Segmented waveform converter on controlled field variable speed generator

• US 10,148,207 B2
• Filed: 10/16/2015
• Issued: 12/04/2018
• Est. Priority Date: 10/16/2015
• Status: Active Grant

• Current Assignee: Discovery Energy LLC
• Original Assignee: Kohler Company
• Inventors: Frampton, Isaac S., Larson, Adam
• Primary Examiner(s): Gonzalez Ramirez, Julio C.
• Application Number:
  US14/885,112
• Publication Number:
  US 20170110996A1
• Time in Patent Office: 1,145 Days
• Field of Search: 322 59, 322 44, 322 28, 322 89, 322 7, 310114
• CPC Class Codes: H02P 25/22 Multiple windings; Windings for more than three phases
• CPC Class Codes: H02P 9/48 Arrangements for obtaining a constant output value at varying speed of the generator, e.g. on vehicle H02P9/04 - H02P9/46 take precedence

Abstract

A generator or another type machine includes a controlled field alternator, a segmented waveform converter, and a controller. The controlled field alternator is configured to generate a polyphase signal. The segmented waveform converter includes multiple switches connected between the polyphase signal of the controlled field alternator and an output filter. The controller is configured to provide a control signal for the switches based on measured electrical quantities associated with the output filter and provide a field current control signal to the controlled field alternator.

Claims

1. An apparatus comprising:

a controlled field alternator configured to generate a polyphase signal including a first component and a second component;

a segmented waveform converter including a plurality of switches connected between the polyphase signal of the controlled field alternator and an output filter; and

a controller configured to calculate a plurality of combinations of available voltages through combinations of phase components of the polyphase signal through different settings for the plurality of switches, and access a target waveform, wherein, in response to the target waveform and measurements of an output at the output filter having an output frequency, the controller is configured to select one of the plurality of combinations of phase components to provide a control signal having piecewise segments at a predetermined frequency to provide a field current control signal to the controlled field alternator, wherein the predetermined frequency is greater than the output frequency.

2. The apparatus of claim 1, wherein the controlled field alternator is a wound field alternator.

3. The apparatus of claim 2, wherein the wound field alternator is a dual axis alternator with a main stator device and an exciter field device on a common plane normal to an axis of rotation.

4. The apparatus of claim 1, wherein the plurality of combinations represent different paths through the segmented waveform converter.

5. The apparatus of claim 1, wherein the plurality of switches includes a first switch associated with a first output range and a second switch associated with a second output range.

6. The apparatus of claim 1, wherein the controller is configured to generate a start signal to start an engine associated with the controlled field alternator.

7. The apparatus of claim 6, wherein one of the plurality of combinations is for starting the engine by a reverse flow through the segmented waveform converter.

8. The apparatus of claim 1, further comprising:

a battery circuit electrically connected to the segmented waveform converter and a battery.

9. The apparatus of claim 8, wherein the battery circuit is configured to provide a cranking signal to an engine associate with the controlled field alternator.

10. The apparatus of claim 1, wherein the segmented waveform converter is a matrix cycloconverter.

11. A method comprising:

generating a polyphase signal at a controlled field alternator, the polyphase signal including a first phase component and a second phase component;

calculating a plurality of combinations of available voltages through combinations of the first phase component and the second phase component of the polyphase signal;

accessing a target waveform from memory;

selecting, in response to the target waveform and measured electrical quantities associated with an output having an output frequency, one of the plurality of combinations of phase components;

determining an output control signal including segments based on a predetermined frequency to control a plurality of switches connected between the polyphase signal of the controlled field alternator and the output, wherein the predetermined frequency is greater than the output frequency; and

determining a field current control signal including the selected one of the plurality of combinations of phase components to control a field current of the controlled field alternator.

12. The method of claim 11, further comprising:

sending the output control signal to a load; and

providing the field current control signal to a generator controller.

13. The method of claim 11, wherein the plurality of combinations represent different paths through the segmented waveform converter.

14. The method of claim 11, wherein the plurality of switches includes a first switch associated with a first output range and a second switch associated with a second output range.

15. The method of claim 11, further comprising:

generating a start signal to start an engine associated with the controlled field alternator.

16. An apparatus comprising:

a segmented waveform converter including a plurality of switches connected between the polyphase signal of a controlled field alternator and an output filter providing an output at an output frequency;

a memory including a lookup table associating a plurality of combinations of the plurality of switches with available voltage levels; and

a controller configured to provide a control signal for the plurality of switches based on measured electrical quantities associated with the output filter and provide a field current control signal to the controlled field alternator based on a combination of the plurality of switches, wherein the field current control signal includes segments at a predetermined frequency that is greater than the output frequency.