Generator controller

• US 7,353,084 B2
• Filed: 02/27/2004
• Issued: 04/01/2008
• Est. Priority Date: 02/27/2003
• Status: Active Grant

• Current Assignee: Cummins Incorporated
• Original Assignee: Acutrak Incorporated
• Inventors: Proctor, Richard L., Aupperle, Donald P., Schaper, Scott R.
• Primary Examiner(s): Bahta; Kidest
• Assistant Examiner(s): SHECHTMAN, SEAN P
• Application Number:
  US10/788,814
• Publication Number:
  US 20040199297A1
• Time in Patent Office: 1,495 Days
• Field of Search: 700/9, 700287-290, 700292-294, 700/297, 700/298, 429/12, 429/13, 429/17, 429/22, 180/65.1, 361/52
• US Class Current: 700/287
• CPC Class Codes: H02J 2310/40 The network being an on-board power network, i.e. within a vehicle
• CPC Class Codes: H02J 2310/42 for ships or vessels
• CPC Class Codes: H02J 3/00 Circuit arrangements for ac mains or ac distribution networks
• CPC Class Codes: H02J 7/0029 with safety or protection devices or circuits
• CPC Class Codes: H02J 7/0049 Detection of fully charged condition
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/009 having two or more independently controlled outputs for DC-DC converter with intermediate AC H02M3/33561

Abstract

A generator controller, in its various embodiments, displays genset fault messages, a genset elapsed time hour meter, service countdown reminder, monitors battery voltage changes over multiple periods of time to establish and display the “battery level,” uses the “battery level” to automatically start and stop the genset, and accepts multiple run requests from AC loads such as HVAC systems, and incorporates safety or other start inhibit features.

Claims

1. A generator controller, comprising:

a processor;

a first input configured to receive signals from a generator, the generator being an engine-driven power generator configured to generate and deliver 50 or 60 cycle alternating electrical current to a recreational vehicle;

an output configured to send signals to the generator;

a second input configured to receive signals from a plurality of operating condition sources;

a memory accessible by the processor, the memory containing stored programming instructions operable by the processor to define an automatic mode of operation in which the processor operates to selectively start and stop the generator in accordance with stored parameters, and further to stop the generator upon receipt by the second input of a signal representative of an undesirable condition from at least one of the plurality of operating condition sources, the programming instructions further causing the processor to switch the controller to a manual mode of operation when the signal representative of an undesirable condition is received, whereby in the manual mode of operation the generator is operable under manual control, further whereby in the manual mode of operation the processor enables continued operation of the generator to produce the alternating electrical current even in the presence of the undesirable condition;

the stored programming further enabling the processor to decode electronic indicators produced by the generator; and

a display configured to present text messages related to the electronic indicators.

2. The generator controller of claim 1, further comprising a stop input in communication with the processor, whereby in response to a selection of the stop input by a user the controller allows the operation of the generator even if the signal representative of an undesirable condition is received from at least a selected one of the plurality of operating condition sources.

3. The generator controller of claim 1, wherein one of the plurality of operating condition sources comprises a gas detector.

4. The generator controller of claim 1, wherein one of the plurality of operating condition sources comprises a parking brake.

5. The generator controller of claim 1, wherein the undesirable condition comprises an ignition being switched to an on position.

6. The generator controller of claim 1, wherein the undesirable condition comprises the presence of a building adjacent to a vehicle to which the generator is connected.

7. The generator controller of claim 1, wherein the undesirable condition comprises the presence of power available at an external alternating current source.

8. The generator controller of claim 1, wherein the plurality of operating condition sources comprises a parking brake, a transmission neutral switch, and an ignition switch.

9. A generator controller, comprising:

an output configured to send signals to an internal combustion engine-driven generator configured to generate and deliver electrical power to a recreational vehicle;

a first input configured to receive signals from a plurality of operating condition sources; and

a control component in communication with the output and the first input, the control component having a manual mode and an automatic mode, the automatic mode being configured to automatically stop operation of the generator upon receipt of a first signal representative of an undesirable condition from at least one of a first subset of the plurality of operating condition sources, the control component further being configured to switch the operation of the controller from the automatic mode to the manual mode upon receipt of a second signal representative of an undesirable condition from at least one of a second subset of the plurality of operating condition sources, whereby in the manual mode the generator is operable under manual control even in the continued presence of the second signal representative of the undesirable condition.

10. The generator controller of claim 9, further comprising:

a second input configured to receive signals from the generator;

a decoding component in communication with the second input, the decoding component being configured to decode electronic indicators produced by a plurality of generators wherein the engine-driven generator comprises one of the plurality of generators; and

a display configured to present text messages related to the electronic indicators.

11. The generator controller of claim 9, wherein one of the first subset of operating condition sources comprises a gas detector.

12. The generator controller of claim 9, wherein the one of the second subset of operating condition sources comprises a parking brake.

13. The generator controller of claim 9, wherein one of the second subset of operating condition sources comprises a vehicle ignition and wherein the undesirable condition comprises the ignition being switched to an on position.

14. The generator controller of claim 9, wherein the first subset of operating condition sources comprises a building presence detector and wherein the undesirable condition comprises the presence of a building adjacent to a vehicle to which the generator is connected.

15. The generator controller of claim 9, wherein the first subset of operating condition sources comprises an external alternating current source, and wherein the undesirable condition comprises the presence of power available at the external alternating current source.

16. The generator controller of claim 9, wherein second subset of operating condition sources comprises a parking brake, a transmission neutral switch, and an ignition switch.

17. A generator controller, comprising:

an output configured to send signals to a generator for generating and delivering electrical power to a recreational vehicle;

a first input configured to receive signals from a plurality of operating condition sources;

a second input operable by a user to enable the user to select one of a plurality of controller modes of operation, each of the controller modes of operation defining conditions under which the generator selectively operates to produce electrical power; and

a control component controlling the operation of the generator controller in accordance with the selected one of the plurality of controller modes of operation, the control component being in communication with the output and the first input, the control component having a manual mode and an automatic mode the manual mode being configured to automatically inhibit operation of the generator if a signal representative of an undesirable condition is received from at least one of a first subset of the plurality of operating condition sources, the control component further being configured to switch to the manual mode when a signal representative of an undesirable condition is received from at least one of a second subset of the plurality of operating condition sources, whereby in the manual mode the generator is operable under manual control even in the continued presence of the signal representative of the undesirable condition from at least one of the second subset of the plurality of operating condition sources.

18. The generator controller of claim 17, further comprising:

a third input configured to receive signals from the generator;

a decoding component in communication with the third input, the decoding component being configured to decode electronic indicators produced by the generator; and

a display configured to present text messages related to the electronic indicators.

19. The generator controller of claim 17, wherein one of the first subset of operating condition sources comprises a gas detector.

20. The generator controller of claim 17, wherein the second subset of operating condition sources comprises a parking brake, a transmission neutral switch, and an iguition switch.