Power generation systems and methods of generating power

ES 2 668 356 T3

DESCRIPTION

Power generation systems and power generation methods

Technical field

The present invention relates to power generation systems and power generation methods.

Background of the technique

Current products offered by the portable power generation industry are poor in meeting customer needs. For example, today's portable generator sets are limited to single voltages at a designed output frequency, that is, generator sets operate at fixed revolutions per minute (rpm), which limits the usefulness of portable power generation systems. current. To manage the needs of customers operating in a global environment, portable generator sets are reconfigured after purchase, or multiple portable generator sets operating with different frequencies and respective voltages are purchased. Portable power generation systems are needed to solve these problems and more easily meet customer needs.

Additionally, the portable power generation industry continues to strive to meet customer demands for products featuring light weight, small size (including footprint dimensions), and low fuel consumption. For example, a conventional generator (generator) set comprises a length or length dimension of approximately 152.50 cm, without a heat exchanger, and weighs approximately 907 kg.

Additionally, the portable power generation industry continues to strive to meet the needs of customers using generators and generator sets as auxiliary power units (APUs). For example, improvements are needed for auxiliary power units that are used in the trucking business, such as machinery towing and / or the long haul industry. As environmental concerns lead to stricter noise and air emission regulations, it is increasingly common for truck drivers to be unable to run their engines in a greater number of areas, for example at truck stops, loading docks and rest areas, due to emissions regulations and idle laws. This means that the truck driver cannot operate modern appliances, such as an on-board air conditioner, a refrigerator, a radio and / or television. It also means that the truck driver cannot perform work-related tasks that require an on-board computer. Portable power generation systems are needed as solutions to solve these problems, and to respond to regulatory and market pressures in the trucking industry. Additionally, the portable power generation industry continues to strive to meet truck drivers' demands for APUs to keep parasitic loads on a truck engine to a minimum.

Furthermore, the transportation industry continues to strive to produce fuel efficient and environmentally friendly vehicles. This motivation has resulted in alternative energy generation designs and technologies for vehicles, such as electric vehicles and hybrid electric vehicles. These vehicle designs present unique power demands and applications, where a power plant provides battery charging, power for peak load requirements, braking energy absorption, and power for main loads. Important design parameters and considerations for power plants are size and weight, as these parameters dictate the load and physical size of the vehicle. Additional design consideration will reflect customers' need for systems capable of withstanding exposure to rain, dust, or other external environmental conditions.

Additionally, conventional generator sets or generator sets are used to transform energy and / or isolate energy from one source to another. The application generally involves the coupling of an AC motor, which is coupled with an AC or DC radial space generator, to create DC power or a different AC voltage and frequency. There is a continuing need to optimize the size, weight, and cost of conventional generator set systems. This is especially true for military applications, for example for the Navy and any industry related to navigation, which require high tolerance parameters and specifications regarding cooling, weight and space requirements for power generation. Thermodynamic handling in these applications is complicated and very expensive. Accordingly, there is a need to provide a generator set system or assembly that solves these problems of conventional generator set systems.

Summary

In one aspect of the invention, a power generation system is provided as defined in the claims. In one aspect of the invention, a power generation system is provided that includes a

ES 2 668 356 T3 internal combustion engine configured to provide rotational mechanical energy. A generator is configured to receive rotational mechanical energy and generate electrical power in response to rotational mechanical energy. A fluid medium is provided to the internal combustion engine and generator, to remove thermal energy from the internal combustion engine and generator.

Brief description of the drawings

Preferred embodiments of the invention are described below, with reference to the following accompanying drawings.

Fig. 1 is a block diagram of an exemplary power generation system in accordance with embodiments of the invention.

Fig. 2 is a block diagram of an exemplary power generation system in accordance with other embodiments of the invention.

FIG. 3 is a side elevation view of an exemplary power generation system in accordance with one embodiment of the invention.

Fig. 4 is the same view as Fig. 3 but emphasizes the components of the exemplary power generation system.

Fig. 5 is a front elevation view of the power generation system of Fig. 3.

Fig. 6 is the same view as Fig. 5 but emphasizes the components of the exemplary power generation system.

Fig. 7 is a side elevation view of the power generation system of Fig. 3, illustrating a side view opposite the side view of Fig. 3.

Fig. 8 is the same view as Fig. 7 but emphasizes the components of the exemplary power generation system.

Fig. 9 is a top plan view of the power generation system of Fig. 3.

Fig. 10 is the same view as Fig. 9 but emphasizes the components of the exemplary power generation system.

Fig. 11 is an elevated rear view of the power generation system of Fig. 3.

FIG. 12 is a perspective view of an exemplary steering wheel in accordance with one embodiment of the invention.

FIG. 13 is a perspective view of an exemplary generator in accordance with one embodiment of the invention. Fig. 14 is a sectional view of the generator of Fig. 13.

Fig. 15 is a perspective view of an exemplary heat exchanger in accordance with one embodiment of the invention.

FIG. 16 is a side perspective view of an exemplary power electronic device in accordance with one embodiment of the invention.

Fig. 17 is a perspective side view of the power electronic device of Fig. 16, illustrating a side view opposite the side view of Fig. 16.

Fig. 18 is a perspective view of an exemplary support structure in accordance with one embodiment of the invention.

FIG. 19 is a block diagram of exemplary components, monitored by an exemplary packet control unit (also called a control unit) in accordance with embodiments of the invention.

FIG. 20 is a block diagram of exemplary components, monitored by an exemplary power control (also called an electronic power device) in accordance with embodiments of the invention. FIG. 21 is a block diagram of an exemplary ignition control in accordance with embodiments of the invention.

FIG. 22 is a block diagram of an exemplary logic control / control unit in accordance with embodiments of the invention.

FIG. 23 is a block diagram of another exemplary logic control / control unit in accordance with embodiments of the invention.

Detailed description of exemplary embodiments

Referring to FIG. 1, a general view of an exemplary embodiment of a power generation system 10 is illustrated, as a block diagram. An exemplary power generation system 10 includes a system for a generator and / or generator set. In an exemplary embodiment of the power generation system 10, a rotational energy source 20 has an output in the form of rotational mechanical energy, provided by an output shaft 22 that rotates with a rotational speed measured in revolutions per minute (rpm). The rotational mechanical energy of the rotating output shaft 22 is transferred to a generator 24, which converts the rotational mechanical energy of the rotating output shaft 22 into electrical energy and thermal energy (ie, electricity and heat, respectively). The electrical output of the generator 24 is related to the speed of the output shaft 22 of the rotational power source 20. During the process of conversion of rotational mechanical energy into electrical energy, energy loss is incurred, in the form of heat. In an 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 medium. fluid, by

For example, air and / or a liquid is provided to the generator 24 through a fluid conduit (shown below), for example a hose or pipe between the generator 24 and the heat exchanger.

Additionally, a part of the heat is transferred to the outer surfaces of the generator 24, from which the heat is transferred to the air or the surrounding environment. In some embodiments, the power generation system includes a heat exchanger 26. In some embodiments, the heat exchanger or cooler 26 is included within a matrix or network of heat exchanger units. An exemplary matrix or network is coupled to a fluid in a heat exchange relationship, using a fluid conduit, for example a hose or tube.

Still referring to Fig. 1, generator 24 is coupled with a power electronic device 28 or power conversion device, using interface 32. Electricity produced by generator 24 is transferred to power electronic device 28, to its conversion to a desired shape by the operator of the power generation system 10. In one embodiment of the system 10, the thermal energy generated by a power electronic device 28 is at least partially removed by a fluid, for example air and / or a liquid. In some embodiments of system 10, the thermal energy generated by a power electronic device 28 is at least partially removed by a liquid. The power electronic device 28 comprises a heat exchanger 30 coupled in fluid communication with a heat exchanger 30, by means of a liquid cooling circuit (illustrated in more detail below). The heat produced during the conversion process, from the electricity generated to a form selected by the operator, is transferred to the liquid cooling circuit from the electronic power device 28, and to a heat exchanger 30. The heat from the heat exchanger 30 is transferred to the environment and / or other medium. In some embodiments of system 10, heat exchanger 30 comprises a separate unit. In other embodiments of system 10, heat exchanger 30 is combined within a network of at least one other heat exchanger unit, for example a network that includes a heat exchanger 26. An electronic power device 28 is capable of power conversions, or signal conversions, from an input source to an output source, for example AC to DC, DC to AC, and AC to AC. Power electronic device 28 is capable of one or more of the aforementioned conversions. In some embodiments of the power generation system 10, an operator can configure, reconfigure, and / or modify the power electronic device 28 so that the output current, frequency, voltage, and / or polarity are selectable.

Still referring to Fig. 1, the power electronic device 28 is coupled to one or more output connections 36. Electricity converted with the selected output current, frequency, voltage and / or polarity is transferred to the one or more output connections 36. In some embodiments, the output connection 36 is an integral component of the power electronic device 28. In other embodiments, the output connection 36 comprises a separate component, connected to the power electronic device 28 via an interface 34. The output connection 36 provides an interface between the power generation system 10 and an electrical load (not shown). .

Still referring to Fig. 1, an exemplary power generation system 10 comprises a control unit 38 that monitors the respective components and devices described above, eg, rotational power source 20, generator 24, electronic device 28 power and outlet connection 36, respectively. A data conduit array 40 is coupled between the packet control unit 38 and the respective devices, to communicate input and output data between the respective devices. Exemplary control unit 38 has the ability to perform one or more of the following functions: monitor power generation system 10, diagnose problems within power generation system 10, control components of power generation system 10, announce the status of the components of the power generation system 10 and monitoring the power generation system 10. In some embodiments, the packet control unit 38 may also function as an interface for local and / or remote monitoring and control.

It should be understood that various combinations of devices (eg, rotational energy source 20, generator 24, electronic power device 28, and outlet connection 36, respectively) can be coupled in fluid communication with various combinations of heat exchangers. . For example, a power generation system 10 may comprise a single heat exchanger, operating alone and coupled in fluid communication with a single device 20, 24, 28, 36. That is, a single heat exchanger may be coupled to a single device 20, 24, 28, 36. Alternatively, one or more heat exchangers may be coupled to a single device. For example, two or more heat exchangers may be coupled in fluid communication with the generator 24, and the combination of heat exchangers may be in fluid communication with each other, or not in fluid communication with each other. Alternatively, one or more devices can be coupled to a single heat exchanger. For example, two or more devices, for example rotational energy 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 each other, or not be in fluid communication. in fluid communication with each other. Additionally, an exemplary power generation system 10 may 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 may include a single device coupled to a single heat exchanger, and include another single heat exchanger coupled to a plurality of devices. Additionally, an exemplary power generation system 10

ES 2 668 356 T3 can include any combination of the examples presented above. For example, an exemplary power generation system 10 may 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 individual device or coupled to another plurality of heat exchangers; and in addition, this exemplary power generation system 10 may include any additional combination of devices coupled to an additional combination of heat exchangers.

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 generator set. In an exemplary embodiment of the power generation system 60, a fuel supply 62 provides chemical energy to a rotational energy source 64, through a fuel conduit 66. In accordance with the invention, supply 62 is cooled by a fluid, for example a liquid. In accordance with the invention, fuel supply 62 is coupled, for example in fluid communication, to a heat exchanger 68 to at least partially remove thermal energy from fuel supply 62. An exemplary heat exchanger 68 defines a separate component of the power generation system 60. In accordance with the invention, the heat exchanger 68 is combined within a network of at least one other heat exchanger unit. Rotational energy source 64 comprises an output shaft 70 and converts chemical energy from fuel supply 62 into rotational mechanical energy in output shaft 70. Rotational energy source 64 is coupled in fluid communication with a heat exchanger 72. At least a part of the heat generated during the conversion of chemical energy to rotational mechanical energy is transferred to a fluid medium, for example a liquid provided to the rotational energy source 64 through a cooling circuit. An exemplary heat exchanger 72 defines a separate component of the power generation system 60. According to the invention, heat exchanger 72 is combined within a network of at least one other heat exchanger unit, for example heat exchanger 68.

Still referring to FIG. 2, rotational output shaft 70 of rotational energy source 64 is coupled to gearbox 74, to transfer rotational mechanical energy from rotational energy source 64 to gearbox 74. . Gearbox 74 comprises an output shaft or drive shaft 78, which is coupled to a generator 76. Shaft 78 transfers rotational mechanical energy from output shaft 70 from rotational energy source 64 to drive shaft 78, which drives generator 76. An exemplary gearbox 74 is configured to selectively increase or decrease the rotational speed of the output shaft 70 of the rotational energy source 64, which corresponds to selectively increasing or decreasing the rotational speed of the drive shaft 78, which corresponds to increasing or selectively decrease the rotational speed of generator 76. Such exemplary selectivity of gearbox 74 ensures that generator 76 operates at optimum speed. During the conversion of the increasing or decreasing rotational speed of the output shaft 70 to the drive shaft 78, thermal energy is generated within the gearbox 74. According to the invention, the drive shaft 78 is coupled in fluid communication with a heat exchanger 80, in which at least part of the heat generated by converting the rotational mechanical energy of the respective shafts 70 and 78 is transferred to a fluid medium. , for example air and / or a liquid that is provided to the gearbox 74 through a conduit, for example a hose or pipe (shown below). An exemplary heat exchanger 80 defines a separate component of the power generation system 60. According to the invention, the heat exchanger 80 is combined within a matrix or network of at least one other heat exchanger unit, for example with the heat exchanger 68 or with the heat exchanger 72, or with both. An exemplary matrix or network is coupled in fluid communication via an exemplary conduit, for example a hose or tube.

The generator 76 converts rotational mechanical energy into electrical energy and thermal energy (ie, electricity and heat). According to the invention, the generator 76 is coupled in fluid communication with a heat exchanger 82, in which at least part of the heat generated in the process of converting mechanical energy to electricity is transferred to a fluid medium, for example air and / or a liquid that is provided to generator 76 through a conduit, for example a hose or pipe (shown below). An exemplary heat exchanger 82 defines a separate component of the power generation system 60. In accordance with the invention, the heat exchanger 82 is combined within a matrix or network of at least one other heat exchanger unit, for example with the heat exchanger 68 or with the heat exchanger 72, or both. An exemplary matrix or network is coupled in fluid communication via an exemplary conduit, for example a hose or tube.

The electricity produced by the generator 76 is transferred to a power electronic device or power conversion device 84. The electricity produced by the generator 76 is transferred to the electronic power device 84 for conversion to one or more forms desired by the operator of the power generation system 60. In an exemplary embodiment, the power electronic device 84 is coupled in fluid communication with a heat exchanger 86, in which at least part of the 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 that is provided to the power electronic device 84 through a conduit, for example a

ES 2 668 356 T3 hose or pipe (shown below). An exemplary heat exchanger 86 defines a separate component of the power generation system 60. In accordance with the invention, the heat exchanger 86 is combined within a matrix or network of heat exchanger units, with the heat exchanger 68, 72, 80 and 82. An exemplary matrix or network is coupled in fluid communication via an exemplary conduit, for example a hose or tube. In an exemplary embodiment, the electronic power device 84 has the ability to interface with a secondary power source 100. Secondary power source 100 is capable of providing secondary power input to electronic power device 84, through an interface, and / or receiving power from electronic power device 84 for distribution or storage. Some exemplary devices for exemplary secondary power source 100 include another generator, a utility power outlet, a flywheel energy storage device, batteries, (super) capacitors, or other power sources. An exemplary power electronic device 84 will handle various combinations of electrical current, for example:

<td>Main entrance</td><td>Secondary entrance</td><td>Departure</td>

<td>AC</td><td></td><td>CA *</td>

<td>AC</td><td>AC</td><td>CA *</td>

<td>AC</td><td>DC</td><td>CA *</td>

<td>AC</td><td></td><td>DC*</td>

<td>AC</td><td>AC</td><td>DC*</td>

<td>AC</td><td>DC</td><td>CA *</td>

<td>DC</td><td></td><td>CA *</td>

<td>DC</td><td>AC</td><td>CA *</td>

<td>DC</td><td>DC</td><td>CA *</td>

<td>DC</td><td></td><td>CA *</td>

<td>DC</td><td>AC</td><td>DC*</td>

<td>DC</td><td>DC</td><td>DC*</td>

* Capable of one or a multiple of outputs.

An exemplary power electronic device 84 provides an output from which frequency, voltage, and polarity can be selected. An exemplary power electronic device 84 provides an output that includes digital grade energy. An exemplary power generation system 60 comprises an output from power electronic device 84, which is transferred to transformer 88 through an interface. An exemplary power generation system 60 comprises an exemplary transformer 88, coupled to a distribution panel 94 through an interface 92, wherein the distribution panel 94 is coupled to power loads to be used by a consumer. In an exemplary embodiment, an exemplary transformer 88 is coupled in fluid communication with a heat exchanger 90, wherein at least part of the heat generated in the transformer 88 is transferred to a fluid medium, for example air and / or a liquid that it is provided to the transformer 88 through a conduit, for example a hose or pipe (shown below). An exemplary heat exchanger 90 defines a separate component of the power generation system 60. In another embodiment, heat exchanger 90 is combined within a matrix or network of at least one or more heat exchanger units, for example with heat exchanger 68, 72, 80, 82 and / or 86, individually or in any combination thereof. An exemplary matrix or network is coupled in fluid communication via an exemplary conduit, for example a hose or tube.

Still referring to Fig. 2, the power generation system 60 comprises a control unit package 96 that monitors the respective components and devices mentioned above, for example the fuel supply 62, the rotational power source 64, the box. 74 gearbox, generator 76, electronic power device 84, transformer 88, and distribution panel 94, respectively. A data conduit array 98 is coupled from the power electronic device 84 to the respective devices, to communicate the input and output data between the respective devices and the power electronic device 84. Exemplary control package unit 96 has the ability to perform one or more of the following: monitor components of power generation system 60, diagnose problems with components of power generation system 60, control components of power generation system 60 , announce status information related to the components of the power generation system, and monitor the power generation system 60. In another exemplary embodiment, the packet control unit 96 may also function as an interface for local and / or remote monitoring and control.

With reference to Figs. 3-11, an exemplary embodiment of a power generation system 200 is illustrated. In Figs. 12-18 illustrate the components of an exemplary embodiment of a power generation system 200. It should be understood that the power generation system 200 can be used for the power generation systems mentioned above with respect to Figs. 1 and 2. It should also be understood that the specific components of Figs. 12-18, and the schemes presented in Figs. 20-24, can be used for the power generation systems discussed above with respect to Figs. 1-2 and system 200

ES 2 668 356 T3 of power generation. 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 schemes presented in Figs. 20-24.

The 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 an exemplary embodiment, the rotational power source comprises a diesel engine 208. An exemplary 208 diesel engine is designed with an optimal gear train (not shown) within the engine, with a high contact ratio two gear front gear train mounted on the engine block, and has the added advantage of offering low noise characteristics. An exemplary 208 diesel engine includes a fuel system that has mechanically controlled pump units (not shown), mounted within the engine block, eliminating external high pressure lines, minimizing leak paths, and reducing fuel levels. noise. This fuel system contributes to cost efficiency and a clean design. An example of a diesel engine that could be used for the 208 diesel engine is an industrial engine marketed by John Deere as the Model 4024T 66 hp Diesel Engine (www.deere.com).

The diesel engine 208 has an output that provides rotational mechanical energy in the form of an output shaft (not shown) that is rotatable and is coupled to a rotary coupling device, which couples the engine 208 to a generator (in Fig. 3 only generator 360 is shown). An example of a rotary coupling device comprises a flywheel that provides rotational mechanical energy from the rotary output shaft to the generator, for conversion to electrical and thermal energy (ie, electricity and heat, respectively). An example of a handwheel that could be used as the handwheel 600 illustrated in Fig. 13 (in Fig. 3 only 340 flywheel housing shown) is marketed as an ARCUSAFLEX® model Ringfeder Arcusaflex Coupling (www.ringfeder.com).

Referring to FIG. 12, an exemplary flywheel 600 comprises a coupling ring 602 that forms a cylindrical opening 604, for receiving the generator shaft that provides the coupling of flywheel 600 to the generator. In one embodiment, an exemplary flywheel 600 comprises a rubber disc component 606 that allows the generator shaft to be provided with angular, axial, and parallel misalignments, and also dampens vibrations.

With reference to Figs. 13-14, an exemplary generator 640 is illustrated (only the generator housing 360 is shown in Fig. 3) and comprises a flange portion 642 for securing the generator 640 to a structure or component of the power generation system 200 ( Fig. 3). An exemplary generator 640 comprises a housing 644 integral with a flange portion 642, to protect and enclose the internal structure and components 648 of generator 640. Referring to Fig. 3, an exemplary generator housing 360 seals and protects the generator 640 from the environment, and can withstand exposure to water and sand. An example of a generator that could be used for the 640 generator is marketed by TM4 Energy as a 40 kW model TM4 generator.

Referring to FIG. 3, an exemplary power electronic device 300 positioned elevated on the generator housing 360 is illustrated. It should be understood that the power electronic device 300 could be positioned at any location relative to the other components of the power generation system 200. Power electronic device 300 comprises a matrix 302 of output connections 308. The output connections 308 comprise electrical ports for use by the consumer, for connection to loads that allow the consumer to use the electrical energy produced by the generator. An exemplary power electronic device 300 is a power conversion device that converts the generator output (AC or DC) into a usable voltage (AC or DC) and frequency (50 Hz, 60 Hz, etc.). The exemplary power electronic device 300 is sealed from the environment and can withstand immersion in water, and can withstand repetitive shock (vibration) loads of up to 50g. The components of the power electronic device 300 are mounted on a hollow plate through the hollow portion of which a fluid (refrigerant) from a heat exchanger passes, to remove the heat from the power electronic device 300 generated during the energy conversion process (loss due to inefficiencies). In one embodiment, the power electronic device 300 is integrated into the generator housing 360 or it can be a separate component, which is mounted to the frame (discussed in more detail below). An exemplary power electronic device 300 is five to ten times smaller in size than a conventional power electronic device.

With reference to Figs. 16-17, an exemplary power electronic device 700 is illustrated in more detail. Power electronic device 700 comprises cooling ports 706 and 708 for coupling to an exemplary heat exchanger for fluid transport. The power electronic device 700 further comprises electrical connections / ports 716 and communication ports 710 and 712. An exemplary power electronic device 700 comprises a resistance temperature device (RTD) 714, and center of gravity mounts 718 to prevent shock and vibration to the power electronic device 700. Housing portions 702 and 704 protect and enclose the structure within power electronic device 700. An example of a power electronic device that could be used as a device

ES 2 668 356 T3 Power Electronic 700 is available from Rockwell Automation as the LiquiFlo ProPulse Power Module.

With reference to Figs. 7-8, an exemplary power generation system 200 includes a packet control unit 500, illustrated positioned adjacent to the motor 208 and includes a viewing window 502. It should be understood that the package control unit 500 could be placed in any location relative to the other components of the power generation system 200. An exemplary control package unit collects, shares, and transmits pertinent information between specific components of the 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 control package 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 control package unit 500 will control the generator output and the temperature of the fluid (refrigerant) within the generator from the heat exchanger. With respect to the power electronic device, an exemplary control unit package 500 will control the temperature of the fluid (refrigerant) within the power electronic device, and will control the electrical input and output from the power electronic device.

With respect to the heat exchanger, an exemplary control package unit 500 will monitor two components (discussed in more detail below) of the heat exchanger, a hot loop and a cold loop. The hot circuit has two components that are represented herein as hot circuit # 1 and hot circuit # 2, and the cold circuit has one component. Exemplary control package unit 500 will control the cold loop inlet and outlet temperatures and monitor the inlet and outlet temperatures of hot loop # 1 and hot loop # 2, respectively. An example package control unit that could be used for package control unit 500 is marketed by Woodward as a Model 1500 generator set controller.

Referring to FIG. 3, an exemplary heat exchanger 400 positioned at one end of the power generation system 200, opposite the engine 208, is illustrated. It should be understood that the heat exchanger could be positioned at any location relative to the others. components of the power generation system 200. An example of a heat exchanger comprises a plate and frame design and is sold by Sondex as model Jernet 9 (www.sondexuk.com/gasketed). This exemplary heat exchanger plate and frame design comprises two fluids passing in opposite directions, up and down alternate channels formed in the exemplary press plate packs 409 and 413 discussed in more detail below.

Referring to FIG. 15, in an exemplary embodiment, heat exchanger 400 comprises side frame structures 405 and 407 secured on opposite sides of respective plate packs 409 and 413, for example by clamping bolts 423. Exemplary side frame structures 405 and 407 comprise metal and exemplary plate packs 409 and 413 comprise metal. Plate packs 409 and 413 are divided by a central frame structure 411 comprising, for example, a metal plate. Each side frame of the frame defines openings that function as entrances and exits, for example openings 410, 414, 417, 419 defined by the side 407 of the frame.

In some embodiments, the exemplary heat exchanger plate and frame design comprises the two hot circuits and the single cold circuit. In some embodiments, hot circuit # 1 is represented as board pack 413 and is dedicated to 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 frame structure or center 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 heat exchanger 400. That is, each hot circuit # 1 and hot circuit # 2 (packets 409 and 413 of plates) also comprises a cold fluid, in which the two fluids, one hot and one cold, pass in opposite directions, up and down. by alternate 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 a cooling tower.

With reference to Figs. 3-4, an exemplary conduit system is illustrated for transferring a fluid medium between the heat exchanger 400 and the respective components of the power generation system 200. The conduit system includes a plurality of discrete conduits that may comprise, for example, flexible materials such as rubber hoses or inflexible materials such as metal tubes, or any combination of the various materials. A conduit 216 extends from an opening 404 located in heat exchanger 400 to an opening (not referenced) located in engine 208, and provides a cooled or cold fluid medium to engine 208 from heat exchanger 400. The fluid medium enters the motor 208, where the thermal energy from the motor 208 is transferred to the fluid medium, and then the fluid medium exits the motor 208 through an opening (not referenced) in the motor 208 to enter the conduit 214, at where the heated fluid medium re-enters the heat exchanger through opening 406, for cooling and recirculation through conduit 216 and

ES 2 668 356 T3 the motor 208. It should be understood that the path just described for the fluid medium could be reversed, through the respective conduits 214 and 216, the motor 208 and the heat exchanger 400.

With reference to Figs. 7-8, an exemplary conduit system is shown for transferring a fluid medium between the heat exchanger 400 and the respective components of the power generation system 200. The plurality of discrete conduits comprise, for example, flexible materials such as rubber hoses or inflexible materials such as metal tubes, or any combination of the various materials. A first conduit 228 extends from an opening 414 located in the heat exchanger 400 to a first stud 226 of a pump 220, for example an auxiliary pump, and a second conduit 228 extends from a second stud 222 of the auxiliary pump 220 up to power electronic device 300. An exemplary auxiliary pump 220 provides pumping power to transfer a chilled or cold fluid medium to electronic power device 300 from heat exchanger 400. The fluid medium enters the power electronic device 300, where the thermal energy from the power electronic device 300 is transferred to the fluid medium, and then the fluid medium exits the power electronic device 300 and enters the conduit 304. Conduit 304 extends from power electronic device 300 to generator (represented as generator housing 360), and receives heated fluid medium from power electronic device 300, the heated fluid medium further heating upon receiving thermal energy from 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 heat exchanger 400 from the generator. The fluid medium is recirculated through the heat exchanger, for cooling and recirculation through the respective conduits 228, 304 and 234 and the respective components.

It should be understood that conduits 416 and 418 of respective openings 417 and 419 of heat exchanger 400 are provided to receive a fluid medium, provided by the consumer. For example, if a power generation system 200 is to be provided on a vessel, such as a boat, the fluid medium provided to conduits 416 and 418 may include salt water from the ocean. Another exemplary fluid medium includes water or air. Either conduit 416 or 418 will be an inlet for the fluid medium, the other conduit comprising an outlet for the fluid medium to be discharged, for example back to the ocean.

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 the pump 220 may be positioned at any location relative to the respective components of the power generation system 200, for example below the electronic power device 300 and adjacent generator housing 360. It should be understood that pump 220 may comprise an electric pump or a mechanical pump. It should be understood that pump 220 can be a stand-alone pump, powered by its own power or driven from motor 208.

Referring to FIG. 4, the power generation system 200 has a length 203 ranging from about 114 to about 124 cm, and is defined from one end of the engine 208 to an opposite end of the heat exchanger 400. The power generation system 200 has a length 201 ranging from about 91 to about 101 cm without the heat exchanger 400, and is defined from one end of the motor 208 to an opposite side of the power electronic device 300. With reference to Fig. 5, the power generation system 200 has a height 205 ranging from about 71 to about 81 cm, and is defined from a bottom of the motor 208 to an upper part of the motor 208 opposite the bottom. Still referring to FIG. 5, the power generation system 200 has a width 207 that ranges from about 18 to about 22 inches, and is defined from one side of the motor 208 to an opposite side of the motor 208. The power generation system 200 comprises a weight ranging from about 363 to about 408 kg, for example 385.55 kg. Other dimensions or weights are possible.

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 robust enough to support motor 208 and system components, for example, example a metal such as steel. In an exemplary embodiment, U-shaped base portions 802 extend longitudinally and generally in parallel relationship, with spacers 806 being used to maintain the spaced relationship of the U-shaped base portions 802 as they extend between the U-shaped base portions 802. U-shaped base. 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 may be provided for the support structure 800. In an exemplary embodiment, the base portions 802 comprise the portion of the frame 801 to which the additional frame parts or sections of the frame 801 are attached. Additionally, exemplary base portions 802 comprise the portion of frame 801 that rests on and contacts a surface (not shown) to support an exemplary power generation system.

Still referring to FIG. 18, an exemplary frame 801 comprises supports 808 that are secured to and extend upwardly from base portions 802 at one end of an exemplary support structure 800. In an exemplary embodiment, brackets 808 are secured to base portions 802 by

ES 2 668 356 T3 bushings 805 comprising rubber, for example, to damp the vibrations of the power generation system 200. Brackets 808 are secured to motor 208, either directly or with additional bushings (not shown) between brackets 808 and motor 208. A pair of transverse rails 826 extend between and are secured thereto. . In one embodiment, the transverse rails 826 support posts 832 that extend upwardly from the transverse rails 826. The exemplary posts 832 are at least two in number, for example four, and are in a spatial relationship that defines a square or rectangle. . The exemplary posts 832 are used to support any combination of a plurality of components for the power generation system 200, for example an electronic power device 834, a generator housing 836, and other components not shown secured to the posts 832, such as as a package control unit and an auxiliary pump. Another pair of transverse 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 posts 816 extend vertically from a base portion 802 adjacent to two supports 808, and include a crossbar 817 extending therebetween, and in an exemplary embodiment posts 816 and crossbar 817 support an auxiliary pump. 822 and a control unit package 820.

It should be understood that additional structures and beams may be provided in frame 801 to support additional components, for example the generator. It should be understood that vibration isolators may be provided between any of the components of the power generation system and the exemplary frame 801. Conventional generator sets use frames and / or frame rails strong enough to resist torsional bending between the engine and the generator. However, the exemplary power generation systems described herein may comprise materials other than steel, since the engine is directly coupled to the generator. In other words, as the motor is coupled directly to the generator, torsional bending is reduced and the design allows for better isolation of external components from motor vibrations. Accordingly, in exemplary embodiments, frame 801 need not be designed to overcome the substantial torsional flexing of conventional frames, and therefore can be designed with materials that provide a frame that is compact and lightweight.

With reference to FIG. 19, an overview 900 of the main components monitored by the control unit package (identified as Control Unit 960 in FIG. 19) in accordance with the invention is illustrated as a block diagram. The control unit package 960 supervises the engine (referenced as prime mover 906), generator 908, an ignition control 942 for the engine (prime mover 906), heat exchanger 902, electronic power device (identified as control 920 power) and customer connections, for example a 3-phase switch 912 for a consumer system 914. These components are coupled by means of electrical and / or communication lines 910 and a system 904 of water cooling line conduits.

Referring to FIG. 20, in some embodiments of the power control (electronic power device) 920, an exemplary system interface 924 is coupled to a logic control 922 that allows the consumer / user to enter user settings 934. Interface 924 also provides output signals 936. Exemplary output signals 936 may be in text or graphic format on system interface 924, and may be exported as an electronic signal for remote viewing. System interface 924 communicates with logic control 922, logic control 922 receiving user settings 934 from system interface 924, and monitoring / regulating water cooling and internal temperature sensing, 926, regulation 930 DC, and DC-AC conversion 928. In one embodiment, the DC regulation 930 is coupled with the DC input or output to the remote storage system 938. In one embodiment, DC regulation 930 is coupled with AC to DC conversion 932 for exemplary 50-690 VAC, polyphase (eg, 3-18 phases) and 50-900 Hertz (Hz) conversion outputs 940. . In one embodiment, DC regulation 930 is coupled with DC to Ca conversion 928 for exemplary 120-690 VAC, 1 or 3 phase, 50-1,000 hertz conversion outputs. Based on the conditions of the user settings 934, the logic control 922 will manage the power generation system and communicate with the system interface 924 to provide output signals 936.

Exemplary user configurations 934 comprise: a frequency output that sets the generator set output frequency; a voltage output that sets the output voltage of the generator set; a maximum output power that establishes the maximum power of the generator set, and that cannot exceed a maximum rated output of the motor / generator; a maximum current output that sets the maximum current output of the generator set; and the maximum water temperature, which establishes the maximum temperature of the water (or any exemplary fluid medium) exiting from an exemplary heat exchanger to the generator, the electronic power device, and the engine.

Exemplary output signals 936 comprise: an overheat warning, which warns of an overheating condition of the refrigerants, fluids, intake air, and the exhaust of the power generation system; an overtemperature shutdown, in which a shutdown signal is provided due to an overtemperature condition of the refrigerants, fluids, intake air, and the exhaust of the power generation system; an overload warning, which is a warning of an overpower condition

ES 2 668 356 T3 of the engine, the generator and / or the generator set; an overcurrent warning, which is a warning of an overcurrent condition of the generator and / or generator set; an output voltage indicating the voltage output for the generator, and / or generator set; a current output indicating the current output for the generator and / or generator set; a frequency output, indicating the frequency output for the generator and / or generator set; DC bus bar volts, which indicates the voltage of a DC bus bar; the input volts, which indicates the input volts to the power electronics and / or a secondary power source; the input frequency, which indicates the input frequency to the power electronics and / or the secondary power supply; and internal shutdown (fault), which provides a signal to indicate internal shutdown due to failure of an internal generator set component.

Referring to FIG. 21, there is illustrated an overview 961 of an exemplary ignition control 942 in accordance with embodiments of the invention. The 942 ignition control monitors, manages and controls the logic blocks that influence the ignition of the 947 engine. The logic control blocks that influence the ignition of the 947 engine include an air control 952, a fuel control 950, a control 942 ignition and a cooling water temperature detector 946. Based on user settings 954 (via system interface 948), logic control 944 will monitor, manage, and control logic blocks that influence starting of engine 947.

An exemplary logic control 944 receives user settings 954 from system interface 948. Through user settings 954, logic control 944 will monitor all parameters for specified maximum or minimum limits. The logic control 944 will manage a block, any combination of blocks, or all blocks that influence the ignition of the engine 947, to prevent the overall power generation system from exceeding the specified maximum or minimum limits. Depending on user settings 954, logic control 944 will also communicate with system interface 948 to provide output signals 956.

Still referring to Fig. 21, exemplary user configurations 954 comprise: a user-specified or automatically determined operating mode, in which the generator set (engine) can be configured to operate at maximum torque, maximum power, minimum fuel (fuel efficiency) and / or minimal emissions (low emissions); a desired speed, which specifies the desired speed of the generator set and / or the components of the power generation system; a temperature warning level, which sets the warning level for various temperatures of the coolants, fluids, intake air and / or the exhaust of the power generation system; a shutdown temperature level, which sets the shutdown level of the power generation system or its components based on various temperatures of the refrigerants, fluids, intake air, and the exhaust of the power generation system; and a start / start contact that specifies the engine start time to start the power generation system.

Still referring to Fig. 21, exemplary output signals 956 comprise: an overheat warning, which warns of an overheating condition of the refrigerants, fluids, intake air, and the exhaust of the power generation system; an overtemperature shutdown, which provides a shutdown signal due to an overtemperature condition of the refrigerants, fluids, intake air, and the exhaust of the power generation system; an overload warning, which is a warning of an overpower condition of the motor, generator, and / or generator set; a speed (RPM), which indicates the speed of the prime mover (motor) and the generator in RPM; Delta RPM, which indicates the differential of the desired and actual speeds of the prime mover and generator, in RPM. (Differential is used when comparing motor speed and electrical load (demand) on output connections); a current engine mode, indicating the current engine mode; a fuel control state, indicating the current mode of the fuel control 950; an air control state, indicating the current mode of the air control 952; an ignition control state, indicating the current mode of the ignition control 942; and an internal shutdown (fault), which provides a signal to indicate an internal shutdown due to the failure of an internal generator set component.

Referring to FIG. 22, an exemplary logic control / control unit 901 interacts with the ignition control, heat exchanger, generator, power control, and electrical switch. Logic control 962 is managed based on inputs from operator / user interface 974. The operator / user interface 974 may be located on board, or it may be remote via a communication connection. The logic control 962 will monitor and manage the following: cooling water temperature sensing 964, which senses the inlet and outlet temperatures of the cooling fluid medium (eg, water) and the refrigerant circuits; the interface with the ignition control 966 , which monitors and manages the ignition control unit; the power control interface 968, which monitors and manages the parameters associated with the power control unit; the 970 current and voltage interface, which monitors the current and voltage of the generator output; and switch interface 972, which determines whether the circuit breaker is open or closed. If a circuit breaker is used, logic control 962 can be used to control the opening and closing of the breaker.

Referring to FIG. 23, another configuration of an exemplary logic control / control unit 903 is illustrated. An exemplary logic control / control unit comprises a high-level interaction between various control components of the system. Control components include: a main unit controller 992, a main unit control 976,

ES 2 668 356 T3 engine, a power electronic control 982 and a control unit BIOS 977. For example, an exemplary control unit BIOS 977 interfaces with main unit controller 992, engine control 976, and electronic power control 982. The control unit BIOS 977 contains: a communications port 939 for the power unit; a communications port 941 for the ignition unit; monitoring for generator voltage 943; monitoring of the generator output current 945 (the parameter values ​​provided in this figure for any element / component are only exemplary, the ranges of values ​​provided herein being applicable); monitoring for output voltage 991; monitoring the output current 985; monitoring of switch control 983; monitoring of temperature sensing components 981; and monitoring for an optional 979 analog I / O.

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. The output frequency 987 is calculated from the output voltage 991. The output power 989 is calculated from the output voltage 991 and the output current 985. Additionally, in an exemplary embodiment engine control 976 interacts with control unit BIOS 977, electronic power control 982, and main unit control 992. The engine control 976 contains the 978 on / off and the 980 speed control blocks. The on / off 978 interacts with the control unit BIOS 977 and the speed control blocks 980. Speed ​​control 980 interfaces with control unit BIOS 977, electronic power control 984, and frequency control 986. An exemplary power electronic control 984 interfaces with control unit BIOS 977, engine control 976, and main unit control 992. Electronic power control 984 contains voltage control 990, VAR control 988, frequency control 986, and power control 984. An exemplary voltage control block 990 interfaces with the control unit BIOS 977, an exemplary VAR control 988 interfaces with the control unit BIOS 977, an exemplary frequency control 986 interfaces with the control unit BIOS 977, and the engine control 976, and an exemplary power control 984 interacts with control unit BIOS 977 and engine control 976.

In an exemplary embodiment, main unit control 992 interacts with engine control 976, electronic power control 982, and control unit BIOS 977. The main unit control 992 contains the mode control blocks 995, switch control 994, load control 996, and timing control 997. Mode control 995 interacts with switch control 994, load control 996, and timing control 997 within head unit control 992. Mode control 995 also interacts with engine control 976 and electronic power control 982. The switch control 994 interacts with the main unit control 992, the mode control 995, and the control unit BIOS 977. Load control 996 interacts with main unit control 992, mode control 995, engine control 976, and electronic power control 982. Timing control 997 interacts with main unit control 992, mode control 995, engine control 976, and electronic power control 982. It should be understood that the whole scheme

The exemplary embodiments described herein provide advantages and benefits not recognized by conventional power generation systems. For example, embodiments of the power generation systems described throughout the present application (eg, as described in Figs. 1 and 2, and for the power generation system 200) comprise exemplary generator sets, with the ability to provide multiple load capacity. These exemplary generator sets are capable of handling a primary electrical load as well as a secondary electrical load. In contrast, conventional generator sets are only capable of one output for a load, which is distributed on a high-voltage switchgear or distribution board. Additionally, exemplary generator sets in accordance with the invention of the present disclosure are capable of handling multiple loads, each with a different voltage, and, again, conventional generator sets are only capable of one output for one load.

Additionally, exemplary power generation assemblies / systems disclosed herein comprise overall power generation packages, which can be configured for a selectable voltage and / or frequency. Additionally, due to the size (eg, footprint and weight) of the exemplary power generation assemblies / systems disclosed herein, advantageous mounting configurations are possible. For example, due to the smaller footprint and / or size of the generator sets provided herein, the generator can be mounted directly to the (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 generator sets. Additionally, the support structure 800 for the exemplary power generation systems disclosed herein, for example the frame 801 illustrated in Fig. 18, is lighter in weight compared to the frame rails of the assemblies. of conventional generation, and allows to isolate the sensitive components against the vibration of the engine.

Additionally, since the exemplary power generation systems disclosed herein comprise liquid-cooled components, for example the (prime mover), generator, and power electronics, and in combination with variable speed operation that enables the system disclosed herein, the combination enables a power generation system with a

ES 2 668 356 T3 quieter operation. Additionally, the liquid-cooled components of the exemplary power generation systems disclosed herein remove heat from the respective components, and transmit it to the air, most optimally by for example a radiator, a tower of cooling, a keel cooler, etc. In addition, liquid-cooled components make it possible to seal more hermetically an enclosure of the power generation systems, or of several components thereof, which reduces the output of sound waves, produced by the operation of the power generation systems. energy, outside the environment of an exemplary enclosure. Additionally, hermetically sealed power electronic devices and generators are less prone to entry of environmental contaminants, such as snow, dirt, sand, insects and other debris. This increases the reliability of the exemplary power generation systems disclosed herein compared to conventional systems, which is important for some applications, if not essential, for example in military operations. In fact, the exemplary power generation systems disclosed herein have built-in N + 2 reliability and are comparatively more reliable systems as a result.

Additionally, the variable speed capability of exemplary power generation systems, in combination with liquid-cooled components, allows power generation systems to operate at higher RPM than conventional power generation systems. Higher RPMs produce shorter sound waves emanating from exemplary power generation systems, and therefore less sound damping material is needed to acoustically isolate the power generation system. Since less sound insulation material is used, the exemplary power generation system will be lighter in weight than conventional power generation systems. Alternatively, in case of using in the power generation systems disclosed herein the same amount of sound insulation material that is routinely used for conventional power generation systems, then the power generation system given to know in this document will be more silent.

Additionally, liquid-cooled components of exemplary power generation systems can contribute to increased fuel use. For example, conventional combined heat and power (CHP) applications consist of a generator set producing electricity with heat recovery equipment in the exhaust system. This conventional CHP application transmits heat from the engine (for example, it is transmitted to a water system in the engine jacket) and from the exhaust system to the environment, for example a building in the case of heating and cooling applications. Additionally, the rejected heat from the air passing through the generator is vented to the atmosphere as lost energy. However, exemplary power generation systems disclosed herein can capture rejected thermal energy from components coupled to the one or more heat exchangers, in addition to thermal energy captured from the engine exhaust and water system. Additionally, the exemplary power generation systems disclosed herein allow more efficient cooling of the environment, for example the engine room of a ship or boat, given that the fluid medium that has captured the thermal energy of the respective Components can be transmitted to remotely mounted cooling devices such as radiators, cooling towers, etc. Remotely mounting cooling devices reduces the need for sizable air handling equipment in the exemplary engine room of the ship or vessel.

Another advantage / benefit of the exemplary power generation systems disclosed herein is that the addition of a secondary input allows the power cycle outages to be zero (0). For example, exemplary power generation systems may use batteries as a secondary input connected to a building distribution system. If a district's power supply is interrupted or fails, the secondary input will provide power until the generator in the power generation system can be operational. In contrast, conventional power generation systems have to be increased to approximately 1,800 RPM before a coupled switch system can be closed to provide power to the load (eg, the building distribution system).

With respect to 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 may have the ability to manage or have the operator (consumer / customer) select between torque, power, and fuel consumption. These exemplary system configurations will allow the operator (consumer / customer) to optimize the capabilities of the exemplary systems, with respect to different applications requiring different power demands.