HYBRID ELECTRICAL POWER GENERATOR AND BATTERY CHARGING SYSTEM
A power generating system comprising an electrical generating set and a modulator configured to maintain optimal voltage regulation under varying load conditions. The system includes a controllable current power source; an active rectifier coupled to the controllable current power source, configured to rectify an output of the controllable current power source to supply utility-grade power or for recharge of a battery or batteries. A controller is configured to adjust at least one of the parameters of the controllable current power source and/or supply from the generator and a parameter of the active rectifier in response to a target output.
1 . A generator set system, comprising:
an engine coupled with an alternator;
a variable voltage regulator coupled to the alternator supplying output power with a voltage output; and
a control system connected to the variable voltage regulator, said control system configured to monitor and respond to deviations in a power demand, whereby when the power demand deviates from a threshold level, the control system signals the variable voltage regulator to modulate the voltage output from the alternator.
2 . The generator set system of claim 1 , wherein the generator system is coupled to a load, and wherein the control system monitors a current demanded by the load, and wherein when the current demanded exceeds a predefined threshold, the control system signals the variable voltage regulator to adjust the alternator's voltage output, thereby limiting current drawn by the load.
3 . The generator set system of claim 2 , wherein a component of the control system is configured to monitor current demanded by the load based on a load state of charge determined via a battery management system (BMS).
4 . The generator set of claim 3 , wherein the wherein the control system reads a state of charge of a target battery from a CAN bus of the target battery.
5 . The generator set system of claim 2 , wherein the control system monitors the current demanded by the load by monitoring a generator current output.
6 . The generator set system of claim 1 , wherein when the control system detects a current draw in excess of an upper threshold, the variable voltage regulator modulates voltage output from the alternator, wherein voltage output temporarily cycles between a lower voltage range and an upper voltage range, until amperage draw stabilizes.
7 . The generator set system of claim 6 , wherein the load is a lithium-ion battery, wherein the voltage cycling occurs when the lithium-ion battery has an approximate state of charge of approximately twenty percent, until the lithium-ion battery charges reach an approximate range of seventy to eighty percent.
8 . The generator set system of claim 6 , wherein the load is a lithium-ion battery, wherein the voltage cycling occurs when the lithium ion battery has an approximate battery voltage of three volts per cell until the battery voltage reaches approximately four point two volts per cell.
9 . The generator set system of claim 1 , wherein when the control system detects a current draw in excess of eighty-five amperes, the variable voltage regulator modulates voltage output from the alternator, wherein voltage output temporarily cycles between twenty-six volts and twenty-nine volts, until amperage draw stabilizes at approximately seventy-five amperes.
10 . The generator set system of claim 1 , wherein the control system modulates the voltage regulator to increase or reduce voltage output in short-duration pulses or longer as the load decreases.
11 . The generator set system of claim 1 , wherein the control system software is configured to modulate the generator output voltage in a stepwise manner via a variable voltage regulator, wherein the software defines a minimum voltage supported by the voltage regulator and establishes a target voltage set point, and wherein, upon detection of an excess current condition, the software commands the voltage regulator to reduce the output voltage to the defined minimum voltage and subsequently increase the output voltage toward the target voltage set point.
12 . The control system of claim 11 , wherein upon detection of an excess load condition, the control system software commands the variable voltage regulator to reduce the output voltage, and subsequently restore the voltage toward a predefined target voltage set point in a stepwise manner.
13 . The generator set system of claim 12 , wherein a rate of voltage restoration toward the target voltage set point is varied based on electrical load demand.
14 . The generator set system of claim 12 , wherein a rate of voltage restoration toward the target voltage set point is varied based on real-time measurements of engine rotational speed and electrical load demand.
15 . The generator set system of claim 1 , wherein the control system commands the variable voltage regulator to adjust current supplied to a rotor field coil of the alternator to control alternator output voltage in response to excess load conditions.
16 . The generator set system of claim 1 , wherein the engine is coupled with a controller unit, whereby the controller unit may initiate the engine; wherein the controller unit is configured to provide a plurality of selectable operating modes and to initiate engine operation in a selected operating mode.
17 . The generator set system of claim 1 , wherein at least one operating mode is configured to initiate the control system to monitor deviations in current output by modulating voltage output, and wherein at least one operating mode is configured to override the control system, wherein voltage output is not modulated.
18 . The generator set system of claim 1 , wherein the control system adjusts the output voltage by controlling the variable voltage regulator, and wherein the output voltage is modulated in a stepwise manner based on the monitored electrical load and engine operating conditions.
19 . The generator set system of claim 1 , wherein the control system comprises sensors and software, wherein the sensors continuously monitor current output data, and wherein the software receives the monitored data and programs the controller to “pulse” or modulate generator voltage as needed to maintain a target engine power band.
20 . A generator set system, comprising:
an engine coupled with an alternator;
a variable voltage regulator coupled to the alternator; and
a control system connected to the variable voltage regulator, configured to monitor and respond to deviations in power demand and deviations in engine revolutions per minute, whereby when power demand deviates from a threshold level, the control system signals the variable voltage regulator to modulate the voltage output from the alternator, and whereby when the control system detects deviations in engine revolutions per minute, outside of a preset range, the control system being configured to signal the engine to pulse export voltage in a cyclic pattern.
21 . The generator set system of claim 20 , wherein a control system software monitors the engine's revolutions per minute, and upon detecting revolutions per minute below a predefined threshold, disconnects export power for a preset time, and subsequently reconnects export power when the revolutions per minute stabilize within user-specified limits.
22 . The generator set system of claim 20 , wherein the control system is configured to pulse power output by disconnecting and reconnecting export power in a cyclic manner when engine revolutions per minute drop beyond a predetermined threshold.
23 . The generator set system of claim 20 , wherein a control system software is configured to monitor current output, wherein when current output exceeds a preset threshold, the software is programmed to command the alternator's variable voltage regulator to modulate voltage to produce a pulsing effect.
24 . The generator set system of claim 20 , wherein the control system is further configured with sensors to monitor engine revolutions per minute, and wherein when a number of revolutions per minute drops below a programmed limit, the control system triggers export power to disconnect and reconnect periodically, until the engine revolutions per minute returns to a predetermined threshold.
25 . The generator set system of claim 20 , wherein a duration of the pulsing intervals is established in response to an electrical load demand and engine capacity.
26 . A method for preventing engine stall in a generator set the method comprising:
coupling an engine to an alternator;
coupling an alternator to a variable voltage regulator; and
programming the variable voltage regulator with a control system that is configured to monitor and respond to deviations in power demand and deviations in engine revolutions per minute, whereby when power demand deviates from a threshold level, the control system signals the variable voltage regulator to modulate the voltage output from the alternator, and whereby when the control system detects deviations in engine revolutions per minute, outside of a preset range, the control system being configured to signal the engine to disconnect and reconnect export power in a cyclic pattern.
27 . The method of claim 26 , whereby the control system includes software that modulates the generator output voltage in a stepwise manner via a variable voltage regulator, whereby the software defines a minimum voltage supported by the voltage regulator and establishes a target voltage set point, and whereby, upon detection of an excess current condition, the software commands the voltage regulator to reduce the output voltage to the defined minimum voltage and subsequently increase the output voltage toward the target voltage set point.
28 . The method of claim 26 , wherein the control system signals software to prompt the variable voltage regulator to modulate alternator voltage by adjusting the current supplied to a rotor field coil of the alternator, the alternator having a rotor with an electromagnet.