Portable energy generation systems

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.

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, 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, iii) at least one electrical controller structured and arranged to control such at least one output of electrical energy, iv) at least one wheeled 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, 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 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. 
     
     
         13 . The portable system according to  claim 8  wherein each one of said at least nine cylinders comprises substantially at least one boron-iron alloy. 
     
     
         14 . The portable system according to  claim 8  wherein each one of said at least nine cylinders comprises substantially boron-alloy cast iron. 
     
     
         15 . 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. 
     
     
         16 . 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. 
     
     
         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 c) at least one prime mover structured and arranged to output rotary power, d) at least one electrical generator structured and arranged to convert at least one input of rotary power to at least one output of electrical energy, and e) at least one rotary-power coupler structured and arranged to operably couple such at least one output of rotary power with such at least one input of rotary power, f) at least one electrical controller structured and arranged to control such at least one output of electrical energy, and g) at least one support frame structured and arranged to support said at least one prime mover, said at least one electrical generator, said at least one electrical controller, and said at least one rotary-power coupler; h) wherein said such at least one output of rotary power is directed along at least one output shaft of said at least one prime mover; i) wherein such at least one input of rotary power is received along at least one input shaft of said at least one electrical generator; j) wherein said at least one output shaft and said at least one input shaft do not share a common rotational axis; and k) wherein said at least one rotary-power coupler comprises at least one drive belt structured and arranged to rotationally couple said at least one output shaft and said at least one input shaft. 
     
     
         18 . The system according to  claim 17  wherein said at least one rotary-power coupler is further structured and arranged to vary the relative rotational speeds of said at least one output shaft and said at least one input shaft. 
     
     
         19 . 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, 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, and 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; 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. 
     
     
         20 . The system according to  claim 19  wherein said outer housing comprises a maximum outer dimension of less than about four meters. 
     
     
         21 . The system according to  claim 20  wherein said at least one portable electric generator comprises a weight less than about 5000 kilograms. 
     
     
         22 . A method of increasing the time between overhauls within at least one aviation-derived engine during use in non-aviation service, said method comprising the steps of: a) identifying within such at least one aviation-derived engine, at least one first set of engine components to be modified to extend the time between overhauls of such at least one aviation-derived engine during such non-aviation service; b) providing at least one second set of industrialized engine components to replace substantially such engine components within such at least one set; and c) replacing such engine components of such at least one set with such at least one industrialized engine component; d) wherein such at least one first set comprises at least about fifty percent of the overall engine components comprising such at least one aviation-derived engine; and e) wherein such replacement of engine components extends the time between overhauls of such at least one aviation-derived engine during such non-aviation service. 
     
     
         23 . A method related to providing standard modular power units capable of producing electrical power comprising the steps of: a) determining an approximate size and power output for at least one modular generator engine unit to service at least one large-power consumer: b) determining a first set of component arrangements comprising efficient concatenations of at least one prime-mover, at least one electrical generator, and at least one control component of such at least one generator engine unit; c) determining a second set of minimum spaces into which such power components, electrical-generation components, and control components are together packageable; d) selecting from within such set at least one minimum space to become such standard modular power unit; e) providing such standard modular power unit comprising such power components, such electrical-generation components, and such control components packaged within the selected such at least one minimum space. 
     
     
         24 . The method according to  claim 23  wherein such set of minimum spaces comprises at least one standard intermodal-transport shipping-container. 
     
     
         25 . A method related to reducing vehicular transportation costs associated with the transport of at least one engine-generator unit, said method comprising the steps of: a) selecting at least one transport mode to physically transport such at least one engine-generator unit; b) determining for such at least one transport mode at least one set of hauling-capacity constraints associated with a maximum hauling capacity of such at least one transport mode; c) determining for such at least one engine-generator unit at least one set of minimum performance parameters; d) determining for such at least one engine-generator unit at least one set of possible physical enclosure configurations capable of packaging at least one engine-generator unit comprising such minimum performance parameters; e) selecting from such at least one set of possible physical packaging configurations at least one transport-compliant set of physical packaging configurations, each one falling substantially within such at least one set of hauling-capacity constraints; f) calculating for such at least one transport-compliant set of physical packaging configurations, unit production costs associated with each; and g) selecting from such at least one transport-compliant set of physical packaging configurations, at least one transport-compliant physical packaging configuration falling within at least one acceptable unit production cost goal; h) wherein at least one minimum performance parameter of such at least one set of minimum performance parameters comprises a peak electrical output of about one megawatt. 
     
     
         26 . 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; and   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.   
     
     
         27 . The electric generator system according to  claim 26  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. 
 
     
     
         28 . The electric generator system according to  claim 26  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. 
     
     
         29 . The electric generator system according to  claim 28  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. 
     
     
         30 . The electric generator system according to  claim 28  wherein each link rod of said eight link rods has a length of between fourteen and fifteen inches. 
     
     
         31 . The electric generator system according to  claim 30  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. 
     
     
         32 . The electric generator system according to  claim 28  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. 
     
     
         33 . The electric generator system according to  claim 32  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. 
     
     
         34 . The electric generator system according to  claim 26  wherein each piston comprises at least one piston ring and at least one piston control ring. 
     
     
         35 . The electric generator system according to  claim 26  wherein each piston further comprises at least two piston rings and at least three piston control rings. 
     
     
         36 . The electric generator system according to  claim 26  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. 
     
     
         37 . The electric generator system according to  claim 36  wherein each said cylinder barrel is shell-molded.