NVH reduction in a Diesel powered power generator

A very unique project.  A customer bought a crude diesel generator to us and asked us to reduce the NVh levels and make it more mobile. We proposed 4 designs and the customer selected the one in the photographs. The alternator and engine were joined together using 2 clam like housings. One half of the housing was fixed on the engine while the other was on the alternator. The 2 halves were joined together with 15 M12, nickel plated Allen bolts. The 2 bearing design of the alternator was converted into a single bearing one by cutting the excess shaft from the rotor by lathe machining. Once both housings were joined the engine and alternator were a single unit. The housings were sand cast cast iron with wooden patterns. Power was transmitted from engine to alternator through a Fenner Lovejoy coupling. The whole engine+alternator combo was mounted on a pallet truck with rubber anti-vibration mounts in between. Pallet truck ensured more mobility, cast iron housings, vibro isolators ensured significant reduction of NVH levels.

Wheelchair Hub Gearbox

A planetary gearbox mounted inside the hub of a wheelchair wheel. The axle passed through the center of hub. Converted a single speed manual gearbox into a 2 speed wheelchair. A second handrail was connected to the center gear thereby stepping up torque. This second hand rail was used for inclines. The whole gearbox was less than 2 inches in thickness.

Hydraulic Cylinder assembly workstation

Complete workstation for assembly of a tractor's hydraulic cylinder. Assembly consisted of hydraulic cylinder, piston with O ring and a circlip. Consisted of custom designed input trolleys, bins, pneumatic presses, fixtures, poke yoke systems, output trolleys, etc. Faced challenges due to high variations in the dimensions of hydraulic cylinder which was because unfinished sand cast exterior. Detailed pre design study ensured the operator never had to lift the component at any stage of assembly including when transferring from station to output trolley.

Cam shaft press

Simple pneumatic press for insertion of circlip and key into automotive engine camshaft. Faced challenges  in orienting perfectly round camshaft for key insertion. Used Janatics pneumatics and Omron PLCs.