Controller for AC generator

• US 8,093,772 B2
• Filed: 08/02/2010
• Issued: 01/10/2012
• Est. Priority Date: 02/02/2006
• Status: Expired due to Fees

• Current Assignee: Magnetic Applications, Inc.
• Original Assignee: Magnetic Applications, Inc.
• Inventors: Scott, Harold C., Williams, Dave E., Lafontaine, Charles Y
• Primary Examiner(s): Le, Dang D
• Application Number:
  US12/848,980
• Publication Number:
  US 20110025143A1
• Time in Patent Office: 526 Days
• Field of Search: 310/71, 310/68.D, 310/68.C, 322/20, 322/25, 322/27, 322/28, 322/29, 322/37, 322/45, 322/46, 322/59, 322/89, 322/99
• US Class Current: 310/71
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/24 with channels or ducts for cooling medium between the conductors
• CPC Class Codes: H02K 3/50 Fastening of winding heads, equalising connectors, or connections thereto
• CPC Class Codes: H02P 2101/45 for motor vehicles, e.g. car alternators
• 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 control system that can accommodate the wide variations in the output of a generator, such as a permanent magnet alternator, while providing an output with relatively uniform phase ripple. The control system includes a zero crossing detector and variable ramp generator for generating control signals to a switching rectifier to generate a regulated DC signal.

Claims

1. A system comprising:

a generator configured to generate an AC signal, the generator comprising;

a stator, wherein an outer peripheral surface of the stator is axially crenellated with a predetermined number of teeth and slots;

an output terminal electrically coupled to a fusible link;

an electrically conductive phase ring coupled to the fusible link; and

a pole phase coil conductor, electrically coupled to the phase ring and to a winding of insulated wiring disposed around at least one of the teeth of the stator; and

a control system coupled to the generator, the control system responsive to at least one phase of the AC signal from the generator, the control system for generating control signals to a switching rectifier to generate a regulated DC signal, the control system comprising;

a zero crossing detector, responsive to a first signal representative of the AC phase, for generating indicia of zero crossings in the AC phase;

a variable ramp generator, responsive to a second signal representative of the AC phase and the indicia of zero crossings, for generating a ramp signal indicative of the time integral of the voltage of the AC phase accumulated from the occurrence of a zero crossing and reset upon the occurrence of the next successive zero crossing; and

a trigger generator, responsive to the time integral ramp signal and a reference signal indicative of a desired firing angle to maintain a set DC output, for generating the control signals to the switching rectifier in accordance with a comparison of the time integral ramp signal to the reference signal.

2. The system of claim 1, wherein the first and second signals representative of the AC phase are different isolated signals.

3. The system of claim 1, wherein the first and second signals are representative of the AC phase are generated by respective secondary windings of an isolation transformer having a primary driven by the AC phase.

4. The system of claim 1, wherein the zero crossing detector comprises:

a comparator, responsive to the first signal representative of the AC phase, for generating a signal indicative of the polarity of the AC phase signal, and transitions in the polarity signal indicating a zero-crossing;

a variable blanker for generating a blanking pulse initiated in response to transitions in the polarity signal and having a duration equal to a predetermined portion of the period between successive zero crossings; and

a reset pulse generator for generating, in response to transitions of a predetermined polarity in the polarity signal, a pulse of predetermined duration as said indicia of zero crossings in the AC phase.

5. The system of claim 4, wherein the variable blanker comprises a one-shot having an associated timing capacitor, the pulse generated by the one-shot having a duration controlled by the time required to charge the timing capacitor, a current source disposed to charge the timing capacitor, the current source being driven by a signal proportional to the duty cycle of the one shot output so that the time required to charge the timing capacitor is inversely proportional to the duty cycle of the one shot output.

6. The system of claim 1, wherein the control system is responsive to multiple phases of an AC signal, the control system comprising for each phase:

a zero crossing detector, responsive to a first signal representative of the AC phase, for generating indicia of zero crossings in the AC phase;

a variable ramp generator, responsive to a second signal representative of the AC phase and the indicia of zero crossings, for generating a ramp signal indicative of the time integral of the voltage of the AC phase accumulated from the occurrence of a zero crossing and reset upon the occurrence of the next successive zero crossing;

a trigger generator, responsive to the time integral ramp signal and a reference signal indicative of a desired firing angle to maintain a set DC output, for generating the control signals to the switching rectifier in accordance with a comparison of the time integral ramp signal to the reference signal.

7. The system of claim 6, wherein the control system is responsive to a first phase of the AC signal, and at least one other phase, the control system further including for each other phase a respective AGC Amp to compare the average voltage of the ramp from the ramp generator associated with the first phase with the average voltage of the ramp from the ramp generator associated with such other phase and adjusts the gain of the ramp generator associated with such other phase so that the time integral of the ramp from the ramp generator associated with such other phase is equal to the time integral of the ramp from the ramp generator associated with the first phase.

8. The system of claim 1, wherein the generator further comprises:

a second and third output terminal respectively electrically coupled to a second and third fusible link;

a second and third electrically conductive phase ring respectively coupled to the second and third fusible links; and

a second and third pole phase coil conductor, respectively electrically coupled to the second and third phase rings and to a second and third windings of insulated wiring respectively disposed around teeth of the stator.

9. The system of claim 8, wherein the winding, the second winding, and the third winding are electrically coupled in one of a wye configuration and a delta configuration.

10. The system of claim 9, wherein the electrical wye coupling is exposed to a cooling fluid.

11. The system of claim 9, wherein the electrical delta coupling is exposed to a cooling fluid.

12. The system of claim 8, wherein the phase ring, the second phase ring, and the third phase ring are exposed to a cooling fluid.

13. The system of claim 1, wherein a pole phase coil conductor is disposed as to exit the stator in a direction substantially orthogonal from a face surface of the stator.

14. The system of claim 1, wherein:

the winding of insulated wiring comprises at least two turns of windings disposed around the at least one tooth of the stator; and

the insulated wiring is selected from a predetermined gauge, wherein an internal short circuit within the winding between two or more turns in the winding produces sufficient heat to melt the wiring and clear the internal short.

15. The system of claim 1, wherein the generator comprises:

a plurality of output terminals respectively electrically coupled to a plurality of fusible links;

a plurality of electrically conductive phase rings respectively coupled to the plurality of fusible links; and

a plurality of pole phase coil conductors, respectively electrically coupled to the plurality of phase rings, and respectively electrically coupled to a plurality of windings of insulated wiring respectively disposed around a plurality of teeth of the stator.

16. The system of claim 15, wherein a cooling fluid is exposed to at least one of:

the plurality of output terminals;

the plurality of fusible links;

the plurality of electrically conductive phase rings;

the plurality of pole phase coil conductors, and

the plurality of windings of insulated wiring.

17. The system of claim 15, wherein the plurality of windings are electrically coupled in one of a wye configuration and a delta configuration.

18. The system of claim 17, wherein the electrical wye coupling is exposed to a cooling fluid.

19. The system of claim 17, wherein the electrical delta coupling is exposed to a cooling fluid.

20. The system of claim 15, wherein a pole phase coil conductors are disposed to as to exit the stator in a direction substantially orthogonal from a face surface of the stator.

21. The system of claim 15, wherein:

the plurality of windings of insulated wiring respectively comprise at least two turns of windings disposed around at least one tooth of the plurality of teeth of the stator; and

the insulated wiring is selected from a predetermined gauge, wherein an internal short circuit in one of the plurality of windings produces sufficient heat to melt the insulated wiring and clear the internal short circuit.

22. The system of claim 1, wherein the generator comprises:

a first, second and third phase ring, respectively coupled to first, second, and third output terminals through respective fusible links;

a first, second, and third phase coil, each phase coil;

respectively electrically coupled to the first, second, and third phase ring through respective first, second, and third phase coil conductors; and

comprising a plurality of windings of insulated wiring respectively disposed around a plurality of teeth of a stator; and

wherein the first, second, and third phase coils are disposed about the plurality of the teeth of the stator so as to produce electrical current in three predetermined phases.

23. The system of claim 22, wherein a cooling fluid is exposed to at least one of:

the first, second and third phase rings;

the first, second, and third output terminals;

the first, second, and third phase coils; and

the first, second, and third phase coil conductors, and

the plurality of windings of insulated wiring.

24. The system of claim 22, wherein the first, second, and third phase coil conductors are disposed to as to exit the stator in a direction substantially orthogonal from a face surface of the stator.

25. The system of claim 22, wherein:

the winding of insulated wiring comprises at least two turns of windings disposed around the at least one tooth of the stator; and

the insulated wiring is selected from a predetermined gauge, wherein an internal short circuit within the winding between two or more turns in the winding produces sufficient heat to melt the wiring and clear the internal short.

26. The system of claim 22, wherein the plurality of windings are electrically coupled in one of a wye configuration and a delta configuration.