Portable energy generation systems

• US 8,567,354 B2
• Filed: 07/14/2009
• Issued: 10/29/2013
• Est. Priority Date: 07/17/2008
• Status: Active Grant

• Current Assignee: Arizona Commerce Authority
• Original Assignee: World Energy Systems
• Inventors: Kealy, Joseph P., Carmen, Anthony J., Heise, Douglas R.
• Primary Examiner(s): KAMEN, NOAH P
• Application Number:
  US12/503,066
• Publication Number:
  US 20100072757A1
• Time in Patent Office: 1,568 Days
• Field of Search: 123/2, 123/3, 290/1.R, 290/1.A, 290/1.B
• US Class Current: 123/2
• CPC Class Codes: F01B 9/023 of Bourke-type or Scotch yoke
• CPC Class Codes: F01N 13/04 having two or more silencers in parallel, e.g. having interconnections for multi-cylinder engines
• CPC Class Codes: F02B 2075/1836 nine
• CPC Class Codes: F02B 37/001 using exhaust drives arranged in parallel
• CPC Class Codes: F02B 37/007 with exhaust-driven pumps arranged in parallel , e.g. at least one pump supplying alternatively
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02B 63/044 the engine-generator unit being placed on a frame or in an housing
• CPC Class Codes: F02B 63/047 Movable engine-generator combinations on wheels
• CPC Class Codes: F02B 75/222 with cylinders in star arrangement
• CPC Class Codes: F02F 1/065 with means for directing or distributing cooling medium
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Portable energy generation systems are disclosed. More particularly, a high-output mobile electrical generator system comprising a radial engine power source providing a highly compact physical format.

Claims

1. A portable system relating to the generation of electric power comprising:

a) at least one portable electric generator structured and arranged to generate such electrical power;

b) wherein said at least one portable electric generator comprises

i) at least one internal combustion engine structured and arranged to produce at least one output of rotary power, and an engine cradle for supporting said at least one internal combustion engine, said engine cradle coupled to said at least one internal combustion engine for support during operation and transportation;

ii) at least one electrical generator structured and arranged to convert such at least one output of rotary power to at least one output of electrical energy,

iii) at least one electrical controller structured and arranged to control such at least one output of electrical energy,

iv) at least one towable wheeled trailer chassis structured and arranged to assist wheeled transport of said at least one internal combustion engine, said at least one electrical generator, and said at least one electrical controller and wherein said at least one towable wheeled trailer chassis includes a frame for supporting said engine cradle and said at least one internal combustion engine at a foreward location and for supporting said at least one electrical generator at a location aft of said at least one internal combustion engine and wherein said portable electric power generation system has a towing weight of less than about 7200 kilograms such that said portable electric power generation system may be towed by a pickup truck having a one ton rating and may be driven by a non-commercial driver,

v) an outer housing, having an enclosed volume, structured and arranged to house said at least one internal combustion engine, said at least one electrical generator, and said at least one electrical controller, and

vi) at least one mount structured and arranged to mount said outer housing to said at least one wheeled chassis;

c) wherein said at least one internal combustion engine comprises a plurality of combustion chambers organized in at least one radial geometry; and

d) wherein each combustion chamber of said plurality of combustion chambers comprises at least one piston reciprocably disposed within at least one cylinder.

2. The portable system according to claim 1 wherein said at least one portable electric generator comprises:

a) a system weight excluding operating fuel; and

b) a peak electrical output to system weight ratio of about 0.17 kilowatts per kilogram.

3. The portable system according to claim 1 wherein said at least one portable electric generator comprises a peak electrical output of about one megawatt.

4. The system according to claim 3 wherein said at least one portable electric generator comprises a maximum system weight of less than about 7800 kilograms.

5. The portable system according to claim 3 wherein said at least one portable electric generator comprises a peak electrical output to enclosed housing volume ratio of about 41.5 kilowatts per cubic meter.

6. The portable system according to claim 3 wherein said outer housing comprises an enclosed volume of less than about 24 cubic meters.

7. The portable system according to claim 6 wherein said outer housing comprises a maximum outer length of less than about 4 meters.

8. The portable system according to claim 6 wherein said plurality of combustion chambers comprises at least nine pistons reciprocably disposed within at least nine cylinders.

9. The portable system according to claim 8 wherein each combustion chamber of said plurality of combustion chambers comprises a cylinder bore diameter of about 6.125 inches and a piston stroke of about 6.875 inches.

10. The portable system according to claim 8 wherein said at least one internal combustion engine comprises a displacement of greater than about 1,800 cubic inches.

11. The portable system according to claim 10 wherein said at least one internal combustion engine further comprises:

a) at least one induction pathway structured and arranged to introduce a combustible air fuel mixture into said plurality of combustion chambers of said at least one internal combustion engine;

b) wherein said at least one induction pathway comprises i) at least one air fuel mixer structured and arranged to produce such at least one combustible air fuel mixture, and ii) at least one compressor structured and arrange to pressurize such at least one combustible air fuel mixture prior to introduction into said plurality of combustion chambers.

12. The portable system according to claim 11 wherein said at least one compressor comprises at least one exhaust-driven turbocharger structured and arrange to be driven by exhaust gas exiting said at least one internal combustion engine.

13. The portable system according to claim 8 further comprising at least one oil-based piston cooler structured and arranged to cool each one of said at least nine pistons using at least one pressurized stream of lubricating oil.

14. The portable system according to claim 8 wherein each one of said at least nine cylinders comprises substantially at least one boron-iron alloy.

15. The portable system according to claim 8 wherein each one of said at least nine cylinders comprises substantially boron-alloy cast iron.

16. The portable system according to claim 8 wherein:

a) each one of said plurality of combustion chambers comprises at least one cylinder-head assembly structured and arranged to provide valve-assisted control of combustion cycle gases of said at least one internal combustion engine;

b) wherein said at least one cylinder-head assembly comprises substantially at least one Al—

Si—

Cu—

Mg alloy.

17. A system relating to the generation of electric power comprising:

a) at least one portable electric generator structured and arranged to generate such electrical power;

b) wherein said at least one portable electric generator comprises i) at least one internal combustion engine structured and arranged to produce at least one output of rotary power and an engine cradle for supporting said at least one internal combustion engine, said engine cradle coupled to said at least one internal combustion engine for support during operation and transportation, ii) operationally coupled with said at least one internal combustion engine, at least one electrical generator structured and arranged to convert such at least one output of rotary power to at least one output of electrical energy, and iii) at least one electrical controller structured and arranged to control such at least one output of electrical energy, iv) an outer housing structured and arranged to house said at least one internal combustion engine, said at least one electrical generator, and said at least one electrical controller, and at least one towable wheeled trailer chassis structured and arranged to provide wheeled transport of said at least one internal combustion engine, said at least one electrical generator, and said at least one electrical controller and wherein said at least one towable wheeled trailer chassis includes a frame for supporting said engine cradle and said at least one internal combustion engine at a forward location and for supporting said at least one electrical generator at a location aft of said at least one internal combustion engine and wherein said portable electric power generation system has a towing weight of less than about 7200 kilograms such that said portable electric power generation system may be towed by a pickup truck having a one ton rating and may be driven by a non-commercial driver;

c) wherein said at least one portable electric generator comprises a peak electrical output of about 1 megawatt; and

d) wherein said outer housing comprises an enclosed volume of less than about 24 cubic meters.

18. The system according to claim 17 wherein said outer housing comprises a maximum outer dimension of less than about four meters.

19. The system according to claim 18 wherein said at least one portable electric generator comprises a weight less than about 5000 kilograms.

20. A portable electric generator system for the generation of electric power, comprising:

a) at least one electric generator structured and arranged to generate such electrical power, said at least one electric generator having a peak electrical output of about one megawatt;

b) at least one internal combustion, radial engine structured and arranged to produce at least one output of rotary power operationally coupled with said at least one electrical generator to convert such at least one output of rotary power to at least one output of electrical energy, wherein said at least one internal combustion, radial engine comprises nine combustion chambers and nine oil-cooled pistons structured and arranged to cool each one of said at least nine pistons using at least one pressurized stream of lubricating oil sprayed on the underside of the piston crown within a region of a piston skirt; and

wherein said at least one internal combustion, radial engine further comprises a master rod having a first end coupled to a first piston and a second end for coupling to a crankshaft, wherein said master rod comprises a longitudinal oil passage formed along a central web of the master rod for communicating oil to said first piston;

c) at least one electrical controller structured and arranged to control such at least one output of electrical energy;

d) an outer housing, having an enclosed volume, structured and arranged to house said at least one internal combustion engine, said at least one electrical generator, and said at least one electrical controller; and

e) an engine cradle for supporting said at least one internal combustion engine, said engine cradle coupled to said at least one internal combustion engine for support during operation and transportation; and

f) at least one towable wheeled trailer chassis structured and arranged to provide wheeled transport of said at least one internal combustion engine, said at least one electrical generator, and said at least one electrical controller and wherein said at least one towable wheeled trailer chassis includes a frame for supporting said engine cradle and said at least one internal combustion engine at a forward location and for supporting said at least one electrical generator at a location aft of said at least one internal combustion engine and wherein said portable electric power generation system has a towing weight of less than about 7200 kilograms such that said portable electric power generation system may be towed by a pickup truck having a one ton rating and may be driven by a non-commercial driver.

21. The electric generator system according to claim 20 further comprising:

a chassis for supporting said at least one electric generator, and said at least one internal combustion, radial engine; and

a mount for coupling said outer housing to said chassis and wherein said outer housing and said chassis comprise an enclosed volume of less than 24 cubic meters.

22. The electric generator system according to claim 20 wherein said master rod includes a plurality of link-pin bores machined in said second end, said plurality of link-pin bores spaced evenly by angular position about a main bearing bore in said second end of said master rod.

23. The electric generator system according to claim 22 wherein at least one internal combustion, radial engine further comprises eight link rods, each link rod having a first end for coupling to a respective piston and a second end for coupling each link rod to a respective link-pin bore in said second end of said master rod;

and wherein said master rod has a center of gravity located closer to said second end of said master rod to reduce the angular momentum and the friction of said piston in said cylinder.

24. The electric generator system according to claim 22 wherein each link rod of said eight link rods has a length of between fourteen and fifteen inches.

25. The electric generator system according to claim 24 wherein each link rod of said eight link rods has a length of approximately 14.763 inches and a tolerance of approximately +/−

0.002 inches to increase the moment arm applied to said master rod by said link rods.

26. The electric generator system according to claim 22 wherein said at least one internal combustion, radial engine further comprises a crankpin for coupling said main bearing bore in said second end of said master rod to the crankshaft and said crankpin comprises a set of lubrication holes for communication with a pressured lubrication system of said at least one internal combustion, radial engine and said longitudinal oil passage formed along said central web of said master rod for communicating oil to said first piston to dissipate heat from said first piston and to improve the durability level of said at least one internal combustion, radial engine.

27. The electric generator system according to claim 26 wherein each link rod of said at least one internal combustion, radial engine comprises an internal oil flow passage extending through a longitudinal axis of said link rod to deliver lubricating oil to a respective piston of said eight pistons.

28. The electric generator system according to claim 20 wherein each piston comprises at least one piston ring and at least one piston control ring.

29. The electric generator system according to claim 20 wherein each piston further comprises at least two piston rings and at least three piston control rings.

30. The electric generator system according to claim 20 wherein said at least one internal combustion, radial engine comprises nine cylinder barrels comprising a ferrous alloy, each said cylinder barrel including said combustion chamber located internally and a plurality of externally located structural cooling fins integrally cast about the outer circumference of said cylinder barrel to structurally reinforce said cylinder barrel while evenly distributing heat around said cylinder barrel to thereby maintain a consistent shape during extended operation.

31. The electric generator system according to claim 30 wherein each said cylinder barrel is shell-molded.