Generator system with vertically shafted engine

• US 6,084,313 A
• Filed: 08/13/1998
• Issued: 07/04/2000
• Est. Priority Date: 08/13/1998
• Status: Expired due to Fees

• Current Assignee: Pramac America LLC
• Original Assignee: Coleman Company Incorporated (Newell Brands Inc.)
• Inventors: Frank, Kenneth M.
• Primary Examiner(s): Ponomarenko, Nicholas
• Application Number:
  US09/133,864
• Time in Patent Office: 691 Days
• Field of Search: 290/1 A, 290/40 R, 290/40 C, 322/14, 322/15, 322/16, 322/1, 123/2, 123/3
• US Class Current: 290/40.00C
• CPC Class Codes: F02B 2063/045 Frames for generator-engine sets
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02B 63/047 Movable engine-generator combinations on wheels
• CPC Class Codes: F02B 75/007 having vertical crankshafts
• CPC Class Codes: F02B 75/16 Engines characterised by number of cylinders, e.g. single-cylinder engines F02B75/26 takes precedence
• CPC Class Codes: H02J 9/066 characterised by the use of dynamo-electric machines H02J9/08 takes precedence
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04

Abstract

A portable generator system includes an interface mounting element for supporting a selected engine, from a plurality of engines, with a vertically oriented output shaft when the generator system is positioned on a substantially horizontal surface. A generator is directly coupled to the output shaft of the engine and rotates therewith about a common axis. The generator is selectable from a plurality of generators having different output power characteristics. A movable support cart supports interface, engine and generator and is formed of a single piece of tubular stock. The tubular stock is bent to form two substantially parallel, displaced, U-shaped regions bounded by a third U-shaped region substantially perpendicular thereto wherein the interface element, the selected engine and the selected generator are supported and protected. The cart supports first and second displaced wheels which rotate about a common axis which extends between the first and second regions, parallel to the third region. A fuel tank is carried on the cart and extends from the first side of the axis while the interface extends from the second side enabling the fuel tank to counterbalance the weight of the selected engine, the selected generator and the interface about the axis of rotation of the wheels.

Claims

1. A generator system positionable on a supporting surface comprising:

an engine with a rotary output shaft intended to be oriented substantially perpendicular to the supporting surface in normal operation;

wherein the engine has a mounting surface;

a source of electrical energy having a rotor and a stator wherein the rotor is adapted to be coupled, for rotation, to the output shaft along a common rotational center line;

a speed control coupled to the engine for causing the engine to rotate the shaft with a substantially constant speed over a range of energy delivered from the source; and

a sensor of delivered energy and a control element for disabling operation of the speed control during intervals of energy delivery below a preset threshold whereupon the engine enters a predetermined quiescent state outside of its normal operating range;

a two part interface structure, positioned between the engine and the source, wherein one part mechanically receives the other, wherein one part carries an alignment element for the stator which is coupled thereto and wherein the other carries a surface, machined relative to the alignment element, whereby the machined surface aligns the shaft of the engine, relative to the stator and the common center line when the engine is coupled to the interface structure; and

wherein the engine, the source and the interface structure are movably carried on a wheeled cart.

2. A system as in claim 1 which includes an elongated fuel tank oriented such that an elongated dimension thereof extends generally parallel to the output shaft.

3. A system as in claim 2 wherein the fuel tank and the engine are located on opposite sides of the selected axis whereby at least the fuel tank counterbalances the engine as the engine is being moved.

4. A system as in claim 1 which includes output terminals coupled to the source, wherein the terminals are adapted to removably engage electrical cables and a cable retainer carried on the system for engaging portions of at least one of the cables to prevent unintended disengagement of the at least one cable when engaged with a respective terminal.

5. A system as in claim 4 wherein the cable retainer comprises a cable retaining, elongated member formed at least in part, with a cable receiving and retaining loop.

6. A system as in claim 4 wherein the retainer comprises a length of wire.

7. A system as in claim 4 wherein the retainer comprises a length of plastic.

8. A system as in claim 1, wherein the speed control includes a pivoted engine fuel control lever.

9. A system as in claim 8 wherein the control element includes a coil wherein the coil is energized during the intervals of energy delivery below the threshold thereupon causing the lever to move to a speed control disabling position.

10. A system as in claim 9 wherein the coil is symmetrical about an axis, and wherein the axis is substantially perpendicular to the control lever.

11. A system as in claim 10 wherein the axis of the coil is substantially perpendicular to the output shaft.

12. A system as in claim 1, wherein the energy delivered sensor receives power generated by rotation of the shaft.

13. A system as in claim 2 which includes a supporting frame formed of a tubular member wherein the member is bent to have a plurality of continuous curves wherein the frame has first and second, spaced apart, U-shaped sections which extend on each side of the engine and are joined by a third, inverted, generally U-shaped section, having two non-parallel sides wherein the three sections are integrally formed in the tubular member and, enclose and support the engine on three sides.

14. A system as in claim 13 wherein the fuel tank extends between the first and second U-shaped sections spaced from the third section thereby forming a bounded, engine containing region.

15. A system as in claim 14 wherein the frame carries a plurality of shock mounts for supporting the engine.

16. A system as in claim 15 which includes a planar support member, sandwiched between the engine mounting surface and the interface wherein the planar member is coupled to the shock mounts.

17. A system as in claim 16 which includes first and second planar perforated panels, coupled to respective ones of the first and second U-shaped sections whereby the panels extend between the planar support member and portions of the first and second U-shaped sections.

18. A system as in claim 17 wherein one of the panels carries a plurality of energy output terminals.

19. A system as in claim 17 wherein one of the panels carries a rechargeable battery.

20. An energy system movable and supportable on a surface comprising:

an engine with a rotatable output with an axis of rotation oriented so as to be substantially perpendicular to the surface;

a source of electrical energy coupled to the engine output;

a sensor for detecting an electrical withdrawal from the source of electrical energy;

a speed control causing the output of the engine to hold a substantially constant speed over a selected range of electrical withdrawals from the source of electrical power;

a disabling device, coupled between the sensor and the speed control, for disabling the speed control in the absence of an electrical withdrawal, whereupon in the presence of the disabled speed control the speed of the engine output decreases from the substantially constant speed to a lower, idle speed; and

wherein the engine, the source, the sensor, the speed control and the disabling device are carried on a wheeled cart.

21. A system as in claim 20 wherein the disabling device includes an elongated coil, wherein the coil is oriented with an axis that is substantially perpendicular to the shaft.

22. A system as in claim 21 wherein the speed control element includes a movable output element, coupled to a speed control input port of the engine and wherein when the coil is in a selected state, the movable element moves to an engine idle speed position.

23. A system as in claim 22 wherein the coil, when energized, is in the selected state.

24. A system as in claim 23 wherein the output element pivots and moves toward the energized coil to the engine idle speed position.

25. A system as in claim 20 wherein the speed control element includes a contactless speed sensor.

26. A system as in claim 25 wherein the disabling device includes a solid state circuit for disabling the speed control element.

27. A system as in claim 20 which includes circuitry for supplying energy, generated from operation of the engine, to the sensor and the disabling device.

28. A system as in claim 27 wherein the circuitry for supplying energy includes a selected alternator coil carried adjacent to the engine.

29. A system as in claim 22 wherein the speed control element includes a mechanical governor.

30. A movable system for generating electrical energy comprising:

an engine with a rotary output wherein the engine is attached to a movable cart;

an electrical source with a rotatable portion;

a two-sided mounting element for coupling to the engine on one side and source on the other and aligning the output of the engine relative to the rotatable portion of the source;

a speed control system for operating the engine at a predetermined output speed when electrical power is being drawn from the source by a load and for operating the engine at a reduced speed in a no load condition; and

a counterbalancing fuel tank coupled to the engine.

31. A system as in claim 30 wherein the source is selected from a class which includes an alternator and a DC generator.

32. A system as in claim 30 wherein the mounting element is formed of first and second slidably engageable components.

33. A source of electrical energy movable on a surface comprising:

a movable cart;

a coupled engine/generator combination carried on the cart wherein the combination has a common axis of rotation oriented, when the combination is producing usable electrical energy, substantially perpendicular to the surface; and

a solid state control module, carried on the cart, for producing engine speed control signals whereby the engine is enabled to operate at a first speed when electrical energy is being withdrawn from the source and adjusted to operate at a second, lower, speed in the absence of a selected electrical parameter having a predetermined value.

34. A source as in claim 33 wherein the generator comprises an alternator for producing a varying output current.

35. A source as in claim 34 wherein the control module includes alternator energizing circuitry.

36. A source as in claim 33 wherein the cart is formed of a shaped tubular member which encloses the combination on four sides.

37. A source as in claim 36 which includes an elongated fuel tank, attached, at least in part, to the cart using at least one resilient mount whereby the fuel tank counterbalances the combination as the cart is being moved.

38. A source as in claim 37 which includes an axle coupled to the cart and at least one wheel rotatably mounted thereon wherein the wheel rotates along a second axis of rotation wherein the fuel tank is on one side and the combination is on the other side of that axis.

39. A source as in claim 37 wherein the fuel tank is formed with a rotation facilitating depression.

40. A source as in claim 39 which includes first and second wheel wells formed in the tank with the depression located therebetween.

41. A source as in claim 37 wherein the fuel tank is formed with a rotation facilitating depression wherein the depression is positioned adjacent to the second axis.

42. A source as in claim 33 wherein the control module includes feedback circuitry for dynamically adjusting an output voltage from the combination.

43. A source as in claim 33 which includes a fuel tank coupled to the cart wherein the tank is carried on the cart with an orientation that counterbalances the coupled engine/generator at least while the cart is being moved.

44. A source as in claim 33 wherein the cart carries a support member with a planar region and the interface is adapted to be coupled to a first surface of the planar region, the engine coupled to a displaced second surface thereof and wherein the planar region is sandwiched between the engine and the interface.

45. A source as in claim 43 wherein a muffler is coupled to an exhaust port of the engine, wherein the muffler is displaced from the engine and wherein the generator is positioned between the muffler and the fuel tank.

46. A source as in claim 43 wherein the tank has an elongated dimension and extends at least between an axle and a user friendly side of the engine.

47. A source as in claim 33 wherein the cart is formed of a length of a tubular support formed with first and second spaced apart substantially U-shaped sections wherein each section has a linear element oriented substantially perpendicular to a shaft of the combination and an open region wherein the open region is displaced from the linear element wherein the engine/generator is positioned between the open regions.

48. A source as in claim 47 wherein the cart carries at least one rotatable wheel for facilitating movement thereof.

49. A source as in claim 48 wherein the wheel rotates about an axis which extends between the linear elements and is substantially perpendicular thereto.

50. A source as in claim 47 wherein the first and second sections of the tubular support are joined by a substantially linear, tubular element continuously formed therewith and positioned adjacent to the user friendly surface thereby forming a third U-shaped section wherein the linear tubular element is displaced from the linear elements.

51. A source as in claim 50 wherein the linear tubular element is substantially perpendicular to the linear elements.

52. A source as in claim 50 wherein the U-shaped sections are all joined at integrally formed, tubular, curved regions.

53. A source as in claim 48 which includes a fuel tank, wherein the fuel tank is symmetrical about a central plane extending therethrough and wherein the central plane extends equidistantly between the first and second sections, substantially perpendicular to the third section.

54. A source as in claim 52 wherein the third U-shaped section incudes first and second sides, formed respectively by the first and second sections, and wherein the first and second sides substantially lie in a common plane and are non-parallel to one another.

55. A source as in claim 54 which includes first and second side panels wherein the side panels fill, at least in part, respective ones of the first and second U-shaped sections.

56. A source as in claim 33 wherein the generator comprises an alternator and wherein a cooling air flow path for the engine is substantially isolated from an air flow path for the alternator.