Control system for a generator

• US 10,233,829 B2
• Filed: 05/24/2018
• Issued: 03/19/2019
• Est. Priority Date: 03/23/2012
• Status: Active Grant

• Current Assignee: Thermo King Corporation (Trane Technologies plc)
• Original Assignee: Thermo King Corporation (Trane Technologies plc)
• Inventors: Burnham, Randall Scott, Renken, David Jon, Lucht, Erich Albert, Hall, Cullen Evan, Jeffery, Alec, Villalba, Cesar Armengod
• Primary Examiner(s): Amick, Jacob
• Assistant Examiner(s): Brauch, Charles
• Application Number:
  US15/988,545
• Publication Number:
  US 20180306105A1
• Time in Patent Office: 299 Days
• CPC Class Codes: B60H 1/00014 for load cargos on load transporting vehicles
• CPC Class Codes: B60H 1/00428 electric
• CPC Class Codes: B60H 1/3232 particularly adapted for load transporting vehicles B60H1/3226 takes precedence
• CPC Class Codes: F02B 2063/045 Frames for generator-engine sets
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02B 63/044 the engine-generator unit being placed on a frame or in an housing
• CPC Class Codes: F02B 75/16 Engines characterised by number of cylinders, e.g. single-cylinder engines F02B75/26 takes precedence
• CPC Class Codes: F02B 77/13 Acoustic insulation
• CPC Class Codes: F02D 2200/0614 Actual fuel mass or fuel injection amount
• CPC Class Codes: F02D 2200/1002 Output torque
• CPC Class Codes: F02D 2200/101 Engine speed
• CPC Class Codes: F02D 29/06 peculiar to engines driving electric generators
• CPC Class Codes: F02D 31/001 Electric control of rotation speed
• CPC Class Codes: F02D 31/007 controlling fuel supply
• CPC Class Codes: F02D 41/18 by measuring intake air flow
• CPC Class Codes: F02D 41/266 the computer being backed-up or assisted by another circuit, e.g. analogue
• CPC Class Codes: Y02T 10/88 Optimized components or subsystems, e.g. lighting, actively controlled glasses

Abstract

A generator set for a transport refrigeration unit that is operable at a first frequency and a second frequency. The generator set includes a generator and a prime mover. The generator set is controlled by an electronic control unit (ECU) that is coupled to a controller. The ECU is configured to monitor the engine operation condition to obtain an engine operation condition value; whereas the controller is configured to receive the engine operation condition value and compare the value with an engine operation condition threshold. When the engine operation condition value, for example, exceeds the engine operation condition threshold, the controller instructs the ECU to operate the engine at a first speed; and when the engine operation condition value, for example, is below the engine operation condition threshold, the controller instructs the ECU to operate the engine at a second speed that is slower than the first speed.

Claims

1. A method of operating a prime mover of a generator set comprising:

a controller receiving an engine operation condition value of the prime mover from an electronic control unit of the prime mover;

the controller comparing the engine operation condition value of the prime mover with an engine operation condition threshold;

the controller instructing the electronic control unit of the prime mover to adjust an operating speed of the prime mover based on the comparison of the engine operation condition value with the engine operation condition threshold.

2. The method of claim 1, wherein the engine operation condition value of the prime mover is one of an amount of fuel delivered to the engine, an air intake flow, or a shaft speed of the engine.

3. The method of claim 1, wherein the engine operation condition value of the prime mover is an engine load of the prime mover.

4. The method of claim 1, further comprising:

the controller instructing the electronic control unit of the prime mover to change the operating speed of the prime mover from a first operating speed to a second operating speed when the controller determines that the engine operation condition value of the prime mover is below the engine operation condition threshold for a first minimum tune period.

5. The method of claim 1, further comprising:

the controller instructing the electronic control unit of the prime mover to change the operating speed of the prime mover from a first operating speed to a second operating speed when the controller determines that the engine operation condition value of the prime mover is above the engine operation condition threshold for a second minimum time period.

6. The method of claim 1, wherein the engine operation condition threshold is a first value when the prime mover is operating at a first operating speed and is a second value when the prime mover is operating at a second operating speed.

7. A generator set comprising:

a prime mover with an electronic control unit; and

a controller;

wherein the controller receives an engine operation condition value of the prime mover from the electronic control unit, compares the engine operation condition value of the prime mover with an engine operation condition threshold, and instructs the electronic control unit of the prime mover to adjust an operating speed of the prime mover based on the comparison of the engine operation condition value with the engine operation condition threshold.

8. The generator set of claim 7, wherein the engine operation condition value of the engine is one of an amount of fuel delivered to the engine, an air intake flow, or a shaft speed of the engine.

9. The generator set of claim 7, wherein the engine operation condition value of the engine is an engine load of the engine.

10. The generator set of claim 7, further comprising:

a generator;

wherein the electronic control unit controls operation of the engine and monitors and obtains the engine operation condition value, and

wherein the controller communicates with the electronic control unit, monitors an operation status of the generator, and monitors and controls operation of the generator set.

11. The generator set of claim 7, wherein the electronic control unit includes a processor and sends the engine operation condition value of the prime mover to the controller, and

wherein the controller includes a processor and compares the engine operation condition value of the prime mover with the engine operation condition threshold to generate an engine operation instruction for the electronic control unit of the prime mover.

12. The generator set of claim 7, wherein the engine operation condition threshold is a first value when the prime mover is operating at a first operating speed and is a second value when the prime mover is operating at a second operating speed.

13. The generator set of claim 7, further comprising a controller panel that includes:

the controller,

a memory unit connected to the controller,

a timer incorporated into the controller, and

an operator interface connected to the controller.

14. A method of operating a prime mover of a generator set comprising:

a controller receiving an engine operation condition value of the prime mover;

the controller comparing the engine operation condition value of the prime mover with an upshift engine operation condition threshold;

the controller instructing the electronic control unit of the prime mover to adjust an operating speed of the prime mover based on the comparison of the engine operation condition value with the upshift engine operation condition threshold;

the controller comparing the engine operation condition value of the prime mover with a downshift engine operation condition threshold; and

the controller instructing the electronic control unit of the prime mover to adjust an operating speed of the prime mover based on the comparison of the engine operation condition value with the downshift engine operation condition threshold.

15. The method of claim 14, further comprising:

maintaining the prime mover at a first operating speed when the engine operation condition value of the prime mover is lower than the upshift engine operation condition threshold.

16. The method of claim 14, further comprising:

maintaining the prime mover at a second operating speed when the engine operation condition value of the prime mover is higher than the upshift engine operation condition threshold.

17. The method of claim 14, wherein the engine operation condition value of the prime mover is one of an amount of fuel delivered to the engine, an air intake flow, or a shaft speed of the engine.

18. The method of claim 14, wherein the engine operation condition value of the prime mover is an engine load of the prime mover.

19. The method of claim 14, wherein the upshift engine operation condition threshold is a first percentage full rated engine output torque, and the downshift engine operation condition threshold is a second percentage full rated engine output torque,

wherein the first percentage full rated engine output torque is greater than the second percentage full rated engine output torque.

20. The method of claim 14, further comprising:

the controller calculating an engine load of the prime mover based on the engine operation condition value of the prime mover.