providing a power generating system particularly suitable for field use in remote locations, which is fuel-efficient, relatively quiet, tolerant of dust, capable of operating on low grade logistics and diesel-like fuels and capable of generating between 500 W and 2 KW of continuous electrical power. This generator employs a miniature internal combustion engine/generator (MICE) having a piston moving within a cylinder arranged for two-cycle operation, and an interconnected, axially arranged piston shaft that oscillates an alternator coil within a magnetic core. The piston shaft is opposed by a strong, multiple-helix spring. The cylinder head, in which the piston operates, is cooled by moving (electrically pumped) fluid in a cooling head, or by another heat-transfer mechanism. The MICE generator'"'"'s intake arrangement includes a preheater heated by a heated fluid flow thereon. The MICE generator is vibration-isolated using a base that supports the MICE on a plurality of soft coil springs. The MICE generator is encased in an acoustic enclosure having a shell composed of sheet metal or another stiff material extending from the base plate and being covered by a top side. Holes in the enclosure top are covered by porous discs that allow exhaust gasses from the internal muffler to pass therethrough. The acoustic enclosure resides in a large, typically portable, external package enclosure.

Claims

1. A power generating system comprising:

a miniature internal combustion engine (MICE) generator having a piston and shaft axially moving within a casing and the shaft being operatively connected to a first end of a spring a second end of the spring being fixed to the casing, the shaft being further interconnected to an alternator assembly in which axial movement of the shaft causes relative movement of an alternator coil with respect to a magnet assembly;

a support surface that supports the MICE generator and is isolated from the MICE generator vibration; and

an acoustic enclosure extending from the support surface and encasing the MICE generator, the enclosure defining passages through which combustible fuel and air enter the MICE generator and exhaust and electrical power exit the MICE generator.

2. The power generating system as set forth in claim 1 wherein the acoustic enclosure defines a rigid shell having sound dampening material applied thereto.

3. The power generating system as set forth in claim 2 further comprising an external package enclosure and wherein the acoustic enclosure resides within an interior of the external package enclosure.

4. The power generating system as set forth in claim 3 wherein the external package enclosure includes sound dampening material applied to interior walls thereof.

5. The power generating system as set forth in claim 1 wherein the MICE generator is supported on the support surface by a plurality of soft springs.

6. The power generating system as set forth in claim 5 wherein the soft springs comprise conically shaped springs.

7. The power generating system as set forth in claim 1 wherein the MICE generator includes a muffler attached to an exhaust port of the MICE generator and encased by the acoustic enclosure and wherein the acoustic enclosure further includes at least one opening covered by at least one porous plug, respectively, that allows exhaust gasses from the muffler to pass therethrough.

8. The power generating system as set forth in claim 1 wherein the acoustic enclosure includes a passage through which a conduit including a fuel/air mixture passes, the conduit being interconnected with an intake port of the MICE generator.

9. The power generating system as set forth in claim 8 wherein the MICE generator is supported on the base plate by a plurality of soft springs and wherein the conduit and electrical leads are staked at mounting points between each of the support surface and the MICE generator and wherein a length of the conduit and the leads between each of the mounting points remains free of restraint.

10. The power generating system as set forth in claim 1 wherein the support surface comprises a separate base plate that rests upon a floor of an external enclosure.

11. A power generating system comprising:

a miniature internal combustion engine (MICE) having a piston and shaft axially moving within a casing and the shaft being operatively connected to a first end of a spring a second end of the spring being fixed to the casing, the shaft being further inter-connected to an alternator assembly in which axial movement of the shaft causes relative movement of an alternator coil with respect to a magnet assembly; and

a fuel/air mixture intake assembly in fluid communication with an intake port of the MICE generator including a heater that elevates a temperature of the intake assembly and of the fuel air mixture above an ambient environmental temperature.

12. The power generating system as set forth in claim 11 wherein the intake assembly includes an intake plenum defining an enclosed space around the intake port, and the plenum being in fluid communication with a fuel atomizer and air intake that delivers the fuel/air mixture in an atomized state to the intake plenum.

13. The power generating system as set forth in claim 12 wherein the intake plenum includes a moving-fluid-based heat-transfer assembly in thermal communication therewith.

14. The power generating system as set forth in claim 13 wherein the heat transfer assembly receives heated fluid from at least one of (a) a head-cooling assembly located in thermal communication with the casing adjacent to the piston and (b) an exhaust heat-transfer assembly located adjacent to an exhaust outlet of the MICE generator.

15. The power generating system as set forth in claim 14 wherein the fuel/air mixture intake assembly includes an electrically powered preheater that elevates the temperature prior to startup of the MICE generator.

16. The power generating system as set forth in claim 12 wherein the fuel/air mixture intake assembly includes an electrically powered preheater that elevates the temperature prior to startup of the MICE generator.

17. A power generating system comprising:

a miniature internal combustion engine (MICE) having a piston and shaft axially moving within a casing and the shaft being operatively connected to a first end of a spring a second end of the spring being fixed to the casing, the shaft being further interconnected to an alternator assembly in which axial movement of the shaft causes relative movement of an alternator coil with respect to a magnet assembly; and

a temperature-regulating assembly in thermal communication with the casing adjacent to the piston, the temperature-regulating assembly being constructed and arranged to maintain a post-startup, steady state operating temperature of the casing adjacent to the piston within a predetermined temperature range that optimizes a fit between the piston and a cylinder wall within the casing.

18. The power generating system as set forth in claim 17 wherein the temperature range is adapted to allow buildup of lubricating carbon between the piston and the cylinder wall.

19. The power generating system as set forth in claim 17 wherein the temperature regulating assembly includes a fluid pump and an operatively connected assembly that removes heat from the fluid.

20. The power generating system as set forth in claim 19 wherein the assembly that removes heat comprises a heat exchanger in communication with an airflow.

21. The power generating system as set forth in claim 19 wherein the assembly that removes heat comprises a heat-transfer assembly that is in fluid communication with a fuel/air intake assembly operatively connected to an intake port of the MICE generator.

22. The power generating assembly as set forth in claim 19 wherein the temperature regulating assembly includes at least one temperature sensor that senses a current temperature of the casing adjacent to the piston and a controller, responsive to the current temperature, that adjusts a flow of the fluid to increase or decrease the temperature at the casing adjacent to the piston.

23. The power generating assembly as set forth in claim 19 wherein the temperature regulating assembly includes a power output sensor that senses a present state of power output from the alternator coil and a controller, responsive to the power output sensor, that adjusts a flow of the fluid to increase or decrease the temperature at the casing adjacent to the piston.

24. A power generating system comprising:

a miniature internal combustion engine (MICE) having a piston and shaft axially moving within a casing and the shaft being operatively connected to a first end of a spring a second end of the spring being fixed to the casing, the shaft being further interconnected to an alternator assembly in which axial movement of the shaft causes relative movement of an alternator coil with respect to a magnet assembly; and

wherein the spring defines a plurality of helices attached to each of the first end and the second end, each of the first end and the second end defining an annular shape and wherein a respective joint between each of the helices and the first end and the second end includes a rounded stress relief.

25. The power generating system as set forth in claim 24 wherein the spring comprises a milled titanium spring.

26. The power generating system as set forth in claim 25 wherein each of the helices defines a substantially rectangular cross section shape.

27. A power generating system comprising:

a miniature internal combustion engine (MICE) having a piston and shaft axially moving within a casing, the shaft being interconnected to an alternator assembly in which axial movement of the shaft causes relative movement of an alternator coil with respect to a magnet assembly; and

a spring assembly comprising a first spring having a first end and a second end and a second spring comprising a first end and a second end and wherein the first end of the first spring and the first end of the second spring each engage opposing ends of a spring portion of the casing and wherein the second end of the first spring and the second end of the second spring each engage a spring base operatively connected to the shaft, the first spring and the second spring being axially aligned and concentric on opposing sides of the base so that movement of the shaft in a first axial direction causes compression of the first spring and movement of the shaft in a second axial direction causes compression of the second spring.

28. The power generating system as set forth in claim 27 further comprising a third spring intermingled with the first spring including a first end engaging the casing and a second end engaging the spring base and a fourth spring intermingled with the second spring including a first end engaging the casing and a second end engaging the spring base.

29. The power generating system as set forth in claim 28 wherein each of the first spring, the second spring, the third spring and the fourth spring defines a substantially circular cross section shape.

30. A power generating system comprising:

a miniature internal combustion engine (MICE) having a piston and shaft axially moving within a casing and the shaft being operatively connected to a first end of a spring a second end of the spring being fixed to the casing, the shaft being further interconnected to an alternator assembly in which axial movement of the shaft causes relative movement of an alternator coil with respect to a magnet assembly; and

a valve that routes a predetermined quantity of fuel/air mixture from a fuel/air conduit in fluid communication with an intake of the MICE generator to a heat exchanger in communication with an exhaust conduit of the MICE generator so as to introduce the predetermined quantity of fuel/air mixture to a combustion chamber of the MICE generator at a temperature elevated by the communication with the exhaust conduit.