U.S. patent application number 15/356474 was filed with the patent office on 2017-03-09 for power generation systems.
This patent application is currently assigned to PowerSys, LLC. The applicant listed for this patent is PowerSys, LLC. Invention is credited to Douglas Alan Koeneman, Edward J. Woods.
Application Number | 20170070122 15/356474 |
Document ID | / |
Family ID | 34434933 |
Filed Date | 2017-03-09 |
United States Patent
Application |
20170070122 |
Kind Code |
A1 |
Koeneman; Douglas Alan ; et
al. |
March 9, 2017 |
Power Generation Systems
Abstract
A power generation system is provided that includes an internal
combustion engine configured to provide rotational mechanical
energy. A generator is configured to receive the rotational
mechanical energy and generate electrical power in response to the
rotational mechanical energy. A fluid medium is provided to the
internal combustion engine and to the generator for removing
thermal energy from the internal combustion engine and from the
generator.
Inventors: |
Koeneman; Douglas Alan;
(Carmel, IN) ; Woods; Edward J.; (Carmel,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PowerSys, LLC |
Carmel |
IN |
US |
|
|
Assignee: |
PowerSys, LLC
|
Family ID: |
34434933 |
Appl. No.: |
15/356474 |
Filed: |
November 18, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14479041 |
Sep 5, 2014 |
9502943 |
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15356474 |
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13948132 |
Jul 22, 2013 |
8829698 |
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14479041 |
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13550410 |
Jul 16, 2012 |
8492913 |
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13948132 |
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13170108 |
Jun 27, 2011 |
8222756 |
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13550410 |
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12719726 |
Mar 8, 2010 |
7969030 |
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13170108 |
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10577577 |
Sep 21, 2006 |
7675187 |
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PCT/US04/32857 |
Oct 5, 2004 |
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12719726 |
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60508857 |
Oct 6, 2003 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F02B 63/04 20130101;
H02K 7/1815 20130101; G05B 13/02 20130101; H02K 9/19 20130101; F01P
2050/00 20130101; F01P 3/00 20130101; F01P 3/20 20130101; F02D
29/06 20130101; Y02E 20/14 20130101; H02K 11/25 20160101 |
International
Class: |
H02K 7/18 20060101
H02K007/18; H02K 11/25 20060101 H02K011/25 |
Claims
1-20. (canceled)
21. A power generation system comprising: a generator; a
combination of power applications, each power application connected
to a power demand different from another; a logic control
configured to model designed capabilities of respective power
applications; and a mode control configured to combine the design
capabilities to create a design capability of the power generating
system which is different from the design capabilities of the
respective power applications.
22. The system in claim 21 wherein the logic control models:
maximum sustainable available power to a connected power demand;
and maximum intermittent and instantaneous available power.
23. The system of claim 21 wherein the logic control is configured
to assess the durability of respective power applications within
the model and indicates the assessment to the power generation
system.
24. The system of claim 22 wherein the logic control is configured
to change proportions of contributions of the respective power
applications to change power available to the respective power
demands to another maximum sustainable available power.
25. The system of claim 21 wherein the mode control is configured
to: receive an indication from at least one of the power
applications; and in response to the indication, modify activation
and proportion contributions to the respective power
applications.
26. A power generation system comprising: a generator; a
combination of power applications, each power application connected
to a power demand different from another; a thermal system
connected to components of the power generation system; a thermal
system sensor in sensing relation with the thermal system; and a
thermal component sensor in sensing relation with at least one
component of the system.
27. The system of claim 26 wherein the thermal system sensor is
configured to indicate a temperature of the thermal system that is
representative of the maximum sustainable design capability of the
power generation system.
28. The system of claim 27 further comprising, if the temperature
is exceeded, a capability to establish a new maximum sustainable
design capability for the power generation system.
29. The system of claim 27 further comprising, if the temperature
is exceeded, a capability to modify proportions of power
application contributions to meet the respective power demands.
30. The system of claim 27 wherein the thermal component sensor is
configured to indicate a temperature of the at least one component
that is representative of the maximum sustainable design capability
of the at least one component.
31. The system of claim 30 further comprising the capability to
establish a different maximum sustainable design capability for the
power generation system in response to a temperature differential
between the thermal system and the at least one component that
exceeds a threshold temperature differential representative of the
maximum sustainable design capability of the power generation
system.
32. The system of claim 30 further comprising, in response to the
different maximum sustainable design capability, the capability to
modify proportions of power application contributions to meet the
respective power demands.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This patent resulted from a divisional application of and
claims priority to U.S. patent application Ser. No. 14/479,041,
filed Sep. 5, 2014, which was a continuation application of and
claims priority to U.S. patent application Ser. No. 13/948,132,
filed Jul. 22, 2013, now U.S. Pat. No. 8,829,698, which was a
continuation application of and claims priority to U.S. patent
application Ser. No. 13/550,410, filed Jul. 16, 2012, now U.S. Pat.
No. 8,492,913, which was a continuation application of and claims
priority to U.S. patent application Ser. No. 13/170,108, filed Jun.
27, 2011, now U.S. Pat. No. 8,222,756, which was a continuation
application of and claims priority to U.S. patent application Ser.
No. 12/719,726, filed Mar. 8, 2010, now U.S. Pat. No. 7,969,030,
which was a continuation application of and claims priority to U.S.
patent application Ser. No. 10/577,577, filed Sep. 21, 2006, now
U.S. Pat. No. 7,675,187 which is a 371 of PCT International
Application Number PCT/US04/32857, filed 5 Oct. 2004, and was
published in English, which claims priority to U.S. Provisional
Patent Application Ser. No. 60/508,857, filed Oct. 6, 2003, all the
disclosures of which are incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to power generation systems
and methods of generating power.
BACKGROUND ART
[0003] The current products offered by the portable power
generation industry are deficient in meeting customer needs. For
example, current portable generator sets are limited to single
voltages at a designed output frequency, that is, the generator
sets operate at fixed revolutions per minute (rpms) which is
limiting the usefulness of current portable power generation
systems. To handle the needs of customers that operate in a global
environment, portable generator sets are either reconfigured after
purchase, or multiple portable generator sets are purchased that
operate with different respective frequencies and voltages.
Portable power generation systems are needed to resolve these
issues and more readily meet the needs of customers.
[0004] Moreover, the portable power generation industry continues
to strive to meet customer demands for products that are light in
weight, small in size (including footprint dimensions) and fuel
efficient. For example, a conventional generator set (gen set)
comprises a longitudinal or length-wise dimension of approximately
sixty inches without a heat exchanger and weighs approximately
2,000 pounds. Furthermore, the portable power generation industry
continues to strive to meet the needs of customers that use
generators and generator sets as auxiliary power units (APUs). For
example, improvements are needed for auxiliary power units used in
the trucking business such as the tractor trailer and/or long haul
trucking industry. As environmental concerns result in more
stringent noise and air emission regulations, truck operators are
continually being prevented from operating their engines in more
areas, for example, truck stops, loading docks and rest areas due
to emission regulations and no-idle laws. This translates into the
truck operator being prevented from operating modern conveniences
such as an on-board air conditioner, refrigerator, radio and/or
television. It also translates into the truck operator not being
able to perform business tasks that are work-related which require
an on-board computer. Portable power generation systems are needed
as solutions to resolve these issues and respond to market and
regulatory pressures in the trucking industry. Additionally, the
portable power generation industry continues to strive to meet the
demands of truck drivers for APUs that ensure that parasitic loads
of a truck engine are maintained at a minimum.
[0005] Still further, the transportation industry continues to
strive to produce fuel efficient and environmentally-friendly
vehicles. This motivation has led to alternative power generation
designs and technologies for the vehicles, such as electric
vehicles and hybrid electric vehicles. These vehicular designs have
unique power applications and demands wherein a power plant
provides battery charging, power for peak load requirements,
absorption of braking energy and power for prime loads. Important
design considerations and parameters for the power plants are size
and weight because such parameters drive the load and physical size
of the vehicle. An additional design consideration should be
reflected in a customer's need for systems capable of withstanding
exposure of rain, dust or other external environmental conditions.
A need exists for power generation systems designed to meet the
unique considerations and parameters of electric vehicles and
hybrid electric vehicles.
[0006] Additionally, conventional motor-generator systems or
generator sets are used to transform power and/or isolate power
from one source to another. The application typically involves the
coupling of an AC motor which is coupled with an AC or DC radial
gap generator to create DC power or a different voltage &
frequency of AC power. There is a continual need to optimize the
size, weight and cost of conventional motor-generator systems. This
is especially true for military applications, for example the Navy
branch and any industry dealing with boating, which require high
tolerance parameters and specifications with regard to cooling,
weight and space requirements for power generation. Thermodynamic
management in these applications have proven difficult and very
expensive. Accordingly, there is a need to provide a
motor-generator system or set that resolves these problems of the
conventional motor-generator systems.
SUMMARY
[0007] In one aspect of the invention, a power generation system is
provided that includes an internal combustion engine configured to
provide rotational mechanical energy. A generator is configured to
receive the rotational mechanical energy and generate electrical
power in response to the rotational mechanical energy. A fluid
medium is provided to the internal combustion engine and to the
generator for removing thermal energy from the internal combustion
engine and from the generator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Preferred embodiments of the invention are described below
with reference to the following accompanying drawings.
[0009] FIG. 1 is a block diagram of an exemplary power generation
system according to embodiments of the invention.
[0010] FIG. 2 is a block diagram of an exemplary power generation
system according to other embodiments of the invention.
[0011] FIG. 3 is a side elevational view of an exemplary power
generation system according to an embodiment of the invention.
[0012] FIG. 4 is the FIG. 3 view emphasizing components of the
exemplary power generation system.
[0013] FIG. 5 is an elevational front view of the FIG. 3 power
generation system.
[0014] FIG. 6 is the FIG. 5 view emphasizing components of the
exemplary power generation system.
[0015] FIG. 7 is a side elevational view of the FIG. 3 power
generation system illustrating a side view opposite the FIG. 3 side
view.
[0016] FIG. 8 is the FIG. 7 view emphasizing components of the
exemplary power generation system.
[0017] FIG. 9 is a top plan view of the FIG. 3 power generation
system.
[0018] FIG. 10 is the FIG. 9 view emphasizing components of the
exemplary power generation system.
[0019] FIG. 11 is an elevational back view of the FIG. 3 power
generation system.
[0020] FIG. 12 is a perspective view of an exemplary flywheel
according to an embodiment of the invention.
[0021] FIG. 13 is a perspective view of an exemplary generator
according to an embodiment of the invention.
[0022] FIG. 14 is a sectional view of the FIG. 13 generator.
[0023] FIG. 15 is a perspective view of an exemplary heat exchanger
according to an embodiment of the invention.
[0024] FIG. 16 is a perspective side view of an exemplary power
electronics device according to an embodiment of the invention.
[0025] FIG. 17 is a perspective side view of the FIG. 16 power
electronics device illustrating a side view opposite the side view
of FIG. 16.
[0026] FIG. 18 is a perspective view of an exemplary support
structure according to an embodiment of the invention.
[0027] FIG. 19 is a block diagram of the exemplary components
monitored by an exemplary package control unit (also referred to as
unit control) according to embodiments of the invention.
[0028] FIG. 20 is a block diagram of the exemplary components
monitored by an exemplary power control (also referred to as power
electronics device) according to embodiments of the invention.
[0029] FIG. 21 is a block diagram of an exemplary ignition control
according to embodiments of the invention.
[0030] FIG. 22 is a block diagram of an exemplary Unit
Control/Logic Control according to embodiments of the
invention.
[0031] FIG. 23 is a block diagram of an other exemplary Unit
Control/Logic Control according to embodiments of the
invention.
[0032] FIG. 24 is a block diagram of an exemplary method for
generating power according to one of various embodiments of the
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Referring to FIG. 1, an overview of an exemplary embodiment
of a power generation system 10 according to the invention is
illustrated as a block diagram. An exemplary power generation
system 10 includes a system for a generator and/or a generator set.
In one exemplary embodiment of the power generation system 10, a
rotational power source 20 has an output in the form of rotational
mechanical energy provided by an output shaft 22 which rotates
having a rotational speed in revolutions per minute (rpm). The
rotational mechanical energy of rotating output shaft 22 is
transferred to a generator 24 which converts the rotational
mechanical energy of rotating output shaft 22 into electrical
energy and thermal energy (i.e., electricity and heat,
respectively). Electrical output of the generator 24 is in relation
to the speed of the output shaft 22 of the rotational power source
20. Energy loss in the form of heat is incurred in the process of
converting rotational mechanical energy into electrical energy. In
one exemplary embodiment of system 10, generator 24 is coupled in
fluid communication with a heat exchanger 26 wherein at least a
portion of the thermal energy (i.e., heat) produced in generator 24
is transferred to a fluid medium, for example, air and/or a liquid
which is provided to generator 24 via a fluid conduit (shown
subsequently), for example, a hose or pipe between the generator 24
and heat exchanger. Additionally, portions of heat are transferred
to outside surfaces of generator 24 from which the heat is
transferred to the surrounding air or environment. In some
embodiments, the power generation system includes a heat exchanger
26. In some embodiments, heat exchanger 26 or cooler is included
within an array or network of heat exchanger units. An exemplary
array or network is coupled in heat exchanging relation to fluid
using a fluid conduit, for example, a hose or tube.
[0034] Still referring to FIG. 1, the generator 24 is coupled,
using interface 32, with a power electronics device 28, or power
conversion device. Electricity produced by the generator 24 is
transferred to the power electronics device 28 to be converted into
a form desired by the operator of the power generation system 10.
In one embodiment of system 10, thermal energy generated by a power
electronics device 28 is at least partially removed by a fluid, for
example, by air and/or a liquid. In some embodiments of system 10,
thermal energy generated by a power electronics device 28 is at
least partially removed by a liquid. The power electronics device
28 comprises a heat exchanger 30 coupled in fluid communication
with a heat exchanger 30 by a liquid cooling circuit (illustrated
more thoroughly subsequently). Heat produced in the process of
converting the generated electricity into a form that is selected
by the operator is transferred to the liquid cooling circuit from
the power electronics device 28 and to a heat exchanger 30. Heat
from the heat exchanger 30 is transferred to the environment and/or
another medium. In some embodiments of system 10, the heat
exchanger 30 comprises an independent unit. In other embodiments of
system 10, the heat exchanger 30 is combined within a network of at
least one other heat exchanger unit, for example, a network that
includes heat exchanger 26. A power electronics device 28 is
capable of power conversions or signal conversions from an input
source to an output source, for example, from AC to DC, DC to AC,
and AC to AC. The power electronics device 28 is capable of one or
a multiple of the aforementioned conversions. In some embodiments
of power generation system 10, an operator is able to configure,
reconfigure and/or modify the power electronics device 28 such that
output current, frequency, voltage and/or polarity are
selectable.
[0035] Still referring to FIG. 1, the power electronics device 28
is coupled to output connection(s) 36. Converted electricity having
the selected output current, frequency, voltage and/or polarity is
transferred to the output connection(s) 36. In some embodiments,
the output connection 36 is an integral component of the power
electronics device 28. In other embodiments, the output connection
36 comprises a stand-alone component connected to the power
electronics device 28 by an interface 34. The output connection 36
provides an interface between the power generation system 10 and an
electrical load (not shown).
[0036] Still referring to FIG. 1, an exemplary power generation
system comprises a control unit 38 that monitors the respective
components and devices discussed previously, for example,
rotational power source 20, generator 24, power electronics device
28 and output connection 36, respectively. An array 40 of data
conduits are coupled between the package control unit 38 and the
respective devices to communicate input and output data between the
respective devices. The exemplary control unit 38 has the
capability to perform one or more of the following functions:
monitor the power generation system 10, diagnose problems within
the power generation system 10, control components of the power
generation system 10, annunciate status of components of the power
generation system 10, and supervise the power generation system 10.
In some embodiments, the package control unit 38 may also function
as an interface for local and/or remote monitoring and control.
[0037] It should be understood that various combinations of devices
(e.g., rotational power source 20, generator 24, power electronics
device 28 and output connection 36, respectively) can be coupled in
fluid communication to various combinations of heat exchangers. For
example, a power generation system 10 can comprise a single heat
exchanger standing alone and coupled in fluid communication with a
single device 20, 24, 28, 36. That is, a single heat exchanger can
be coupled to a single device 20, 24, 28, 36. Alternatively, one or
more heat exchangers can be coupled to a single device. For
example, two or more heat exchangers can be coupled in fluid
communication with generator 24, and the combination of heat
exchangers can be in fluid communication with one another, or not
in fluid communication with one another. Alternatively, one or more
devices can be coupled to a single heat exchanger. For example, two
or more devices, for example, rotational power source 20 and
generator 24, can be coupled in fluid communication with a single
heat exchanger 26, and the combination of devices can be in fluid
communication with one another, or not in fluid communication with
one another. Moreover, an exemplary power generation system 10 can
include a single device 20, 24, 28, 36 coupled to a single heat
exchanger and include another single device coupled to a plurality
of heat exchangers. Additionally, an exemplary power generation
system 10 can include a single device coupled to a single heat
exchanger and include another single heat exchanger coupled to a
plurality of devices. Furthermore, an exemplary power generation
system 10 can include any combination of the examples presented
above. For example, an exemplary power generation system 10 can
include a plurality of devices coupled to a single heat exchanger
or a plurality of heat exchangers; and include another single
device coupled to another single heat exchanger; and include a
plurality of heat exchangers coupled to another single device or
coupled to another plurality of heat exchangers; and added to this
exemplary power generation system 10 can include any additional
combination of devices coupled to additional combination of heat
exchangers.
[0038] Referring to FIG. 2, an overview of another exemplary
embodiment of a power generation system 60 is illustrated as a
block diagram. Power generation system 60 includes a system for a
generator and/or a generator set. In one exemplary embodiment of
the power generation system 60, a fuel supply 62 provides chemical
energy to a rotational power source 64 via a fuel conduit 66. In
some embodiments, fuel supply 62 is cooled by a fluid, for example,
a liquid. In these embodiments, fuel supply 62 is coupled, for
example, in fluid communication to a heat exchanger 68 to at least
partially remove thermal energy from the fuel supply 62. An
exemplary heat exchanger 68 defines an independent component of
power generation system 60. In another embodiment, heat exchanger
68 is combined within a network of at least one other heat
exchanger units. Rotational power source 64 comprises an output
shaft 70 and converts chemical energy from fuel supply 62 into
rotational mechanical energy at the output shaft 70. Rotational
power source 64 is coupled in fluid communication with a heat
exchanger 72. At least a portion of heat generated in converting
chemical energy to rotating mechanical energy is transferred to a
fluid medium, for example, a liquid provided to the rotational
power source 64 via a cooling circuit. An exemplary heat exchanger
72 defines an independent component of power generation system 60.
In other embodiments, heat exchanger 72 is combined within a
network of at least one other heat exchanger unit, for example,
heat exchanger 68.
[0039] Still referring to FIG. 2, the rotating output shaft 70 of
rotational power source 64 is coupled to a gearbox 74 to transfer
rotating mechanical energy from the rotational power source 64 to
the gearbox 74. The gearbox 74 comprises an output shaft or drive
shaft 78 that is coupled to a generator 76. The shaft 78 transfers
rotational mechanical energy of output shaft 70 from rotational
power source 64 to the drive shaft 78 which drives generator 76. An
exemplary gearbox 74 is configured to selectively increase or
decrease the rotating speed of output shaft 70 of rotational power
source 64 which corresponds to selectively increasing or decreasing
the rotating speed of drive shaft 78 which corresponds to
selectively increasing or decreasing the rotating speed of
generator 76. Such exemplary selectivity of gearbox 74 ensures
generator 76 operates at an optimal speed. Thermal energy is
generated within the gearbox 74 during the conversion of increasing
or decreasing rotational speed of the output shaft 70 to drive
shaft 78. In one exemplary embodiment, drive shaft 78 is coupled in
fluid communication with a heat exchanger 80 wherein at least a
portion of heat generated in converting the rotating mechanical
energy of respective shafts 70 and 78 is transferred to a fluid
medium, for example, air and/or a liquid which is provided to the
gearbox 74 via a conduit, for example, a hose or pipe (shown
subsequently). An exemplary heat exchanger 80 defines an
independent component of power generation system 60. In other
embodiments, heat exchanger 80 is combined within an array or
network of at least one other heat exchanger unit, for example,
with heat exchanger 68 or with heat exchanger 72, or with both. An
exemplary array or network is coupled in fluid communication by an
exemplary conduit, for example, a hose or tube.
[0040] The generator 76 converts rotating mechanical energy into
electrical energy and thermal energy (i.e., electricity and heat).
In one exemplary embodiment, generator 76 is coupled in fluid
communication with a heat exchanger 82 wherein at least a portion
of heat generated in the process of converting mechanical energy
into electricity is transferred to a fluid medium, for example, air
and/or a liquid which is provided to the generator 76 via a
conduit, for example, a hose or pipe (shown subsequently). An
exemplary heat exchanger 82 defines an independent component of
power generation system 60. In another embodiment, heat exchanger
82 is combined within an array or network of at least one other
heat exchanger unit, for example, with heat exchanger 68 or with
heat exchanger 72, or with both. An exemplary array or network is
coupled in fluid communication by an exemplary conduit, for
example, a hose or tube.
[0041] Electricity produced by the generator 76 is transferred to a
power electronics device or power conversion device 84. Electricity
produced by the generator 76 is transferred to the power
electronics device 84 to be converted into one or more forms as
desired by the operator of the power generation system 60. In one
exemplary embodiment, power electronics device 84 is coupled in
fluid communication with a heat exchanger 86 wherein at least a
portion of heat generated in the process of converting one form of
electricity to another form of electricity is transferred to a
fluid medium, for example, air and/or a liquid which is provided to
the power electronics device 84 via a conduit, for example, a hose
or pipe (shown subsequently). An exemplary heat exchanger 86
defines an independent component of power generation system 60. In
another embodiment, heat exchanger 86 is combined within an array
or network of at least one or more heat exchanger units, for
example, with heat exchanger 68, 72, 80, and/or 82, singularly or
in any combination thereof. An exemplary array or network is
coupled in fluid communication by an exemplary conduit, for
example, a hose or tube. In an exemplary embodiment, the power
electronics device 84 has the capability to interface with a
secondary power source 100. The secondary power source 100 is
capable of providing a secondary power input to the power
electronics device 84 via an interface and/or receiving power from
the power electronics device 84 for distribution or storage.
Exemplary devices for exemplary secondary power source 100 include
another generator, utility feed, flywheel energy storage device,
batteries, capacitors (super) or other energy sources. An exemplary
power electronics device 84 will manage various combinations of
electrical current for example:
TABLE-US-00001 Primary input Secondary input Output AC -- AC* AC AC
AC* AC DC AC* AC DC* AC AC DC* AC DC AC* DC AC* DC AC AC* DC DC AC*
DC AC* DC AC DC* DC DC DC* *Capable of one or a multiple of the
outputs.
[0042] An exemplary power electronics device 84 provides an output
that is frequency selectable, voltage selectable, and polarity
selectable. An exemplary power electronics device 84 provides an
output that includes digital grade power. An exemplary power
generation system 60 comprises an output of the power electronics
device 84 that is transferred to transformer 88 via an interface.
An exemplary power generation system 60 comprises an exemplary
transformer 88 coupled to a distribution panel 94 via an interface
92 wherein the distribution panel 94 is coupled to power loads to
be used by a consumer. In one exemplary embodiment, an exemplary
transformer 88 is coupled in fluid communication with a heat
exchanger 90 wherein at least a portion of heat generated in the
transformer 88 is transferred to a fluid medium, for example, air
and/or a liquid which is provided to the transformer 88 via a
conduit, for example, a hose or pipe (shown subsequently). An
exemplary heat exchanger 90 defines an independent component of
power generation system 60. In another embodiment, heat exchanger
90 is combined within an array or network of at least one or more
heat exchanger units, for example, with heat exchanger 68, 72, 80,
82 and/or 86, singularly or in any combination thereof. An
exemplary array or network is coupled in fluid communication by an
exemplary conduit, for example, a hose or tube.
[0043] Still referring to FIG. 2, power generation system 60
comprises a package control unit 96 that monitors the respective
components and devices discussed previously, for example, fuel
supply 62, rotational power source 64, gearbox 74, generator 76,
power electronics device 84, transformer 88 and distribution panel
94, respectively. An array 98 of data conduits are coupled from the
power electronics device 84 to the respective devices to
communicate input and output data between the respective devices
and the power electronics device 84. The exemplary package control
unit 96 has the capability to perform one or more of the following:
monitor components of the power generation system 60, diagnose
problems with components of the power generation system 60, control
components of the power generation system 60, annunciate status
information relating to components of the power generation system,
and supervise the power generation system 60. In another exemplary
embodiment, the package control unit 96 may also function as an
interface for local and/or remote monitoring and control.
[0044] It should be understood that the plurality of various
combinations of devices (e.g., fuel supply 62, rotational power
source 64, gearbox 74, generator 76, power electronics device 84,
transformer 88, respectively) can be coupled in fluid communication
to the following plurality of various combinations of heat
exchangers for an exemplary power generation system 60. For
example, an exemplary power generation system 60 can comprise a
single heat exchanger standing alone and coupled in fluid
communication with a single device. That is, a single heat
exchanger can be coupled to a single device. Alternatively, one or
more heat exchangers can be coupled to a single device. For
example, two or more heat exchangers can be coupled in fluid
communication with generator 76, and the combination of heat
exchangers can be in fluid communication with one another, or not
in fluid communication with one another. Alternatively, one or more
devices can be coupled to a single heat exchanger. For example, two
or more devices, for example, rotational power source 64 and
generator 76, can be coupled in fluid communication with a single
heat exchanger, and the combination of devices can be in fluid
communication with one another, or not in fluid communication with
one another. Moreover, an exemplary power generation system 60 can
include a single device coupled to a single heat exchanger and
include another single device coupled to a plurality of heat
exchangers. Additionally, an exemplary power generation system 60
can include a single device coupled to a single heat exchanger and
include another single heat exchanger coupled to a plurality of
devices. Furthermore, an exemplary power generation system 60 can
include any combination of the examples presented above. For
example, an exemplary power generation system 60 can include a
plurality of devices coupled to a single heat exchanger or a
plurality of heat exchangers; and include another single device
coupled to another single heat exchanger; and include a plurality
of heat exchangers coupled to another single device or coupled to
another plurality of heat exchangers; and added to this exemplary
power generation system 60 can include any additional combination
of devices coupled to additional combination of heat
exchangers.
[0045] Referring to FIGS. 3-11, an exemplary embodiment of a power
generation system 200 is illustrated. Components of an exemplary
embodiment of a power generation system 200 are illustrated in
FIGS. 12-18. It should be understood that power generation system
200 can be used for the power generation systems discussed above
with respect to FIGS. 1 and 2. It should also be understood that
the specific components of FIGS. 12-18 and schematics presented in
FIGS. 20-24 can be used for the power generation systems discussed
above with respect to FIGS. 1-2 and power generation system 200. It
should be understood that FIG. 19 illustrates another exemplary
power generation system 840 that can be used for the power
generation systems discussed above with respect to FIGS. 1 and 2,
and include the specific components of FIGS. 12-18 and include the
schematics presented in FIGS. 20-24.
[0046] Power generation system 200 comprises a rotational power
source 208, for example, an internal combustion engine, such as a
gasoline engine or a diesel engine. In one exemplary embodiment,
the rotational power source comprises a diesel engine 208. An
exemplary diesel engine 208 is designed with an optimal gear train
(not shown) within the engine by having a front gear train of two
high-contact-ratio gears mounted to the engine block and has the
added benefit of low noise characteristics. An exemplary diesel
engine 208 includes a fuel system that has mechanically governed
unit pumps (not shown) mounted inside the engine block which
eliminates external high-pressure lines, minimizes leak paths and
reduces noise levels. This fuel system contributes to cost
effectiveness and clean design. One example of a diesel engine that
could be employed for the diesel engine 208 is an industrial engine
that is commercially available from John Deere as model 4024T 66 hp
Diesel Engine (www.deere.com).
[0047] The diesel engine 208 has an output providing rotational
mechanical energy in the form of an output shaft (not shown) which
is rotatable and is coupled to a rotational coupling device which
couples engine 208 to a generator (only generator housing 360 shown
in FIG. 3). An exemplary rotational coupling device comprises a
flywheel which provides the rotational mechanical energy of
rotating output shaft to the generator for conversion into
electrical and thermal energy (i.e., electricity and heat,
respectively). An example of a flywheel that could be employed for
the flywheel 600 illustrated in FIG. 13 (only flywheel housing 340
is shown in FIG. 3) is commercially available from ARCUSAFLEX.RTM.
Flywheel Couplings as model Ringfeder Arcusaflex Coupling
(www.ringfeder.com).
[0048] Referring to FIG. 12, an exemplary flywheel 600 comprises a
coupling ring 602 which forms a cylindrical opening 604 to receive
the shaft of the generator which provides the coupling of the
flywheel 600 to the generator. In one embodiment, an exemplary
flywheel 600 comprises a rubber disk component 606 which permits
the shaft of the generator to be provided at angular, axial and
parallel misalignments and also dampens vibrations.
[0049] Referring to FIGS. 13-14, an exemplary generator 640 is
illustrated (only generator housing 360 is shown in FIG. 3) and
comprises a flange portion 642 for securing generator 640 to a
structure or component of power generation system 200 (FIG. 3), An
exemplary generator 640 comprises a housing 644 integral with
flange portion 642 for protecting and enclosing the internal
structure and components 648 of generator 640. Referring to FIG. 3,
an exemplary generator housing 360 seals and protects generator 640
from the environment and can withstand water and sand exposure. An
example of a generator that could be employed for the generator 640
is commercially available by TM4 Energy as model TM4 40 kw
generator.
[0050] Referring to FIG. 3, an exemplary power electronics device
300 is illustrated positioned elevationally above generator housing
360. It should be understood that power electronics device 300
could be positioned in any location relative the other components
of power generation system 200. Power electronics device 300
comprises an array 302 of output connections 308. Output
connections 308 comprise electrical ports to be used by the
consumer for connection to loads permitting the consumer to use the
electrical energy produced by the generator. An exemplary power
electronics device 300 is a power conversion device that converts
the output of the generator (AC or DC) into a useable voltage (AC
or DC) and frequency (50 Hz, 60 Hz, etc.). The exemplary power
electronics device 300 is sealed from the environment and can
withstand water immersion and survive up to 50 g repetitive shock
(vibration) loads. Components of the power electronics device 300
are mounted on a hollow plate wherein fluid (coolant) from an heat
exchanger passes through the hollow portion of the plate to remove
heat from the power electronics device 300 generated in the power
conversion process (loss due to inefficiencies). In one embodiment,
the power electronics device 300 is integrated into the generator
housing 360, or can be an independent component that is mounted on
the frame (discussed more thoroughly subsequently). An exemplary
power electronics device 300 comprises a size that ranges from five
times to ten times less than the size of a conventional power
electronics device.
[0051] Referring to FIGS. 16-17, an exemplary power electronics
device 700 is illustrated in more detail. Power electronics device
700 comprises cooling ports 706 and 708 for coupling to an
exemplary heat exchanger for fluid transport. Power electronics
device 700 further comprises electrical connections/ports 716 and
communication ports 710 and 712. An exemplary power electronics
device 700 comprises a resistance temperature device (RTD) 714 and
center-of-gravity mounts 718 to impede shock and vibrations to the
power electronics device 700. Housing portions 702 and 704 protect
and enclose structure within power electronics device 700. An
example of a power electronics device that could be employed for
the power electronics device 700 is commercially available from
Rockwell Automation as model LiquiFlo ProPulse Power Module.
[0052] Referring to FIGS. 7-8, an exemplary power generation system
200 includes a package control unit 500 illustrated as being
positioned adjacent engine 208 and includes a display window 502.
It should be understood that package control unit 500 could be
positioned in any location relative the other components of power
generation system 200. An exemplary package control unit collects,
shares and transmits pertinent information between specific system
components of power generation system 200 to effectively manage and
optimize the collective cooperation between the components of the
power generation system 200. For example, with respect to the
engine, an exemplary package control unit 500 will monitor engine
output (hp, torque, speed), battery voltage, engine temperature,
exhaust temperature and engine oil temperature. With respect to the
generator, an exemplary package control unit 500 will monitor the
generator output and the temperature of the fluid (coolant) within
the generator from the heat exchanger. With respect to the power
electronics device, an exemplary package control unit 500 will
monitor the temperature of the fluid (coolant) within the power
electronics device, and monitor the electrical input to and output
from the power electronics device.
[0053] With respect to the heat exchanger, an exemplary package
control unit 500 will monitor two components (discussed more
thoroughly below) of the heat exchanger, a hot circuit and a cold
circuit. The hot circuit has two components which are represented
here as hot circuit #1 and hot circuit #2, and the cold circuit has
one component. The exemplary package control unit 500 will monitor
inlet and outlet temperatures of the cold circuit and monitor the
inlet and outlet temperatures of the hot circuit #1 and hot circuit
#2, respectively. An example of a package control unit that could
be employed for the package control unit 500 is commercially
available from Woodward as model EasY.TM. gen generator set control
model "1500".
[0054] Referring to FIG. 3, an exemplary heat exchanger 400 is
illustrated positioned at an end of the power generation system 200
opposite engine 208. It should be understood that the heat
exchanger could be positioned in any location relative the other
components of power generation system 200. An example of a heat
exchanger comprises a plate and frame design and is commercially
available by Sondex as model Jernet 9 (www.sondexuk.com/gasketed).
This plate and frame design of the exemplary heat exchanger
comprises two fluids that pass in opposite directions up and down
alternative channels formed in exemplary pressed plate packs 409
and 413 discussed more thoroughly below.
[0055] Referring to FIG. 15, in one exemplary embodiment, the heat
exchanger 400 comprises frame side structures 405 and 407 secured
on opposite sides of the respective plate packs 409 and 413 by, for
example, clamping bolts 423. Exemplary frame side structures 405
and 407 comprise metal and exemplary plate packs 409 and 413
comprise metal. Plate packs 409 and 413 are divided by a center
frame structure 411 which comprises, for example, a metal plate.
Each frame side structure defines openings which function as inlets
and outlets, for example, openings 410, 414, 417, 419 defined by
frame side 407.
[0056] In some embodiments, the plate and frame design of the
exemplary heat exchanger comprises the two hot circuits and the
single cold circuit. In some embodiments, hot circuit #1 is
represented as plate pack 413 and is dedicated for the power
electronics and generator. In some embodiments, hot circuit #2 is
represented as plate pack 409 and is dedicated for the engine
cooling circuit. Hot circuit #1 and hot circuit #2 (plate packs 409
and 413) are separated by the center frame structure or plate 411.
The cold circuit passes first through hot circuit #1 (plate pack
413), and then through hot circuit #2 (plate pack 409) before
exiting the heat exchanger 400. That is, each hot circuit #1 and
hot circuit #2 (plate packs 409 and 413) also comprises a cold
fluid wherein the two fluids, one hot and one cold, pass in
opposite directions, up and down in alternative channels formed in
the respective plate packs 409 and 413. It should be understood
that other exemplary heat exchangers could be used and include a
water to air heat exchanger, for example, a radiator and/or cooling
tower.
[0057] Referring to FIGS. 3-4, an exemplary conduit system for
transferring a fluid medium between the heat exchanger 400 and
respective components of power generation system 200. The conduit
system includes a plurality of discrete conduits which can
comprise, for example, flexible materials such as rubber hoses or
inflexible materials such as metal pipes, or any combination of the
various materials. Conduit 216 extends from an opening 404 in heat
exchanger 400 to an opening (not referenced) in engine 208 and
provides a cooled or cold fluid medium to engine 208 from heat
exchanger 400. The fluid medium enters engine 208 wherein heat
energy from engine 208 is transferred to the fluid medium, and then
the fluid medium exits engine 208 from an opening (not referenced)
of engine 208 to enter conduit 214 wherein the warmed fluid medium
returns to enter the heat exchanger through opening 406 to be
cooled and re-circulated through conduit 216 and engine 208. It
should be understood that the path just described for the fluid
medium could be reversed through the respective conduits 214 and
216, and engine 208 and heat exchanger 400.
[0058] Referring to FIGS. 7-8, an exemplary conduit system for
transferring a fluid medium between the heat exchanger 400 and
respective components of power generation system 200 is shown. The
plurality of discrete conduits comprise, for example, flexible
materials such as rubber hoses or inflexible materials such as
metal pipes, or any combination of the various materials. A first
conduit 228 extends from an opening 414 in heat exchanger 400 to a
first nipple 226 of a pump 220, for example an auxiliary pump, and
a second conduit 228 extends from a second nipple 222 of auxiliary
pump 220 to power electronic device 300. An exemplary auxiliary
pump 220 provides pumping power to transfer a cooled or cold fluid
medium to power electronics device 300 from heat exchanger 400. The
fluid medium enters power electronics device 300 wherein heat
energy from power electronics device 300 is transferred to the
fluid medium, and then the fluid medium exits power electronics
device 300 and enters conduit 304. Conduit 304 extends from power
electronics device 300 to the generator (represented as generator
housing 360) and receives the warmed fluid medium from the power
electronics device 300 wherein the warmed fluid medium is further
warmed by receiving heat energy from the generator. Conduit 234
extends from the generator to opening 410 of heat exchanger 400 and
provides the path for the fluid medium to return to the heat
exchanger 400 from the generator. The fluid medium is re-circulated
through the heat exchanger to be cooled and re-circulated through
the respective conduits 228, 304 and 234, and the respective
components.
[0059] It should be understood that conduits 416 and 418 from
respective openings 417 and 419 of heat exchanger 400 are provided
to receive a fluid medium furnished by a consumer. For example, if
power generation system 200 is to be provided on a vessel such as a
boat, the fluid medium provided to conduits 416 and 418 can include
seawater from the ocean. Other exemplary fluid medium include water
or air. Either conduit 416 or 418 will be an inlet for the fluid
medium with the other conduit comprising an outlet for the fluid
medium to be dumped, for example, back into the ocean.
[0060] It should be understood that the path just described for the
fluid medium could be reversed through the respective conduits and
the respective components. It should be understood that pump 220
can be positioned in any location relative the respective
components of power generation system 200, for example, below power
electronics device 300 and adjacent generator housing 360. It
should be understood that pump 220 can comprise an electric pump or
a mechanical pump. It should be understood that pump 220 can be an
independent pump driven under its own power or driven from engine
208.
[0061] Referring to FIG. 4, power generation system 200 has a
length 203 ranging from about 45 to about 49 inches and defined
from one end of engine 208 to an opposite end of heat exchanger
400. Power generation system 200 has a length 201 ranging from
about 36 to about 40 inches without the heat exchanger 400, and
defined from the one end of engine 208 to an opposite side of the
power electronics device 300. Referring to FIG. 5, power generation
system 200 has a height 205 ranging from about 28 to about 32
inches and defined from a bottom of engine 208 to a top of engine
208 opposite the bottom. Still referring to FIG. 5, power
generation system 200 has a width 207 ranging from about 18 to
about 22 inches and defined from the one side of engine 208 to an
opposite side of engine 208. Power generation system 200 comprises
a weight ranging from about 800 to about 900 pounds, for example,
850 pounds. Other dimensions or weights are possible.
[0062] Referring to FIG. 18, an exemplary support structure 800 for
power generation system 200 is illustrated and comprises a frame
801 of any material that is adequately sturdy to support engine 208
and system components, for example, a metal such as steel. In one
exemplary embodiment, u-shaped base portions 802 extend
longitudinally and generally in parallel relation wherein spacers
806 are used to maintain the spaced relation of the u-shaped base
portions 802 by extending between and secured to the respective
u-shaped base portions 802. It should be understood that while only
two base portions 802 and two spacers 806 are shown, any number of
base portions 802 and spacers 806 can be provided for support
structure 800. In one exemplary embodiment, base portions 802
comprise the portion of frame 801 to which the additional structure
pieces or sections of frame 801 are secured. Moreover, the
exemplary base portions 802 comprise the portion of frame 801 which
rests and contacts a surface (not shown) to support an exemplary
power generation system.
[0063] Still referring to FIG. 18, an exemplary frame 801 comprises
brackets 808 that are secured to and extend upwardly from base
portions 802 at one end of an exemplary support structure 800. In
one exemplary embodiment, brackets 808 are secured to base portions
802 by bushings 805 that comprise, for example, rubber to dampen
vibrations of the power generation system 200. Brackets 808 are
secured to engine 208, either directly or with additional bushings
(not shown) between brackets 808 and engine 208. A pair of cross
rails 826 extend between and are secured to respective base
portions 802. In one embodiment, cross rails 826 support posts 832
which extend upwardly from cross rails 826. Exemplary posts 832
comprise at least two in number, for example, four and are in space
relation defining a square or rectangle. Exemplary posts 832 are
used to support any combination of plurality of components for
power generation system 200, for example, a power electronics
device 834, a generation housing 836, and other components not
shown secured to posts 832 such as a package control unit and
auxiliary pump. Another pair of cross rails 828 are located
adjacent posts 832 and extend between and are secured to respective
base portions 802 to support heat exchanger 838. A pair of pillars
816 extend vertically from one base portion 802 adjacent two
brackets 808 and include a crossbar 817 extending there between,
and in one exemplary embodiment, pillars 816 and cross bar 817
support an auxiliary pump 822 and package control unit 820.
[0064] It should be understood that additional structure and beams
can be provided on frame 801 to support additional components, for
example, the generator. It should be understood that vibration
isolators can be provided between any of the components of the
exemplary power generation system and frame 801. Conventional
generator sets use frames and/or frame rails strong enough to
withstand torsional flexing between the engine and generator.
However, the exemplary power generation systems disclosed herein
can be comprised of materials other than steel as a result of the
engine being coupled directly to the generator. That is, with the
engine directly coupled to the generator, torsional flexing is
reduced and the design allows for off-board components to be better
isolated from vibrations of the engine. Accordingly, in exemplary
embodiments, frame 801 does not have to be designed to overcome the
substantial torsional flexing of the conventional frames, and
therefore, can be designed with materials to provide a frame that
is compact and lightweight.
[0065] Referring to FIG. 19, an overview 900 of the major
components being monitored by the Package Control Unit (identified
as Unit Control 960 in FIG. 19) according to the invention is
illustrated as a block diagram. The Package Control Unit 960
monitors the engine (referenced as prime mover 906), generator 908,
an ignition control 942 for the engine (prime mover 906), heat
exchanger 902, the power electronics device (identified as power
control 920) and customer connections, for example, a 3-phase
breaker 912 to a consumer system 914. These components are coupled
by electrical and/or communication lines 910 and a conduit system
904 of water cooling lines.
[0066] Referring to FIG. 20, in some embodiments of the power
control (power electronics device) 920, an exemplary system
interface 924 is coupled to logic control 922 that allows the
consumer/user to input user settings 934. The interface 924 also
provides output signals 936. Exemplary output signals 936 can be in
text or graphical format on the system interface 924, and can be
exported as an electronic signal for remote viewing. The system
interface 924 communicates with the logic control 922 wherein the
logic control 922 receives the user settings 934 from the system
interface 924 and monitors/regulates Water Cooling and Internal
Temperature Sensing 926, DC Regulation 930 and DC-AC Conversion
928. In one embodiment, DC Regulation 930 is coupled with DC input
or output to remote storage system 938. In one embodiment, DC
Regulation 930 is coupled with AC to DC conversion 932 for
exemplary conversion outputs 940 of 50-690 VAC, poly-phase (for
example, 3-18 phases) and 50-900 Hertz (Hz). In one embodiment, DC
Regulation 930 is coupled with DC to AC conversion 928 for
exemplary conversion outputs of 120-690 VAC, 1 or 3 phase and
50-1,000 Hertz. Based on User Settings 934 conditions, the Logic
Control 922 will manage the power generation system and communicate
with the System Interface 924 to provide Output Signals 936.
[0067] Exemplary User Settings 934 comprise: Frequency Output which
sets the output frequency of the generator set; Voltage Output
which sets the output voltage of the generator set; Maximum Power
Output which sets the maximum power of the generator set and cannot
exceed a rated maximum output of the engine/generator; Maximum
Current Output which sets the maximum current output of the
generator set; and Maximum Water Temperature which sets the maximum
water temperature of water (or of any exemplary fluid medium)
exiting an exemplary heat exchanger to the generator, power
electronics device, and engine.
[0068] Exemplary Output Signals 936 comprise: Overtemp Warning
which warns of an over-temperature condition for coolants, fluids,
intake air and exhaust of the power generation system; Overtemp
Shutdown wherein a shutdown signal is provided due to an
over-temperature condition for coolants, fluids, intake air and
exhaust of the power generation system; Overpower Warning which is
a warning of an overpower condition for the engine, generator,
and/or generator set; Overcurrent Warning which is a warning of an
over-current condition for the generator, and/or generator set;
Voltage Output which indicates voltage output for the generator,
and/or generator set; Current Output which indicates current output
for the generator, and/or generator set; Frequency Output which
indicates frequency output for the generator, and/or generator set;
DC Bus Volts which indicates voltage of a DC Bus; Input Volts which
indicates input volts to power electronics and/or from secondary
power supply; Input Freq which indicates input frequency to power
electronics and/or from secondary power supply; and Internal
Shutdown (Failure) which provides a signal to indicate internal
shutdown due to failure of a component internal to the generator
set.
[0069] Referring to FIG. 21, an overview 961 of an exemplary
ignition control 942 according to embodiments of the invention is
illustrated. The ignition control 942 monitors, manages and
controls logic blocks that influence ignition of the engine 947.
Control logic blocks that influence the ignition of the engine 947
include Air Control 952, Fuel Control 950, Ignition Control 942,
and Water Cooling Temperature Sensing 946. Based on User Settings
954 (via the System Interface 948), the Logic Control 944 will
monitor, manage and control logic blocks that influence ignition of
the engine 947.
[0070] An exemplary Logic Control 944 receives the User Settings
954 from the System Interface 948. Via the user settings 954, the
Logic Control 944 will monitor all parameters for specified maximum
or minimum limits. The Logic Control 944 will then manage one, any
combination or all of the blocks that influence the ignition of the
engine 947 to prevent the overall power generation system from
exceeding the specified maximum or minimum limits. Based on User
Settings 954, the Logic Control 944 will also communicate with the
System Interface 948 to provide Output Signals 956.
[0071] Still referring to FIG. 21, exemplary User Settings 954
comprise: Operating Mode which can be user specified or
automatically determined wherein Generator Set (engine) can be
configured to operate for maximum torque, maximum power, minimum
fuel (fuel efficiency), and/or minimum emissions (low emissions)
mode; Desired Speed which specifies the desired speed of the
generator set and/or components of the power generation system;
Temperature Warning Level which sets the warning level for various
temperatures of coolants, fluids, intake air and/or exhaust of the
power generation system; Temperature Shutdown Level which sets the
shutdown level for the power generation system or components
thereof based on various temperatures of coolants, fluids, intake
air and exhaust of the power generation system; and Run/Start
Contact which specifies time to crank engine for starting the power
generation system.
[0072] Still referring to FIG. 21, exemplary output signals 956
comprise: Overtemp Warning which warns of an overtemperature
condition for coolants, fluids, intake air and exhaust of the power
generation system; Overtemp Shutdown which provides shutdown signal
due to an overtemperature condition for coolants, fluids, intake
air and exhaust of the power generation system; Overpower Warning
which warns of an overpower condition for the engine, generator,
and/or generator set; Speed (RPM) which indicates speed of prime
mover (engine) and generator in RPM; Delta RPM which indicates
differential in desired and actual speed of prime mover and
generator in RPM. (Differential is used when comparing engine speed
and electrical load (demand) at the output connections); Actual
Engine Mode which indicates actual Mode of engine; Fuel Control
Status which indicates actual Mode of Fuel Control 950; Air Control
Status which indicates the actual Mode of the Air Control 952;
Ignition Control Status which indicates the actual Mode of the
Ignition Control 942; Internal Shutdown (Failure) which provides
signal to indicate internal shutdown due to failure of a component
which is internal to the generator set.
[0073] Referring to FIG. 22, an exemplary Unit Control/Logic
Control 901 interacts with the Ignition Control, Heat Exchanger,
Generator, Power Control and Electrical Breaker. The Logic Control
962 is managed based on inputs from the Operator/User Interface
974. The Operator/User Interface 974 can be onboard or remote via
communication connection. The Logic Control 962 will monitor and
manage the following: Water Cooling Temperature Sensing 964 which
senses inlet and outlet temperatures of cooling fluid medium (e.g.,
water) and coolant circuits; Interface to Ignition Control 966
which monitors and manages the Ignition Control unit; Interface to
Power Control 968 which monitors and manages parameters associated
with the Power Control unit; Current and Voltage Interface 970
which monitors the current and voltage of the generator output; and
Breaker Interface 972 which determines if circuit breaker is open
or closed. If a powered breaker is used, the Logic Control 962 may
be used to control the opening and closing of the breaker.
[0074] Referring to FIG. 23, another exemplary Unit Control/Logic
Control 903 configuration is illustrated. An exemplary Unit
Control/Logic Control comprises a high level interaction between
various system control components. Control components include: Unit
Master Controller 992, Engine Control 976, Power Electronics
Control 982, and Unit Control BIOS 977. For example, an exemplary
Unit Control BIOS 977 interacts with Unit Master Control 992,
Engine Control 976, and Power Electronics Control 982. The Unit
Control BIOS 977 contains: Communications Port 939 for the Power
Unit; Communications Port 941 for the Ignition Unit; monitoring for
Generator Voltage 943; monitoring for Generator Output Current 945
(the parameter values provided in this Fig. for any
element/component are only exemplary, with the ranges of values
provided throughout this document being applicable); monitoring for
Output Voltage 991; monitoring for Output Current 985; monitoring
of the Breaker Control 983; monitoring of Temperature Sensing
components 981; and monitoring for optional Analog I/O 979.
[0075] Still referring to FIG. 23, in exemplary embodiments,
Generator Frequency 937 is calculated from Generator Voltage 943.
Generator Power 933 is calculated from Generator Voltage 943 and
Generator Current 945. Output Frequency 987 is calculated from
Output Voltage 991. Output Power 989 is calculated from Output
Voltage 991 and Output Current 985. Moreover, in an exemplary
embodiment, the Engine Control 976 interacts with Unit Control BIOS
977, Power Electronics Control 982, and Unit Master Control 992.
The Engine Control 976 contains Start/Stop 978 and Speed Control
980 blocks. Start/Stop 978 interacts with Unit Control BIOS 977 and
Speed Control 980 blocks. Speed Control 980 interacts with Unit
Control BIOS 977, Power Electronics Control 984 and Frequency
Control 986. An exemplary Power Electronics Control 984 interacts
with Unit Control BIOS 977, Engine Control 976, and Unit Master
Control 992. Power Electronics Control 984 contains Voltage Control
990, VAR Control 988, Frequency Control 986, and Power Control 984.
An exemplary Voltage Control 990 block interacts with Unit Control
BIOS 977, an exemplary VAR Control 988 interacts with Unit Control
BIOS 977, an exemplary Frequency Control 986 interacts with Unit
Control BIOS 977 and Engine Control 976, and an exemplary Power
Control 984 interacts with Unit Control BIOS 977 and Engine Control
976.
[0076] In an exemplary embodiment, Unit Master Control 992
interacts with Engine Control 976, Power Electronics Control 982
and Unit Control BIOS 977. The Unit Master Control 992 contains
Mode Control 995, Breaker Control 994, Load Control 996, and
Synchronize Control 997 blocks. Mode Control 995 interacts with
Breaker Control 994, Load Control 996, and Synchronize Control 997
within the Unit Master Control 992. Mode Control 995 also interacts
with Engine Control 976 and Power Electronics Control 982. Breaker
Control 994 interacts with Unit Master Control 992, Mode Control
995, and Unit Control BIOS 977. Load Control 996 interacts with
Unit Master Control 992, Mode Control 995, Engine Control 976, and
Power Electronics Control 982. Synchronize Control 997 interacts
with Unit Master Control 992, Mode Control 995, Engine Control 976,
and Power Electronics Control 982.
[0077] Referring to FIG. 24, an exemplary method for generating
power 651 is described according to one of various embodiments of
the invention.
[0078] Still referring to FIG. 24, a first method step 653 includes
providing a generator system comprising a generator having a power
output connector.
[0079] Still referring to FIG. 24, another exemplary method step
655 includes coupling the power output connector to a first power
application, the first power application comprising a first power
demand.
[0080] Still referring to FIG. 24, another exemplary method step
657 includes activating the generator to provide a first power
component to meet the first power demand.
[0081] Still referring to FIG. 24, another exemplary method step
659 includes monitoring the first power demand of the first power
application.
[0082] Still referring to FIG. 24, another exemplary method step
661 includes receiving an indication that the first power demand
has changed to a second power demand different from the first power
demand.
[0083] Still referring to FIG. 24, another exemplary method step
663 includes notifying the generator system of the indication.
[0084] Still referring to FIG. 24, another exemplary method step
665 includes after the notifying, performing one of the following
tasks: maintaining the first power component to meet the second
power demand, or modifying the first power component to a second
power component to meet the second power demand, the second power
component being different from the first power component.
[0085] Still referring to FIG. 24, another exemplary method step
667 includes wherein the first and second power components comprise
different power density outputs.
[0086] Exemplary embodiments described herein provide advantages
and benefits not recognized by the conventional power generation
systems. For example, embodiments of power generation systems
described throughout this application (for example, as described in
FIGS. 1 and 2, and for power generation system 200) comprise
exemplary generator sets with the ability to provide multiple load
capability. These exemplary generation sets are capable of managing
a primary electrical load as well as a secondary electrical load.
In contrast, conventional generator sets are capable of having only
one output for one load which is distributed at a switchgear or a
switchboard. Additionally, the exemplary generation sets according
to the invention of this disclosure are capable of managing
multiple loads, each having a different voltage, wherein again, the
conventional generator sets are capable of having only one output
for one load.
[0087] Moreover, the exemplary power generation systems/generation
sets disclosed herein comprise global power generation packages
that can be configured for selectable voltage and/or selectable
frequency. Additionally, due to the size (e.g., footprint and
weight) of the exemplary power generation systems/generation sets
disclosed herein, advantageous mounting configurations are
possible. For example, because of the smaller footprint and/or size
of the generation sets provided herein, the generator can be
directly mounted to the engine (prime mover) and/or flywheel
housing. By being able to mount the generator directly to the
engine, unique and beneficial mounting configurations are possible
that are not possible with conventional generation sets.
Furthermore, the support structure 800 for exemplary power
generation systems disclosed herein, for example, frame 801
illustrated in FIG. 18 is lighter in weight compared to frame rails
of conventional generation sets, and allows for sensitive
components to be isolated from engine vibration.
[0088] Furthermore, since the exemplary power generation systems
disclosed herein comprise liquid cooled components, for example,
the engine (prime mover), generator and power electronics, and in
combination with the variable speed operation possible with the
system disclosed herein, the combination allows for a quieter
operating power generation system. Additionally, the liquid cooled
components of exemplary power generation systems disclosed herein
removes heat from the respective components to the air in a more
optimum mode by, for example, a radiator, cooling tower, keel
cooler, etc. Still further, the liquid cooled components allow for
an enclosure of the power generation systems, or various components
thereof, to be more tightly sealed which reduces sound waves
produced from the operation of the power generation systems to exit
outside the environment of an exemplary enclosure. Additionally,
tightly sealed power electronic devices and generators are less
prone to ingress by environmental contaminants such as snow, dirt,
sand, bugs and other debris. This increases the reliability of the
exemplary power generation systems disclosed herein compared to
conventional systems, which is important if not imperative for some
applications, such as military operations. In fact, the exemplary
power generation systems disclosed herein have a N+2 reliability
built in, and as a result, is a comparatively higher reliable
system.
[0089] Furthermore, the variable speed capability of the exemplary
power generation systems in combination with the liquid cooled
components allows the power generation systems to operate at higher
RPMs than conventional power generation systems. Higher RPMs
produce shorter sound waves emanating from the exemplary power
generation systems, and therefore, less sound attenuation material
is needed to sound proof the power generation system. Since less
sound-proof material is used, the exemplary power generation system
will be lighter in weight than conventional power generation
systems. Alternatively, if the same amount of sound-proof material
routinely used for conventional power generation systems is used
for the power generation systems disclosed herein, then the power
generation system disclosed herein will be quieter.
[0090] Moreover, the liquid cooled components of the exemplary
power generation systems can contribute to increased fuel
utilization. For example, conventional combined heat and power
(CHP) applications consist of a generator set producing electricity
with a heat recovery equipment on the exhaust system. This
conventional CHP has the heat from the engine (for example,
transmitted to an engine jacket water system) and exhaust system
transferred to the environment, for example, a building for heating
and cooling applications. Moreover, heat rejected from air passing
through the generator is vented to the atmosphere as lost energy.
However, the exemplary power generation systems disclosed herein
can capture the heat energy rejected from the components that are
coupled to heat exchanger(s) in addition to the heat energy
captured from the engine water and exhaust system. Additionally,
the exemplary power generation systems disclosed herein allow for
more efficient cooling of the environment, for example, the engine
room of a vessel or ship because the fluid medium which has
captured the thermal energy from the respective components can be
transmitted to remotely mounted cooling devices such as radiators,
cooling towers, etc. The remotely mounting of cooling devices
reduces the need for sizable air handling equipment in the
exemplary engine room of the vessel or ship.
[0091] Another advantage/benefit of the exemplary power generation
systems disclosed herein is the addition of a secondary input
allows for zero (0) cycle power outage. For example, the exemplary
power generation systems can use batteries as a secondary input
connected to a building distribution system. If the power supply
from a municipality is interrupted or fails, the secondary input
will provide power until the generator set of the power generation
system can be operational. In contrast, conventional power
generation systems need to be ramped up to approximately 1,800 RPMs
before closing a coupled breaker system to provide the power energy
to the load (for example, the building distribution system). The
exemplary power generation systems disclosed herein will begin
producing and providing power energy as soon as the generator is
turning without any noticeable interruption of power to the
consumer/customer.
[0092] Regarding exemplary control schemes for some exemplary
embodiments of the power generation systems disclosed herein, the
system is designed to provide the engine RPM and generator output
to follow the electrical load. Alternatively, for some exemplary
embodiments of the power generation systems disclosed herein, the
systems can have the capability to manage or have the operator
(consumer/customer) select between torque, horsepower and fuel
consumption. These configurations for exemplary systems will allow
the operator (consumer/customer) to optimize capabilities of the
exemplary systems with respect to different applications requiring
different power demands.
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