Starter system for portable internal combustion engine electric generators using a portable universal battery pack

• US 7,180,200 B2
• Filed: 06/04/2003
• Issued: 02/20/2007
• Est. Priority Date: 06/06/2002
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Forster, Michael K., Walter, Richard T., Waikar, Shailesh P.
• Primary Examiner(s): Gonzalez; Julio C.
• Application Number:
  US10/453,988
• Publication Number:
  US 20040012204A1
• Time in Patent Office: 1,357 Days
• Field of Search: 290/1.A, 290/34, 322/10, 322/16, 322/29
• US Class Current: 290/1.00A
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02N 11/06 and with ignition apparatus
• CPC Class Codes: F02N 11/12 Starting of engines by means of mobile, e.g. portable, starting sets
• CPC Class Codes: H01M 10/00 Secondary cells; Manufacture thereof
• CPC Class Codes: H01M 6/00 Primary cells; Manufacture thereof
• CPC Class Codes: H02P 6/14 Electronic commutators

Abstract

A generator starting system utilizes a portable universal battery pack to start an internal combustion engine of the generator. The system is adapted to utilize any one of a plurality of universal battery packs having outputs of varying voltage. The generator can include a permanent magnet generator having first and second sets of windings. One set of windings generates AC power. The second set of windings is used to drive the PMG as an electric motor using power from the universal battery pack. In an embodiment, the system includes a brushless DC controller that electronically commutates the second set of windings to drive the PMG as a brushless DC motor.

Claims

1. An electrical generator system, said system comprising:

a generator device that generates AC power that includes a permanent magnet generator (PMG);

an internal combustion (IC) engine coupled to the generator device that drives the generator device;

a starting device coupled to the IC engine, the starting device including the PMG;

the PMG electrically connected to a brushless DC controller (BLDC) that electronically commutates windings of the PMG to drive the PMG as a brushless DC motor to start the IC engine;

the PMG including first windings for generating the AC power and second windings for driving the PMG as the starting device, the BLDC connected to the second windings of the PMG; and

a portable universal battery pack coupled to the starting device that provides DC power to the starting device.

2. The system of claim 1, wherein the portable universal battery pack includes any one of a plurality of portable universal battery packs with various voltage ratings used to power a cordless tool.

3. The system of claim 1, wherein the generator device includes an alternator.

4. The system of claim 1, wherein the PMG is electrically connected to an electronic converter that converts AC power generated by the first windings to AC power usable by a load.

5. The system of claim 1 wherein the PMG includes a first set of tapped windings having a full portion and a tapped portion, the full portion comprising the first windings and the tapped portion comprising the second windings.

6. The system of claim 1, wherein the BLDC includes a drive circuit having a plurality of switching devices that are sequenced to electronically commutate the second windings to drive the PMG as an electric motor.

7. An electrical generator system, said system comprising:

a generator device that generates AC power that includes a permanent magnet generator (PMG);

an internal combustion (IC) engine coupled to the generator device that drives the generator device;

a starting device coupled to the IC engine, the starting device including the PMG;

the PMG electrically connected to a brushless DC (BLDC) controller that electronically commutates windings of the PMG to drive the PMG as a brushless DC motor to start the IC engine;

a portable universal battery pack coupled to the starting device that provides DC power to the starting device; and

the BLOC controller including;

a H-Bridge circuit that provides pulse width modulated current to the second windings to drive the PMG as a motor to start the IC engine; and

a full wave rectifier circuit that converts AC power generated by the first windings to AC power usable by a load.

8. A method for operating a portable generator that includes a permanent magnet generator (PMG), said method comprising:

starting the generator using a portable universal battery pack that provides DC power to operate a brushless DC controller (BLDC) connected to the PMG to commutate windings of the PMG to drive the PMG as a motor that rotates an internal combustion (IC) engine to start the IC engine, the portable universal battery pack comprising any one of a plurality of portable universal battery packs with various voltage ratings used to power a cordless tool; and

driving the PMG with the IC engine after the IC engine is started and outputting AC power from the PMG driven by the IC engine wherein outputting AC power includes outputting AC power from first windings of the PMG and commutating the windings of the PMG with the BLDC to drive the PMG as a motor includes commutating second windings of the PMG with the BLDC.

9. The method of claim 8, wherein outputting AC power includes driving an alternator with the IC engine.

10. The method of claim 8, wherein outputting AC power further includes converting the AC power output by the first windings to AC power usable by a load utilizing an electronic converter electrically connected to the PMG.

11. The method of claim 8, wherein commutating the second windings of the PMG includes sequencing a plurality of switching devices of a motor drive circuit included in the BLDC controller to commutate the second windings.

12. The method of claim 8 wherein the PMG includes a first set of tapped windings having a full portion and a tapped portion, the full portion comprising the first windings and the tapped portion comprising the second windings.

13. A method for operating a portable generator that includes a permanent magnet generator (PMG) having first and second windings, said method comprising:

starting the generator using a portable universal battery pack that provides DC power to operate a brushless DC controller (BLDC) connected to the PMG to commutate the second windings of the PMG to drive the PMG as a motor that rotates an internal combustion (IC) engine to start the IC engine, the portable universal battery pack comprising any one of a plurality of portable universal battery packs with various voltage ratings used to power a cordless tool; and

driving the PMG with the IC engine after the IC engine is started and outputting AC power from the first windings of the PMG; and

wherein energizing the second windings of the PMG includes providing pulse width modulated current to the second windings utilizing the BLDC electrically connected to the PMG, the BLDC including a H-Bridge circuit adapted to generate the pulse width modulated current.

14. The method of claim 13, wherein outputting AC power further includes converting the AC power output by the first windings to AC power usable by a load utilizing a rectifier circuit included in the BLDC controller.

15. A starting system for starting an internal combustion (IC) engine, said system comprising:

a starting device for rotating the IC engine including a permanent magnet generator (PMG) electrically connected to a brushless DC controller (BLDC), the BLDC electrically connected to the battery pack;

the PMG comprising first windings for generating AC power and second windings for driving the PMG as an electric motor; and

a portable universal battery pack adapted to provide DC power to operate the starting device, the portable universal battery pack comprising any one of a plurality of portable universal battery packs with various voltage ratings.

16. The system of claim 15, wherein the second windings of the PMG are electrically connected to the brushless BLDC that electrically commutates the second windings to drive the PMG as an electric motor.

17. The system of claim 16, wherein the BLDC includes a drive circuit having a plurality of switching devices that are sequenced to electronically commutate the second windings to drive the PMG as an electric motor.

18. The system of claim 16 wherein the PMG includes a first set of tapped windings having a full portion and a tapped portion, the full portion comprising the first windings and the tapped portion comprising the second windings.

19. A starting system for starting an internal combustion (IC) engine, said system comprising:

a starting device for rotating the IC engine including a permanent magnet generator (PMG) electrically connected to a brushless DC controller (BLDC), the BLDC electrically connected to the battery pack; and

a portable universal battery pack adapted to provide DC power to operate the starting device, the portable universal battery pack comprising any one of a plurality of portable universal battery packs with various voltage ratings;

the PMG comprising first windings for generating AC power and second windings for driving the PMG as an electric motor

the BLDC including;

a H-bridge circuit that provides pulse width modulated current to the second windings to drive the PMG as an electric motor to start the IC engine; and

a full wave rectifier circuit that converts AC power generated by the first windings to AC power usable by a load.