Custom configuration strategy for on-package genset controllers

• US 7,509,221 B2
• Filed: 01/17/2007
• Issued: 03/24/2009
• Est. Priority Date: 01/17/2007
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Folken, Keith R., Zwetz, David L. II, Boley, Julie, McBurney, James D., Black, Andrew W., Dvorsky, Michael A., Nofsinger, Stephen C.
• Primary Examiner(s): Lau; Tung S
• Assistant Examiner(s): Kundu; Sujoy K
• Application Number:
  US11/654,424
• Publication Number:
  US 20080172200A1
• Time in Patent Office: 797 Days
• Field of Search: 700/292, 700/286, 700/287, 702/93, 702/104, 702/193, 702/188, 702/108, 702/122, 361/193
• US Class Current: 702/104
• CPC Class Codes: F02D 29/06 peculiar to engines driving electric generators
• CPC Class Codes: G05B 19/0423 Input/output
• CPC Class Codes: G05B 2219/21065 Module calibrates connected sensor
• CPC Class Codes: G05B 2219/21138 Variable filtering as function of kind of sensor signal
• CPC Class Codes: G05B 2219/23332 Overide stored parameters
• CPC Class Codes: G05B 2219/25302 Program and data in separate memory
• CPC Class Codes: G05B 2219/2623 Combustion motor

Abstract

A method of setting up a genset system for operation includes selecting one of a plurality of different sensors to monitor an operating parameter of a genset system, and coupling the selected sensor with a data processor of the genset system. The method further includes configuring the data processor for processing inputs from the selected sensor, for example an optional replacement sensor, by entering custom sensor calibration data for the selected sensor and recording the custom sensor calibration data on at least one computer writable medium of a control system for the genset system. A genset system includes a combustion engine, a generator, a set of standard sensors, and a control system. The control system includes a data processor configured to receive and process inputs from custom sensors, and includes a computer writable medium for storing custom sensor calibration data.

Claims

1. A method of setting up a genset system for operation comprising the steps of:

selecting a sensor from among a plurality of different sensors configured to monitor an operating parameter of a genset system;

coupling the selected sensor with the genset system, including coupling the selected sensor with a data processor of the genset system, the data processor being configured to process inputs from a set of standard sensors via stored standard sensor calibration data; and

configuring the data processor for processing inputs from the selected sensor, including a step of entering custom sensor calibration data for the selected sensor via a user interface of the genset system;

wherein the step of configuring further includes a step of constructing a calibration profile for the selected sensor, including entering discrete calibration data inputs with the user interface.

2. The method of claim 1 wherein the step of entering custom sensor calibration data includes entering sensor map data.

3. The method of claim 2 wherein the step of entering custom sensor calibration data further includes inputting maximum and minimum map values defining a map range and at least one other map value between the maximum and minimum values which is within a non-linear portion of the map range.

4. The method of claim 3 wherein the configuring step further comprises a step of assigning the selected sensor to one of a predetermined set of sensor assignments.

5. The method of claim 3 wherein the step of entering custom sensor calibration data further includes inputting five or more map values.

6. The method of claim 2 wherein the configuring step further includes a step of recording the custom sensor calibration data on a computer writable medium of the genset system.

7. The method of claim 6 wherein the step of recording the custom sensor calibration data further includes overwriting standard sensor calibration data stored on a computer writable medium of the genset system.

8. The method of claim 2 wherein the selecting step comprises selecting an optional sensor, and wherein the coupling step comprises establishing a data link between the optional sensor and an optional input of the data processor.

9. The method of claim 8 wherein the data processor is configured via coded instructions to reference custom sensor map data for the optional sensor at a predetermined address, and wherein the configuring step further comprises a step of configuring the data processor to reference custom sensor map data at the same predetermined address.

10. The method of claim 2 further comprising a step of decoupling a first sensor from an input of the data processor, wherein the selecting step comprises selecting a replacement sensor for the first sensor, and wherein the coupling step comprises coupling the replacement sensor with the data processor via the input.

11. The method of claim 10 wherein the data processor is configured via coded instructions to reference standard sensor map data at a predetermined address, and wherein the configuring step further comprises a step of configuring the data processor to reference custom sensor map data at the same predetermined address.

12. The method of claim 2 wherein the selecting step comprises selecting one of, a fluid level sensor, a pressure sensor and a temperature sensor, and wherein the configuring step further includes entering custom map data corresponding to a non-linear curve.

13. The method of claim 12 wherein the step of configuring the data processor further comprises configuring the data processor via a user interface coupled with the genset system.

14. The method of claim 13 wherein the user interface is coupled with a memory writing device of the genset system, and wherein the configuring step further includes activating the memory writing device via the user interface for recording the custom sensor calibration data on a computer writable medium.

15. A genset system comprising:

a combustion engine;

an electrical generator coupled with said combustion engine;

a set of standard sensors each configured to monitor an operating parameter associated with at least one of the combustion engine and the electrical generator; and

a control system for the genset system comprising a data processor configured to receive and process inputs from said standard sensors and having a computer readable medium whereon sensor calibration data for said standard sensors is stored;

said data processor further being configured to receive and process inputs from at least one custom sensor, said control system further comprising at least one computer writable medium, and said genset system having a user interface configured for entering custom sensor calibration data for at least one custom sensor for storing on said at least one computer writable medium; and

said control system further being configured via receiving discrete calibration data inputs via said user interface to construct a calibration profile for the selected sensor.

16. The genset system of claim 15 further comprising a memory writing device configured to record inputted custom sensor calibration data on said at least one computer writable medium.

17. The genset system of claim 16 wherein said computer readable medium also comprises a computer writable medium, said memory writing device being configured to replace standard sensor calibration data with custom sensor calibration data for said at least one custom sensor which is inputted via said user interface.

18. The genset of claim 16 wherein said data processor is configured to receive and process inputs from at least one optional sensor, wherein said user interface is configured for inputting custom non-linear map data for at least one optional sensor, and wherein said memory writing device is configured to record the custom non-linear map data on said at least one computer writable medium.

19. The genset system of claim 18 further comprising an optional sensor coupled with said data processor, including one of a fluid level sensor, a pressure sensor and a temperature sensor.

20. The genset system of claim 18 wherein said data processor is configured to process inputs from said at least one custom sensor via custom non-linear map data at one or more predetermined addresses on said at least one computer writable medium, and further configured to process inputs from each of said set of standard sensors via map data at one or more predetermined addresses on said computer readable medium.