Generator set integrated gearbox

A gearbox for coupling a crankshaft of an engine to a generator shaft of a generator, comprising:

• a gearbox housing having a first end and a second end, the first end structured to couple to an engine first end of the engine and the second end structured to couple to a generator first end of the generator, the gear box housing structured to be positioned on and rigidly coupled to a skid frame, the gearbox further including
• a first flange rigidly coupling the first end of the gearbox housing to the engine first end, and
• a second flange rigidly coupling the second end of the gearbox housing to the generator first end,
• wherein at least one of the first flange or the second flange includes an adaptor, the adaptor including a first piece and a second piece removably coupled to each other, at least one of the first piece or the second piece removable to allow access to a coupling positioned therewithin;
• and
• a gear set including a plurality of gears, a first gear shaft and a second gear shaft, the first gear shaft structured to couple to a crank shaft first end of the crankshaft, and a second gear shaft structured to couple to a generator shaft first end of the generator shaft such that the crankshaft, at least a portion of the plurality of gears, and the generator shaft are axially aligned when the gearbox is coupled to the engine and generator.

A method of coupling a crankshaft of an engine to a generator shaft of a generator, comprising:

• providing a gear box, the gearbox including a gearbox housing having a first end and a second end, and a gear set including a plurality of gears, a first gear shaft and a second gear shaft;
• coupling the first end of the gearbox housing to an engine first end of the engine;
• coupling the first gear shaft to a crankshaft first end of the crankshaft, at least a portion of the plurality of gears axially aligned with the crankshaft;
• coupling the second end of the gearbox housing to a generator first end of the generator;
• coupling the second gear shaft to a generator shaft;
• and
• positioning each of the engine, the generator and the gearbox on a skid frame, the engine, the gearbox and the generator rigidly coupled to the skid frame,
• wherein the coupling of the first gear shaft to the crankshaft and the second gear shaft to the generator shaft causes the crankshaft, at least a portion of the plurality of gears and the crankshaft to be axially aligned so that that the engine, the gearbox and the generator form a rigid torque tube structure, and
• wherein at least one of coupling the first end of the gearbox housing to the engine first end of the engine and coupling the second end of the gearbox housing to the generator first end of the generator includes coupling with an adaptor, the adaptor including a first piece and a second piece removably coupled to each other, at least one of the first piece or the second piece removable to allow access to a coupling positioned therewithin.

A generator set, comprising:

• an engine including a crankshaft rotatable in a first direction about a longitudinal axis of the generator set;
• a generator including a generator shaft;
• a gearbox positioned between the engine and the generator and coupling the crankshaft to the generator shaft, the gearbox comprising:
• a gearbox housing having a first end and a second end,
• a first flange rigidly coupling the first end of the gearbox housing to an engine first end of the engine,
• a second flange rigidly coupling the second end of the gearbox housing to a generator first end of the generator, and
• a gear set including a plurality of gears, a first gear shaft coupled to a crankshaft first end of the crankshaft, and a second gear shaft coupled to a generator shaft first end of the generator shaft,
• wherein at least one of the first flange or the second flange includes an adaptor, the adaptor including a first piece and a second piece removably coupled to each other, at least one of the first piece or the second piece removable to allow access to a coupling positioned therewithin;
• and
• a skid frame, each of the engine and the generator positioned on and rigidly coupled to the skid frame.