Systems and methods for controlling power output to a load by multiple gensets based on load operation modes

Patent metadata

Field	Value
Publication number	US-10491004-B2
Application number	US-201615297843-A
Country	US
Kind code	B2
Filing date	Oct 19, 2016
Priority date	Oct 19, 2016
Publication date	Nov 26, 2019
Grant date	Nov 26, 2019

Abstract

A control system for a plurality of generator sets (gensets) includes a plurality of controllers and a data link. Each of the plurality of controllers is operatively associated with at least one of the plurality of gensets. The plurality of controllers is configured to control power output of each of the plurality of gensets, based on a plurality of operating modes. Each of the plurality of operating modes is configured for a power consumption scenario associated with the load. The datalink connects each of the plurality of controllers to at least one other controller of the plurality of controllers. The plurality of controllers is further configured to select a current operating mode, from the plurality of operating modes, for the plurality of gensets and control power output of at least one of the plurality of gensets based on the current operating mode.

First claim

What is claimed is:

1. A control system for a plurality of generator sets (gensets), the plurality of gensets configured to provide power to a load, the system comprising:
a plurality of controllers, each of the plurality of controllers operatively associated with at least one of the plurality of gensets and each of the plurality of gensets being operatively associated with at least one of the plurality of controllers, the plurality of controllers being configured to control power output to the load of each of the plurality of gensets based on a plurality of operating modes for the load, wherein each of the plurality of operating modes for the load are configured for a power consumption scenario associated with the load; and
a datalink connecting each of the plurality of controllers to at least one other controller of the plurality of controllers,
wherein the plurality of controllers are configured to:
select a current operating mode for the load, from the plurality of operating modes, wherein selecting the current operating mode for the load is based at least in part on a current operating state of the load;
determine which gensets of the plurality of gensets are available for outputting power to the load;
select at least one genset of the available gensets to be active or redundant based on the power consumption scenario for the current operating mode for the load; and
control power output of at least one of the active or redundant gensets based on the power consumption scenario for the current operating mode for the load.

2. The control system of claim 1 , wherein the plurality of controllers includes a plurality of genset controllers, each of the plurality of genset controllers corresponding to one of the plurality of gensets and being operatively associated with said corresponding one of the plurality of gensets, and wherein each of the plurality of genset controllers communicate amongst themselves to determine optimal genset control operations based on the current operating mode.

3. The control system of claim 2 , wherein a first genset controller, of the plurality of genset controllers, is configured to instruct a first genset, of the plurality of gensets, to power on and communicate with at least one other genset controller, of the plurality of genset controllers, to determine the current operating mode for the load, of the plurality of operating modes, based upon which the first controller will control a power output of the first genset.

4. The control system of claim 1 , wherein the plurality of controllers includes a master controller and a plurality of genset controllers, each of the plurality of genset controllers corresponding to one of the plurality of gensets and being operatively associated with said corresponding one of the plurality of gensets, and wherein the master controller is configured to:
determine optimal genset control operations based on the current operating mode for the load, and
communicate the optimal genset control operations to each of the plurality of genset controllers, and
wherein each of the plurality of genset controllers is configured to control power output of its respective genset of the plurality of gensets based on the optimal genset control operations.

5. The control system of claim 1 , further comprising an input device configured to generate load information associated with the load and provide the load information to the plurality of controllers, wherein the plurality of controllers are further configured to receive the load information; and wherein selecting the current operating mode for the load, from the plurality of operating modes, by the plurality of controllers, for the plurality of gensets is based on the load information.

6. The control system of claim 5 , wherein the input device includes a load sense determiner operatively associated with a transmission network that is associated with the plurality of gensets, and wherein the load sense determiner is configured to determine the load information by sensing power characteristics at the load via the transmission network.

7. The control system of claim 5 , wherein the input device includes a digital input, wherein the digital input is configured to provide the load information to the plurality of controllers, based on input from a user.

8. The control system of claim 7 , wherein the load information provided by the digital input is mode selection information indicative of an operator selected operating mode for the load, and wherein selecting the current operating mode for the load, from the plurality of operating modes, by the plurality of controllers for the plurality of gensets is based at least in part on the mode selection information.

9. The control system of claim 8 , wherein the current operating mode for the load selected by the plurality of controllers is the operator selected operating mode, and wherein the plurality of controllers are configured to override the operator selected operating mode for the load and select a different operating mode for the load based on an internal logic.

10. The system of claim 1 , wherein selecting the current operating mode for the load, from the plurality of operating modes, by the plurality of controllers for the plurality of gensets is based at least in part on a schedule associated with the load.

11. A power system for providing electrical power to an external load, the power system comprising:
a plurality of gensets configured to generate electrical power for the external load;
a transmission network configured to provide the electrical power generated by the plurality of gensets to the external load;
a plurality of controllers, wherein each of the plurality of controllers is operatively associated with at least one of the plurality of gensets, and wherein each of the plurality of gensets is operatively associated with at least one of the plurality of controllers, wherein each of the plurality of controllers is configured to control power output to the external load of each of the plurality of gensets based on a plurality of operating modes for the external load, and wherein each of the plurality of operating modes for the external load is configured for a power consumption scenario associated with the external load;
a datalink connecting each of the plurality of controllers to at least one other controller of the plurality of controllers,
wherein the plurality of controllers are configured to:
select a current operating mode for the external load from the plurality of operating modes for the external load for one or more active gensets of the plurality of gensets, wherein the current operating mode for the external load for each of the active gensets is at least partially based on a determination of available gensets; and
control power output of at least one of the available gensets based on the power consumption scenario for the current operating mode for the external load.

12. The power system of claim 11 , wherein at least one of the plurality of gensets includes:
a prime mover configured to mechanically rotate; and
a generator coupled to the prime mover and configured to generate electrical power in response to mechanical rotation of the prime mover.

13. The power system of claim 11 , wherein the external load is associated with an oil rig and each of the plurality of operating modes for the external load are configured for a power consumption scenario associated with the oil rig.

14. The power system of claim 13 , wherein one of the plurality of operating modes for the external load is a standby mode, the standby mode being associated with a standby power consumpti

Assignees

• Caterpillar Inc

Inventors

• Gerdes Josenia
• Janardhan Vijay
• Schroeder Edward
• Nofsinger Stephen

Classifications

• H02K7/1815

  structurally associated with reciprocating piston engines (general aspects of generating sets, e.g. housing, F02B63/04) · CPC title

• F02B63/04

  for electric generators · CPC title

• H02J3/381 Primary

  Dispersed generators · CPC title

• H02J3/38

  Arrangements for feeding a single network from two or more generators or sources in parallel; Arrangements for feeding already energised networks from additional generators or sources in parallel · CPC title

• H02P9/00 Primary

  Arrangements for controlling electric generators for the purpose of obtaining a desired output · CPC title