Digital control system and method for generator sets

• US 6,172,428 B1
• Filed: 12/30/1998
• Issued: 01/09/2001
• Est. Priority Date: 12/30/1998
• Status: Expired due to Term

• Current Assignee: L-3 Communications Corporation (L3Harris Technologies, Inc.)
• Original Assignee: Westwood Corp. (L3Harris Technologies, Inc.)
• Inventors: Jordan, Thomas Harmon
• Primary Examiner(s): Ponomarenko, Nicholas
• Application Number:
  US09/224,562
• Time in Patent Office: 741 Days
• Field of Search: 290/1.A, 290/4.R, 290/4.A, 290/40.C, 322/1, 123/179
• US Class Current: 290/40.00C
• CPC Class Codes: H02P 9/04 Control effected upon non-electric prime mover and dependent upon electric output value of the generator

Abstract

A digital control system and method for monitoring, acquiring data, and controlling the operation of a generator set. The digital control system comprises a computer that receives multiple discrete parameter inputs representing values of analog characteristics and digital characteristics of a generator set. The computer runs a software program to interpret the received inputs as measurements of analog characteristics and status of digital characteristics of the generator set. The computer is capable of graphically displaying and monitoring the measurements and status of the generator set. A method of monitoring and controlling a generator set comprises receiving multiple discrete parameter inputs representing the value of analog and digital characteristics of a generator set, interpreting the received inputs as measurements of analog characteristics and status of digital characteristics of the generator set, and graphically displaying the measurements and status of the generator set. Advantages of the digital control system include the capability to provide a user-friendly graphical display to an operator of a generator set, the capability to display interactive messages that may recommend actions to take in response to a detected fault, the capability to provide warnings based upon multiple discrete parameter inputs, the capability to provide multiple levels of warnings varying in degree of severity, and the capability to write entries to a data file containing information about the operation of the generator set periodically and upon occurrence of a fault.

Claims

1. A digital control system for a electric generator set, said digital control system comprising:

a computer for receiving multiple discrete parameter inputs, wherein said multiple discrete parameter inputs include at least one first signal representing the value of an analog characteristic associated with the generator set;

a display for displaying measurements of said analog characteristics associated with the generator set;

a software program running on said computer to interpret the received at least one first signal as measurements of analog characteristics associated with the generator set, to monitor said measurements, and to graphically display at least one of said measurements, wherein said software program is capable of adapting its execution to different generator set configurations in real-time.

2. The digital control system of claim 1, further comprising:

wherein said multiple discrete parameter inputs further include at least one second signal representing the status of a digital characteristic associated with the generator set; and

said software program running on said computer to interpret the received at least one second signal as status of digital characteristics associated with the generator set.

3. The digital control system of claim 1, further comprising:

an input device for allowing an operator to interact with said computer.

4. The digital control system of claim 2, further comprising:

said digital characteristic associated with the generator set includes mechanical switches on the generator, whereby said computer running said software program may determine the position of said mechanical switches.

5. The digital control system of claim 1, further comprising:

said software program containing at least one Set Point for at least one of said measurements, wherein said at least one Set Point indicates a reference level for said at least one of said measurements; and

said software program capable of determining that a fault condition exists when one or more of said measurements achieves a Set Point associated with said one or more of said measurements.

6. The digital control system of claim 5, further comprising:

said software program containing multiple Set Points for at least one of said measurements; and

said software program providing multiple fault levels differing in severity for said at least one of said measurements.

7. The digital control system of claim 5, further comprising:

said software program capable of monitoring said multiple discrete parameter inputs; and

said software program capable of determining that a fault condition exists based upon at least two of said multiple discrete parameter inputs.

8. The digital control system of claim 5, further comprising:

said software program capable of displaying a textual message when said software program determines that a fault condition exists, wherein said textual message includes text suggesting an action to take in response to the detected fault condition.

9. The digital control system of claim 8, wherein said textual message further includes at least one statement selected from the group consisting of:

a description of the detected fault condition, and a reference to a source of information about the detected fault condition.

10. The digital control system of claim 1, further comprising:

a data file, wherein said software program is capable of writing an entry to said data file, said entry containing information regarding the generator set'"'"'s characteristics.

11. The digital control system of claim 10, wherein said entry contains at least one data element selected from the group consisting of:

date of entry being written to said data file, time of entry being written to said data file, amount of time that the generator set has been energized, measurement of a characteristic of said generator set, and special comments about the operation of said generator set.

12. The digital control system of claim 10, further comprising:

said software program writing said entry to a data file periodically.

13. The digital control system of claim 10, further comprising:

said software program writing said entry to a data file upon occurrence of a fault condition.

14. The digital control system of claim 1, further comprising:

said software program capable of monitoring configuration switches on the generator set and adapting said software program'"'"'s operation according to the generator set'"'"'s configuration in real-time, wherein adapting said software program'"'"'s operation includes adapting Set Points contained within the software program for determining whether a fault condition exists to the generator set'"'"'s configuration.

15. The digital control system of claim 1, further comprising:

said software program providing at least one configurable graphical display.

16. The digital control system of claim 15, wherein a first graphical display includes displaying only measurements received by said computer that are critical for normal operation of the generator set.

17. The digital control system of claim 15, wherein a second graphical display includes displaying all measurements of the generator set received by said computer.

18. The digital control system of claim 17, wherein said displaying all measurements includes displaying voltage for all 3 phases of a generator set simultaneously.

19. The digital control system of claim 1, further comprising:

said software program capable of determining the difference in the output voltage of a generator set and the voltage existing on the bus, which represents the difference in voltage across the output breaker of the generator set; and

said software program capable of displaying the difference in voltage across the output breaker of the generator set.

20. The digital control system of claim 19, further comprising:

said software program capable of monitoring the difference in voltage across the output breaker of the generator set; and

said software program capable of allowing the contactor of a generator set to close only if said difference in voltage across the output breaker is below a preset level.

21. The digital control system of claim 1, wherein said computer, said display and said software program are operating at a site remote to the generator set.

22. A method of monitoring and controlling a generator set, said method comprising:

receiving multiple discrete parameter inputs, wherein said multiple discrete parameter inputs include at least one first signal representing the value of an analog characteristic associated with the generator set;

interpreting the received at least one first signal as measurements of analog characteristics associated with the generator set; and

graphically displaying as a configurable graphical display at least one of said measurements of analog characteristics associated with the generator set.

23. The method of claim 22, further comprising:

wherein said multiple discrete parameter inputs further include at least one second signal representing the status of a digital characteristic associated with the generator set; and

interpreting the received at least one second signal as status of digital characteristics associated with the generator set.

24. The method of claim 22, further comprising:

monitoring said multiple discrete parameter inputs; and

determining whether a fault condition exists.

25. The method of claim 24, wherein said step of monitoring includes:

setting at least one Set Point for one or more of the received at least one first signal, wherein said Set Point indicates a reference level for said one or more of the received at least one first signal; and

comparing said one or more of the received at least one first signal with said at least one Set Point to determine whether said one or more of the received at least one first signal has achieved said at least one Set Point.

26. The method of claim 25, wherein said step of determining includes determining that a fault condition exists when said one or more of the received at least one first signal achieves said at least one Set Point.

27. The method of claim 26, further comprising:

setting at least two Set Points for one or more of the received at least one first signal, wherein a first Set Point indicates a fault level having a first severity and a second Set Point indicates a fault level having a second severity;

determining that a fault condition having a first severity exists when said one or more of the received at least one first signal achieves said first Set Point; and

determining that a fault condition having a second severity exists when said one or more of the received at least one first signal achieves said second Set Point.

28. The method of claim 24, wherein said step of determining includes determining whether a fault condition exists based upon at least two of said multiple discrete parameter inputs.

29. The method of claim 24, further comprising:

displaying a textual message if it is determined that a fault condition exists, wherein said textual message includes text suggesting an action to take in response to the determined fault condition.

30. The method of claim 29, wherein said textual message further includes at least one statement selected from the group consisting of:

a description of the detected fault condition, and a reference to a source of information about the detected fault condition.

31. The method of claim 22, further comprising:

writing an entry to a data file, said entry containing information regarding the generator set'"'"'s characteristics.

32. The method of claim 31, wherein said entry contains at least one data element selected from the group consisting of:

date of said entry being written to said data file, time of said entry being written to said data file, amount of time that the generator set has been energized, measurement of a characteristic of said generator set, and special comments about the operation of said generator set.

33. The method of claim 31, further comprising:

writing said entry to a data file periodically.

34. The method of claim 31, further comprising:

writing said entry to a data file upon occurrence of a fault condition.

35. The method of claim 22, further comprising:

adapting said method of monitoring and controlling a generator set to different generator set con-figurations in real-time, wherein said step of adapting includes adjusting Set Points indicating a reference level for at least one of said measurements, said Set Points aid in determining whether a fault condition exists.

36. The method of claim 35, wherein said step of adapting includes:

monitoring configuration switches on the generator set; and

adjusting said Set Points in accordance with the generator set'"'"'s configuration switches.

37. The method of claim 22, wherein said configurable graphical display is a user-configurable graphical display in which a user can select at least one of multiple display configurations for displaying said at least one of said measurements.

38. The method of claim 37, wherein a first selectable graphical display includes only measurements critical for normal operation of the generator set.

39. The method of claim 37, wherein a second selectable graphical display includes all of said received measurements of the generator set.

40. The method of claim 39, wherein said displaying all of said received measurements includes displaying voltage for all 3 phases of the generator set simultaneously.

41. The method of claim 22, further comprising:

computing the difference in the output voltage of the generator set and the voltage existing on the bus, said difference represents the difference in voltage across the output breaker of the generator set; and

displaying said difference in voltage across the output breaker of the generator set.

42. The method of claim 41, further comprising:

monitoring said difference in voltage across the output breaker of the generator set; and

allowing a generator set'"'"'s contactor to close only if said difference in voltage across the output breaker is below a preset level.

43. The method of claim 22, wherein said computer, said steps of receiving multiple discrete parameter inputs, interpreting the received first signals, and graphically displaying are performed at a site remote to the generator set.

44. The method of claim 22, wherein said software program configures said configurable graphical display in which said software program selects at least one of multiple display configurations for displaying said at least one of said measurements.

45. The method of claim 44, wherein said software program selects said at least one of multiple display configurations based at least in part on said monitored measurements.

46. A generator set comprising:

a digital control system;

said digital control system includes a computer for receiving multiple discrete parameter inputs, wherein said multiple discrete parameter inputs includes at least one first signal representing the value of an analog characteristic associated with the generator set;

said digital control system further includes a display for displaying measurements of said analog characteristics associated with the generator set;

said digital control system further includes a software program running on said computer to interpret the received at least one first signal as measurements of analog characteristics associated with the generator set, to monitor said measurements, and graphically display at least one of said measurements; and

said software program includes code for displaying a textual message when said software program determines that a fault condition exists, wherein said textual message includes text suggesting an action to take in response to the detected fault condition.

47. The generator set of claim 46, further comprising:

wherein said multiple discrete parameter inputs includes at least one second signal representing the status of a digital characteristic associated with the generator set; and

said software program running on said computer to interpret the received at least one second signal as status of digital characteristics associated with the generator set.

48. The generator set of claim 46, further comprising:

said digital control system further includes an input device for allowing an operator to interact with said computer.

49. The generator set of claim 46, further comprising:

said software program containing at least one Set Point for at least one of said measurements, wherein said at least one Set Point indicates a reference level for said at least one of said measurements; and

said software program capable of determining that a fault condition exists when one or more of said measurements achieves a Set Point associated with said one or more of said measurements.

50. The generator set of claim 49, further comprising:

said software program containing multiple Set Points for at least one of said measurements; and

said software program providing multiple fault levels differing in severity for said at least one of said measurements.

51. The generator set of claim 49, further comprising:

said software program including code for monitoring said multiple discrete parameter inputs; and

said software program including code for determining that a fault condition exists based upon at least two of said multiple discrete parameter inputs.

52. The generator set of claim 46 wherein said textual message further includes at least one statement selected from the group consisting of:

a description of the detected fault condition, and a reference to a source of information about the detected fault condition.

53. The generator set of claim 46, further comprising:

a data file, wherein said software program includes code for writing an entry to said data file, said entry containing information regarding the generator set'"'"'s characteristics.

54. The generator set of claim 53, wherein said entry contains at least one data element selected from the group consisting of:

date of entry being written to said data file, time of entry being written to said data file, amount of time that the generator set has been energized, measurement of a characteristic of said generator set, and special comments about the operation of said generator set.

55. The generator set of claim 53, further comprising:

said software program writing said entry to a data file periodically.

56. The generator set of claim 53, further comprising:

said software program writing said entry to a data file upon occurrence of a fault condition.

57. A digital control system for a electric generator set, said digital control system comprising:

a computer for receiving multiple discrete parameter inputs, wherein said multiple discrete parameter inputs include at least one first signal representing the value of an analog characteristic associated with the generator set;

a display for displaying measurements of said analog characteristics associated with the generator set;

a software program running on said computer to interpret the received at least one first signal as measurements of analog characteristics associated with the generator set, to monitor said measurements, and to graphically display, as a configurable graphical display, at least one of said measurements.

58. The digital control system of claim 57 wherein said configurable graphical display is a user-configurable graphical display in which a user can select at least one of multiple display configurations for displaying said at least one of said measurements.

59. The digital control system of claim 58 wherein a first selectable graphical display includes only measurements critical for normal operation of the generator set.

60. The digital control system of claim 58 wherein a second selectable graphical display includes all of said received measurements of the generator set.

61. The digital control system of claim 60 wherein said displaying all of said received measurements includes displaying voltage for all 3 phases of the generator set simultaneously.

62. The digital control system of claim 57 wherein said software program configures said configurable graphical display in which said software program selects at least one of multiple display configurations for displaying said at least one of said measurements.

63. The digital control system of claim 62 wherein said software program selects said at least one of multiple display configurations based at least in part on said measurements.

64. The digital control system of claim 57, further comprising:

said software program containing at least one Set Point for at least one of said measurements, wherein said at least one Set Point indicates a reference level for said at least one of said measurements; and

said software program capable of determining that a fault condition exists when one or more of said measurements achieves a Set Point associated with said one or more of said measurements.

65. The digital control system of claim 64, further comprising:

said software program containing multiple Set Points for at least one of said measurements; and

said software program providing multiple fault levels differing in severity for said at least one of said measurements.

66. The digital control system of claim 64, further comprising:

said software program capable of monitoring said multiple discrete parameter inputs; and

said software program capable of determining that a fault condition exists based upon at least two of said multiple discrete parameter inputs.

67. The digital control system of claim 64, further comprising:

said software program capable of displaying a textual message when said software program determines that a fault condition exists, wherein said textual message includes text suggesting an action to take in response to the detected fault condition.

68. The digital control system of claim 67, wherein said textual message further includes at least one statement selected from the group consisting of:

a description of the detected fault condition, and a reference to a source of information about the detected fault condition.

69. The digital control system of claim 57, further comprising:

a data file, wherein said software program is capable of writing an entry to said data file, said entry containing information regarding the generator set'"'"'s characteristics.

70. The digital control system of claim 69 wherein said entry contains at least one data element selected from the group consisting of:

date of entry being written to said data file, time of entry being written to said data file, amount of time that the generator set has been energized, measurement of a characteristic of said generator set, and special comments about the operation of said generator set.

71. The digital control system of claim 57, further comprising:

said software program capable of monitoring configuration switches on the generator set and adapting said software program'"'"'s operation according to the generator set'"'"'s configuration in real-time, wherein adapting said software program'"'"'s operation includes adapting Set Points contained within the software program for determining whether a fault condition exists to the generator set'"'"'s configuration.

72. A method of monitoring and controlling a generator set, said method comprising:

receiving into a digital control system multiple discrete parameter inputs, wherein said multiple discrete parameter inputs include at least one first signal representing the value of an analog characteristic associated with the generator set;

said digital control system interpreting the received at least one first signal as measurements of analog characteristics associated with the generator set;

said digital control system graphically displaying at least one of said measurements of analog characteristics associated with the generator set; and

said digital control system determining whether a fault condition exists based at least in part on whether one or more of said measurements achieves a determined reference level for said one or more of said measurements; and

said digital control system adapting in real-time to a change in the generator set'"'"'s configuration, wherein said adapting allows said digital control system to correctly perform said determining whether a fault condition exists given said change in the generator set'"'"'s configuration.

73. The method of claim 72 wherein said multiple discrete parameter inputs further include at least one second signal representing the status of a digital characteristic associated with the generator set.

74. The method of claim 72 further comprising:

said digital control system interpreting the received at least one second signal as status of digital characteristics associated with the generator set.

75. The method of claim 74 wherein said digital characteristic associated with the generator set includes one or more mechanical switches.

76. The method of claim 75 wherein said digital control system interprets the received at least one second signal as the position of said one or more mechanical switches.

77. The method of claim 72 wherein said determining whether a fault condition exists further comprises:

said digital control system determining whether one or more of said measurements achieves a determined reference level associated with said one or more of said measurements, wherein said digital control system determines that a fault condition exists when one or more of said measurements achieves said determined reference level.

78. The method of claim 77 wherein said determining whether a fault condition exists further comprises:

said digital control system determining whether one of multiple fault levels differing in severity exist for said at least one of said measurements.

79. The method of claim 77 wherein said determining whether a fault condition exists further comprises:

said digital control system monitoring said multiple discrete parameter inputs; and

said digital control system determining whether a fault condition exists based upon at least two of said multiple discrete parameter inputs.

80. The method of claim 72, further comprising:

said digital control system displaying a textual message when said digital control system determines that a fault condition exists, wherein said textual message includes text suggesting an action to take in response to the detected fault condition.

81. The method of claim 80 wherein said textual message further includes at least one statement selected from the group consisting of:

a description of the detected fault condition, and a reference to a source of information about the detected fault condition.

82. The method of claim 72, further comprising:

said digital control system writing an entry to a data file, said entry containing information regarding the generator set'"'"'s characteristics.

83. The method of claim 82, wherein said entry contains at least one data element selected from the group consisting of:

date of entry being written to said data file, time of entry being written to said data file, amount of time that the generator set has been energized, measurement of a characteristic of said generator set, and special comments about the operation of said generator set.

84. The method of claim 82 wherein said digital control system writes said entry to a data file upon determining the existence of a fault condition.

85. The method of claim 72 wherein said digital control system adapting in real-time to a change in the generator set'"'"'s configuration further comprises:

said digital control system monitoring one or more configuration switches on the generator set and adapting reference levels used for determining whether a fault condition exists according to the setting of said one or more configuration switches.