Patent ID: 12209530

Reference is made to the accompanying drawings throughout the following detailed description. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.

DETAILED DESCRIPTION

Following below are more detailed descriptions of various concepts related to, and implementations of systems and methods of a hybrid electric powertrain without the use of expensive and hard to find equipment. Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

According to various example embodiments, the systems and methods disclosed herein relate to chassis assembly. The chassis assembly can be configured to support a generator set (“genset”) and house or define a fuel tank configured to store fuel used to power the genset. The chassis assembly includes a pair of side rails with a fuel tank disposed therebetween. The chassis assembly includes at least one crossmember that extends between the side rails to provide additional support for the genset. The at least one crossmember is disposed at least partially in the fuel tank. Thus, the crossmember can contribute no additional height to the chassis assembly. The lack of additional height can maintain a lower center of gravity of the genset, and allow the fuel tank to occupy more space between the side rails. Accordingly, the storage capacity of the fuel tank can be increased without increasing the footprint of the chassis assembly.

The at least one crossmember includes a top plate that forms a part of or is coupled with the top surface of the fuel tank. For example, the at least one crossmember can be either fully submerged in the fuel tank such that the top plate interfaces with an inner surface of the top surface of the fuel tank. Alternatively, the at least one crossmember can be partially submerged such that the top plate forms a part of the top surface and sidewalls of the crossmember are disposed in the fuel tank. With the top plate forming a part of the top surface, the top surface can include the top plates and other panels sealably coupled together (e.g., welded) to reduce leakage of fuel. In particular, fuel can be prevented from exiting the fuel tank via the top surface.

The sidewalls of the crossmember can include at least one opening to allow fluid to flow therethrough. For example, the top plate and the sidewalls of the crossmember can form a channel in the fuel tank. As fuel fills the fuel tank, an air pocket may form in the channel. The openings allow the air in the channel to escape the channel to allow the fuel to fill the channels. The openings may be disposed proximate to the top plate of the crossmember to minimize the amount of air to be trapped in the channel and maximize the storage space for the fuel. Hence, air pocket formation can be reduced.

The top plate of the at least one crossmember can include at least one pocket. The pocket may be configured to couple an external component (e.g., an anti-vibration mount) with the at least one cross-member. The pocket can be sealably coupled (e.g., welded) with the top plate to prevent fuel from exiting the fuel tank via the interface between the top plate and the pocket. The pocket can extend into the channel of the crossmember and into the fuel tank.

Referring toFIGS.1and2, a perspective view and a top view of a chassis assembly100for a generator set (“genset”) are shown, according to an example embodiment. The chassis assembly100is a structural support system configured to support a genset. For example, a genset can be disposed on the chassis assembly100. The chassis assembly100includes a frame105. The frame105includes at least one side member, shown as side rail110. The side rail110can extend a length of the chassis assembly100. The frame105can include at least one end member115. The end member115can extend a width of the chassis assembly100.

The frame105can include a first side rail110and a second side rail110. The end member115can extend between the first side rail110and the second side rail110. For example, the first side rail110can be positioned away from the second side rail110. For example, the first side rail110can be parallel to and spaced apart from the second side rail110. A first end of the end member115can couple with the first side rail110and a second end of the end member115can couple with the second side rail110. The end member115can couple with a side rail110at an end of the side rail110. The frame105can include a plurality of end members115. For example, the frame105can include a first or front end member115and a second or rear end member115. The front and rear end members115can extend between the first and second side rails110. The front end member115can couple with a front end of the side rails110and the rear end member11can couple with a rear end of the side rails110.

The frame105can define a cavity120. For example, two end members115coupled with and disposed between two side rails110can define the cavity120. As described in more detail herein, at least a portion of the cavity120can be used as a fuel tank125. The fuel tank125is disposed between the first side rail110and the second side rail110. The fuel tank125can store fuel to power the genset that is supported by the chassis assembly100. The fuel tank125can extend along at least a portion of the frame105. The side rails110can be the sides of the fuel tank125.

The chassis assembly100includes at least one structural support member, shown as crossmember130. The crossmember130can be configured to provide additional support for the genset. For example, the crossmember130can spread the load from the genset to the side rails110. The crossmember130is disposed at least partially in the fuel tank125of the chassis assembly100. The crossmember130can extend between and couple with the side rails110. For example, a first end of the crossmember130can couple with a first side rail110and a second end of the crossmember130can couple with a second side rail110. In some embodiments, the ends of the crossmember130are welded to the side rails110. The chassis assembly100can include a plurality of crossmembers130. For example, the chassis assembly100can include two, three, four, or more crossmembers130. In some embodiments, different crossmembers130can support different components of a genset. For example, a first crossmember130can be configured to support a first component (e.g., an engine) of the genset and a second crossmember130can be configured to support a second component (e.g., a generator or alternator) of the genset.

The chassis assembly100includes a top surface135. The top surface135can be configured to support the genset. For example, the genset can be disposed on the top surface135of the chassis assembly100. The top surface135can be the top of the fuel tank125. The top surface135can extend between the first side rail110and the second side rail110. The top surface135can include at least one panel140. The panel140can be a flat and thin piece of material (e.g., sheet metal) to create at least a portion of the top surface135. The top surface135can include a plurality of panels140. The panels140can be coupled together to form the top surface135. For example, the panels140can be welded together.

In some embodiments, the top surface135can also include a portion of a crossmember130. For example, as described in more detail herein, a top portion of the crossmember130can form a portion of the top surface135. In such embodiment, a panel140can couple with the top portion of the crossmember130to form the top surface135. For example, a panel140can be welded to the crossmember130. In some embodiments, the top surface135can include a plurality of panels140and portions of a plurality of crossmembers130. At least one panel140can be disposed between each crossmember130. The panels140and the crossmember130can be sealably coupled together (e.g., welded together) to form the top surface135.

The chassis assembly100may include at least one other structural support member, shown as external crossmember145. The external crossmember145can be disposed outside of the fuel tank125. The external crossmember145can be the same as the crossmember130or can be different. For example, the size, the shape, the number and type of openings, or other features of the external crossmember145can be the same or different than the crossmember130.

Referring toFIGS.3and4, a bottom perspective view and a top view of a crossmember130are shown, according to an example embodiment. The crossmember130has a top portion, shown as top plate305. The crossmember130has at least one sidewall310extending from the top plate305. In some embodiments, the crossmember130can be curved. For example, the crossmember130can have a C-shape. For example, the crossmember130can have a first sidewall310extending from a first edge of the top plate305and a second sidewall310extending from a second edge of the top plate305. The sidewalls310can be coupled with or integral (e.g., monolithic) with the top plate305. For example, the sidewalls310and the top plate305can be formed from a single component, with the sidewalls310being bent to extend in the same direction from the top plate305to form the C-shape.

The sidewalls310can have a first edge, shown as top edge315, and a second edge, shown as bottom edge320. The top edge315can be the edge of the sidewall310that couples with or is integral with (e.g., transitions into) the top plate305. The bottom edge320can be the edge of the sidewall310opposite the top edge315and spaced apart from the top plate305. The crossmember130can include a transition portion325. The transition portion325can be disposed between the top plate305and the sidewall310. For example, the transition portion325can be a bent portion that transitions the top plate305into the sidewall310. The transition portion325can be a joint or coupling mechanism that couples the sidewall310with the top plate305.

In some embodiments, all the crossmembers130can have the same configuration (e.g. a C-shape). In some embodiments, crossmembers130can have different configurations or shapes. For example, a first crossmember130can have a first shape and a second crossmember130can have a second shape. For example, a first crossmember130can have a C-shape. A second crossmember130can have a top hat shape (e.g., a flange extends from a free edge of both sidewalls310away from each other). The shape of the crossmember130can be based on the amount of load the crossmember130is to support. For example, a crossmember130with a first shape can be configured to support a greater load than a crossmember130with a second shape.

The crossmember130can define a channel330. The channel330can be defined by the top plate305, a first sidewall310, and a second sidewall310. The channel330can extend a length of the crossmember130.

The crossmember130includes at least one opening335. The opening335can extend through the crossmember130to fluidly couple the channel330with the environment external to the crossmember130. The opening335can be a vent for fluid (e.g., air) to exit the channel330. For example, the opening335can be configured for fluid to flow through. The opening335can be any shape or size. For example, the opening335can be a circle or square or can have an elongated shape, among others. The sidewall310of the crossmember130defines at least one opening335. The opening335can extend through the sidewall310. The opening335can be positioned closer to the top edge315of the sidewall310than the bottom edge320. In some embodiments, the opening335is positioned as close to the top plate305as possible. For example, the opening335can be positioned at the top edge315of the sidewall310. The opening335can be positioned in the transition portion325of the crossmember130.

The crossmember130can include a plurality of openings335. For example, a plurality of openings335can be disposed along the length of the crossmember130. A plurality of openings335can be disposed along a sidewall310of the crossmember130. A first opening or a first plurality of openings335can be disposed on a first sidewall310and a second opening335or a second plurality of openings335can be disposed on a second sidewall310. The openings335can be disposed adjacent to the top plate305of the crossmember130.

The crossmember130can include at least one pocket340. The pocket340can be configured to receive a projection of an external component. For example, the pocket340can be a projection that extends from the top plate305of the crossmember130into the channel330. The pocket340can be configured to receive the projection from the external component. For example, the pocket340can define a cavity configure to receive the projection. A depth of the pocket340can be based on a length of the projection to be disposed in the pocket340. The pocket340can be a closed pocket340. For example, the cavity defined by the pocket340can not be exposed to the channel330to prevent any fluid or material from within the channel from entering the pocket340. The pocket340can be coupled with the top plate305of the crossmember130. For example, the pocket340can be welded or bonded with the top plate305, or otherwise secured to the top plate305. The pocket340can be coupled with the top plate305such that no fluid or material from within the channel330can exit the channel330via the interface between the pocket340and the top plate305.

The crossmember130can have a plurality of pockets340. The number of pockets340can be based on the number of external components to be coupled with or disposed on the crossmember130. The pockets340can be disposed along the top plate305of the crossmember130.

Referring now toFIG.5, a front view of the crossmember130is shown, according to an example embodiment. The pocket340can extend into the channel330of the crossmember130. The pocket340can extend perpendicular to the top plate305. In some embodiments, the chassis assembly100can include an external component505. The external component505can be, for example, an anti-vibration mount. The external component505can include at least one projection510configured to be disposed in the pocket340. The pocket340can be configured to receive a projection510of the external component505. The size and shape of the pocket340can be based on the size and shape of the projection510to be received. The pocket340can be configured to couple the external component505with the crossmember130. For example, the pocket340can include a coupling mechanism515. The coupling mechanism515can be configured to interface with the projection510of the external component505. In some embodiments, the coupling mechanism515can be threads configured to interface with corresponding threads of the projection510. The coupling mechanism515can be any type of mechanism configured to interface with the projection510of the external component505and couple the external component505with the crossmember130.

Referring toFIG.6, a cross-sectional view of a portion of the chassis assembly100is shown, as seen along Section A inFIG.1, according to an example embodiment. A fuel tank125can be formed within the cavity120of the chassis assembly100. For example, the fuel tank125has a top surface135. The top surface135of the fuel tank125is the top surface135of the chassis assembly100. The side rails110of the chassis assembly100can be the sides of the fuel tank125. The chassis assembly100can have additional structural members or tank walls605that define the shape of the fuel tank125within the cavity120.

The chassis assembly100includes at least one crossmember130disposed at least partially in the fuel tank125. Disposing the crossmember130in the fuel tank125can increase the capacity of the fuel tank125, while reducing the overall height. Therefore, the center of gravity of the genset disposed on the chassis assembly100can be lowered relative to the center of gravity if the crossmember130were elevated. For example, the sidewalls310of the crossmember130can be disposed in the fuel tank125. The top plate305of the crossmember130is disposed level with or below the top surface135. For example, in some embodiments, the top plate305of the crossmember130can form a part of the top surface135of the fuel tank125. For example, a panel140of the top surface135can sealably couple with the top plate305of the crossmember130to create the top surface135. In some embodiments, the top surface135can comprise only panels140with the top plate305disposed below the top surface135in the fuel tank125. The top plate305can still be coupled with a panel140, but an inner surface of the panel140.

According to an example embodiment, the fuel tank125includes a top surface135. The top surface135includes a panel140and a top plate305of a crossmember130. The top plate305is coupled with the panel140. The crossmember130includes the top plate305. The crossmember130includes a first sidewall310extending from a first edge of the top plate305and a second sidewall310extending from a second edge of the top plate305. The first sidewall310and the second sidewall310extend in the same direction from the top plate305. The first sidewall310has a first opening335and the second sidewall310has a second opening335. The first sidewall310, the first opening335, the second sidewall310, and the second opening335are disposed in the fuel tank125.

In some embodiments, the top surface135comprises a plurality of panels140and a plurality of top plates305of a plurality of crossmembers130. At least one of the plurality of panels140can be disposed between each of the plurality of top plates305. The plurality of panels140can be sealably coupled with the plurality of top plates305to create the top surface135of the fuel tank125.

The chassis assembly100can may include a plurality of crossmembers130comprising a plurality of top plates305. The top surface135of the fuel tank125can include a plurality of panels140coupled with the plurality of top plates305. The panels140can be sealably coupled with the top plates305to prevent fuel from leaking out of the fuel tank125via the top surface135.

The sidewalls310are disposed in the fuel tank125such that the crossmember130can define a channel330within the fuel tank125. The openings335of the crossmember130can be disposed on the sidewalls310of the crossmember130such that the openings335are disposed in the fuel tank125. The openings335can be disposed as close to the top plate305or the top surface135as possible. For example, as fuel fills the fuel tank125, fuel can begin to fill the channel330of the crossmembers130. The openings335can provide a path for air to exit from the channel330as fuel fills the channel330. The openings335can allow the fluid to flow therethrough to reduce or prevent air pocket formation within the channel330. Further, the openings335can allow fuel to fill the channel330to create additional available space for fuel, thus increasing the fuel capacity of the fuel tank125.

The pocket340of the crossmember130can be disposed in the fuel tank125. The pocket can be configured to reduce leakage of fuel from the fuel tank125. For example, the pocket340can be a closed pocket340to prevent leakage from the fuel tank125via the interface between the pocket340and the top plate305of the crossmember130. In some embodiments, the pocket340can be welded to the top plate305to reduce leakage of fuel from the fuel tank125. In particular, the pocket340can be welded to the top plate.

The chassis assembly100may include a plurality of crossmembers130. The plurality of crossmembers130can be disposed at least partially in the fuel tank125. For example, as shown inFIG.4, a first crossmember130can be disposed at a first position in the fuel tank125and a second crossmember130can be disposed at a second position in the fuel tank125. The top plate305of the first crossmember130and a top plate305of the second crossmember130can be portions of the top surface135of the fuel tank125. Any number of crossmembers130can be disposed at least partially inside the fuel tank125.

In some embodiments, the chassis assembly100may include at least one external crossmember145. In some embodiments, the external crossmember145disposed external to the fuel tank125can be different than the crossmembers130disposed in the fuel tank125. For example, the crossmembers130may have a C-shape, have at least one pocket340, and have at least one opening335. The external crossmember145may have a top hat shape, and may not have a pocket340or an opening335, or may only have one of a pocket340or an opening335. In some embodiments, the external crossmember145can be the same as the crossmember130.

Referring toFIG.7, a method700of assembling a chassis assembly100for a generator set is shown, according to an example embodiment, wherein the chassis assembly100includes at least one crossmember130. Method700includes positioning at least a portion of the at least one crossmember130in a fuel tank125(step705). The fuel tank125has a top surface135. The crossmember130includes at top plate305disposed level with or below the top surface135of the fuel tank125. The crossmember includes a sidewall310that extends from the top plate305. The sidewall310includes at least one opening335for fluid to flow through.

In some embodiments, step705can include sealably coupling a panel140of the top surface135of the fuel tank125with the top plate305of the crossmember130. The panel140and the top plate305can be disposed between a first side rail110and a second side rail110.

In some embodiments, method700can include coupling a pocket340to the top plate305of the crossmember130. For example, the pocket340can be welded or bonded to the top plate305, or otherwise secured to the top plate305. The pocket340can extend into a channel330defined by the crossmember130from the top plate305. The pocket340can be configured to receive a projection510of an external component505to couple the external component505with the crossmember130. For example, method700can include coupling the external component505with the crossmember130via the pocket340. The pocket340can be provided with a coupling mechanism515configured to interface with the projection510of the external component505. In some embodiments, the external component505can be an antivibration mount.

In some embodiments, method700includes positioning an opening335of a sidewall310of the crossmember130adjacent to the top plate305of the crossmember130.

Method700includes inserting the sidewall310of the at least one crossmember130in the fuel tank125(step710). In some embodiments, the crossmember130can include a plurality of sidewalls310. Each of the sidewalls130can be disposed in the fuel tank125.

Method700includes coupling the at least one crossmember130with a first side rail110and a second side rail110(step715). In some embodiments, step715can include coupling the crossmember130with the first side rail110and the second side rail110. For example, the crossmember130can be welded, bonded, or otherwise secured to the first side rail110and the second side rail110. In some embodiments, the panel140and the top plate305can be coupled with the first side rail110and the second side rail110.

In some embodiments, method700can include providing a plurality of crossmembers130, including a first crossmember130and a second crossmember. The first crossmember130can be disposed at least partially in the fuel tank125such that a top plate305of the first crossmember130is level with a panel140of the top surface135of the fuel tank125. The top plate305can be coupled with the panel140to create the top surface135of the fuel tank125. The second crossmember130can be disposed external to the fuel tank125.

As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using one or more separate intervening members, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic. For example, circuit A communicably “coupled” to circuit B may signify that the circuit A communicates directly with circuit B (i.e., no intermediary) or communicates indirectly with circuit B (e.g., through one or more intermediaries).

References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

It is important to note that the construction and arrangement of the flexible hybrid system100as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.