Controller for permanent magnet generator

• US 5,625,276 A
• Filed: 01/09/1995
• Issued: 04/29/1997
• Est. Priority Date: 09/14/1994
• Status: Expired due to Fees

• Current Assignee: Powermate Corporation (Pramac America LLC)
• Original Assignee: Coleman Company Incorporated (Newell Brands Inc.)
• Inventors: Scott, Harold C., Anderson, William
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): Ponomarenko, Nicholas
• Application Number:
  US08/370,577
• Time in Patent Office: 841 Days
• Field of Search: 322/1, 322/24, 322/28, 322/47, 322/90, 310/114, 310/156, 310/179
• US Class Current: 322/24
• CPC Class Codes: B23K 9/1062 with computing means
• CPC Class Codes: F02B 2063/045 Frames for generator-engine sets
• CPC Class Codes: F02B 2063/046 Handles adapted therefor, e.g. handles or grips for movable units
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02B 75/16 Engines characterised by number of cylinders, e.g. single-cylinder engines F02B75/26 takes precedence
• CPC Class Codes: F05C 2201/021 Aluminium
• CPC Class Codes: H02K 1/278 Surface mounted magnets; Inset magnets
• CPC Class Codes: H02K 21/48 Generators with two or more outputs
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• CPC Class Codes: H02M 1/0085 Partially controlled bridges
• CPC Class Codes: H02M 7/00 Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
• CPC Class Codes: H02P 2101/45 for motor vehicles, e.g. car alternators
• CPC Class Codes: H02P 25/188 wherein the motor windings are switched from series to parallel or vice versa to control speed or torque
• CPC Class Codes: H02P 9/04 Control effected upon non-electric prime mover and dependent upon electric output value of the generator
• CPC Class Codes: H02P 9/305 controlling voltage H02P9/302 takes precedence
• 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 according to the disclosure includes a control system for regulating the output of the generator. The generator, such as a permanent magnet generator, includes multiple windings. For high current applications, the windings are connected in parallel. For high voltage applications, each three-phase set of windings is connected in series. The various windings may be selectively and individually activated by the control system to achieve a desired output current or voltage.

Claims

1. A control system for a generator, said generator having a plurality of substantially magnetically independent windings generating electricity and a connector for connecting a load to the windings, comprising:

a plurality of switches, wherein each of said switches is connected between one of the generator windings and the load connector such that said switch may connect and disconnect the windings to the load connector; and

a controller connected to said plurality of switches for selectively activating and deactivating said switches to vary the number of windings connected to the load connector in accordance with an operating parameter of the generator.

2. The control system of claim 1, further comprising a sensor responsive to the operating parameter of the generator for generating indicia of said operating parameter, wherein said controller is responsive to said sensor indicia.

3. The control system of claim 2, wherein said operating parameter is the output voltage of the generator.

4. The control system of claim 2, wherein said operating parameter is the output current of the generator.

5. The control system of claim 2, wherein said operating parameter is temperature of a portion of the generator.

6. A control system for a generator having a plurality of windings generating electricity and a connector for connecting a load to the windings to receive the electricity, comprising:

a plurality of switches, wherein each of said switches is connected to selectively effect a current path between respective windings and the load connector; and

a controller connected to said plurality of switches for selectively activating and deactivating said switches wherein said controller varies the sequence of said selective activation and deactivation of said switches to distribute heat generation among the generator windings.

7. The control system of claim 6, wherein at least one of said switches comprises a silicon controlled rectifier (SCR).

8. The control system of claim 6, wherein said controller includes a microprocessor.

9. The system of claim 8 wherein at least some of the windings are selectively connected across by-pass diodes, the by-pass diodes effectively connected to the load connector in series.

10. The system of claim 8 wherein at least some of the windings are effectively connected to the load connector in parallel.

11. The system of claim 8 wherein the plurality of windings comprise a plurality of groups of stator windings disposed such that rotation of the rotor induces current in the stator windings, the plurality of groups of windings being substantially magnetically independent from each other.

12. The system of claim 8 wherein:

the windings comprises a plurality of three-phase windings;

the switches constitute part of at least one controlled rectifying circuit cooperating with each winding group; and

the system further comprises a respective supplemental diode connected across each rectifying circuit, the supplemental diodes being connected in series.

13. The system of claim 12 wherein the switching circuit further includes a capacitance connected in parallel with the output terminals.

14. The system of claim 8 wherein the windings include a first set of individual groups of windings arranged for selective connection in parallel, and a second set of individual groups of windings arranged for selective connection in parallel, the first and second sets being connected in series.

15. The system of claim 11 wherein:

the generator includes a rotor and a stator;

the rotor has a predetermined number of poles; and

the stator includes a soft magnet core having a crenelated inner periphery with a predetermined number of equally spaced teeth and slots, equal to a predetermined multiple of the number of rotor poles times the number of phases, with a predetermined number of said windings wound through the slots about predetermined numbers of the teeth.

16. The system of claim 8 wherein the switches constitute a portion of a controlled rectifier.

17. The system of claim 16, further including an inverter cooperating with the rectifier.

18. The system of claim 8 wherein the controller comprises a microcomputer.

19. The system of claim 8 wherein:

the generator includes a rotor and a stator; and

the stator includes a soft magnet core having a crenelated inner periphery with a predetermined number of equally spaced teeth and slots, with a predetermined number of said windings wound through the slots about predetermined numbers of the teeth.

20. The system of claim 19 wherein the rotor comprises a predetermined number of poles and the windings comprise groups of respective phase windings connected together at one end in a star configuration, and the winding corresponding to each phase wound about a predetermined number of teeth corresponding to a rotor pole, with each successive phase winding shifted by one slot, and wound in the opposite direction from the preceding phase winding.

21. The system of claim 19 wherein the rotor comprises:

a core having a surface proximate to the stator with insets and portions between the insets forming respective consequence poles, each consequence pole having a predetermined surface area proximate to the stator; and

a plurality of permanent high energy product magnets mounted in the insets separated from adjacent consequence poles by a predetermined distance, the magnets having a predetermined surface area proximate to the stator greater than the surface area of the consequence poles proximate to the stator, separated from the stator by a predetermined gap distance such that relative motion of the rotor and stator causes magnetic flux from the magnets to interact with and induce current in the stator windings.

22. The generator of claim 21 wherein the surface area of the permanent magnets proximate to the stator is greater than the surface area of the consequence poles proximate to the stator by the ratio of the flux density produced by the permanent magnet to the allowed flux density of the consequence pole.

23. The apparatus of claim 21 wherein the magnets have a flux density of at least on the order five kilogauss.

24. The apparatus of claim 21 wherein the distance separating the magnets from the consequence poles is greater than the predetermined gap distance separating the rotor surface from the stator.

25. The system of claim 8 further comprising at least one sensor for generating indicia of a control parameter, and wherein the control circuit, responsive to said indicia, generates control signals to the switches to vary the number of windings connected to the load connector in accordance with the control parameter.

26. The system of claim 25, wherein the control parameter is the speed of rotation of the rotor.

27. The system of claim 11 further comprising at least one sensor for generating indicia of a control parameter, and wherein the control circuit, responsive to said indicia, generates control signals to the switches to vary the number of individual groups of stator windings connected to the load connector in accordance with the control parameter.

28. The system of claim 27, wherein the control parameter is the speed of rotation of the rotor.

29. The system of claim 8 further comprising at least one sensor for generating a feedback signal indicative of a control parameter, and wherein the control circuit, responsive to said feedback signal, generates control signals to the switches to vary the number of windings connected to the load connector in accordance with the control parameter.

30. The system of claim 29, wherein the control parameter is the magnitude of the current drawn at the load connector.

31. The system of claim 29, wherein the control parameter is the magnitude of the voltage at the load connector.

32. The system of claim 29 wherein the controller comprises a microcomputer.

33. The system of claim 29 wherein the controller comprises:

a voltage divider with a predetermined number of steps, having a signal indicative of the control parameter applied thereto; and

,

a respective comparator associated with each step of the divider, the comparator generating an output signal indicative of a comparison of the voltage at the associated divider step and a predetermined reference voltage associated with the step;

the output signals of the comparators being applied as the control signals to the switches.

34. The system of claim 33 wherein the predetermined number of steps corresponds to the number of stator windings.

35. The system of claim 33 wherein the controller further comprises means for altering the sequence in which the windings are activated.

36. The system of claim 11 further comprising at least one sensor for generating a feedback signal indicative of a control parameter, and wherein the control circuit, responsive to said feedback signal, generates control signals to the switches to vary the number of individual groups of stator windings with current paths to the load connector in accordance with the control parameter.

37. The system of claim 36, wherein the control parameter is the magnitude of the current drawn at the load connector.

38. The system of claim 36, wherein the control parameter is the magnitude of the voltage at the load connector.

39. The system of claim 36 wherein the controller comprises:

a voltage divider with a predetermined number of steps, having a signal indicative of the control parameter applied thereto; and

,

a respective comparator associated with each step of the divider, the comparator generating an output signal indicative of a comparison of the voltage at the associated divider step and a predetermined reference voltage associated with the step;

the output signals of the comparators being applied as the control signals to the switches.

40. The system of claim 39 wherein the predetermined number of steps corresponds to the number of stator windings.

41. The system of claim 39 wherein the controller further comprises means for altering the sequence in which the windings are activated.

42. The system of claim 36 wherein the controller comprises a microcomputer.

43. The system of claim 25 wherein the control circuit comprises:

a microcomputer, generating an output signal indicative of a count, incremented at predetermined intervals, and responsive to interrupt signals, generating control signals to the switching circuit to vary the number of individual groups of stator windings with current paths to the output terminals;

a resistor ladder;

a bus selectively coupling the microcomputer to the resistor ladder and to the switching circuit;

the resistor ladder, responsive to the microcomputer count, generating a ramp reference signal reflecting that count; and

at least one comparator, responsive to the ramp reference signal and to indicia of the control parameter, for generating a microcomputer interrupt signal in accordance with a comparison of the control parameter with the ramp signal, the instantaneous value of the microcomputer count when the parameter indica and reference ramp signal voltage are equal being indicative of the value of the control parameter;

the microcomputer generating control signals to the switching circuit to vary the number of individual groups of stator windings with current paths to the output terminals in accordance with the value of the control parameter indicated by such instantaneous value of the microcomputer count.

44. The system of claim 43 wherein the comparator is internal to the microcomputer.

45. The system of claim 43 further including means for selectively applying indicia of one of a plurality of control parameters to the comparator.

46. The system of claim 43 further including respective input switches for providing operator input to the microcomputer, and a latch, connected to the bus, for capturing the state of the switches.

47. The system of claim 43 wherein the controller further comprises:

at least one output register having a respective bit corresponding to each of the switches, the register being selectively receptive of input signals from the microcomputer; and

an output latch corresponding to each output register, responsive to control signals from said microcomputer and selectively receptive of indicia of the contents of the output register, providing control signals to the switches.

48. The system of claim 47 wherein:

the output register is a serial-input-parallel-output register; and

the microcomputer provides a bit pattern corresponding to the desired states of the switches as serial data, and a load command signal to the output register.

49. The system of claim 43 wherein:

the controller includes a plurality of serial-input-parallel-output registers having respective bits corresponding to an associated group of switches; and

the microcomputer provides

a serial bit pattern, corresponding to the desired states of a group of switches, applied as data inputs to all of the output registers; and

serial data clock signals, selectively provided synchronously with the serial data, the serial data clock signals being applied to a selected one of the output registers to select, and load the data into, the such register; and

a latch control signal, applied to each of the output registers, subsequent to the serial bit pattern data, to load the accumulated pattern into a corresponding output latch, and hence, apply the bit pattern as control signals to designated switches.

50. Apparatus for converting mechanical energy into electrical energy at respective output terminals, comprising:

a rotor, adapted for selective rotation;

a stator, including a plurality of groups of stator windings disposed such that rotation of the rotor induces current in the stator windings, the plurality of groups of windings being substantially magnetically independent from each other;

a switching circuit, responsive to control signals applied thereto, selectively completing current paths between individual groups of stator windings and the output terminals; and

a control circuit for generating control signals to the switching circuit to vary the number of individual groups of stator windings with current paths to the output terminals to achieve a desired output.

51. The apparatus of claim 50 wherein the switching circuit comprises a controlled rectifier.

52. The apparatus of claim 50 further comprising at least one sensor for generating indicia of a control parameter, and wherein the control circuit, responsive to said indicia, generates control signals to the switching circuit to vary the number of individual groups of stator windings with current paths to the output terminals in accordance with the control parameter.

53. The apparatus of claim 52, wherein the control parameter is the speed of rotation of the rotor.

54. The apparatus of claim 50 further comprising at least one sensor for generating a feedback signal indicative of a control parameter, and wherein the control circuit, responsive to said feedback signal, generates control signals to the switching circuit to vary the number of individual groups of stator windings with current paths to the output terminals in accordance with the control parameter.

55. The apparatus of claim 54, wherein the control parameter is the magnitude of the current drawn at the output terminals.

56. The apparatus of claim 54, wherein the control parameter is the magnitude of the voltage at the output terminals.

57. The apparatus of claim 56 wherein the control circuit comprises:

a voltage divider with a predetermined number of steps, having a signal indicative of the output voltage applied thereto; and

,

a respective comparator associated with each step of the divider, the comparator generating an output signal indicative of a comparison of the voltage at the associated divider step and a predetermined reference voltage associated with the step;

the output signals of the comparators being applied as the control signals to the switching circuit.

58. The apparatus of claim 57 wherein the predetermined number of steps corresponds to the number of stator windings.

59. The apparatus of claim 57 wherein the control circuit further comprises a respective buffer circuit electrically interposed between the voltage divider steps and associated comparators.

60. The apparatus of claim 57 wherein the control circuit further comprises a Zener diode of pre-determined breakdown voltage corresponding to the divider input voltage indicative of a maximum permitted output voltage, connected in parallel with the voltage divider.

61. The apparatus of claim 57 wherein the control circuit further comprises means for providing over-current protection.

62. The apparatus of claim 57 wherein the control circuit further comprises a second voltage divider, including a manually adjustable potentiometer, and connected to an internal, substantially constant voltage and ground, for generating the reference voltages to the comparators.

63. The apparatus of claim 57 wherein the control circuit further comprises means for altering the sequence in which the windings are activated.

64. The apparatus of claim 50 wherein the control circuit comprises a microcomputer.

65. The apparatus of claim 52 wherein the control circuit comprises a microcomputer.

66. The apparatus of claim 52 wherein the control circuit comprises:

a microcomputer, generating an output signal indicative of a count, incremented at predetermined intervals, and responsive to interrupt signals, generating control signals to the switching circuit to vary the number of individual groups of stator windings with current paths to the output terminals;

a resistor ladder;

a bus selectively coupling the microcomputer to the resistor ladder and to the switching circuit;

the resistor ladder, responsive to the microcomputer count, generating a ramp reference signal reflecting that count; and

at least one comparator, responsive to the ramp reference signal and to indicia of the control parameter, for generating a microcomputer interrupt signal in accordance with a comparison of the control parameter with the ramp signal, the instantaneous value of the microcomputer count when the parameter indica and reference ramp signal voltage are equal being indicative of the value of the control parameter;

the microcomputer generating control signals to the switching circuit to vary the number of individual groups of stator windings with current paths to the output terminals in accordance with the value of the control parameter indicated by such instantaneous value of the microcomputer count.

67. The apparatus of claim 66 wherein the comparator is internal to the microcomputer.

68. The apparatus of claim 66 further including means for selectively applying indicia of one of a plurality of control parameters to the comparator.

69. The apparatus of claim 66 further including respective input switches for providing operator input to the microcomputer, and a latch, connected to the bus, for capturing the state of the switches.

70. The apparatus of claim 66 wherein the switching includes at least one switching device for each group of windings, and

the controller further comprises:

at least one output register having a respective bit corresponding to each of the switching devices, the register being selectively receptive of input signals from the microcomputer; and

an output latch corresponding to each output register, responsive to control signals from said microcomputer and selectively receptive of indicia of the contents of the output register, providing control signals to the switching devices.

71. The apparatus of claim 70 wherein:

the output register is a serial-input-parallel-output register;

the microcomputer provides a bit pattern corresponding to the desired states of the switching devices as serial data, and a load command signal to the output register.

72. The apparatus of claim 66 wherein:

the controller includes a plurality of serial-input-parallel-output registers having respective bits corresponding to an associated group of the switching devices; and

the microcomputer provides

a serial bit pattern, corresponding to the desired states of a group of switching devices, applied as data inputs to all of the output registers; and

serial data clock signals, selectively provided synchronously with the serial data, the serial data clock signals being applied to a selected one of the output registers to select, and load the data into, the such register; and

a latch control signal, applied to each of the output registers, subsequent to the serial bit pattern data, to load the accumulated pattern into a corresponding output latch, and hence, apply the bit pattern as control signals to designated switching devices.

73. The apparatus of claim 52 wherein the switching circuit includes at least one switching device for each group of stator windings and the control circuit comprises:

a voltage divider with a pre-determined number of steps corresponding to the number of groups of stator windings, having applied thereto a voltage indicative of the control parameter;

for each step, an associated buffer, an associated comparator, and an associated interface circuit, receptive of the comparator output, for generating control signals to the switching devices to selectively complete current paths between the respective winding groups to the output terminals in accordance with the control parameter.

74. The apparatus of claim 73 wherein the control parameter is the level of output voltage.

75. The apparatus of claim 50 wherein the switching circuit selectively connects individual groups of stator windings in parallel.

76. The apparatus of claim 50 wherein the switching circuit comprises:

a capacitance and a at least one controlled rectifying circuits cooperating with each winding group, the rectifying circuits being connected in parallel to the capacitance.

77. The apparatus of claim 50 wherein:

each independent group of windings comprises a plurality of three-phase windings, and the switching circuit comprises;

at least one controlled rectifying circuit cooperating with each winding group; and

a respective supplemental diode connected across each rectifying circuit, the supplemental diodes being connected in series.

78. The apparatus of claim 77 wherein the switching circuit further includes a capacitance connected in parallel with the output terminals.

79. The apparatus of claim 50 wherein the switching circuit selectively connects individual groups of stator windings in series.

80. The apparatus of claim 50 comprising a first set of individual groups of stator windings arranged for selective connection in parallel, and a second set of individual groups of stator windings arranged for selective connection in parallel, the first and second sets being connected in series.

81. The apparatus of claim 80 including a first output terminal, associated with the first set of individual groups of stator windings for providing a first regulated DC rail voltage, and a second output terminal associated with the second set of individual groups of stator windings for providing a second regulated DC rail voltage.

82. The apparatus of claim 81 further including an inverter deriving power from at least one of the regulated DC rail voltages.

83. The apparatus of claim 81 further including a third set of individual groups of stator windings, respective rectifiers cooperating with the third set of windings to generate an independent inverter rail voltage, and an inverter deriving power from the independent inverter rail voltage.

84. The apparatus of claim 50 further comprising an energy source disposed to selectively rotate the rotor.

85. The apparatus of claim 84 wherein the energy source comprises an internal combustion engine.

86. The apparatus of claim 85 wherein the engine includes an output shaft and a throttle, the output shaft, in operation, rotating at a speed in accordance with the setting of the throttle and the apparatus further includes:

a circuit for generating indicia of the output of the stator;

an electromechanical actuator, responsive to control signals applied thereto, for controlling the setting of the throttle;

said control circuit, responsive to the indicia of the stator output, generating the control signals to the actuator.

87. The apparatus of claim 86 wherein the control circuit comprises a microcomputer.

88. The apparatus of claim 86 wherein the circuit for generating indicia of the output of the stator comprises a zero crossing detector cooperating with one of the stator windings.

89. The apparatus of claim 84 wherein the energy source and stator are mounted on a common frame.

90. The apparatus of claim 85 wherein the engine and stator are mounted on a common frame.

91. The apparatus of claim 85 wherein the stator is mounted to the engine.

92. The apparatus of claim 50 wherein the rotor is a permanent magnet rotor.

93. The apparatus of claim 85 wherein the engine has an output shaft, and the rotor is mounted for rotation with the engine shaft.

94. The apparatus of claim 93 wherein the stator is mounted to the engine coaxially disposed with the rotor, such that the rotor is rotated in close proximity to the stator.

95. The apparatus of claim 93 wherein the stator is generally annular with a central aperture, disposed such that the rotor rotates within the aperture.

96. The apparatus of claim 50 wherein the rotor comprises:

a core having a surface proximate to the stator with insets and portions between the insets forming respective consequence poles, each consequence pole having a predetermined surface area proximate to the stator; and

a plurality of permanent high energy product magnets mounted in the insets separated from adjacent consequence poles by a predetermined distance, the magnets having a predetermined surface area proximate to the stator greater than the surface area of the consequence poles proximate to the stator, separated from the stator by a predetermined gap distance such that relative motion of the rotor and stator causes magnetic flux from the magnets to interact with and induce current in the stator windings.

97. The generator of claim 96 wherein the surface area of the permanent magnets proximate to the stator is greater than the surface area of the consequence poles proximate to the stator by the ratio of the flux density produced by the permanent magnet to the allowed flux density of the consequence pole.

98. The apparatus of claim 96 wherein the magnets have a flux density of at least on the order five kilogauss.

99. The apparatus of claim 96 wherein the distance separating the magnets from the consequence poles is greater than the predetermined gap distance separating the rotor surface from the stator.

100. The apparatus of claim 96 wherein the distance separating the magnets from the consequence poles is at least five times greater than the predetermined gap distance separating the rotor surface from the stator.

101. The apparatus of claim 50 wherein the apparatus provides a predetermined power output, and the ratio of the power output to the weight of the rotor is greater than 150 watts per pound.

102. The apparatus of claim 50 wherein the apparatus provides a predetermined power output, and the ratio of the power output to the weight of the rotor is greater than 200 watts per pound.

103. The apparatus of claim 50 wherein the apparatus provides a predetermined power output, and the ratio of the power output to the weight of the rotor is greater than 500 watts per pound.

104. The apparatus of claim 50 wherein the apparatus provides a predetermined power output, and the ratio of the power output to the weight of the rotor is greater than 700 watts per pound.

105. The apparatus of claim 50 wherein the apparatus provides a predetermined power output, and the ratio of the power output to the weight of the rotor is greater than 800 watts per pound.

106. The apparatus of claim 50 wherein:

the rotor has a predetermined number of poles; and

the stator includes a soft magnet core having a crenelated inner periphery with a predetermined number of equally spaced teeth and slots, equal to a predetermined multiple of the number of rotor poles times the number of phases, with a predetermined number of said independent groups of windings wound through the slots about predetermined numbers of the teeth.

107. The apparatus of claim 86 wherein:

the rotor has a predetermined number of poles; and

the stator includes a soft magnet core having a crenelated inner periphery with a predetermined number of equally spaced teeth and slots, equal to a predetermined multiple of the number of rotor poles times the number of phases, with a predetermined number of said independent groups of windings wound through the slots about predetermined numbers of the teeth.

108. The apparatus of claim 106 wherein the number of slots is equal to the number of rotor poles times the number of phases.

109. The apparatus of claim 106 wherein the apparatus has 3 phases, the rotor has 12 poles, and the stator core includes at least 36 slots.

110. The apparatus of claim 106 wherein the predetermined number of independent groups of windings is an integer fraction of the number of rotor poles.

111. The apparatus of claim 106 wherein the apparatus has 3 phases, the windings of the groups comprise respective phase windings connected together at one end in a star configuration, and the winding corresponding to each phase is wound about a predetermined number of teeth corresponding to a rotor pole, with each successive phase winding shifted by one slot, and wound in the opposite direction from the preceding phase winding.

112. The apparatus of claim 106 wherein the apparatus further comprises at least one sensor for generating indicia of a control parameter, and wherein the control circuit, responsive to said indicia, generates control signals to the switching circuit to vary the number of individual groups of stator windings with current paths to the output terminals in accordance with the control parameter.

138. The apparatus of claim 50, wherein the switching circuit comprises at least one controlled rectifier, and the apparatus further includes:

a power converter, cooperating with said controlled rectifier, for generating an AC signal.

139. The apparatus of claim 50, wherein the switching circuit comprises means for generating a DC signal between first and second DC rails, and the apparatus further includes:

AC output terminals; and

means, responsive to control signals applied thereto, for selectively effecting and disabling connections between the first and second DC rails and said AC output terminals to create a predetermined waveform simulating a desired AC signal.

140. The apparatus of claim 138 wherein the switching circuit comprises means for generating a DC signal between a first and a second DC rail, and the power converter comprises:

first and second converter output terminals;

a first power switch circuit, electrically connected to the positive DC rail, and to the first converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the positive DC rail and the first converter output terminal; and

a second power switch circuit, electrically connected to the positive DC rail, and to the second converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the positive DC rail, and the second converter output terminal;

a third power switch circuit, electrically connected to the common DC rail, and to the first converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the common DC rail and the first converter output terminal; and

a fourth power switch circuit, electrically connected to the common DC rail, and to the second converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the common DC rail and the second converter output terminal.

141. The apparatus of claim 140 wherein the first and second power switch circuits are isolated power switch circuits and the third and fourth power switch circuits are non-isolated power switch circuits.

142. The apparatus of claim 140 wherein each power switch circuit comprises a power switching device and a firing circuit for turning the power switching device on and off in accordance with the control signals.

143. The apparatus of claim 142 wherein the power switching device is a power transistor.

144. The apparatus of claim 142 wherein the firing circuits for the first and second power switch circuits comprise means for quickly driving the associated power transistor into a saturated state when the associated control signal changes state to minimize power dissipation during the switching interval.

145. The apparatus of claim 140 wherein the controller comprises a microprocessor and further generates the control signals to the power switch circuits.

146. The apparatus of claim 50, wherein the switching circuit comprises means for generating an intermediate DC rail signal between an intermediate DC rail and a common rail, and a high DC rail signal between a high DC rail and the common rail, and the apparatus further includes:

AC output terminals; and

means, responsive to control signals applied thereto, for selectively effecting and disabling connections between the intermediate and common DC rails and said AC output terminals, and between the high and common DC rails and said AC output terminals, to create a predetermined waveform simulating a desired AC signal.

147. The apparatus of claim 146 wherein the power converter comprises:

first and second converter output terminals;

a juncture node, receptive of the intermediate DC rail signal;

a first power switch circuit, electrically connected to the juncture node, and to the first converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the juncture node and the first converter output terminal; and

a second power switch circuit, electrically connected to the juncture node, and to the second converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the juncture node, and the second converter output terminal;

a third power switch circuit, electrically connected to the juncture node, and to the high DC rail, disposed to, responsive to control signals applied thereto, selectively effect a current path between the high DC rail and the juncture node;

a fourth power switch circuit, electrically connected to the common DC rail, and to the first converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the common DC rail and the first converter output terminal; and

a fifth power switch circuit, electrically connected to the common DC rail, and to the second converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the common DC rail and the second converter output terminal.

113. A system for generating an electrical output signal responsive to a wide range of input rotational drive speeds, the system comprising:

a rotor, adapted for selective rotation responsive to the input drive;

a stator, including a plurality of groups of stator windings disposed such that rotation of the rotor induces current in the stator windings, each of the plurality of groups of windings being substantially magnetically independent from the other groups of windings;

respective regulators, one associated with each winding group, the regulators including a respective switching device, responsive to control signals applied thereto, associated with each phase,

a predetermined number of said regulators being connected in series;

a first sensor for generating a signal indicative of a predetermined system parameter; and

a controller, responsive to the signals indicative of output voltage, and indicia of phase, for generating control signals to the regulator switching devices to effectively connect and disconnect respective windings in the operative circuit and adjust the relative firing angles of the regulators to control output voltage.

114. The system of claim 113, further including:

a predetermined number of regulators connected in parallel with said series connected regulators; and

a second sensor for generating a signal indicative of output current level;

the controller, responsive to the signals indicative of output current, generating control signals to the 3-phase regulator switching devices to effectively connect and disconnect respective windings in the operative circuit to control output current.

115. The system of claim 113, further including:

a power converter, cooperating with at least one of said regulators, for generating an AC signal.

116. The system of claim 113, further including:

AC output terminals; and

means, responsive to control signals applied thereto, for selectively effecting and disabling connections between the output of at least one of said regulators and said AC output terminals to create a predetermined wave form simulating the desired AC signal.

117. The system of claim 115 wherein said regulators provide at least a positive and a common DC rail, and the power converter comprises:

first and second converter output terminals;

a first power switch circuit, electrically connected to the positive DC rail, and to the first converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the positive DC rail and the first converter output terminal; and

a second power switch circuit, electrically connected to the positive DC rail, and to the second converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the positive DC rail, and the second converter output terminal;

a third power switch circuit, electrically connected to the common DC rail, and to the first converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the common DC rail and the first converter output terminal; and

a fourth power switch circuit, electrically connected to the common DC rail, and to the second converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the common DC rail and the second converter output terminal.

118. The system of claim 117 wherein the first and second power switch circuits are isolated power switch circuits and the third and fourth power switch circuits are non-isolated power switch circuits.

119. The system of claim 117 wherein each power switch circuit comprises a power switching device and a firing circuit for turning the power switching device on and off in accordance with the control signals.

120. The system of claim 119 wherein the power switching device is a power transistor.

121. The system of claim 119 wherein the firing circuits for the first and second power switch circuits comprise means for quickly driving the associated power switching device into a saturated state when the associated control signal changes state to minimize power dissipation during the switching interval.

122. The system of claim 113, further including:

a single phase control winding disposed on the stator, physically wound with one of the phases of a winding group; and

a zero crossing detector, for generating a signal indicative of zero crossings in the signal induced in the control winding for use as the indicia of phase to the controller.

123. The system of claim 122 further including a single phase regulator, cooperating with the control winding.

124. The system of claim 122 further including a single phase regulator, cooperating with the control winding, the single phase regulator including a switching device, responsive to control signals applied thereto, for adjusting the relative firing angle of the single phase regulator to control the output voltage thereof.

125. The system of claim 124 wherein the input rotational drive speed ranges from a predetermined minimum operational value to a predetermined maximum operational value, and the control winding is configured to generate, at the minimum operational value, and with the firing angle of the single phase regulator at a predetermined maximum value, a DC output signal having predetermined voltage and current levels.

126. The system of claim 125 wherein the predetermined minimum operational input rotational drive speed value equals the input drive idle speed.

127. The system of claim 123 further including at least one regulator device cooperating with the single phase regulator to provide a stable regulated DC outputs at a designated level.

128. The system of claim 113, wherein the input rotational drive speed ranges from a predetermined minimum operational value to a predetermined maximum operational value, and:

the windings are configured such that, at the minimum operational value, with a first predetermined number of winding groups connected in the operative circuit, and firing angles of the respective phases of the regulator at a predetermined maximum value, a DC output signal having predetermined voltage and current levels is generated thereby.

129. The system of claim 128, wherein the first predetermined number of winding groups connected in the operative circuit is all of the winding groups, and the predetermined maximum firing angle value is full on.

130. The system of claim 128 wherein the predetermined minimum operational input rotational drive speed value equals the input drive idle speed.

131. The system of claim 113, further including:

at least one further group of stator windings, disposed on the stator such that rotation of the rotor induces current in the stator windings;

a further regulator, associated with the further winding group;

respective converter output terminals; and

a power converter, responsive to signals from the controller, for selectively applying the output of the further regulator to the converter output terminals to generate an output signal with a predetermined waveform.

132. The system of claim 131 wherein said regulators provide at least a positive and a common DC rail, and the power converter comprises:

first and second converter output terminals;

a first power switch circuit, electrically connected to the positive DC rail, and to the first converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the positive DC rail and the first converter output terminal; and

a second power switch circuit, electrically connected to the positive DC rail, and to the second converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the positive DC rail, and the second converter output terminal;

a third power switch circuit, electrically connected to the common DC rail, and to the first converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the common DC rail and the first converter output terminal; and

a fourth power switch circuit, electrically connected to the common DC rail, and to the second converter output terminal, disposed to, responsive to control signals applied thereto, selectively effect a current path between the common DC rail and the second converter output terminal.

133. The system of claim 132 wherein the first and second power switch circuits are isolated power switch circuits and the third and fourth power switch circuits are non-isolated power switch circuits.

134. The system of claim 132 wherein each power switch circuit comprises a power switching device and a firing circuit for turning the power switching device on and off in accordance with the control signals.

135. The system of claim 134 wherein the firing circuits for the first and second power switch circuits comprise means for quickly driving the associated power switching device into a saturated state when the associated control signal changes state to minimize power dissipation during the switching interval.

136. The system of claim 134 wherein the power switching device is a power transistor.

137. The system of claim 113, further including:

a further plurality of groups of stator windings, disposed on the stator such that rotation of the rotor induces current in the stator windings;

the further plurality of groups of windings being substantially magnetically independent from each other;

a further set of regulators, one associated with each of the further plurality of winding groups, the regulators including a respective switching device, responsive to control signals applied thereto, associated with each phase;

the further set of regulators being electrically interconnected to provide an inverter DC rail signal;

an inverter, responsive to the inverter DC rail signal and control signals applied thereto, for generating an AC output signal;

a first sensor for generating a signal indicative of AC output voltage;

the controller, responsive to the signals indicative of AC output voltage, and indicia of rotor cycle phase, generating control signals to the regulator switching devices to effectively connect and disconnect respective windings in the operative circuit and adjust the relative firing angles of the respective phases of the further set of regulators to control the inverter DC rail signal voltage;

the controller, responsive to indicia of AC output phase, further generating the control signals to the inverter.

148. The system of claim 113 wherein the controller comprises:

a microcomputer;

at least one output register having a respective bit corresponding to each of the switching devices of said regulators, the register being selectively receptive of input signals from the microcomputer; and

an output latch corresponding to each output register, responsive to control signals from said microcomputer and selectively receptive of indicia of the contents of the output register, providing control signals to the switching devices of said regulators.

149. The system of claim 148 wherein:

the output register is a serial-input-parallel-output register;

the microcomputer provides a bit pattern corresponding to the desired states of the switching devices as serial data, and a load command signal to the output register.

150. The system of claim 148 wherein:

the system includes a plurality of serial-input-parallel-output registers having respective bits corresponding to an associated group of the switching devices; and

the microcomputer provides

a serial bit pattern, corresponding to the desired states of a group of switching devices, applied as data inputs to all of the output registers;

serial data clock signals, selectively provided synchronously with the serial data, the serial data clock signals being to a selected one of the output registers to select, and load the data into, the such register; and

a latch control signal, applied to each of the output registers, subsequent to the serial bit pattern data, to load the accumulated pattern into a corresponding output latch, and hence, apply the bit pattern as control signals to designated switching devices.