Kohler Company

Douglas W Dorn

Isaac S Frampton

Richard Allen Mauk

Eric D Albsmeier

Harrison Chiu

Steve Jungers

Allen Frederick

Zane Eaton

Richard A Mauk

Richard D Van Maaren

Anthony James Hackbarth

Zane C Eaton

Paul Honkanen

William Herman Gross

Andrew John Sember

Patrice Mallejac

Vikram Kaura

A voltage regulator for a generator having a dynamic voltage-to-frequency (V/F) ratio includes a memory, a voltage calculator, and a selection module. The memory is configured to store a plurality of voltage-frequency curves for the generator. The voltage calculator is configured to receive data indicative of an output of the generator and configured to determine a resistance value from the output of the generator and a voltage value from the output of the generator. The selection module configured to select a voltage-frequency curve from the plurality of voltage-frequency curves in response to the resistance value and configured to select a voltage-frequency ratio from the selected voltage-frequency curve in response to the voltage value. An output adjustment for the generator is determined in response to the selected voltage-frequency ratio.

Dynamic frequency to voltage ratio for regulator machine

A generator system for operation of at least one generator and at least one breaker includes an interface, a database, and a generator controller. The interface is configured to receive an architecture for the generator system. The database includes at least one generator parameter and at least one breaker parameter. The generator controller is configured to determine generator layouts from the architecture for the generator system. The generator controller determines a generator system command based on a comparison of the generator layouts, the at least one generator parameter, and the at least one breaker parameter.

Generator system architecture

A generator waveform is measured using one or more techniques that reduce the computing resources for measuring the generator waveform and the time required for measuring the generator waveform. One example includes a template matching technique that iteratively selects templates to estimate the phase offset of the generator waveform. One example includes a root mean squared value calculated from less than sample time period that is less than one half of a cycle of the generator waveform. A generator controller calculates a command or parameter for the generator based on the estimated phase offset or the root mean squared value.

Generator waveform measurement

An electrical power generator system may include two or more paralleled generators. At least one of the generators includes a first power source and a second power source. A disconnection of a first power source is identified at a generator controller of one of the generators. The generator controller may be configured to access or generate a power failure message indicative of the disconnection of the first power source. The generator controller may be configured to transmit the power failure message using the second power source because the second power source is switched to the generator controller in response to the disconnection of the first power source. The system may enter a communication failure handling mode based on the power failure message.

Communication failure handling

A generator system may include two or more generators electrically connected through a generator bus. A controller receives operation data from a first generator. The operation data may describe a power flow from a second generator to the first generator. From the operation data, either a loss of speed control or a loss of voltage control may be identified at the second generator. The controller may generate a command for the second generator based on the loss of speed control or the loss of voltage control.

Protective functions for parallel generators

A power system may include a first generator configured to be connected to at least one other generator. Each generator may be configured to be connected to a bus. The bus may be connected to at least one load. The first generator includes a controller that operates the first generator and determines a need to regenerate a diesel particulate filter in the first generator. The controller communicates the need to regenerate the diesel particulate filter to the at least one other generator.

DPF regeneration in a power system that includes parallel generators

Some embodiments relate to an example generator management system. The generator management system includes a first generator that is adapted to supply power to load and a first generator controller that operates the first generator. The generator management system further includes a second generator that is adapted to supply power to the load and a second generator controller that operates the second generator. The generator management system further includes a communication bus that connects the first generator controller and the second generator controller such that the first generator controller and the second generator controller exchange data. At least one of the first generator controller and the second generator controller selectively activates the first generator and the second generator in an order that depends on an operating parameter of the first generator and the second generator (as opposed to a fixed sequence which is done in existing systems).

Generator management system that selectively activates generators based on an operating parameter

A power management system may include a generator controller. The generator controller may (i) operate the generator; and (ii) prohibit a transfer switch from supplying first or second power to an output of the transfer switch. In some systems, the first power may be primary power (e.g., from a primary power source such as a utility) while the second power is secondary power (e.g., from a secondary power source such as a generator). In other systems, the second power may be primary power while the first power is secondary power, or both the first and second power may be secondary power.

Generator controller configured for preventing automatic transfer switch from supplying power to the selected load

Some embodiments relate to a standby power system. The standby power system includes a sensor that is adapted to monitor a primary power source which provides power to a load. In some embodiments, the sensor may monitor characteristics of the power supplied by the primary power sourcethat may be used to sense abnormalities. The standby power system further includes a generator that is also adapted to supply power to the load. As an example, the generator may include an internal combustion engine that drives an alternator. The standby power system further includes a generator controller that operates the generator and exchanges data with the sensor. The generator controller predicts a need to supply power to the load based on data received from the sensor. The generator controller then acts to minimize a time to availability of the generator based on the prediction.

Standby power system that predicts a need to supply power to a load to minimize start time of a generator

Torque is balanced among generators in a system of parallel generators. Control of the generators may be performed by one or more individual generator controllers or by a centralized controller. The torque on two or more generators is detected. The controller calculates a torque target based on the torque on the two generators or other operating characteristics of the system. The operation of at least one of the generators is controlled based on the torque target.

Torque sharing on paralleled generators

Some embodiments relate to an example generator management system. The generator management system includes a first generator having a first set of power leads and a second generator having a second set of power leads. The generator management system further includes a bus that connects the first output and the second output. A controller selectively cuts off fuel to the second generator to add a load to the bus. It should be noted that embodiments are contemplated where the generator management system alternatively cuts off fuel to the first generator to add a load to the bus.

Generator management system that selectively cuts off fuel to a generator to add a load to a bus

A plurality of generators can be connected in parallel to a common electrical bus. Each generator has a controller that regulates the voltage and frequency of the electricity being produced. Before a given generator connects to the electrical bus, its controller senses whether electricity is present on the bus and if not, the connection is made. Otherwise, the controller synchronizes the electricity being produced to the electricity is present on the bus before the connection occurs. The controller in each generator may also implement a load sharing function which ensures that the plurality of generators equitably share in providing the total amount of power demanded by the loads. The load sharing can be accomplished by controlling the generators to operate a substantially identical percentages of their individual maximum power generation capacity.

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Sheboygan Falls, WI, United States of America

Douglas W Dorn