Engine-generator with load bank and control system
DCFirst Claim
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1. An engine-generator and load bank system comprising:
- an engine mechanically connected to and capable of driving an alternator;
said engine having an engine control module and a particulate filter;
said alternator in electrical communication with an output bus and a load bank bus;
at least one load monitoring device in electrical communication with said output and load bank buses;
a generator controller comprising a load dump output and a load enable output, said generator controller in electrical communication with said engine control module;
a load bank controller comprising a load enable input, a load dump input, a load sensor, and at least one load step output;
said load dump output in electrical communication with said load dump input;
said load enable output in electrical communication with said load enable input;
said load monitoring device in electrical communication with said load sensor;
at least one load step contactor in electrical communication with said at least one load step output; and
at least one load step resistor in electrical communication with said load bank bus by way of said at least one load step contactor;
wherein said generator controller provides a control signal via said load enable output in at least one of the following cases;
neglect and regeneration; and
wherein said generator controller provides a control signal via said load dump output in case of a load spike.
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Abstract
A load bank comprises one or more load resistors connected to an engine-generator and a control system for maintaining a minimum generator load when necessary for optimal operation. The control system operates the load bank to mitigate harmful effects of generator neglect and maintains loading for efficient DPF regeneration while allowing the generator to quickly dump the load bank when real load increases.
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Citations
38 Claims
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1. An engine-generator and load bank system comprising:
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an engine mechanically connected to and capable of driving an alternator; said engine having an engine control module and a particulate filter; said alternator in electrical communication with an output bus and a load bank bus; at least one load monitoring device in electrical communication with said output and load bank buses; a generator controller comprising a load dump output and a load enable output, said generator controller in electrical communication with said engine control module; a load bank controller comprising a load enable input, a load dump input, a load sensor, and at least one load step output; said load dump output in electrical communication with said load dump input; said load enable output in electrical communication with said load enable input; said load monitoring device in electrical communication with said load sensor; at least one load step contactor in electrical communication with said at least one load step output; and at least one load step resistor in electrical communication with said load bank bus by way of said at least one load step contactor; wherein said generator controller provides a control signal via said load enable output in at least one of the following cases;
neglect and regeneration; andwherein said generator controller provides a control signal via said load dump output in case of a load spike. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. An engine-generator and load bank system comprising:
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an engine mechanically connected to and capable of driving an alternator; said engine having an engine control module and a particulate filter; said alternator in electrical communication with an output bus and a load bank bus; a generator controller in electrical communication with said engine control module, said generator controller having at least one load step output; at least one load step contactor in electrical communication with said at least one load step output; and at least one load step resistor in electrical communication with said load bank bus by way of said at least one load step contactor; wherein said generator controller is capable of operating said load step contactor to connect said load step resistor in at least one of the following cases;
neglect and regeneration; andwherein said generator controller is capable of operating said load step contactor to disconnect said load step resistor in case of a load spike. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36)
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37. A method for operating an engine-generator and load bank system with a generator controller and an engine control module, the generator controller configured with logic and hardware to control the load bank, the method comprising the following steps:
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a. setting a rated operating load; b. setting a load window bounded by a low load and an upper load in said generator controller; c. setting a duration in said generator controller; d. setting a minimum acceptable load corresponding to optimal engine exhaust temperature for regeneration; e. monitoring connected load of said engine-generator; f. monitoring regeneration of said engine-generator with said engine control module; g. activating said load bank if said generator operates in a neglect scenario as defined by said window and said duration; h. activating said load bank if said connected load is less than said minimum acceptable load and said engine-generator initiates regeneration; and i. dumping said load bank if a load spike is detected. - View Dependent Claims (38)
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Specification