Direct current power plant

Patent metadata

Field	Value
Publication number	US-12352230-B2
Application number	US-202318514452-A
Country	US
Kind code	B2
Filing date	Nov 20, 2023
Priority date	Jun 19, 2015
Publication date	Jul 8, 2025
Grant date	Jul 8, 2025

Abstract

A DC power plant generating DC power from a variety of engines including a Stirling cycle engine. The DC power plant includes a relatively small start-up power source that is discontinued after the engine is running. A method for producing DC power for a load including starting up an engine using power supplied by a relatively small power supply supplemented by a capacitor bank, providing output from the engine to a generator, producing alternating current (AC) power by the generator, converting the AC power to direct current (DC) power, disabling output of the DC power during a first set of pre-selected conditions, limiting a rate of change of current of the DC power during a second set of pre-selected conditions, reducing conducted and radiated emissions of the DC power, disconnecting the DC power from the load under a third set of pre-selected conditions, and providing the DC power to the load.

First claim

What is claimed is:

1. Method of delivering power to an electric grid comprising:
driving a generator;
obtaining AC power from the generator;
converting the AC power to DC power;
providing the DC power to the electric grid;
receiving an angle from a sawtooth waveform generator;
representing the angle by a 16-bit value, the angle having a sine and a cosine;
applying an average increment to the angle, as an angle sweeps from 0-360°, every 100 μsecs, the average increment having a 32-bit center frequency input and a 16-bit delta frequency input driven by a PI controller, the center frequency input representing a fractional value of the angle, the delta frequency oscillating about zero;
producing a sine/cosine pair for the angle;
creating an inverter output waveform based on the sine/cosine pair;
computing a phase error signal based on the sine of the angle and a voltage of a grid supply, the voltage of a grid supply being equal to the cosine of the voltage of the grid supply;
multiplying the sine by the voltage of the grid supply to produce a signal that contains both AC and DC components, the AC component having an amplitude variation based on amplitudes of the grid supply and the inverter output waveform and having a frequency equal to 2× the frequency of the grid supply when loop is locked, the DC component having an amplitude variation based on a phase error between the grid supply and the inverter output waveform;
low pass filtering the phase error; and
eliminating a part of the AC component not relevant to control by supplying the filtered phase error to the PI controller.

2. Method of claim 1 further comprising shunt tripping a DC output breaker during an arc fault condition.

3. Method of claim 1 wherein said providing depends on when a condition is false.

4. Method of claim 1 further comprising disabling said converting and/or said providing based on a condition.

5. Method of claim 4 wherein the condition comprises an overcurrent condition and/or a ground fault condition.

6. Method of claim 1 further comprising limiting a rate of change of current of the DC power based on a condition.

7. Method of claim 6 wherein the condition comprises an abnormal condition.

8. Method of claim 1 further comprising reducing conducted and radiated emissions of the DC power.

9. Method of claim 1 further comprising disconnecting the DC power from a load based on a condition.

10. Method of claim 9 wherein the condition comprises an abnormal overcurrent condition.

11. Method of claim 1 further comprising shunting heat of said driving into a shunt load.

12. Method of claim 11 further comprising heating water with the heat.

13. Method of claim 1 further comprising providing the DC power to: an igniter power board; a pump/fan/blower drive; an engine control I/O PCB; a system control PCB; and/or a power control PCB.

14. Method of claim 1 further comprising:
measuring voltage and frequency of the electric grid; and
recording the voltage and the frequency in a continuously running log file; and/or
reporting the voltage and the frequency to a system controller.

15. Method of claim 1 wherein said driving is performed by a Stirling engine.

16. Method of claim 1 wherein said providing comprises:
measuring a voltage and a frequency by a first digital phase locked loop when the voltage and the frequency are within a range of tolerance;
measuring phase error by a second digital phase locked loop;
referencing the measured voltage to the second digital phase locked loop; and
declaring phase lock when the phase error is less than a value and when the measured voltage is within a range of voltage.

17. Method of claim 1 wherein said driving is performed by an engine, further comprising:
receiving a power from an AC power supply; and
starting the engine using the power.

18. Method of claim 17 wherein said starting comprises using a second power from a capacitor bank.

19. Method of claim 17 further comprising controlling the engine with a power control board powered by a second power.

20. Method of claim 19 wherein the second power derives from a second AC power supply.

21. Method of claim 19 further comprising controlling the power control board with a system controller.

22. Method of claim 21 wherein the system controller is powered by the second power.

23. Method of delivering power to an electric grid comprising:
driving a generator;
obtaining AC power from the generator;
converting the AC power to DC power;
providing the DC power to the electric grid comprising:
measuring a voltage and a frequency by a first digital phase locked loop when the voltage and the frequency are within a range of tolerance;
measuring phase error by a second digital phase locked loop;
referencing the measured voltage to the second digital phase locked loop; and
declaring phase lock when the phase error is less than a value and when the measured voltage is within a range of voltage.

24. Method of claim 23 further comprising shunt tripping a DC output breaker during an arc fault condition.

25. Method of claim 23 wherein said providing depends on when a condition is false.

26. Method of claim 23 further comprising disabling said converting and/or said providing based on a condition.

27. Method of claim 26 wherein the condition comprises an overcurrent condition and/or a ground fault condition.

28. Method of claim 23 further comprising limiting a rate of change of current of the DC power based on a condition.

29. Method of claim 28 wherein the condition comprises an abnormal condition.

30. Method of claim 23 further comprising reducing conducted and radiated emissions of the DC power.

31. Method of claim 23 further comprising disconnecting the DC power from a load based on a condition.

32. Method of claim 31 wherein the condition comprises an abnormal overcurrent condition.

33. Method of claim 23 further comprising shunting heat of said driving into a shunt load.

34. Method of claim 33 further comprising heating water with the heat.

35. Method of claim 23 further comprising providing the DC power to: an igniter power board; a pump/fan/blower drive; an engine control I/O PCB; a system control PCB; and/or a power control PCB.

36. Method of claim 23 further comprising:
receiving an angle from a sawtooth waveform generator;
representing the angle by a 16-bit value, the angle having a sine and a cosine;
applying an average increment to the angle, as an angle sweeps from 0-360°, every 100 μsecs, the average increment having a 32-bit center frequency input and a 16-bit delta frequency input driven by a PI controller, the center frequency input representing a fractional value of the angle, the delta frequency oscillating about zero;
producing a sine/cosine pair for the angle;
creating an inverter output waveform based on the sine/cosine pair;
computing a phase error signal based on the sine of the angle and a voltage of a grid supply, the voltage of a grid supply being equal to the cosine of the voltage of the grid supply;
multiplying the sine by the voltage of the grid supply to produce a signal that contains both AC and DC components, the AC component having an amplitud

Assignees

• Deka Products Lp

Inventors

• Schnellinger Andrew A
• Lowell James R
• Finseth Bryan A
• Barber Christopher L
• Sachs Jason M
• Lucas Donald J
• Prescott Shannon
• Kite Jeffrey W
• Fekete Andras K
• Adams Douglas R

Classifications

• H02J1/10

  Parallel operation of DC sources · CPC title

• F24D11/00

  Central heating systems using heat accumulated in storage masses (self-contained storage heating units F24D15/02) · CPC title

• F02N2011/0885

  Capacitors, e.g. for additional power supply · CPC title

• F02N11/0866

  comprising several power sources, e.g. battery and capacitor or two batteries · CPC title

• F02G1/043 Primary

  the engine being operated by expansion and contraction of a mass of working gas which is heated and cooled in one of a plurality of constantly communicating expansible chambers, e.g. Stirling cycle type engines · CPC title