Patent Publication Number: US-2021164370-A1

Title: Low noise enclosure

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. patent application Ser. No. 15/938,253, filed on Mar. 28, 2018, the entire contents of which are incorporated herein by reference. 
    
    
     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. 
     These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1A  is a top, front, left perspective view of a generator set according to some embodiments; 
         FIG. 1B  is a top, front, left perspective view of a generator set according to some embodiments; 
         FIG. 2  is a detail view of the generator set of  FIG. 1A  taken within a line  2 - 2  of  FIG. 1A ; 
         FIG. 3  is a detail view of the generator set of  FIG. 1A  taken within the line  2 - 2  of  FIG. 1A  with a hook cover removed; 
         FIG. 4  is section view of the generator set of  FIG. 1A  taken along a line  4 - 4  of  FIG. 1A ; 
         FIG. 5A  is a section view of the generator set of  FIG. 1A  taken along a line  4 - 4  of  FIG. 1A  with a roof installed, according to some embodiments; 
         FIG. 5B  is a partially exploded section view of the generator set of  FIG. 1A  taken along a line  4 - 4  of  FIG. 1A  with generator set components removed; and 
         FIG. 6  is a section view of the generator set of  FIG. 1A  taken along a line  4 - 4  of  FIG. 1A . 
     
    
    
     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 in  FIG. 1A , a generator set  10  having a low noise enclosure system includes an enclosure  14  that houses an engine  18  and other generator set components  22 , and a modular canopy  26  that is coupled to the enclosure  14  and provides an intake  30  (see  FIG. 4 ) and an exhaust  34  for the enclosure  14 . The enclosure  14  includes a single point lift access cover plate  38 . The generator set  10  includes the intake  30  and the exhaust  34  positioned at opposite ends from one another such that air enters the intake  30 , flows through and/or across the engine  18  and generator set components  22 , and exits the exhaust  34  in a generally linear direction (e.g., generally left to right in  FIG. 1A ). It is noted that in some embodiments air flows through the enclosure  14  across the generator set components  22  first (in particular, electrical components, such as an alternator, or generator, or control or connection circuits), and then the engine  18  and any cooling system or radiator (not shown). In other embodiments intake air flows initially through or across the cooling system and engine  18  and then the generator set components  22 . In some embodiments, the intake  30  and the exhaust  34  are positioned on the end walls of the modular canopy  26 . In some embodiments, the single point lift access cover plate  38  is positioned on a front wall of the enclosure  14 . 
     As shown in  FIG. 1B , a generator set  10 ′ that is similar to the generator set  10  described above with respect to  FIG. 1A  and labelled with like numbers in the prime series, includes an intake  30 ′ and an exhaust  34 ′ positioned on a top or roof of the modular canopy  26 . Additionally, a single point lift access cover plate  38 ′ is positioned on the roof of the modular canopy  26 . In some embodiments, the intake  30 ,  30 ′ and exhaust  34 ,  34 ′ may be positioned in a combination of side and roof positions. For example, the intake  30 ,  30 ′ may be positioned on a sidewall, and the exhaust  34 ,  34 ′ may be positioned on the roof. Similarly, a combination of positions may be utilized for the single point lift access cover plate  38 ,  38 ′. In some embodiments, multiple single point lift access cover plates  38 ,  38 ′ are installed on the generator set  10 ,  10 ′. 
     As shown in  FIG. 2 , the cover plate  38  is fastened to the enclosure  14  with four fasteners  42 . As shown in  FIG. 3 , the cover plate  38  can be removed to reveal a lift recess or cavity  46  that is recessed into a side of the enclosure  14 . A single point lifting hook or ring  50  is positioned within the cavity  46  and is structured to provide a single point lift feature when the cover plate  38  is removed. The cover plate  38  mitigates noise emission from the lift cavity  46  when installed, which in some embodiments may be in communication with interior spaces or ducting of the enclosure  14 . In some embodiments, the cover plate  38  includes a gasket, sealing member, or sound barrier material that further mitigates noise emission from the lift cavity when the cover plate  38  is installed. It is noted that this cover plate  38  and lifting hook  50  arrangement enables the lifting hook  50  to be attached to underlying structural elements or be a part of the enclosure  14  that the modular canopy  26  covers when attached. 
     As shown in  FIG. 4 , the enclosure  14  further includes a first chamber  54  in a lower portion of the enclosure  14  and a second chamber  58  positioned above and separated from the first chamber  54  by a wall or floor  62 . In some embodiments, the first chamber  54  houses fuel or other components for the generator set  10 . In some embodiments, the first chamber  54  is eliminated. An enclosure intake wall  66  extends the width of the enclosure  14  and defines an enclosure intake cavity  70  between an outer or back wall  74  and the enclosure intake wall  66 . An enclosure intake aperture  78  is defined in the enclosure intake wall  66  and sized to receive an intake manifold, radiator, component, and/or filter  82 . Although the filter  82  is shown as an independent component, those of skill in the art will recognize that the filter  82  can be moved, eliminated, or altered to meet the requirements of the engine  18  and components  22 . In some constructions, an air intake manifold of the engine  18  is structured to engage or cooperate with the enclosure intake aperture  78  to receive intake air. 
     An enclosure exhaust wall  86  extends the width of the enclosure  14  and defines an enclosure exhaust cavity  90  between an outer or front wall  94  and the enclosure exhaust wall  86 . An enclosure exhaust aperture  98  is defined in the enclosure exhaust wall  86  and sized to receive an exhaust manifold, component, and/or filter  102 . Although the filter  102  is shown as an independent component, those of skill in the art will recognize that the filter  102  can be moved, eliminated, or altered to meet the requirements of the engine  18  and components  22 . In some constructions, an air exhaust manifold of the engine  18  is structured to engage or cooperate with the enclosure exhaust aperture  98  to expel exhaust gases. Additionally, a combination of engine exhaust and exhausting cooling air may exit the enclosure exhaust aperture  98  and enter the enclosure exhaust cavity  90 . Further, additional aftertreatment components or mufflers may be positioned or mounted within the enclosure exhaust cavity  90 , the second cavity  58 , and/or external to the enclosure  14  and the modular canopy  26 , as desired. In some embodiments, sound deadening material or insulation is adhered or otherwise attached to the surfaces of the enclosure exhaust cavity  90  and is selected to reduce noise while standing up to or inhibiting degradation in the high heat environment of the enclosure exhaust cavity  90  (i.e., the insulation used in the enclosure exhaust cavity  90  is heat resistant). 
     The modular canopy  26  is structured to couple to the enclosure  14  and includes a canopy roof  103 , a first or canopy back wall  104 , and a second or canopy front wall  105 . A canopy intake aperture  106  is defined in the canopy back wall  104  and is sized to receive a canopy intake filter  110  to provide the intake  30 . A canopy intake baffle  114  extends substantially horizontally from the canopy back wall  104  adjacent the canopy intake aperture  106 . A canopy intake floor  118  is spaced from the canopy intake baffle  114  and defines a canopy intake exit aperture  122  sized to communicate with the enclosure intake cavity  70 . In some embodiments, the canopy intake aperture  106 , the canopy intake baffle  114 , the canopy intake floor  118  and the canopy intake exit aperture  122  all extend substantially the entire width of the modular canopy  26 . 
     A canopy exhaust aperture  126  is defined in the canopy front wall  105  and is sized to receive a canopy exhaust filter  130  to provide the exhaust  34 . A canopy exhaust baffle  134  extends substantially horizontally from the canopy front wall  105  adjacent the canopy exhaust aperture  126 . A canopy exhaust floor  138  is spaced from the canopy exhaust baffle  134  and defines a canopy exhaust entrance aperture  142  sized to communicate with the enclosure exhaust cavity  90 . A partition panel  146  extends substantially the entire width of the modular canopy  26  and separates the intake  30  from the exhaust  34 . The canopy exhaust aperture  126 , the canopy exhaust baffle  134 , the canopy exhaust floor  138 , and the canopy exhaust entrance aperture  142  all extend substantially the entire width of the modular canopy  26 . 
     When the modular canopy  26  is installed on the enclosure  14 , the canopy back wall  104  sealingly engages the enclosure back wall  74 , the canopy intake floor  118  sealingly engages the enclosure intake wall  66 , the canopy exhaust floor  138  sealingly engages the enclosure exhaust wall  86 , and the canopy front wall  105  sealingly engages the enclosure front wall  94 . The intake  30  is provided from the canopy intake aperture  106 , across the canopy intake baffle  114  to the partition panel  146 , across the canopy intake floor  118  to the canopy intake exit aperture  122 , into the enclosure intake cavity  70 , and through the enclosure intake aperture  78  to the second chamber  58 , the engine  18 , and/or one or more components  22 . The exhaust  34  is provided from the enclosure exhaust aperture  98  to the enclosure exhaust cavity  90 , through the canopy exhaust entrance aperture  142 , across the canopy exhaust floor  138  to the partition panel  146 , across the canopy exhaust baffle  134 , and out the canopy exhaust aperture  126 . The partition panel  146  isolates the intake  30  from the exhaust  34 . 
     As shown in  FIG. 5A , the enclosure  14  may be packaged with an enclosure roof  148  that is fastened or otherwise fixed to the enclosure  14  to seal the enclosure  14  from environmental elements or damage. In some embodiments, the enclosure roof  148  is maintained in place during shipping or movement of the enclosure  14 . In some embodiments, the enclosure roof  148  is removed to allow for installation of the modular canopy  26 . In some embodiments, the enclosure roof  148  may be modified to accept and mate with the modular canopy  26 . In some embodiments, the enclosure roof  148 , front wall  94 , or back wall  74 , may be cut or otherwise modified to provide access to the enclosure intake cavity  70  and the enclosure exhaust cavity  90 . For example, the enclosure roof  148 , front wall  94 , or back wall  74 , may be cut or otherwise modified to allow operation of the generator set  10  in the enclosure  10  as a generator set enclosure without the modular canopy  26 , or allowing the modular canopy  26  to be retrofitted at a later date. 
     As shown in  FIG. 5B , the modular canopy  26  is a separate component from the enclosure  14 . In some embodiments, the enclosure  14  originally includes the enclosure roof  148  for shipping and or component protection. The enclosure roof  148  is then removed, or, alternatively, left in place, and the modular canopy  26  coupled to the enclosure  14  to cover the entire enclosure  14 . The intake  30  and the exhaust  34  extend substantially the full width of the enclosure  14  and modular canopy  26 . Utilizing substantially the entire width of the enclosure  14  and modular canopy  26  allows the height of the modular canopy  26  to be reduced while still providing the required airflow for the intake  30  and the exhaust  34 . The modular canopy  26  provides intake and exhaust features on a roof or top portion of the generator set  10  as opposed to the more typical end placement of intake and exhaust on the walls or sides of generator set enclosures. Although shown in  FIGS. 1-6  as extending along a substantially entire width of the enclosure  14 , the modular canopy  26  can extend along a portion of the enclosure  14 . For example, in some embodiments, the modular canopy  26  extends along at least eighty percent (80%) of the width of the enclosure  14 . Likewise, the canopy intake aperture  106 , the canopy intake baffle  114 , the canopy intake floor  118  and the canopy intake exit aperture  122  may extend along at least eighty percent (80%) of the width of the enclosure  14 , or along at least eighty percent (80%) of the width of the modular canopy  26 . Further, the canopy exhaust aperture  126 , the canopy exhaust baffle  134 , the canopy exhaust floor  138 , and the canopy exhaust entrance aperture  142  may extend along at least eighty percent (80%) of the width of the enclosure  14 , or along at least eighty percent (80%) of the width of the modular canopy  26 . 
     As shown in  FIG. 6 , an intake airflow path  150  follows a circuitous path that is indicated by arrows and flows from the canopy intake aperture  106 , across the canopy intake baffle  114  to the partition panel  146 , across the canopy intake floor  118  to the canopy intake exit aperture  122 , into the enclosure intake cavity  70 , and through the enclosure intake aperture  78  to the second chamber  58 , the engine  18 , and/or one or more components  22 . An exhaust flow path  154  follows 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 aperture  98  to the enclosure exhaust cavity  90 , through the canopy exhaust entrance aperture  142 , across the canopy exhaust floor  138  to the partition panel  146 , across the canopy exhaust baffle  134 , and out the canopy exhaust aperture  126 . The partition panel  146  isolates the intake  30  from the exhaust  34 . 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 path  150  flows to the right in  FIG. 6  on a top side of the intake baffle  114 , then to the left on a bottom side of the intake baffle  114 . 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 intake  30 , the exhaust  34 , and/or with the second chamber  58  to 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 baffle  114 , the canopy intake floor  118 , the enclosure intake cavity  70 , the second chamber  58 , the enclosure exhaust cavity  90 , the canopy exhaust floor  138 , the canopy exhaust baffle  134 , the partition  146 , 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 cavity  90  where high heat may be a concern. In some embodiments, acoustic barrier material is bonded to all the surfaces within the modular canopy  26  to reduce noise emission from the intake  30  and the exhaust  34 . 
     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 canopy  26  can 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 canopy  26  including the width of the canopy intake baffle  114  and the canopy exhaust baffle  134 , the height of the partition panel  146 , the size of the canopy intake aperture  106  and the canopy exhaust aperture  126 , and other dimensional components can be altered in order to tune the system to avoid or reduce undesirable frequencies. Additionally, the modular canopy  26  can 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. 
     The foregoing description of embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from this disclosure. The embodiments were chosen and described in order to explain the principals of the disclosure and its practical application to enable one skilled in the art to utilize the various embodiments and with various modifications as are suited to the particular use contemplated. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the embodiments without departing from the scope of the present disclosure as expressed in the appended claims. 
     Accordingly, the present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.