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EP-3811500-B1 - COMPONENT FOR A POWER GENERATION SYSTEM

EP3811500B1EP 3811500 B1EP3811500 B1EP 3811500B1EP-3811500-B1

Inventors

  • ROLSTON, Robert
  • RILEY, MARK

Dates

Publication Date
20260513
Application Date
20190620

Claims (15)

  1. A component (20; 50; 80; 90; 110; 182), for connection between a generator (12) and a prime mover (10) in a power generation system, the component comprising: a rear member (24; 54; 84; 94; 114; 164; 184) arranged to be connected to a non-rotating part of the generator (12); a front member (22; 52; 82; 92; 112; 162) arranged to be connected to a non-rotating part of the prime mover (10) and/or to support a bearing for supporting one end of a generator shaft; and a plurality of cross members (26; 56; 86; 96; 116; 146; 166; 186; 196) which connect the front member to the rear member, wherein the rear member and the front member are arranged to surround a rotating component, the rear member and the front member are axially aligned, and the cross members extend between the rear member and the front member in an axial direction, wherein the component is arranged to house a fan and to allow airflow from the fan to pass between adjacent cross members, and wherein the component is either an adaptor in which the front member (22; 52; 82; 92; 112; 162) is arranged to be connected to a non-rotating part of the prime mover (10) such that the generator shaft is supported by the prime mover (10), or a bracket in which the front member is arranged to support a bearing for supporting one end of the generator shaft; characterised in that : the cross members are wedge-shaped with an edge (38) on a radially inwards end of the cross member and two side surfaces (34, 36) each of which extends radially outwards from the edge (38); and the width of the cross members increases with increasing distance from the inside of the component.
  2. A component according to claim 1, wherein the two side surfaces (34, 36) are inclined with respect to each other and meet at the edge (38) on the radially inward end of the cross member.
  3. A component according to claim 1 or 2, wherein each cross member has an outside surface (32) which extends between the two side surfaces (34, 36), and the two side surfaces are longer than the outside surface.
  4. A component according to any of the preceding claims, wherein the cross members have an axial cross section which is substantially triangular.
  5. A component according to claim 4, wherein one vertex of the triangle lies on the radially inwards end of the cross member, and the other two vertices lie on the radially outwards end of the cross member.
  6. A component according to any of the preceding claims, wherein the cross members are angled with respect to a radial direction.
  7. A component according to any of the preceding claims, wherein the cross members have a centre line which is at an angle approximately equal to an angle at which airflow exits the fan.
  8. A component according to any of the preceding claims, wherein a gap between adjacent cross members increases with increasing distance from the inside of the component.
  9. A component according to any of the preceding claims, wherein the front member and/or the rear member comprise at least one area with a reduced depth in a radial direction, and a gap between two adjacent cross members in a circumferential direction is greater in an area with reduced depth.
  10. A component according to claim 9, wherein the cross members are located in one or more areas where the front member and/or the rear member do not have a reduced depth.
  11. A component according to any of the preceding claims, further comprising at least one removable cover, wherein at least one removable cover comprises a wedge-shaped vane.
  12. A component according to any of the preceding claims, wherein the component includes a peripheral wall which extends between the front member and a point part way through the component in an axial direction.
  13. A generator comprising a component according to any of the preceding claims, wherein the rear member is connected to a non-rotating part of the generator.
  14. A power generation system comprising a prime mover (10), a generator (12) and a component according to any of the preceding claims connected between the generator and the prime mover.
  15. A method of managing air flow in a generator, the method comprising using a fan to draw air through the generator and out through a component (20; 50; 80; 90; 110; 182) housing the fan, wherein the component comprises: a rear member (24; 54; 84; 94; 114; 164; 184) arranged to be connected to a non-rotating part of the generator (12); a front member (22; 52; 82; 92; 112; 162) connected to the prime mover (10) and/or supporting a bearing for supporting one end of a generator shaft; and a plurality of cross members (26; 56; 86; 96; 116; 146; 166; 186; 196) which connect the front member to the rear member, wherein the rear member and the front member surround a rotating component, the rear member and the front member are axially aligned, and the cross members extend between the rear member and the front member in an axial direction, and wherein the component is either an adaptor in which the front member (22; 52; 82; 92; 112; 162) is connected to a non-rotating part of the prime mover (10) such that the generator shaft is supported by the prime mover (10), or a bracket in which the front member supports a bearing for supporting one end of the generator shaft; characterised in that : the cross members are wedge-shaped with an edge (38) on a radially inwards end of the cross member and two side surfaces (34, 36) each of which extends radially outwards from the edge (38); the width of the cross members increases with increasing distance from the inside of the component; and air flow from the fan passes between adjacent wedge-shaped cross members.

Description

The present invention relates to a component for connection between a generator and a prime mover in a power generation system. The invention has particular application as an adaptor for connecting the generator to the prime mover such that the generator shaft is supported by the prime mover, and/or as a bracket for supporting a bearing for supporting one end of a a generator shaft. Power generation systems typically comprise a prime mover connected to a rotating electrical machine. For example, a generating set may comprise an internal combustion engine, such as a diesel engine, coupled to a generator (alternator). The engine is used to drive the generator, in order to generate the output power. This is achieved by mechanically connecting rotating parts of the engine and the generator. The engine and the generator are typically both mounted on a bed frame. An adaptor may be used to connect non-rotating parts of the generator and the engine, such as the generator frame and a flywheel housing. The adaptor may convert one set of connections on the generator to another set of connections on the prime mover. Use of an adaptor helps to prevent relative movement between the engine and the generator. Many rotating electrical machines, particularly those of a larger design, require some form of cooling. This may be achieved by providing a fan which forces air flow through the machine. The fan may be mounted on the rotor shaft, and may be driven directly by the prime mover. Alternatively, an independently-driven fan may be provided. The fan may either push or pull air through the machine. Air flow through the machine is usually in a generally axial direction. The main paths for the air flow are usually through the rotor/stator airgap, and through an airgap between the stator core and the stator frame. In existing adaptor designs, the fan may be mounted on the machine shaft inside the adaptor. Air outlets may be provided in the adaptor in order to provide an exit path for airflow through the machine. The air outlets may also provide access for an operator to connect rotating parts of the prime mover and the electrical machine during assembly. Many power generation systems use a single bearing design. In this case, the generator has a single bearing for supporting one end of the shaft, and the other end of the shaft is supported by bearings in the engine. An adaptor connects the generator frame to the flywheel housing, and may also house a fan. Other power generation systems use a two-bearing design. In this case a bracket may be provided which connects to the generator frame and which supports a bearing. The bracket may also house a fan. Some two-bearing designs do not have the generator frame connected directly with the engine housing, and rely on rigid connections with the bed frame. If it is desired to connect a two-bearing machine with the engine housing, a separate adaptor may be fitted between the two-bearing bracket and the engine housing. Alternatively, these two components (the adaptor and the bracket) may be provided as one piece. WO 2017/158322 in the name of the present applicant discloses an adaptor with four asymmetric air outlets. The adaptor is arranged to provide an increase in the cross-sectional area of the air flow towards the outlet. This can allow a progressive reduction in air velocity to be achieved within the adaptor towards the outlet. This may help to improve the overall amount of cooling air passing through the machine for a given fan input power. The adaptor disclosed in WO 2017/158322 has been found to provide a significant improvement in the cooling flowrate with a corresponding reduction in winding temperatures. However, it has been found that on some machines, such as larger-frame machines, the shape of the adaptor presents challenges from a mechanical strength and cost perspective. In particular, the structural limitations imposed by the design may increase the weight, size and/or cost of the adaptor. WO 2017/009626 in the name of the present applicant discloses an adaptor which is optimised in terms of the amount of material used for a given stiffness, rather than for improved airflow. It would therefore be desirable to provide a component for connection between a generator and a prime mover which is efficient from a structural and cost perspective and which also provides good air-flow and thermal performance. According to one aspect of the present invention there is provided a component for connection between a generator and a prime mover in a power generation system as defined in claim 1. The present invention may provide the advantage that, by using wedge-shaped cross members, it may be possible to achieve good air-flow and thermal performance using a component which is also efficient from a structural and cost perspective. By wedged-shaped it is meant that the cross members have two exterior surfaces which meet together at an inner edge. For example, the cross members may have t