System and method for electric current and power monitoring and control of a generator

• US 20080133064A1
• Filed: 12/01/2006
• Published: 06/05/2008
• Est. Priority Date: 12/01/2006
• Status: Active Grant

• Current Assignee: C.E. Niehoff & Co.
• Original Assignee: C E Niehoff & Company
• Inventors: Patterson, Ciaran, Pourkermani, Mahmood, Basic, Nisvet
• Granted Patent: US 7,466,107 B2
• Time in Patent Office: Days
• US Class Current: 700/287
• CPC Class Codes: H02P 29/64 Controlling or determining the temperature of the winding

Abstract

A control device measures a voltage drop across a conductor in a generator to determine and control the total generator output current. A temperature of the conductor is also measured to improve the accuracy. The control device may further improve on the accuracy by compensating for the electrical current through a field coil that may power the generator. The control device may be used in combination with a generator in a vehicle electrical system. Other system parameters may be monitored to improve on the system monitoring, diagnostics, and control. The generator may include a conductor comprising a process-controlled geometric shape.

Claims

1. A vehicle electrical system comprising:

(a) a generator comprising a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential; and

(b) a control device responsive to the first signal and operative to at least one of limit and cease the total electrical output current, via a generator output power controller, according to the first signal.

2. The system of claim 1, further comprising means to generate a second signal indicative of a temperature of the conductor and wherein the control device is additionally responsive to the second signal and operative to at least one of limit and cease the total electrical output current, via the generator output power controller, according to at least one of the first and second signal.

3. The system of claim 1, further comprising means to generate a second signal indicative of electrical current through a field coil included in the generator and wherein the control device is additionally responsive to the second signal and operative to at least one of limit and cease the total electrical output current, via the generator output power controller, according to at least one of the first and second signal.

4. The system of claim 1, further comprising means to generate a second signal indicative of an output voltage of the generator and wherein the control device is additionally responsive to the second signal and operative to regulate the output voltage, via the generator output power controller, according to the second signal.

5. A vehicle electrical system comprising:

(a) a generator comprising a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential; and

(b) means to generate a second signal indicative of a temperature of the conductor; and

(c) a control device responsive to the first and second signal and operative to at least one of limit and cease the total electrical output current, via a generator output power controller, according to at least one of the first and second signal.

6. A vehicle electrical system comprising:

(a) means to generate a first signal indicative of a rotational speed of an engine coupled with a generator included in the vehicle;

(b) means to generate a second signal indicative of a rotational speed of the generator; and

(c) a control device responsive to the first and second signal and operative to at least one of (i) limit and cease a total electrical output current generated by the generator, via a generator output power controller, and (ii) generate an error signal indicative of a fault condition, when a ratio of the rotational speed of the generator and engine substantially differs from a predetermined value.

7. A vehicle electrical system comprising:

(a) a generator comprising a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential; and

(b) means to generate a second signal indicative of a temperature of the conductor;

(c) means to generate a third signal indicative of electrical current through a field coil included in the generator; and

(d) means to generate a fourth signal indicative of a rotational speed of the generator; and

(e) a control device responsive to the first, second, third, and fourth signal and operative to (i) obtain a first value of the total electrical current according to at least one of the first, second, and third signal, (ii) obtain a second value of the total electrical current according to at least one of the second, third, and fourth signal, and (iii) generate an error signal indicative of a fault condition when a difference between the first and second values of the total electrical current is substantially above a predetermined value.

8. A method for controlling a vehicle electrical system, said system comprising a generator, said method comprising:

(a) generating a first signal indicative of an electrical potential across a conductor included in the generator and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential; and

(b) at least one of limiting and ceasing the total electrical output current, via a generator output power controller, according to the first signal.

9. A method for controlling a vehicle electrical system, said system comprising a generator, said method comprising:

(a) generating a first signal indicative of an electrical potential across a conductor included in the generator and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential;

(b) generating a second signal indicative of a temperature of the conductor; and

(c) at least one of limiting and ceasing the total electrical output current, via a generator output power controller, according to at least one the first and second signal.

10. A method for controlling a vehicle electrical system, said system comprising a generator, said method comprising:

(a) generating a first signal indicative of a rotational speed of an engine included in the vehicle and coupled with the generator;

(b) generating a second signal indicative of a rotational speed of the generator; and

(c) at least one of (i) limiting and ceasing a total electrical output current generated by the generator, via a generator output power controller, and (ii) generating an error signal indicative of a fault condition, when a ratio of the rotational speed of the generator and engine substantially differs from a predetermined value.

11. A method for controlling a vehicle electrical system, said system comprising a generator, said method comprising:

(a) generating a first signal indicative of an electrical potential across a conductor included in the generator and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential;

(b) generating a second signal indicative of a temperature of the conductor;

(c) generating a third signal indicative of electrical current through a field coil included in the generator;

(d) generating a fourth signal indicative of a rotational speed of the generator;

(e) obtaining a first value of the total electrical current according to at least one of the first, second, and third signal;

(f) obtaining a second value of the total electrical current according to at least one of the second, third, and fourth signal; and

(g) generating an error signal indicative of a fault condition when a difference between the first and second values of the total electrical current is substantially above a predetermined value.

12. A control device for a generator, said generator comprising a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential, said control device comprising:

a processor, including a programming code operable on the processor;

wherein said processor is configured to measure the first signal, via a first line, and to apply a control signal to a generator output power controller to at least one of limit and cease the total electrical output current, via a control line, according to the first signal.

13. The control device of claim 12, wherein said generator output power controller comprises at least one of a voltage regulator, a field coil, a silicon controlled rectifier, and a metal oxide semiconductor field effect transistor.

14. The control device of claim 12, wherein the processor is configured to apply a control signal to limit the total electrical output current when a DC component of the first signal is greater than V₁ and less than V₂, and to cease the total electrical output current when the DC component is equal to or greater than V₂, wherein V₁ and V₂ are predetermined values.

15. The control device of claim 12, wherein said generator further comprises a sensor capable of generating a second signal indicative of a temperature of the conductor and wherein said processor is further configured to measure the second signal, via a second line, and to apply a control signal to the generator output power controller to at least one of limit and cease the total electrical output current, via the control line, according to at least one of the first and second signal.

16. The control device of claim 12, wherein said generator further comprises a sensor capable of generating a second signal indicative of electrical current through a field coil included in the generator and wherein said processor is further configured to measure the second signal, via a second line, and to apply a control signal to the generator output power controller to at least one of limit and cease the total electrical output current, via the control line, according to at least one of the first and second signal.

17. The control device of claim 12, wherein said generator further comprises a first sensor capable of generating a second signal indicative of a temperature of the conductor and a second sensor capable of generating a third signal indicative of electrical current through a field coil included in the generator and wherein said processor is further configured to measure the second and third signal, via a second and third line, and to apply a control signal to the generator output power controller to at least one of limit and cease the total electrical output current, via the control line, according to at least one of the first, second, and third signal.

18. The control device of claim 12, wherein said generator further comprises means to generate a second signal indicative of a temperature of an output terminal included in the generator and wherein the processor is further configured to measure the second signal, via a second line, and to apply a control signal to the generator output power controller to at least one of limit and cease the total electrical output current, via the control line, according to at least one of the first and second signal.

19. The control device of claim 12, wherein said generator further comprises means to generate a second signal indicative of an output voltage of the generator and wherein the processor is further configured to measure the second signal, via a second line, and to apply a control signal to the generator output power controller to regulate the output voltage, via the control line, according to the second signal.

20. The control device of claim 19, further comprising means to generate a third signal indicative of a temperature of a battery and wherein the processor is further configured to measure the third signal, via a third line, and to apply a control signal to the generator output power controller to regulate the output voltage, via the control line, according to at least one of the second and third signal.

21. The control device of claim 20, wherein the processor is configured to apply a control signal to the generator output power controller to regulate the output voltage, via the control line, according to a default voltage when the temperature of the battery is substantially outside of a predetermined range.

22. The control device of claim 20, further comprising means to generate a fourth signal indicative of a battery type and wherein the processor is further configured to measure the fourth signal, via a fourth line, and to apply a control signal to the generator output power controller to regulate the output voltage, via the control line, according to at least one of the second, third, and fourth signal.

23. The control device of claim 19, further comprising means to generate a third signal indicative of a voltage of a battery and wherein the processor is further configured to measure the third signal, via a third line, and to apply a control signal to the generator output power controller to regulate the output voltage, via the control line, according to at least one of the second and third signal.

24. The control device of claim 23, wherein the processor is configured to apply a control signal to the generator output power controller to regulate the output voltage, via the control line, according to a default voltage when a difference between the output voltage and battery voltage is substantially above a predetermined value.

25. A control device for a generator, said generator comprising (i) a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential, and (ii) means to generate a second signal indicative of a temperature of the conductor, said control device comprising:

a processor, including a programming code operable on the processor,

wherein said processor is configured to measure the first and second signal, via a first and second line, and to apply a control signal to the generator output power controller to at least one of limit and cease the total electrical output current, via a control line, according to at least one of the first and second signal.

26. A control device for a generator coupled with an engine, said engine comprising means to generate a first signal indicative of a rotational speed of the engine, said generator comprising means to generate a second signal indicative of a rotational speed of the generator, said control device comprising:

a processor, including a programming code operable on the processor, coupled with the engine, generator, and a generator output power controller;

wherein said processor is configured to measure the first and second signal, via a first and second line, to at least one of (i) apply a control signal to the generator output power controller to at least one of limit and cease the total electrical output current, via a control line, and (ii) generate an error signal indicative of a fault condition, via a communication line, when a ratio of the rotational speed of the generator and engine substantially differs from a predetermined value.

27. A control device for a generator, said generator comprising:

(a) a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential;

(b) a first sensor capable of generating a second signal indicative of a temperature of the conductor;

(c) a second sensor capable of generating a third signal indicative of electrical current through a field coil included in the generator; and

(d) a third sensor capable of generating a fourth signal indicative of a rotational speed of the generator;

said control device comprising;

a processor, including a programming code operable on the processor;

wherein said processor is configured to measure the first, second, third, and fourth signal, via a first, second, third, and fourth line, to (i) determine a first value of the total electrical current according to at least one of the first, second, and third signal, (ii) determine a second value of the total electrical current according to at least one of the second, third, and fourth signal, and (iii) generate an error signal indicative of a fault condition, via a communication line, when a difference between the first and second values of the total electrical current is substantially above a predetermined value.

28. A method for controlling a generator, said generator comprising a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential, said method comprising:

(a) measuring the first signal, via a first line; and

(b) applying a control signal to a generator output power controller to at least one of limit and cease the total electrical output current, via a control line, according to the first signal.

29. A method for controlling a generator, said generator comprising (i) a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential, and (ii) means to generate a second signal indicative of a temperature of the conductor, said method comprising:

(a) measuring the first signal, via a first line;

(b) measuring the second signal, via a second line;

(c) applying a control signal to a generator output power controller to at least one of limit and cease the total electrical output current, via a control line, according to at least one of the first and second signal.

30. A method for controlling a generator coupled with an engine, said engine comprising means to generate a first signal indicative of a rotational speed of the engine, said generator comprising means to generate a second signal indicative of a rotational speed of the generator, said method comprising:

(a) measuring the first signal, via a first line;

(b) measuring the second signal, via a second line; and

(c) at least one of (i) applying a control signal to a generator output power controller to at least one of limit and cease the total electrical output current, via a control line, and (ii) generating an error signal indicative of a fault condition, when a ratio of the rotational speed of the generator and engine substantially differs from a predetermined value.

31. A method for controlling a generator, said generator comprising (i) a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential, (ii) means to generate a second signal indicative of a temperature of the conductor, (iii) means to generate a third signal indicative of electrical current through a field coil included in the generator, and (iv) means to generate a fourth signal indicative of a rotational speed of the generator, said method comprising:

(a) measuring the first signal, via a first line;

(b) measuring the second signal, via a second line;

(c) measuring the third signal, via a third line;

(d) measuring the fourth signal, via a fourth line;

(e) determining a first value of the total electrical current according to at least one of the first, second, and third signal;

(f) determining a second value of the total electrical current according to at least one of the second, third, and fourth signal; and

(g) generating an error signal indicative of a fault condition when a difference between the first and second values of the total electrical current is substantially above a predetermined value.

32. A method for communicating a total electrical output current generated by a generator, said generator comprising (i) a conductor operative to generate a first signal indicative of an electrical potential across the conductor and wherein the total electrical output current generated by the generator is substantially proportional to the electrical potential, and (ii) means to generate a second signal indicative of a temperature of the conductor, said method comprising:

(a) measuring the first signal, via a first line;

(b) measuring the second signal, via a second line;

(c) generating a communication signal indicative of the total electrical output current, via a communication line, according to at least one of the first and second signal.

33. A generator, comprising:

a conductor comprising a process-controlled geometric shape and operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential.

34. The generator of claim 33, wherein the process-controlled geometric shape comprises at least one of a specific length and a specific cross section.

35. The generator of claim 34, wherein the specific length is a specified dimension comprising a tolerance range of less than or equal to 1/100 of an inch, and wherein the specific cross section is a specified wire gage.

36. A vehicle electrical system comprising:

(a) a generator comprising a conductor, said conductor comprising a process-controlled geometric shape and operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential; and

(b) a control device responsive to the first signal and operative to at least one of limit and cease the total electrical output current, via a generator output power controller, according to the first signal.

37. A control device for a generator, said generator comprising a conductor, said conductor comprising a process-controlled geometric shape and operative to generate a first signal indicative of an electrical potential across the conductor and wherein a total electrical output current generated by the generator is substantially proportional to the electrical potential, said control device comprising:

a processor, including a programming code operable on the processor;

wherein said processor is configured to measure the first signal, via a first line, and to apply a control signal to a generator output power controller to at least one of limit and cease the total electrical output current, via a control line, according to the first signal.