VGU-Mechanical Engineering - Engineering Design

Engineering Design I and II

Instructor: Prof. Dr.-Ing. Karl - H. Grote, karl.grote@ovgu.de

Engineering Design Project

Design of an Instant Auxiliary Power Generator

PURPOSE Maintain electrical power to the designated facility even upon the
interruption of "Utility Company" supplied power with a machine designed to
maintain this electrical continuity. The design of this machine is the focus here.

ABSTRACT Select and design the appropriate machine elements to complete

the instant on auxiliary power generator (referred to as the APU henceforth). The
design will discuss the type of device selected, loading conditions and size
requirements as well as detailed engineering data required for the actual physical
construction of the complete APU.

Figure 1 System configuration with labels

MAJOR TASKS:
- Calculation and design of the shaft, the flywheel and all shaft hub
connections
- Calculation and design of the bearing blocks and bearings for the shaft
and the bottom - frame of the APU
- Calculation and design of the couplings to the generator and the shaft
- Calculation and design of the clutch between the shaft and the diesel -
engine.
APU – SYSTEM:
The APU configuration is shown in Figure 1. The main components are:
1) electric generator
2) electric motor
3) Diesel combustion engine
4) couplings and energy storage components
4.1) coupling
4.2) coupling
4.3) bearing
4.4) flywheel
4.5) bearing
4.6) clutch/coupling
Refer to the figure labels for the component identification.

The method of operation can be described as follows:

A) Clutch open (disengaged) -- normal operation. Electric power (from the
usual utility company) is supplied to the electric motor (2) which turns
it's output shaft, this power also maintains the clutch in the disengaged
position. This shaft turns both an electric generator (1) via a coupling
device and a shaft free to rotate up to the clutch and including the
massive flywheel. This flywheel is used as an energy storage device.
B) Clutch closed (engaged) -- power failure. The power supply is
interrupted which actuates the clutch. This actuation causes the shaft
with the flywheel to make a solid connection with the Diesel engine,
then the power stored in the rotating flywheel is delivered to start the
engine. With the engine working the shaft is driven and continues to
generate power in the electric generator (1).

Given details A B
Diesel - engine output power P [KW] 175 220
running speed (rpm) n [1/min] 1500 1500
Cylinders of Diesel engine (in line) 6 8
weight (mass) of flywheel m [kg] 900 1200