Control system for hydraulically powered AC generator

• US 9,841,101 B2
• Filed: 09/04/2014
• Issued: 12/12/2017
• Est. Priority Date: 09/04/2014
• Status: Active Grant

• Current Assignee: Cummins Power Generation IP, Inc.
• Original Assignee: Cummins Power Generation IP, Inc.
• Inventors: Torney, Robert E., Halstead, Nick V., Drabek, Hans L., Bollensen, Eric G., Alexander, James C., Leakey, Tony, Williams, Gerald R.
• Primary Examiner(s): GONZALEZ, JULIO CESAR
• Application Number:
  US14/477,539
• Publication Number:
  US 20160072363A1
• Time in Patent Office: 1,195 Days
• Field of Search: 290 43, 290 54, 290 1 A, 290 1 C, 290 7, 322 17, 322 29, 322 31, 322 44, 91499, 123461
• CPC Class Codes: F02B 67/00 Engines characterised by the arrangement of auxiliary apparatus not being otherwise provided for, e.g. the apparatus having different functions; Driving auxiliary apparatus from engines, not otherwise provided for
• CPC Class Codes: F16H 61/46 Automatic regulation in accordance with output requirements

Abstract

Systems and methods for use in controlling a hydraulically powered AC generator are provided. One control system includes a valve system. The valve system includes a fixed valve configured to provide a substantially constant flow rate of the fluid through the fixed valve to the hydraulically powered AC generator. The valve system further includes a variable valve configured to provide a variable flow rate of the fluid through the variable valve to the hydraulically powered AC generator. The control system further includes a sensor device configured to measure a speed of movement of a component of the hydraulically powered AC generator. The control system further includes a control circuit configured to control the variable flow rate of the variable valve based on the speed of movement of the component measured by the sensor device.

Claims

1. A valve system for controlling flow of a fluid to a hydraulically powered alternating current (AC) generator, the valve system comprising:

a first flow path comprising a fixed valve configured to provide a substantially constant flow rate of the fluid through the fixed valve to a common fluid output to reach the hydraulically powered AC generator; and

a second flow path comprising a variable valve configured to provide a variable flow rate of the fluid through the variable valve to the common fluid output to reach the hydraulically powered AC generator;

wherein a flow rate of the fluid output from the common fluid output to drive the hydraulically powered AC generator includes a sum of the substantially constant flow rate of the fluid and the variable flow rate of the fluid, and wherein the variable valve provides control of a portion of the fluid output from the common fluid output to control an electrical output of the hydraulically powered AC generator.

2. The valve system of claim 1, further comprising a control device configured to control the variable flow rate of the variable valve to compensate for changes in one or more operating conditions of the hydraulically powered AC generator.

3. The valve system of claim 2, wherein the one or more operating conditions comprise at least one of a load, a temperature, a pressure, or a pump input speed of the hydraulically powered AC generator.

4. The valve system of claim 2, wherein the control device is configured to control the variable flow rate based on input received from a control circuit, the input based on a speed of movement of a component of the hydraulically powered AC generator detected using a sensor device.

5. The valve system of claim 4, wherein the input is based on the speed of movement of one of a gear, a hydraulic motor, a shaft, and a rotor of the hydraulically powered AC generator.

6. The valve system of claim 1, wherein the variable valve comprises a first variable valve, wherein the variable flow rate comprises a first variable flow rate, and the valve system further comprises a second variable valve, the first variable valve and the second variable valve independently controllable to provide the first variable flow rate and a second variable flow rate, respectively.

25. The valve system of claim 1, wherein the first flow path and the second flow path are parallel flow paths for the fluid to reach the hydraulically powered AC generator.

7. A control system for controlling flow of a fluid to a hydraulically powered alternating current (AC) generator, the control system comprising:

a sensor device configured to measure a speed of movement of a component of the hydraulically powered AC generator; and

a control circuit configured to generate a control signal based on the speed of movement of the component measured by the sensor device, wherein the control circuit is further configured to transmit the control signal to a control device configured to control a variable flow rate of the fluid output to the hydraulically powered AC generator by a variable valve, wherein the variable valve is paralleled with a fixed valve for the fluid to reach the hydraulically powered AC generator, wherein the fixed valve provides a substantially constant flow rate of the fluid output to the hydraulically powered AC generator, wherein a flow rate of the fluid to drive the hydraulically powered AC generator includes a sum of the substantially constant flow rate of the fluid and the variable flow rate of the fluid, and wherein the variable valve provides control of a portion of the fluid output from the common fluid output to control an electrical output of the hydraulically powered AC generator.

8. The control system of claim 7, wherein the sensor device is configured to measure a speed of movement of one of a gear and a rotor of the hydraulically powered AC generator.

9. The control system of claim 8, wherein the sensor device comprises a Hall Effect sensor configured to measure a change in a magnetic field caused by the movement of the gear or the rotor.

10. The control system of claim 8, wherein the sensor device comprises an optical encoder sensor, the optical encoder sensor comprising a light source configured to generate light and a light detection device configured to detect changes in the light reflected off of the gear or rotor as the gear or rotor moves.

11. The control system of claim 8, wherein the sensor device comprises a magnetic pickup sensor.

12. The control system of claim 7, wherein the control circuit is configured to generate the control signal based on both the speed of movement of the component measured by the sensor device and an AC output frequency of the hydraulically powered AC generator measured using a second sensor device.

13. The control system of claim 7, wherein the control circuit is configured to generate the control signal to maintain an AC output frequency of the hydraulically powered AC generator within a threshold range of a target AC output frequency.

14. A hydraulically powered generator system comprising:

a hydraulically powered alternating current (AC) generator configured to generate output power based on flow of a fluid to the hydraulically powered AC generator;

a valve system comprising;

a first flow path comprising a fixed valve configured to provide a substantially constant flow rate of the fluid through the fixed valve to a common fluid output to reach the hydraulically powered AC generator; and

a second flow path comprising a variable valve configured to provide a variable flow rate of the fluid through the variable valve to the common fluid output to reach the hydraulically powered AC generator;

wherein a flow rate of the fluid output from the common fluid output to drive the hydraulically powered AC generator includes a sum of the substantially constant flow rate of the fluid and the variable flow rate of the fluid, and wherein the variable valve provides control of a portion of the fluid output from the common fluid output to control an electrical output of the hydraulically powered AC generator,

a sensor device configured to measure a speed of movement of a component of the hydraulically powered AC generator; and

a control circuit configured to control the variable flow rate of the variable valve based on the speed of movement of the component measured by the sensor device to compensate for changes in one or more operating conditions of the hydraulically powered AC generator, wherein the one or more operating conditions comprise at least one of a load, a temperature, a pressure, or a pump input speed of the hydraulically powered AC generator.

15. The control system of claim 14, wherein the sensor device is configured to measure a speed of movement of one or more of a gear and a rotor of the hydraulically powered AC generator.

16. The control system of claim 15, wherein the sensor device comprises at least one of a Hall Effect sensor, an optical encoder sensor, or a magnetic pickup sensor.

17. The control system of claim 14, wherein the control circuit is configured to generate the control signal based on both the speed of movement of the component measured by the sensor device and an AC output frequency of the hydraulically powered AC generator measured using a second sensor device.

18. The control system of claim 14, wherein the control circuit is configured to generate the control signal to maintain an AC output frequency of the hydraulically powered AC generator within a threshold range of a target AC output frequency.

19. The control system of claim 14, wherein the variable valve comprises a first variable valve and the variable flow rate comprises a first variable flow rate, wherein the valve system further comprises a second variable valve configured to provide a second variable flow rate, and wherein the control circuit is configured to independently control the first variable valve and the second variable valve to provide the first variable flow rate and the second variable flow rate, respectively.

26. The valve system of claim 14, wherein the first flow path and the second flow path are parallel flow paths for the fluid to reach the hydraulically powered AC generator.

20. A control system for controlling flow of a fluid to a hydraulically powered alternating current (AC) generator, the control system comprising:

a speed measurement module configured to measure a speed of movement of a component of the hydraulically powered AC generator; and

a control module configured to generate a control signal based on the speed of movement of the component measured by the speed measurement module, wherein the control module is further configured to transmit the control signal to a control device configured to control a variable flow rate of the fluid output to the hydraulically powered AC generator by a variable valve, wherein the variable valve is paralleled with a fixed valve for the fluid to reach the hydraulically powered AC generator, wherein the fixed valve provides a substantially constant flow rate of the fluid output to the hydraulically powered AC generator, wherein a flow rate of the fluid to drive the hydraulically powered AC generator includes a sum of the substantially constant flow rate of the fluid and the variable flow rate of the fluid, and wherein the variable valve provides control of a portion of the fluid output from the common fluid output to control an electrical output of the hydraulically powered AC generator.

21. The control system of claim 20, wherein the speed measurement module is configured to measure a speed of movement of at least one of a gear and a rotor of the hydraulically powered AC generator.

22. The control system of claim 21, wherein the speed measurement module comprises at least one of a Hall Effect sensor, an optical encoder sensor, or a magnetic pickup sensor.

23. The control system of claim 20, wherein the control module is configured to generate the control signal based on both the speed of movement of the component measured by the speed measurement module and an AC output frequency of the hydraulically powered AC generator measured using a frequency measurement module.

24. The control system of claim 20, wherein the control module is configured to generate the control signal to maintain an AC output frequency of the hydraulically powered AC generator within a threshold range of a target AC output frequency.