Power generating system

• US 7,485,977 B2
• Filed: 01/06/2006
• Issued: 02/03/2009
• Est. Priority Date: 01/06/2006
• Status: Active Grant

• Current Assignee: Aerodyne Corporation
• Original Assignee: Aerodyne Corporation
• Inventors: Woodroffe, Jaime, Stickler, David B., Annen, Kurt D., Agnese, Michael
• Primary Examiner(s): Ponomarenko; Nicholas
• Assistant Examiner(s): Mohandesi; Iraj A
• Application Number:
  US11/326,704
• Publication Number:
  US 20070158946A1
• Time in Patent Office: 1,124 Days
• Field of Search: 29/1.A, 29/1.R
• US Class Current: 290/1.00R
• 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) 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 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.

2. The power generating system as set forth in claim 1 wherein the intake plenum includes a moving-fluid-based heat-transfer assembly in thermal communication therewith.

3. The power generating system as set forth in claim 2 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.

4. The power generating system as set forth in claim 3 wherein the fuel/air mixture intake assembly includes an electrically powered preheater that elevates the temperature prior to startup of the MICE generator.

5. The power generating system as set forth in claim 1 wherein the fuel/air mixture intake assembly includes an electrically powered preheater that elevates the temperature prior to startup of the MICE generator.

6. The power generation system as set forth in claim 3, wherein the heat transfer assembly is constructed and arranged to increase or decrease heat input to the fuel/air mixture to regulate power output from the alternator assembly.

7. The power generation system as set forth in claim 1, wherein the heater is constructed an arranged to increase heat input to the fuel/air mixture so to regulate the power out put.

8. The power generating system as set forth in claim 1 further comprising exhaust components that include an exhaust out let on the casing and muffler connected thereto, and ,wherein the heater comprises a sheath with flowing fluid therein located around at least one of the exhaust outlet and the muffler that receives heat from the exhaust components.

9. the power generation system as set forth in claim 8 further comprising a flow control that controls a fraction of the fluid flowing through the sheath by the exhaust components.

10. The power generating system as set forth in claim 3, wherein the heat transfer assembly comprises a heat pipe.

11. The power generating system as set forth in claim 1 further comprising a valve that routes a predetermined quantity of the 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.

12. The power generating system as set forth in claim 1, 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.

13. The power generating system as set forth in claim 12, wherein the spring comprises a milled titanium spring.

14. The power generating system as set forth in claim 1 further comprising a plurality of soft springs mounted on an end of the casing constructed and arranged to engage a support surface so that the MICE generator is supported on the support surface by the plurality of soft springs.