Low noise enclosure

Systems and apparatuses include an apparatus including an intake defined by an intake aperture, an intake baffle, and an intake floor structured to couple to an intake portion of an enclosure roof, the intake extending along at least eighty percent (80%) of a width of the apparatus on a first side, an exhaust defined by an exhaust aperture, an exhaust baffle, and an exhaust floor structured to couple to an exhaust portion of the enclosure roof, the exhaust extending along at least eighty percent (80%) of the width of the apparatus on a second side opposite the first side, a partition panel isolating the intake from the exhaust, and an engagement mechanism structured to couple the apparatus to a generator set.

TECHNICAL FIELD

The present disclosure relates to enclosures for engines, generators, or generator sets. More particularly, the present disclosure relates to systems and methods for reducing noise emissions from a generator set.

BACKGROUND

It is desirable to reduce the noise emission of power generation components such as generator sets including an engine and a generator. Some systems designed to reduce noise emissions includes a secondary noise reducing enclosure and/or increased thickness barriers. Current solutions to reduce noise emissions add weight and cost, and increase the footprint of the generator set.

SUMMARY

One embodiment relates to an apparatus that includes an intake defined by an intake aperture, an intake baffle, and an intake floor structured to couple to an intake portion of an enclosure roof, the intake extending along at least eighty percent (80%) of a width of the apparatus on a first side, an exhaust defined by an exhaust aperture, an exhaust baffle, and an exhaust floor structured to couple to an exhaust portion of the enclosure roof, the exhaust extending along at least eighty percent (80%) of the width of the apparatus on a second side opposite the first side, a partition panel isolating the intake from the exhaust, and an engagement mechanism structured to couple the apparatus to a generator set.

Another embodiment relates to a system that includes an enclosure defining an enclosure width and including a first enclosure wall extending the entire enclosure width, an enclosure intake wall that extends along at least eighty percent (80%) of the enclosure width, an enclosure intake cavity defined between the first enclosure wall and the enclosure intake wall, a second enclosure wall positioned on an opposite side of the enclosure from the first enclosure wall and extending the entire enclosure width, an enclosure exhaust wall that extends along at least eighty percent (80%) of the enclosure width, an enclosure exhaust cavity defined between the second enclosure wall and the enclosure exhaust wall, and a chamber defined between the enclosure intake wall and the enclosure exhaust wall. A modular canopy defines a canopy width that extends along at least eighty percent (80%) of the enclosure width, and including a canopy intake defined by an intake aperture, an intake baffle, and an intake floor structured to couple to the enclosure to provide fluid communication between the intake aperture and the enclosure intake cavity, the canopy intake extending along substantially the entire canopy width adjacent the first enclosure wall, a canopy exhaust defined by an exhaust aperture, an exhaust baffle, and an exhaust floor structured to couple to the enclosure to provide fluid communication between the exhaust aperture and the enclosure exhaust cavity, the canopy exhaust extending along substantially the entire canopy width adjacent the second enclosure wall, and a partition panel isolating the canopy intake from the canopy exhaust.

Another embodiment relates to a method that includes removing a roof of a generator set enclosure, coupling a modular canopy to the generator set enclosure, providing an intake flow path extending along at least eighty percent (80%) of a width of the generator set enclosure through the coupled modular canopy and the generator set enclosure, the intake flow path includes an intake aperture positioned in the modular canopy, an intake baffle positioned in the modular canopy, an intake floor positioned in the modular canopy, and an intake cavity positioned in the generator set enclosure. The method further includes providing an exhaust flow path extending along at least eighty percent (80%) of the width of the generator set enclosure through the coupled modular canopy and the generator set enclosure, the exhaust flow path includes an exhaust aperture positioned in the modular canopy, an exhaust baffle positioned in the modular canopy, an exhaust floor positioned in the modular canopy, and an exhaust cavity positioned in the generator set enclosure. The method further includes separating the intake flow path and the exhaust flow path with a partition panel.

DETAILED DESCRIPTION

Following below are more detailed descriptions of various concepts related to, and implementations of, methods, apparatuses, and systems for a low noise enclosure for a generator set. The various concepts introduced above and discussed in greater detail below may be implemented in any number of ways, as the concepts described are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

Referring to the figures generally, the various embodiments disclosed herein relate to systems, apparatuses, and methods for a low noise enclosure for a generator set. The enclosure includes a modular canopy that provides a circuitous intake and exhaust path. The modular canopy includes air flow partitions that are formed from sheet metal as thin as two millimeters (2 mm) thick. Air filters, intake silencers, and noise deadening or barrier material can be attached to wall and partition surfaces to further reduce noise emissions. Additionally, lift hooks can be connected to the enclosure within recesses which can be sealed with covers to further reduce noise emission.

As shown inFIG. 1A, a generator set10having a low noise enclosure system includes an enclosure14that houses an engine18and other generator set components22, and a modular canopy26that is coupled to the enclosure14and provides an intake30(seeFIG. 4) and an exhaust34for the enclosure14. The enclosure14includes a single point lift access cover plate38. The generator set10includes the intake30and the exhaust34positioned at opposite ends from one another such that air enters the intake30, flows through and/or across the engine18and generator set components22, and exits the exhaust34in a generally linear direction (e.g., generally left to right inFIG. 1A). It is noted that in some embodiments air flows through the enclosure14across the generator set components22first (in particular, electrical components, such as an alternator, or generator, or control or connection circuits), and then the engine18and any cooling system or radiator (not shown). In other embodiments intake air flows initially through or across the cooling system and engine18and then the generator set components22. In some embodiments, the intake30and the exhaust34are positioned on the end walls of the modular canopy26. In some embodiments, the single point lift access cover plate38is positioned on a front wall of the enclosure14.

As shown inFIG. 1B, a generator set10′ that is similar to the generator set10described above with respect toFIG. 1Aand labelled with like numbers in the prime series, includes an intake30′ and an exhaust34′ positioned on a top or roof of the modular canopy26. Additionally, a single point lift access cover plate38′ is positioned on the roof of the modular canopy26. In some embodiments, the intake30,30′ and exhaust34,34′ may be positioned in a combination of side and roof positions. For example, the intake30,30′ may be positioned on a sidewall, and the exhaust34,34′ may be positioned on the roof. Similarly, a combination of positions may be utilized for the single point lift access cover plate38,38′. In some embodiments, multiple single point lift access cover plates38,38′ are installed on the generator set10,10′.

As shown inFIG. 2, the cover plate38is fastened to the enclosure14with four fasteners42. As shown inFIG. 3, the cover plate38can be removed to reveal a lift recess or cavity46that is recessed into a side of the enclosure14. A single point lifting hook or ring50is positioned within the cavity46and is structured to provide a single point lift feature when the cover plate38is removed. The cover plate38mitigates noise emission from the lift cavity46when installed, which in some embodiments may be in communication with interior spaces or ducting of the enclosure14. In some embodiments, the cover plate38includes a gasket, sealing member, or sound barrier material that further mitigates noise emission from the lift cavity when the cover plate38is installed. It is noted that this cover plate38and lifting hook50arrangement enables the lifting hook50to be attached to underlying structural elements or be a part of the enclosure14that the modular canopy26covers when attached.

As shown inFIG. 4, the enclosure14further includes a first chamber54in a lower portion of the enclosure14and a second chamber58positioned above and separated from the first chamber54by a wall or floor62. In some embodiments, the first chamber54houses fuel or other components for the generator set10. In some embodiments, the first chamber54is eliminated. An enclosure intake wall66extends the width of the enclosure14and defines an enclosure intake cavity70between an outer or back wall74and the enclosure intake wall66. An enclosure intake aperture78is defined in the enclosure intake wall66and sized to receive an intake manifold, radiator, component, and/or filter82. Although the filter82is shown as an independent component, those of skill in the art will recognize that the filter82can be moved, eliminated, or altered to meet the requirements of the engine18and components22. In some constructions, an air intake manifold of the engine18is structured to engage or cooperate with the enclosure intake aperture78to receive intake air.

An enclosure exhaust wall86extends the width of the enclosure14and defines an enclosure exhaust cavity90between an outer or front wall94and the enclosure exhaust wall86. An enclosure exhaust aperture98is defined in the enclosure exhaust wall86and sized to receive an exhaust manifold, component, and/or filter102. Although the filter102is shown as an independent component, those of skill in the art will recognize that the filter102can be moved, eliminated, or altered to meet the requirements of the engine18and components22. In some constructions, an air exhaust manifold of the engine18is structured to engage or cooperate with the enclosure exhaust aperture98to expel exhaust gases. Additionally, a combination of engine exhaust and exhausting cooling air may exit the enclosure exhaust aperture98and enter the enclosure exhaust cavity90. Further, additional aftertreatment components or mufflers may be positioned or mounted within the enclosure exhaust cavity90, the second cavity58, and/or external to the enclosure14and the modular canopy26, as desired. In some embodiments, sound deadening material or insulation is adhered or otherwise attached to the surfaces of the enclosure exhaust cavity90and is selected to reduce noise while standing up to or inhibiting degradation in the high heat environment of the enclosure exhaust cavity90(i.e., the insulation used in the enclosure exhaust cavity90is heat resistant).

The modular canopy26is structured to couple to the enclosure14and includes a canopy roof103, a first or canopy back wall104, and a second or canopy front wall105. A canopy intake aperture106is defined in the canopy back wall104and is sized to receive a canopy intake filter110to provide the intake30. A canopy intake baffle114extends substantially horizontally from the canopy back wall104adjacent the canopy intake aperture106. A canopy intake floor118is spaced from the canopy intake baffle114and defines a canopy intake exit aperture122sized to communicate with the enclosure intake cavity70. In some embodiments, the canopy intake aperture106, the canopy intake baffle114, the canopy intake floor118and the canopy intake exit aperture122all extend substantially the entire width of the modular canopy26.

A canopy exhaust aperture126is defined in the canopy front wall105and is sized to receive a canopy exhaust filter130to provide the exhaust34. A canopy exhaust baffle134extends substantially horizontally from the canopy front wall105adjacent the canopy exhaust aperture126. A canopy exhaust floor138is spaced from the canopy exhaust baffle134and defines a canopy exhaust entrance aperture142sized to communicate with the enclosure exhaust cavity90. A partition panel146extends substantially the entire width of the modular canopy26and separates the intake30from the exhaust34. The canopy exhaust aperture126, the canopy exhaust baffle134, the canopy exhaust floor138, and the canopy exhaust entrance aperture142all extend substantially the entire width of the modular canopy26.

When the modular canopy26is installed on the enclosure14, the canopy back wall104sealingly engages the enclosure back wall74, the canopy intake floor118sealingly engages the enclosure intake wall66, the canopy exhaust floor138sealingly engages the enclosure exhaust wall86, and the canopy front wall105sealingly engages the enclosure front wall94. The intake30is provided from the canopy intake aperture106, across the canopy intake baffle114to the partition panel146, across the canopy intake floor118to the canopy intake exit aperture122, into the enclosure intake cavity70, and through the enclosure intake aperture78to the second chamber58, the engine18, and/or one or more components22. The exhaust34is provided from the enclosure exhaust aperture98to the enclosure exhaust cavity90, through the canopy exhaust entrance aperture142, across the canopy exhaust floor138to the partition panel146, across the canopy exhaust baffle134, and out the canopy exhaust aperture126. The partition panel146isolates the intake30from the exhaust34.

As shown inFIG. 5A, the enclosure14may be packaged with an enclosure roof148that is fastened or otherwise fixed to the enclosure14to seal the enclosure14from environmental elements or damage. In some embodiments, the enclosure roof148is maintained in place during shipping or movement of the enclosure14. In some embodiments, the enclosure roof148is removed to allow for installation of the modular canopy26. In some embodiments, the enclosure roof148may be modified to accept and mate with the modular canopy26. In some embodiments, the enclosure roof148, front wall94, or back wall74, may be cut or otherwise modified to provide access to the enclosure intake cavity70and the enclosure exhaust cavity90. For example, the enclosure roof148, front wall94, or back wall74, may be cut or otherwise modified to allow operation of the generator set10in the enclosure10as a generator set enclosure without the modular canopy26, or allowing the modular canopy26to be retrofitted at a later date.

As shown inFIG. 5B, the modular canopy26is a separate component from the enclosure14. In some embodiments, the enclosure14originally includes the enclosure roof148for shipping and or component protection. The enclosure roof148is then removed, or, alternatively, left in place, and the modular canopy26coupled to the enclosure14to cover the entire enclosure14. The intake30and the exhaust34extend substantially the full width of the enclosure14and modular canopy26. Utilizing substantially the entire width of the enclosure14and modular canopy26allows the height of the modular canopy26to be reduced while still providing the required airflow for the intake30and the exhaust34. The modular canopy26provides intake and exhaust features on a roof or top portion of the generator set10as opposed to the more typical end placement of intake and exhaust on the walls or sides of generator set enclosures. Although shown inFIGS. 1-6as extending along a substantially entire width of the enclosure14, the modular canopy26can extend along a portion of the enclosure14. For example, in some embodiments, the modular canopy26extends along at least eighty percent (80%) of the width of the enclosure14. Likewise, the canopy intake aperture106, the canopy intake baffle114, the canopy intake floor118and the canopy intake exit aperture122may extend along at least eighty percent (80%) of the width of the enclosure14, or along at least eighty percent (80%) of the width of the modular canopy26. Further, the canopy exhaust aperture126, the canopy exhaust baffle134, the canopy exhaust floor138, and the canopy exhaust entrance aperture142may extend along at least eighty percent (80%) of the width of the enclosure14, or along at least eighty percent (80%) of the width of the modular canopy26.

As shown inFIG. 6, an intake airflow path150follows a circuitous path that is indicated by arrows and flows from the canopy intake aperture106, across the canopy intake baffle114to the partition panel146, across the canopy intake floor118to the canopy intake exit aperture122, into the enclosure intake cavity70, and through the enclosure intake aperture78to the second chamber58, the engine18, and/or one or more components22. An exhaust flow path154follows a circuitous path to baffle noise and prevent line of sight noise transmission from the source that is indicated by arrows and flows from the enclosure exhaust aperture98to the enclosure exhaust cavity90, through the canopy exhaust entrance aperture142, across the canopy exhaust floor138to the partition panel146, across the canopy exhaust baffle134, and out the canopy exhaust aperture126. The partition panel146isolates the intake30from the exhaust34. In this application, “circuitous” means a path that travels in a first direction, then later in at least one place travels in a second direction that is substantially opposite the first direction. In the illustrated embodiment, the intake air flow path150flows to the right inFIG. 6on a top side of the intake baffle114, then to the left on a bottom side of the intake baffle114. In some embodiments, the flow paths are reversed from those shown. In other words, components could be rearranged to provide a circuitous path in the second direction, then the first direction, or in other directions oblique to the first and second directions.

Acoustic barrier and/or absorbtive material may advantageously be added in strategic positions within the intake30, the exhaust34, and/or with the second chamber58to absorb and damp sound to further reduce noise emissions. In some embodiments, the acoustic barrier material is adhered or attached to surfaces of the canopy intake baffle114, the canopy intake floor118, the enclosure intake cavity70, the second chamber58, the enclosure exhaust cavity90, the canopy exhaust floor138, the canopy exhaust baffle134, the partition146, or any combination of locations. In some embodiments, more than one type of acoustic barrier material is used. For example, heat resistant acoustic barrier material may be installed within the enclosure exhaust cavity90where high heat may be a concern. In some embodiments, acoustic barrier material is bonded to all the surfaces within the modular canopy26to reduce noise emission from the intake30and the exhaust34.

The low noise enclosure system reduces noise emissions to sixty-five A-weighted decibels (65 dB(A)) or less at one meter (1 m) and provides a low cost, and simple to implement solution. The modular canopy26can be retrofitted to existing enclosures and provide the noise emission reduction benefits.

Applicant has identified that noise quality affects the perceived loudness of noise emissions. In this case, noise quality is defined by a frequency or frequency range. The low noise enclosure system can be tuned to reduce undesirable frequencies or frequency ranges and improve the noise quality. The dimensions of the modular canopy26including the width of the canopy intake baffle114and the canopy exhaust baffle134, the height of the partition panel146, the size of the canopy intake aperture106and the canopy exhaust aperture126, and other dimensional components can be altered in order to tune the system to avoid or reduce undesirable frequencies. Additionally, the modular canopy26can be constructed with relatively thin material. In some embodiments, the modular canopy includes a frame that is covered in sheet metal. In some embodiments, the sheet metal defines a 1.6 millimeter (1.6 mm) or greater thickness. In some embodiments, the sheet metal is about three millimeters (3 mm) thick. In some embodiments, the sheet metal is less than six millimeters (6 mm) thick. In some embodiments, a 10-16 gauge sheet metal is used. Both ferrous and non-ferrous metals and alloys may be suitable in addition to non-metallic materials such as fiberglass, molded plastic, and glass reinforced plastics.

No claim element herein is to be construed under the provisions of 35 U.S.C. § 112(f), unless the element is expressly recited using the phrase “means for.”

For the purpose of this disclosure, the term “coupled” means the joining or linking of two members directly or indirectly to one another. Such joining may be stationary or moveable in nature. For example, a propeller shaft of an engine “coupled” to a transmission represents a moveable coupling. Such joining may be achieved with the two members or the two members and any additional intermediate members.