FORM - 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13) Title:
DIESEL GENERATOR FOOTPRINT REDUCTION THROUGH INNOVATIVE DRIVE AND ALTERNATOR
ARRANGEMENT
Applicant:
MAHINDRA & MAHINDRA LIMITED
Automotive & Farm Equipment Sector,
Mahindra Towers, Dr. G.M, Bhosale Marg, Worli, Mumbai,
MAHARASHTRA, INDIA.
Inventors:
1. TANMAY DESHPANDE of P. S. Angan, C1 -1 Magarpatta Road Hadapsar,
Pune- 411013, M.S. - India,
2. RAUT PARAG of Shubham Bungiows, Plot No:3-3, RSC-15, Gorai,
Borivali (W), Mumbai - 400091, M.S.- INDIA., and
3. KRISHNAMOORTHY R. of 302, Z-Wing, 90 Feet Road, Gokul Garden, Thakur
Complex, Kandivli (E), Mumbai- 400101, India.
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE USED.

FIELD OF THE INVENTION
The present invention relates generally to a diesel generator set, particularly a diesel generator set providing footprint reduction and more particularly, a diesel generator set for reducing the footprint thereof through innovative drive and alternator in double decker arrangement.
BACKGROUND ART
A diesel generator set primarily consists of a diesel engine operably connected to an alternator to generate electric power. Diesel generator sets are used as emergency power supply equipment particularly in those places, where an uninterrupted electric supply is not available for running machinery and devices used in information technology (IT) equipment and retail businesses like malls, showrooms and hotels as well for household purposes. In last two decades, tremendous growth has been registered in IT or telecom sector in India and elsewhere. The diesel generator sets are primarily used for running equipment in mobile towers. Although, these mobile towers are powered by electric power supplied by various electricity boards and/or private electric suppliers and distributors, many a times the dependability of their electric supply is wanting, because of power shortages during peak hours.
In the absence of regular electric supply at these mobile towers, often alternative provisions are made for powering them by means of Battery banks. These batteries need to be charged constantly as soon as they are drained below a predefined threshold value as a result of the consumption of electrical energy normally stored therein.

The diesel generator sets generally are used to charge these battery banks. The diesel generator sets also serve to run air conditioner and other equipment available in shelters near mobile towers. Apart from this, there are vast areas in a large developing country like India, where the remoteness of the regions, inaccessible terrains and poor density of populations poses challenges for cost-effectively laying electric power transmission lines. Diesel generator (DG) sets are also a boon for such sites because of their comparably low costs as compared to laying extremely costly electrical power transmission lines, thus making diesel generator sets indispensable at such sites.
In a conventional diesel generator set, the alternator is closely coupled to the engine and both rest at the same level. In such an arrangement, the alternator is provided with a face plate, which can be inserted into the diesel engine flywheel groove and then bolted to secure them together. SAE standard may be referred to for any such arrangement, in which the alternator and the engine are on the same longitudinal axis and at the same level. However, in the above arrangement, the required footprint is quite high in terms of the floor space or area in square feet required for accommodating the DG set. Particularly in metropolitan cities, the cost of buying or renting space is exorbitantly high. Therefore, the capital investment of the customer for placing a DG set increases according to the footprint area of the DG sets. Moreover, such DG sets very difficult to be placed in commercial places, such as Malls, Showrooms, Hotels, Shops and Commercial complexes, where very less space is allotted /available and also because the cost is also much higher than other places in the same city. Therefore, the space constraint is aggravated in all the cases where the available space is very less and the cost of land is also very high.

To address this problem, instead of the conventional closely coupled arrangement, in accordance with the present invention, the alternator is placed above the diesel engine and a canopy with a double decker structure. This structure mainly includes an alternator chassis mounted over an alternator chassis by means of welding or bolting or any other fastening means and supported on a base frame or canopy frame and alternator.
A plurality of anti-vibration mounts (AVM) is also provided to damp the vibration produced during running of the diesel generator set. Thus, the engine and the alternator are not on the same axis, but the shaft axis of the alternator and the engine are parallel to each other and alternator is disposed above the engine. Accordingly, the arrangement of the present invention substantially reduces the footprint of the DG set, i.e. almost by half the length of the engine-alternator assembly of a conventional DG set.
According to the present invention, the alternator chassis is used for mounting the alternator above the engine. An alternator cooling arrangement is also provided on the alternator chassis. This cooling arrangement consists of a passage a suction vent for sucking fresh air through a suction louver and after passing over and around the alternator the heated exhaust air is mixed with the fresh air coming in through the engine side inlet louver and then passes through radiator to be exhausted to the atmosphere.
The geometry of the passage is configured such that it has a smart positioning for mixing hot air with fresh air coming from engine compartment and then passing towards the radiator fan.

Anti-vibration mount (AVM) arrangement for the alternator necessitates an enhanced strength of the overall structure or chassis. This is done by incorporating suitable features for withstanding additional loads, e.g. by placing the alternator on top of the engine and due by the engine mounting arrangement having a single set of AVMs.
As against the rotational speeds (RPM) of the alternator and the engine being the same in a closely coupled conventional DG sets, a belt and pulley arrangement is used for coupling the engine with the alternator disposed above it in accordance with an embodiment of the present invention. In such an arrangement, the rotational speed (RPM) of the alternator can be suitably varied, i.e. the ratio of RPM of the alternator can be maintained much higher than in the conventional DG sets, if desired. Thus, whenever necessary, instead of a 4-pole alternator used in a conventional DG set, a more compact alternator, i.e. a 2-pole can be incorporated. This may also reduce the weight and cost of the alternator, which may in turn leads to a lighter DG set and canopy structure thereof.
The present invention proposes that the rotary coupling (normally made of a casting) is disposed between the pulley and the alternator is replaced by a coupling made of steel duly machined for the belt and pulley arrangement, thereby reducing the lead time while using a cast coupling. A machined coupling is much stronger than the casted one. In another embodiment of the present invention, a micro-V belt or poly-V belt is used as shown in the drawings. However, timing belt or toothed belt (not shown) can also be used in the belt and pulley arrangement to facilitate in achieving zero slippage.

In another embodiment of the present invention, specially designed faceplate is used for connecting the belt and pulley arrangement with the engine shaft. This face place has tapered configuration with steps mating with the flywheel. In accordance with the present invention, the silencer is disposed inside the canopy, which is useful from safety aspects.
Further, in a conventional DG set, only a punched metal sheet is provided on top of the exhaust side of the DG set, often posing a risk of rainwater entering the hot chamber inside the DG set canopy. The novel configuration of the canopy of DG set according to the invention offers the advantage of completely stopping rainwater from entering the hot chamber. This is achieved by especially configuring the canopy of the DG set on the exhaust side, wherein a plurality of downwardly inclined exhaust louvers is provided on the canopy above the exhaust side thereof. The exhaust louvers sequentially overlap the next one disposed below in a downward direction.
This is further ensured by providing a predetermined projection on the lower edge of the upper louvers extending out with respect to the upper edge of the lower louvers, so that rainwater can easily and definitively flow over to the next lower louver, without being leaked inside the hot chamber. In a more preferable embodiment, these louvers are provided in a stepped manner, thereby further enhancing the protection of the DG set from the rainwater.
OBJECTS OF THE INVENTION
Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide a diesel generator set providing footprint reduction through innovative drive and alternator arrangement thereof.
Another object of the present invention is to provide a diesel generator set having a double decker canopy structure of the diesel generator set with a reduced footprint through innovative drive and alternator arrangement thereof.
Still another object of the present invention is to provide a diesel generator set providing footprint reduction through innovative drive and alternator in a double decker arrangement having separate suction louvers for cooling the alternator and the engine.
Yet another object of the present invention is to provide a diesel generator set providing footprint reduction through innovative drive and alternator in a double decker arrangement with a canopy structure which inhibits rainwater to enter the canopy.
A further object of the present invention is to provide a diesel generator set providing footprint reduction through innovative drive and alternator in a double decker arrangement in which the relative rotational speeds of the engine and alternator can be varied to facilitate use of a 2-pole alternator.
A still further object of the present invention is to provide a diesel generator set providing footprint reduction through innovative drive and alternator in a double decker arrangement with a belt and pulley arrangement for transferring engine power to the alternator for generating electricity.

Other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a diesel generator set within a canopy having a reduced footprint through innovative drive and alternator arrangement as compared to the footprint of conventional DG sets.
The diesel generator set providing footprint reduction through innovative drive and alternator, the diesel generator set comprising:
- a diesel engine;
- an alternator mounted above the diesel engine on an alternator chassis; the shaft axis of the alternator being disposed parallel to the shaft axis of the diesel engine;
- a power transmission means for operatively connecting the diesel engine to the alternator;
- fresh-air inflow and hot-air exhaust arrangement with aerodynamically configured passages for effective cooling of the diesel generator set;
- a canopy structure for enclosing the diesel generator set mounted on a base frame and silencer
- a plurality of anti-vibration mounts arranged between the chassis and the canopy base frame of the canopy structure; and
- an arrangement for protecting the diesel generator set enclosed within the canopy structure from ingress of rain water.

Typically, a fresh-air inflow arrangement is disposed on the upper portion of the canopy structure, the arrangement including inlet louvers on either side at the flywheel end of the DG set, the louvers being connected to the respective suction ducts leading to the alternator for cooling the same and respective hot-air exhaust ports leading to the engine chamber for being mixed with the fresh air coming into the engine chamber.
Typically, a fresh-air inflow and hot-air exhaust arrangement is disposed on the lower portion of the canopy structure, the arrangement including inlet louvers on either side at the flywheel end of the DG set, the louvers opening into the hollow engine chamber, for mixing fresh air with the hot air coming from the exhaust ports of the alternator and the mixed air being passed around the engine for cooling the engine and subsequently passing hot air through a radiator to be finally exhausted to the atmosphere.
Typically, the canopy structure comprises a base frame supporting the diesel generator set on a plurality of anti-vibration mounts, the base frame being supported on ground by means of a plurality of legs; longitudinal side panels with fresh air inlet louvers on upper and lower portions thereof and doors for accessing engine chamber and flywheel side; a closed radiator side for discharging hot air to the atmosphere.
Typically, the power transmission means comprises a micro-V belt or poly-V belt and pulley arrangement including a belt auto tensioner and an idler.
Typically, the power transmission means comprises a toothed belt or timing belt and a timing pulley arrangement including a belt auto tensioner and an
idler.

Typically, the belt and pulley arrangement includes an alternator comprising a 2-pole configuration.
Typically, the rain water protection arrangement comprises a plurality of downwardly sloping louvers, each upper louvers projecting beyond the subsequent louver disposed downstream thereto.
Typically, the rain water protection arrangement comprises a plurality of downwardly sloping louvers, each upper louvers is disposed in a stepped manner below the subsequent louver disposed downstream thereto.
Typically, a machined coupler with tapping is mounted directly-keyed to the alternator shaft, the face plate of the alternator pulley coupling is bolted on the flywheel, the machined coupler is disposed between the alternator pulley and the faceplate is specially configured to connect with the flywheel with tapered and stepped surfaces.
In this double decker DG set, the alternator is stacked above the engine over an alternator chassis made of C or L section, preferably made of channels, e.g. 5mm thickness channels for better stiffness and endurance limits to absorb high vibrations during running of this DG set.
This alternator chassis or C or L section frame is placed above the canopy frame accommodating the engine and which in turn is mounted by means of bolts using anti-vibration mounts (AVM) supported on ground. The AVMs are used for damping the vibrations transmitted from the running engine and alternator to the ground.

Generally, the AVM mounts are provided for the complete assembly of the engine and alternator, so that the same vibration level is maintained at the pulleys connected to the engine and the alternator.
This arrangement facilitates the belt to maintain its position, so that it is not dislocated from the pulley due to vibrations. In the belt and pulley arrangement discussed above, the power is transmitted from the engine to alternator and the ratio of speed or pulley is normally maintained at 1:1. With this ratio, RPM available at the alternator is exactly the same as the engine RPM. Generally, a 4-pole alternator with 1500 RPM is used.
However, in accordance with the present invention, it is also possible to increase the RPM of the alternator and thus use a 2-pole alternator. This can be done by maintaining the alternator RPM greater than the engine RPM. This reduces the reduce weight of the alternator.
To avoid the slippage of the belt and power losses auto tensioner is introduced in the mid span of belt which maintains the optimum belt tension for the expected power transmission. In the embodiment shown in drawings, a micro-V belt or poly-V belt has been used.
Alternatively, a toothed belt or timing belt and a timing pulley arrangement can also be provided for avoiding slippage of the belt over the pulleys. The timing belt and timing pulley arrangement is a completely positive drive, which reduces the voltage fluctuations and provides an excellent power transmission.

The invention also provides an arrangement for mounting the pulleys with a machined coupler having tapping, which is directly keyed to the alternator shaft. A cast pulley and a coupler machined from EN8 material are used. The alternator pulley coupling face plate is bolted on the flywheel and machined coupler is introduced in between pulley and faceplate.
Further, a double bearing is used in the above arrangement for avoiding any bending of the alternator shaft. Thus, the alternator shaft supported on double bearings readily absorbs very high axial loading generated while DG set is
running.
In accordance with the present invention, with the alternator stacked above the engine, fresh air suction louvers leading to duct are provided in the upper portion of the canopy through which fresh air flows directly towards the alternator suction and hot air exhausted from the alternator through exhaust port and which is subsequently mixed with fresh air sucked through the engine inlet louvers provided in the lower canopy. This mixing of hot and fresh air reduces the temperature of the air leading to the radiator and subsequently exiting to the atmosphere. The double decker DG set is enclosed within an acoustic enclosure, wherein air flow is maintained such that the temperature within the DG set canopy is kept substantially constant.
Canopy is designed with silencer housed inside it, thus avoiding any damage to the silencer during transportation, which also improves its noise reduction capability and enhances the operator safety.

The exhaust louvers are provided above the radiator in such a manner that the rain water does not enter inside the hot chamber. This increases the PU foam and structure life located inside the canopy structure.
It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention and together with the description serve to explain the principles and operation of the invention.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The above-mentioned and other features and advantages of the various embodiments of the present invention will now be explained in more detail with reference to the non-limiting accompanying drawings thereof, in which:
FIG. 1A is a perspective view of a double decker diesel generator set in accordance with the present invention shown from flywheel side end.
FIG. IB is a perspective view of a double decker diesel generator set in accordance with the present invention shown from radiator side end.
FIG. 2 is a front side view of a double decker diesel generator set in accordance with the present invention shown from outside of its canopy.

FIG. 2A is a left side view of a double decker diesel generator set in accordance with the present invention shown in Figure 2.
FIG. 2B is a right side view of a double decker diesel generator set in accordance with the present invention shown in Figure 2.
FIG. 2C is atop view of a double decker diesel generator set in accordance with the present invention shown in Figure 2.
FIG. 3A is a perspective external view of the double decker diesel generator set in accordance with the present invention enclosed in a novel canopy structure.
FIG. 3B is a perspective view of a double decker diesel generator set in accordance with the present invention shown in Figure 3A, with partially opened canopy to show the inner arrangement of various subassemblies thereof.
FIG. 3C is a flywheel side view of a double decker diesel generator set in accordance with the present invention shown in Figure 3B.
FIG. 4 is a conventional diesel generator set with closely coupled engine and alternator shown with partially opened canopy thereof.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The present invention will now be described in more details with reference to the accompanying drawings showing various parts and subassemblies thereof.

FIG. 1A and FIG. 1B respectively show a flywheel side and radiator side perspective views of a double decker diesel generator set in accordance with the present invention. A chassis 8 is shown, which has a sturdy structure, preferably made of C or L channel sections. The canopy structure is raised on a plurality of legs 4 (Figure 2, 2A) for keeping it slightly above ground. Normally, four anti-vibration mounts (AVMs) are optimally located about the center of gravity of the whole DG set assembly, i.e. a plurality of AVMs are arranged between the chassis 8 and the canopy base frame 2. These AVMs facilitates in damping the vibrations being generated during the operation of the DG set by the engine 20. The alternator 30 is mounted above the engine 20 on an alternator chassis 8 of C or L section placed just above the engine. The alternator 30 is mounted without any AVMs of its own. This novel configuration of the DG set reduces the foot print on the floor space required for accommodating this double decker DG set. A flywheel 14 is connected to the engine shaft, which also carries a belt and pulley arrangement for transferring rotational movement of the engine shaft for driving the alternator 30. The belt and pulley arrangement includes an engine side pulley 16 and an alternator side pulley 18. A belt 22 is provided between the pulleys 16,18 for transferring the engine power to the alternator for generating electricity. An auto tensioner 19 is introduced in the mid span of the belt which maintains an optimum belt tension for effective power transmission by avoiding the slippage of the belt and so the power losses. A machined coupler 24 with tapping is mounted directly keyed to the alternator shaft. The alternator pulley coupling face plate (not shown) is bolted on the flywheel 14 and machined coupler 24 is introduced in between pulley and faceplate. Figure 1B also shows a radiator 26 fitted on the engine side for effectively cooling engine 10.

FIG. 2 shows a front side external view of the canopy of the double decker diesel generator set according to the present invention. The double decker DG set is mounted on a canopy base frame 2 supported on legs 4 resting on ground. A control panel 6 is also shown, by which the operation of the double decker DG set can be carried out. A set of inlet louvers 28 are also provided on both sides of the upper side of the canopy to allow fresh air to enter the suction duct 42 leading to the alternator 30 for cooling the same.
Similarly, another set of the inlet louvers 28 are provided on both the sides of the lower side of the engine chamber for cooling the engine. The fresh air entering from the lower louvers 28 is mixed with the hot air being exhausted from exhaust port 23 in the upper alternator chamber (Figure 1 A).
The canopy structure includes a roof 32 having a tapered top 34 above the radiator side, which includes exhaust louvers 38 (to be discussed below) for exhausting the hot air inside the engine chamber. Doors for accessing engine compartment or chamber are also provided on both longitudinal sides of the canopy structure (also see Fig. 2A).
FIG. 2A is a left side view of a double decker diesel generator set in accordance with the present invention shown in Figure 2. A hinged door 36 is provided for accessing the engine chamber from flywheel side for routine repair and maintenance work.
FIG. 2B is a right side view of a double decker diesel generator set shown in Figure 2 also showing exhaust louvers 38.

FIG. 2C is a top view of a double decker diesel generator set in accordance with the present invention shown in Figure 2. The exhaust louvers 38 allow fresh air to enter the engine chamber which on mixing with the hot air inside the lower engine chamber and hot air exhausted from exhaust port 23 in the upper alternator chamber. This arrangement effectively cools the air being finally exhausted to the atmosphere. The louvers 38 may be provided in a downwardly sloping manner such that the rain water falling on them cannot enter inside the double decker DG set canopy and thus rain water is prevented from damaging PU foam fitted inside or the components placed inside the DG set canopy. Alternatively, louvers 38 may also be configured in a stepped pattern (not shown), which further hinders ingress of rain water into the engine chamber.
FIG. 3A is a perspective external view of the double decker diesel generator set in accordance with the present invention, which is enclosed within a canopy 40 structure including a roof 32 with sloped face 34 having exhaust louvers 38. The lower and upper inlet louvers 28 sets are provided for entry of fresh air into the canopy for cooling the engine 20 and the alternator 30. A control panel 6 is also shown for operating the double decker DG set. A door 36 is also provided for accessing the engine chamber for routine maintenance and repair work.
FIG. 3B is a perspective view of a double decker diesel generator set in accordance with the present invention shown in Figure 3A, with partially opened canopy structure 40 to show the internal arrangement of various subassemblies thereof One inlet louver 28 is provided on either side of the upper side of the canopy structure 40 forming one set thereof.

This set of louvers leads fresh air through the corresponding suction ducts 42 provided in the upper canopy structure 40 to direct the incoming fresh air towards the alternator 30 and subsequently gets heated while cooling the alternator 30. This heated air exits from the exhaust port 23 to be mixed with the fresh air coming in from another set of inlet louvers 28 disposed on either side of the canopy structure 40. By mixing the heated air present inside the canopy structure 40 with the fresh air sucked through the inlet louvers 28 provided in the lower side of the canopy structure 40 ensures an optimum cooling and thus reducing the temperature of the air being finally exhausted to the atmosphere.
FIG. 3C is a flywheel side view of a double decker diesel generator set in accordance with the present invention shown in Figure 3B. All major subassemblies can be readily seen here. Canopy base frame 8 is seen supported on legs 2 resting on the ground. The flywheel 14 is mounted on the engine shaft 17, which also carries an engine side pulley 16. Another pulley 18 is mounted on the alternator shaft 31. An idler 21 is also provided. The rotational speed of engine 20 is transferred to alternator 30 via a belt 22. This belt is tensioned by means of an auto tensioner 19 to maintain the optimum belt tension for effectively transmitting engine power for electricity generation, by avoiding slippage of the belt and by inhibiting power losses. Here also, inlet louvers 28 leading to the corresponding suction ducts 42 are visible on both sides of the upper canopy structure 40. Through these inlet louvers 28, fresh air is sucked in for more effective cooling of the alternator 30. The arrangement of the upper set of inlet lovers 28 and suction duct 42 separately provided on either side of the upper portion provided in the novel canopy structure 40 is advantageous over the conventional canopy structure.

This is facilitated by separately and directly drawing fresh air and leading it to be pushed over the alternator 30, thereby a better cooling of the alternator 30 is achieved in comparison to common air present inside a conventional canopy structure used for cooling the alternator (Figure 4).
FIG. 4 is a conventional diesel generator set with closely coupled engine 20 and alternator 30 fitted along with a radiator 26 shown with a partially opened canopy structure 40 thereof. Due to in-line or closely coupled engine 20 and alternator 30, the footprint or the floor space required for accommodating this conventional DG set is much higher than the double decker DG set with a substantially double decker canopy structure 40 in accordance with the present invention described above with reference to Figures 1 to 3.
Accordingly, the present invention offers a unique configuration of the stacked or double decker arrangement of the alternator 30 over the engine 20. This arrangement Figures 1 to 3 has the following significant technical advantages over the conventional closely coupled DG set, e.g. shown in Figure 4 above:
TECHNICAL ADVANTAGES & ECONOMIC SIGNIFICANCE
The double decker diesel generator in accordance with the present invention has the following technical advantages:
a) Alternator is mounted above the engine, thereby reducing footprint or floor space required for accommodating the same.
b) Alternator has separate cooling arrangement for directly leading fresh air via suction ducts having specific geometry and smart positioning.

c) Hot air discharged from the exhaust port of the alternator gets mixed with fresh air coming from engine compartment, sending much cooler air towards the radiator fan, thereby discharged much colder air to the atmosphere as compared to the conventional DG sets.
d) Arrangement of the anti-vibration mounts is fine-tuned to support the alternator above the engine by specially configuring the strength of overall structure / chassis by including features withstand additional loads.
e) Instead of 4-pole alternator, by selecting the ratio of RPM of the alternator pulley to engine pulley RPMs higher than 1:1, there is a possibility of a more cost-effective alternator (2-pole), which may also have substantial effect on the cost, weight, size, area etc. of the DG set.
f) Use of rotary couplings normally machined from EN8 material instead ofcastedones.
g) The belt and pulley arrangement includes a micro-V belt or poly-V belt or alternatively a toothed belt or timing belt and a timing pulley for avoiding slippage of the belt over the pulleys.
h) This constitutes a completely positive drive which reduces the voltage fluctuations and provides an excellent power transmission.
i) Specially designed faceplate to connect with the flywheel having tapered and stepped surfaces.
j) Silencer is located inside the canopy structure itself, which increases the safety aspects of the double decker DG set.

k) Specially configured sloping exhaust louvers above the radiator keep rain water from getting into the hot chamber inside the canopy.
Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.
The use of the expression "a", "at least" or "at least one" shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.
A person skilled in the art may make innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies and assemblies, in terms of their size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention. All such changes, variations, modifications, alterations and/or integrations in terms of materials and method used in configuring, manufacturing and assembling the double decker DG set adopted and arrived by any such skilled person are also comprised and embraced within the scope and spirit of the present invention, whereby it shall be distinctly understood that the entire foregoing description and figures are treated merely illustratively and exemplarily and not as a limitation of the present invention.

WE CLAIM:
1. A diesel generator set providing footprint reduction through innovative drive and alternator, said diesel generator set comprising:
- a diesel engine;
- an alternator mounted above said diesel engine on an alternator chassis; the shaft axis of said alternator being disposed parallel to the shaft axis of said diesel engine;
- a power transmission means for operatively connecting said diesel engine to said alternator;
- fresh-air inflow and hot-air exhaust arrangement with aerodynamically configured passages for effective cooling of said diesel generator set;
- a canopy structure for enclosing said diesel generator set mounted on a base frame and silencer;
- a plurality of anti-vibration mounts arranged between the chassis and the canopy base frame of the canopy structure; and
- an arrangement for protecting said diesel generator set enclosed within said canopy structure from ingress of rain water.
2. Diesel generator set as claimed in claim ls wherein a fresh-air inflow arrangement is disposed on the upper portion of said canopy structure, said arrangement including inlet louvers on either side at the flywheel end of said DG set, said louvers being connected to the respective suction ducts leading to said alternator for cooling the same and respective hot-air exhaust ports leading to the engine chamber for being mixed with the fresh air coming into the engine chamber.

3. Diesel generator set as claimed in claim 2, wherein a fresh-air inflow and hot-air exhaust arrangement is disposed on the lower portion of said canopy structure, said arrangement including inlet louvers on either side at the flywheel end of said DG set, said louvers opening into the hollow engine chamber, for mixing fresh air with the hot air coming from said exhaust ports of said alternator and said mixed air being passed around said engine for cooling said engine and subsequently passing hot air through a radiator to be finally exhausted to the atmosphere.
4. Diesel generator set as claimed in claim 1, wherein said canopy structure comprises a base frame supporting said diesel generator set on a plurality of anti-vibration mounts, said base frame being supported on ground by means of a plurality of legs; longitudinal side panels with fresh air inlet louvers on upper and lower portions thereof and doors for accessing engine chamber and flywheel side; a closed radiator side for discharging hot air to the atmosphere.
5. Diesel generator set as claimed in claim 1, wherein said power transmission means comprises a micro-V belt or poly-V belt and pulley arrangement including a belt auto tensioner and an idler.
6. Diesel generator set as claimed in claim 1, wherein said power transmission means comprises a toothed belt or timing belt and a timing pulley arrangement including a belt auto tensioner and an idler.
7. Diesel generator set as claimed in claim 5 or 6, wherein said belt and pulley arrangement includes an alternator comprising a 2-pole
configuration.

8. Diesel generator set as claimed in claim 1, wherein said rain water protection arrangement comprises a plurality of downwardly sloping louvers, each upper louvers projecting beyond the subsequent louver disposed downstream thereto.
9. Diesel generator set as claimed in claim 1, wherein said rain water protection arrangement comprises a plurality of downwardly sloping louvers, each upper louvers is disposed in a stepped manner below the subsequent louver disposed downstream thereto.
10. Diesel generator set as claimed in claim 1, wherein a machined coupler with tapping is mounted directly-keyed to the alternator shaft, the face plate of the alternator pulley coupling is bolted on the flywheel, said machined coupler is disposed between said alternator pulley and said faceplate is specially configured to connect with said flywheel with tapered and stepped surfaces.