Super-compact GEN33D Power Generator

A series of questions have been raised at engineering level:
We have been informed of the need to provide power for high-tech auxiliary electronic equipment located in a special vehicle. The equipment has to be able to operate during long daily periods under adverse conditions (high temperatures), with a load of practically 100%.

Its position in the vehicle must ensure that maintenance can only be carried out from one side, as the outer housing is armoured, and only one of the protective covers can be removed. The air outlet must be located on the top, and the air inlet on the bottom, due to the design of the vehicle.

The ultra-compact layout of the cabin and size/power of the motor means that we have to consider a design in parallel to the monoblock, with a power transmission using a toothed belt. The bottom support for the power generator must also be as low as possible to avoid exceeding the necessary height, which means that the crankcase must be at a distance of only 10 mm from the ground, and the bottom support must have an opening so that it can be fitted in place. A series of anti-vibration mountings have been installed to prevent shearing, which are capable of withstanding the movements and acceleration caused by the vehicle during its normal operation.

Finally it has been decided to use a refrigeration system using an oil-cooled motor instead of a more conventional water-cooled motor. These oil-cooled motors can reach much higher operating temperatures, under the same environmental conditions. In a conventional water-cooled motor, the maximum temperature that can be reached by the coolant is normally 100ºC, while in the case of an oil-cooled motor, this temperature can reach 135ºC, which means that the equipment can operate at environmental temperatures of 50ºC without any loss of performance. Also, there are two funnels for channelling the inlet air (cold air from the bottom part) and outlet air (hot air from the upper part), so that the air circulates correctly and cools the equipment properly.

The electrical installation is supplied separately and in different modules, so that it can be integrated into the vehicle’s control panels that allow it to be controlled from the interior, even if the equipment is installed in an external compartment.

Specifications

• The power generator has to be installed in a small compartment measuring only 1105 x 950 x 750 mm (length x width x height).
• We have to adapt the installation to the existing air inlets and cooling air outlets in the vehicle.
• The power generator has to have a power of at least 30 kVA.
• Integration with the vehicle’s electrical system.
• High cooling capacity and ability to work with overloads at high temperatures.
• Capable of withstanding the typical motion of a vehicle of this kind over rugged terrain.

Project summary

Application: auxiliary power generator for special vehicles.
Power: 30 kVA DC, 33 kVA emergency supply.
Special configuration: super-compact power generator.

 Super-compact GEN33D Power Generator