MOBILE GROUND POWER UNIT WITH ENHANCED HOUSING CONCEPT

Abstract

A mobile ground power unit has a housing in which an engine and an electric generator are disposed. The housing features at least one rotor molded or rotor cast component the housing features at least one rotor molded or rotor cast component that serves as an outer shell or part of the outer shell of the housing, whereby the housing features as the at least one rotor molded or rotor cast component one of a canopy covering at least the upper side of the engine and/or the generator a cable tray arranged sideways in relation to the engine and/or the electric generator.

Claims

1. Mobile ground power unit for supplying power to an aircraft parked on the ground, the ground power unit comprising an engine and an electric generator, whereby the electric generator is configured to be driven by the engine, a housing whereby the engine and the electric generator are disposed within the housing, wherein the housing features at least one rotor molded or rotor cast component that serves as an outer shell or part of the outer shell of the housing, whereby the housing features as the at least one rotor molded or rotor cast component one of: a canopy covering at least the upper side of the engine and/or the generator a cable tray arranged sideways in relation to the engine and/or the electric generator.

2. Ground power unit according to claim 1, wherein the canopy comprises an inner wall facing inside the housing and an outer wall facing outside the housing, wherein the inner wall and the outer wall define a hollow space between each other.

3. Ground power unit according to claim 2, wherein the canopy comprises an integrated ducting system, whereby the ducting system comprises an inlet opening within the outer wall of the canopy.

4. Ground power unit according to claim 3, wherein the ducting system comprises an exhaust opening within the inner wall of the canopy.

5. Ground power unit according to claim 4, wherein the exhaust opening is located above and/or at the side of the engine.

6. Ground power unit according to claim 5, wherein the exhaust opening is covered by a heat shield which is permeable to air.

7. Ground power unit according to claim 5, wherein the exhaust opening is surrounded by a seal, which connects to an air intake of the engine.

8. Ground power unit according to claim 1, wherein the cable tray comprises an integrally molded battery compartment.

9. Ground power unit according to claim 1, wherein the ground power unit comprises a fuel tank, wherein the fuel tank comprises a wall that forms at least one channel that allows air to pass from one side of the fuel tank to another side of the fuel tank.

10. Ground power unit according to claim 9, wherein the wall of the fuel tank is surrounding the channel except for an inlet opening and an outlet opening of the channel.

11. Ground power unit according to claim 9, wherein the channel has an inlet on the bottom side of the fuel tank and an outlet on the top side of the fuel tank.

12. Component of a housing for a ground power unit the ground power unit comprising an engine and an electric generator, wherein the electric generator is configured to be driven by the engine, wherein the component is rotor molded or rotor cast and serves as an outer shell or part of the outer shell of the housing, whereby the component is one of: a canopy for covering at least the upper side of the engine and/or the generator a cable tray to be arranged sideways in relation to the engine and/or the electric generator.

13. Method for manufacturing a mobile ground power unit for supplying power to an aircraft parked on the ground, comprising the steps: mounting an engine and an electric generator and connecting the engine and the electric generator such that the electric generator is configured to be driven by the engine; providing a housing for the engine and the electric generator; wherein providing the housing comprises the step: building at least one component of the housing by rotor molding or rotor casting, wherein the at least one component serves as an outer shell or part of the outer shell of the housing, whereby the component is one of: a canopy for covering at least the upper side of the engine and/or the generator a cable tray to be arranged sideways in relation to the engine and/or the electric generator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0078] Embodiments of the present invention will now be described—by way of example only—with reference to the accompanying drawings, whereby

[0079] FIGS. 1a, 1b are sketches of a GPU according to the invention, having rotor molded or rotor cast components,

[0080] FIGS. 2a-2i are drawings of a GPU according to the invention based on FIGS. 1a and 1b incorporating as well many of the advantageous preferred features.

DETAILED DESCRIPTION OF THE DRAWINGS

[0081] FIGS. 1a, 1b are showing a GPU 1 according to the invention, having rotor molded or rotor cast components 31, 31.1, 31.2. The GPU 1 comprises an engine 10 and an electric generator 20. The electric generator 20 is configured to be driven by the engine. The GPU comprises a housing 30 whereby the engine 10 and the electric generator 20 are disposed within the inside of the housing 30, which features at least one rotor molded or rotor cast component 31. FIG. 1a shows an example of a cover—or canopy-like component 31.1 as a side view, FIG. 1b an example of a side tray component 31.2. as back view.

[0082] The GPU 1 is manufactured by mounting the engine 10 and the electric generator 20 and connecting the engine 10 and the electric generator 20 such that the electric generator 20 is configured to be driven by the engine 10. Then a housing 30 is provided for the engine 10 and the electric generator 20, wherein for this, at least one component 31 of the housing 30 is built by rotor molding or rotor casting.

[0083] This allows to build/have a GPU with one or more lightweight, safe and low cost producible housing component.

[0084] FIGS. 2a-2i are showing a GPU 1 according to the invention based on FIGS. 1a and 1b incorporating as well many of the advantageous preferred features. FIG. 2a is a side view, FIG. 2b a frontal view, FIG. 2c and d cross-sectional views, wherein in FIG. 2d, the canopy is retracted, FIG. 2e a bottom view of only the canopy, wherein the approximate position of the section of FIG. 2c and d is marked by a dash-dot-dotted line, FIG. 2f a side view with parts of the cable tray made transparent, FIG. 2g a back view with parts of the housing and canopy made transparent, FIG. 2h a section through the fuel tank and FIG. 2i the complete fuel tank.

[0085] The housing 30 features as the at least one rotor molded or rotor cast component 31 a canopy 31.1 covering at least the upper side of the engine 10 and the generator 20. The canopy 31.1 is configured to be slid off the engine 10 and the generator 20.

[0086] The canopy 31.1 comprises an inner wall 32 facing inside the housing 30 and an outer wall 33 facing outside the housing 30, wherein the inner wall 32 and the outer wall 33 define a hollow space 34 between each other. The outer wall 33 is having an area consisting of a single piece that is covering an upper side—here all the upper side—of the engine 10 and in this case also of the generator 20 and that extends downwards along three different vertical sides of the ground power unit 1. The inner wall 32 features a horizontal area covering the upper side of the engine 10 and is extending from the horizontal area downwards along three vertical sides of the ground power unit 1. The inner wall 32 is opposing the outer wall 33 on more than 75% of the outer wall's 33 inner surface area. The canopy 31.1 consists of one single piece.

[0087] The canopy 31.1 comprises an integrated ducting system 35, whereby the ducting system comprises an inlet opening 35.1 and an inlet opening 35.1′ within the outer wall 33 of the canopy 31.1. The inlet openings 35.1 and 35.1′ are visible in FIG. 2e. They are positioned in a part of the outer wall 33 that is facing downwards, that prevents rain from falling into the duct system. The flow of air through the canopy 31.1 is depicted in FIG. 2c by a dashed arrow in case of the duct system for the engine air intake 11 and by a dash-dotted arrow in case of the duct system for the engine cooling. Those two duct functions are provided by the common hollow space 34 inside the canopy 31.1. The ducting system 35 comprises exhaust openings, i.e. opening 35.2 and opening 35.2′, within the inner wall 32 of the canopy 31.1. The exhaust openings 35.2, 35.2′ are located within the horizontal area of the inner wall 32. The exhaust opening 35.2 is located above the engine and covered by a heat shield 36 which is permeable to air. The exhaust opening 35.2′ is surrounded by a seal 37, which connects to an air intake 11 of the engine 10. The exhaust opening 35.2 is set up for providing cooling air to the surrounding of the engine 10, whereas the exhaust opening 35.2′ is set up to specifically direct air into the air intake 11 of the engine 10. The inlet openings 35.1, 35.1′ are located on one end of the ground power unit 1, wherein this one end is vis-à-vis an other end of the ground power unit 1, wherein the other end of the ground power unit 1 comprises a housing exhaust, set up for letting escape used air out of the housing 30. Ventilator 60, arranged at the housing exhaust, is set up for propelling used air out of the housing 30.

[0088] The housing 30 also features as the at least one rotor molded or rotor cast component 31 two cable trays 31.2, wherein only one is referred by a reference sign, the other is just on the other side of the GPU 1. The tray 31.2 is arranged sideways in relation to the engine 10 and the electric generator 20. The cable tray 31.2 comprises an integrally molded battery compartment 38. A battery 40 is drawn in FIGS. 2f and 2g to show how the battery fits inside the compartment 38 and is thereby protected by the walls of the tray. The compartment 38 is making use of the hollow space in the inside of the tray to accommodate the battery 40. The battery 40 is inserted through a top opening in the tray that is closed by a cover afterwards.

[0089] The GPU 1 further comprises a fuel tank 50, wherein the fuel tank 50 comprises a wall 51 that forms at least one channel 52 that allows air to pass from one side 50.1 of the tank to another side 50.2 of the fuel tank 50. The wall 51 of the fuel tank 50 is surrounding the channel 52 except for an inlet opening 52.1 and an outlet opening 52.2 of the channel 52. The channel 52 has an inlet on the bottom side of the fuel tank 50, which is the side 50.1, and an outlet on the top side of the fuel tank 50, which is the side 50.2. The channel 52 is located in the tank 50 at a position that is below and at one side of the generator 20 such that the generator 20 is in between the channel 52 and a ventilator 60 of the liquid cooling aggregate and therefore, an air stream will hit the generator 20. The channel 52 is furthermore positioned precisely at a generator 20 air intake. In FIG. 2c, the air flow due to the channel 22 is depicted by dashed arrows.

[0090] With this invention, a better housing concept for a GPU is provided. The use of one or more rotor molded/cast components allows for a safer housing, which is also lighter and therefore easier to handle. Furthermore, the parts can be made bigger, as complex shapes can be mold and therefore, the housing does not have to be built out of many little parts. Especially, a canopy and a cable tray are suited for being rotor molded/cast components of the housing, as the canopy may be used as a good sound and collision damping and a ducting system, whereas the cable tray may also function as a bumper and safe housing for the batteries. Furthermore, when combining the canopy with a fuel tank, preferably also rotor molded/cast, with an integrated channel, a very effective air management in the housing is possible. The subject matter described in this application (applicant's reference 65755 (713-3728)) is also connected to further inventions, described in two additional applications marked with applicant's reference 65756 (713-3727) and 65757 (713-3726), which are hereby incorporated by reference.