Low-noise generator set: Low-noise generator sets are generally divided into ordinary silent box generator sets and container-type low-noise generator sets. The generator sets are generally equipped with diesel engines from well-known domestic and foreign brands such as Cummins, Perkins, Scania, Daewoo, Mitsubishi, Mercedes-Benz, Weichai, Yuchai and Shangchai.

There are some differences in power between ordinary silent box generators and container-type low-noise generator sets:

Power range: The power of ordinary silent box generators is generally around 30kW to 600kW. The power of container-type low-noise generator sets usually covers 500kW to 2500kW. However, the power range of products from different manufacturers may be different.

Common power range: Ordinary silent box generators are more common between tens of kilowatts and hundreds of kilowatts, which are suitable for places where the power requirements are not particularly high and there are certain requirements for noise, such as small factories, commercial shops, schools, etc. Container low-noise generator sets are often used in large industrial sites, mines, oil fields, data centers, airports and other places with high power supply requirements and large power consumption. The common power range is from hundreds of kilowatts to thousands of kilowatts.

In general, the power of ordinary static box generators is relatively small and suitable for some small and medium-sized load scenarios; while container low-noise generator sets have large power and can meet applications with large loads and high power requirements.

Manufacturing process of ordinary silent box generator sets

1. Sound insulation design

EPOWER silent box generator set process, first of all, uses multi-layer composite sound insulation materials at the sound insulation level. The outer layer is made of 2.0-2.5mm national standard cold-rolled steel plate, which is specially treated by zinc washing, phosphating and electrophoresis, and then electrostatically sprayed and cast at high temperature, which not only enhances the anti-corrosion ability, but also has certain sound insulation performance. The interior is treated with high-density flame-retardant high-quality sound-absorbing cotton with a thickness of 50mm: such as glass fiber cotton, sound-absorbing foam, etc., which effectively absorbs and blocks the noise generated by the operation of the unit. The smoke exhaust system is treated with heat insulation cotton and a secondary silencer is installed, and the noise is kept below 80 decibels during operation. For door panels and windows, carbon steel five seamless hinges are used with high-elastic sealing strips, and the gaps are extremely airtight. With high-performance carbon steel door locks, the weather resistance is improved while further enhancing the sound insulation effect.

2. Ventilation and heat dissipation

Good ventilation and heat dissipation is the key to ensure the stable operation of diesel generator sets. The ventilation system design of the EPOWER unit is equipped with independent air inlet and exhaust channels. The air inlet is equipped with a resistive sheet muffler, which can not only meet the ventilation volume requirements but also reduce the air intake noise. The exhaust duct is also equipped with a special muffler to ensure that the normal heat dissipation of the unit is not affected while reducing the exhaust noise. At the same time, the air duct is reasonably arranged inside the box to guide the air to circulate evenly and avoid local overheating. Through strict wind resistance testing, resonance testing and temperature testing, the ventilation and heat dissipation design is optimized to ensure that the unit always works at a suitable ambient temperature.

Three, appearance protection and hoisting

In terms of appearance protection, the overall box adopts standard tooling parts. Each tooling part is stamped and formed at one time, and then connected by high-strength stainless steel 304 material bolts, which greatly improves the overall strength and service life of the product, and can effectively protect the unit in abnormally harsh environments. In terms of hoisting, hoisting points are set at the bottom and top of the box to facilitate transportation, effectively reduce transportation costs, and better protect the unit during transportation.

Fourth, shock absorption and intelligent interconnection

In order to reduce the vibration and resonance during the operation of the unit, mechanical design shock absorption measures are adopted, and the bearing strength components are ribbed. This can not only reduce the impact of the unit's own vibration on the surrounding environment, but also ensure that the unit runs more smoothly and prolongs the service life of the unit. In addition, the introduction of intelligent interconnection technology, drawing on the concept of "EPOWER Intelligent Cloud Platform", realizes remote management and uninterrupted service of the unit through the Internet. Users can monitor the operating status of the unit in real time, such as voltage, current, oil temperature, water temperature and other parameters, timely discover and handle potential faults, ensure that the unit is in the best working state at any time, and meet the requirements of various places for power supply stability and reliability.

Through the above comprehensive solutions, the open diesel generator set is transformed into a high-quality power generation equipment with the characteristics of quietness, efficient heat dissipation, reliable protection, convenient handling and intelligent monitoring, which can meet the power needs of more places with high requirements for noise control and equipment stability.

Container low-noise generator set design specifications and manufacturing process

As a mobile power station, containerized generator sets need to be transported by large means such as cars, ships, and airplanes. Their external dimensions are the same as those of standard containers. There are three specifications of 20ft, 30ft, and 40ft, which are divided into walk-in and non-walk-in. The walk-in type is equipped with facilities such as an operation room, maintenance room, and duty room. The non-walk-in type is compactly designed according to the specifications of the generator set, and is equipped with facilities such as an air intake system, an exhaust system, a high-efficiency muffler, an exhaust system, and an equipment maintenance door. The exterior is made of steel plates, and the interior is made of high-quality sound-absorbing materials. The reasonable environmental design can achieve the effect of reducing shock, and the structure is very stable, which is convenient for lifting and transfer. The internal benchmarking dimensions of the container type vary according to the external dimensions of the relevant main parts. High-performance and high-standard products with reasonable structures can be tailored according to the customer's on-site usage and related requirements.

I. Specifications

The power coverage of container low-noise generator sets is wide. From the perspective of size specifications, 20-foot containers are usually used for generators below 1000kVA, and 40-foot containers are used for generators above 1250kVA. This standardized design complies with the CSC certification of the International Convention for Safe Containers, which facilitates overall sea transportation and greatly reduces transportation costs.

II. Process characteristics

(I) Box structure process

The box is made of 2mm thick steel plate and has good strength and durability. The whole box adopts the overall bending process. This sheet metal processing technology bends the side panels and top panels into shape at one time, reducing welding and splicing. It not only improves the overall strength of the box and ensures stable operation in harsh environments, but also improves the sealing performance, which can effectively prevent rain, snow and dust. At the same time, the overall bending process reduces the number of parts and joints, reduces material consumption and manufacturing costs, and improves production efficiency and product yield. All hinges, locks and bolts are made of stainless steel to enhance corrosion resistance and extend the service life of the equipment.

(II) Noise reduction process

The inner wall of the box is paved with high-frequency, medium-frequency and low-frequency pur-type flame-retardant sound-absorbing cotton to effectively absorb the different frequency noises generated by the operation of the unit. The built-in muffler adopts a high-efficiency resistive muffler to focus on noise reduction of the unit's exhaust port noise, which can effectively control the noise within 1 meter when the unit is running to below 75dB (A), meeting the needs of places with strict noise restrictions, such as residential areas, schools, hospitals, etc.

(III) Ventilation and heat dissipation process

Independent and scientific air inlet and exhaust channels are set up, and a resistive plate muffler is installed at the air inlet. The exhaust channel is also equipped with a special muffler to ensure that the ventilation volume meets the heat dissipation requirements of the unit while reducing the noise of air inlet and exhaust. The air outlet adopts a reflow duct design to optimize the air circulation path, ensure smooth exhaust and heat dissipation, and avoid the unit from overheating and affecting performance and life.

(IV) Other process details

There are two explosion-proof lamps in the box and one explosion-proof lamp on the control panel to facilitate users to operate and maintain the unit inside. The doors can be opened at the front and back, and there are side doors on both sides of the box, with external ladders, providing users with convenient maintenance and inspection channels. The internal floor is paved with anti-slip patterned aluminum plates to enhance safety. The control panel and output switch cabinet are set on the same side of the container to facilitate users' daily operations and output cable connection. The standard configuration of permanent magnet excitation PMG system improves the motor starting ability and enhances the immunity to waveform distortion.