Integrated Power Station – Large Scale Product Design
Graco released the Integrated Power Station system, building and improving on the previous two generations of this product design. Powered by a Tier 4F engine and providing compressed air and auxiliary power for process tools, this system “steals” heat from the engine coolant to heat material intended for application with a Graco Reactor 2 system. Fuel savings, reduced power requirements, footprint reduction, and weight reduction are key benefits over separately sourcing and integrating a generator, air compressor, and high wattage heat Reactor 2.
The Integrated Power Station is one of the Graco’s most complicated product designs, requiring the design team to have knowledge in engine selection and integration, pneumatic and fluid handling systems, multi-region approvals and regulations, power generation and distribution, embedded design, and harness design.
DESIGN RESPONSIBILITIES:
Art Graf served as the Lead Electrical Engineer, overseeing other engineers and lab technicians along with all Electrical aspects of:
- Custom embedded hardware design
- Engine/ECU integration with custom Graco controls and engine display
- Panel design, wiring harness design
- EMC (Electromagnetic Compatibility) testing
- Life-testing, electrical testing
- Instruction and repair manuals
- Safety and Approvals
Art also joined other team members in the process of engine selection, engine manufacturer design approval, component sourcing/quoting, ramp to production/manufacturing, production audit, and other tasks.
Integrated Power Station showing air compressor and controls, engine controls enclosure, electrical panel, heat exchangers, and generator 
The IPS is powered by a Kohler Tier 4F engine (with turbo) mated to 240 VAC alternator head. 
Complete spray package showing combo of hydraulic Reactor 2 and IPS system
