Method and apparatus for configuring a genset controller for operation with particular gensets

• US 6,351,692 B1
• Filed: 10/24/2000
• Issued: 02/26/2002
• Est. Priority Date: 10/24/2000
• Status: Active Grant

• Current Assignee: Kohler Company
• Original Assignee: Kohler Company
• Inventors: Churchill, Jonathan D., Eaton, Zane C.
• Primary Examiner(s): Grant, William
• Assistant Examiner(s): PATEL, RAMESH B
• Application Number:
  US09/695,167
• Time in Patent Office: 490 Days
• Field of Search: 700/18-19, 700/22, 700/86, 700/286, 700/287, 700/289, 700/290, 700/292, 700/295, 700/296, 361/20, 361/21, 361/22, 361/24, 361/93.2, 361/93.6, 361/94-96, 322/10-12, 322/19-24, 323/318, 323/319, 323/320, 323/321, 323/322
• US Class Current: 700/287
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 2219/23429 Selection as function of connected machine

Abstract

A genset controller that is configurable for controlling a variety of types of gensets, as well as a method of configuring a genset controller for controlling a genset, are disclosed. The genset controller includes a memory for storing a plurality of software routines, a personality profile data set, and a user-settable data set, and further includes a processor coupled to the memory for executing the software routines and reading data from the personality profile data set and the user settable data set to control the genset. The genset controller additionally includes an input port coupled to the memory for enabling changes to the personality profile data set and the user-settable data set to be downloaded into the memory. The personality profile data set and the user-settable data set include data that configures the genset controller for operation with a particular genset.

Claims

1. A genset controller that is configurable for controlling a variety of types of gensets, the genset controller comprising:

a memory for storing a plurality of software routines, a personality profile data set, and a user-settable data set;

a processor coupled to the memory for executing the software routines and reading data from the personality profile data set and the user settable data set to control the genset; and

an input port coupled to the memory for enabling changes to the personality profile data set and the user-settable data set to be downloaded into the memory; and

wherein the personality profile data set and the user-settable data set include data that configures the genset controller for operation with at least one of a particular genset and an engine/alternator combination within a particular genset,

wherein the personality profile data set includes at least one of a transient open circuit time constant of the alternator, a number of alternator poles, a fixed voltage flag, a single maximum power rating for a fixed voltage alternator, a plurality of maximum power ratings, a plurality of alternator current limits corresponding to respective alternator voltage settings, a plurality of voltage regulator gain constants, a default gain for a regulator of an engine of the genset, a speed sensor constant to determine engine RPM, a plurality of engine speed warning and shutdown settings, a genset serial number, an alternator model number, an engine model number, and an engine shutdown oil pressure.

2. The genset controller of claim 1, further comprising a keypad interface by which the user-settable data set is downloaded into the memory.

3. The genset controller of claim 1, wherein the user-settable data set includes at least one of a present output voltage of the genset, a present operational frequency of the genset, an identity of an analog input, an identity of a digital input, a genset serial number, an alternator model number, and an engine model number.

4. The genset controller of claim 1, wherein the genset controller is capable of determining whether an engine control module (ECM) is being employed to control the genset based upon at least one of the personality profile data set and the user-settable data set.

5. The genset controller of claim 1, wherein the genset controller is capable of determining whether the genset includes a circuit breaker for preventing excessive current and heat generation within an alternator of the genset.

6. The genset controller of claim 5, wherein the genset controller is configured to execute a thermal protection subroutine when it determines that the genset does not include the circuit breaker.

7. The genset controller of claim 6,

wherein the memory comprises a 512K FLASH memory in which the personality profile data set and the user-settable data set are stored, and further comprises an additional memory element in which the software routines are stored.

8. The genset controller of claim 1, wherein the input port is an RS-232 serial input port by which the user-settable data set is input and downloaded into memory.

9. The genset controller of claim 1,

wherein operation of the genset will be disabled by the genset controller if a personality profile data set has not been downloaded into memory.

10. The genset controller of claim 1, wherein a fault will occur if at least one of a genset serial number, an alternator model number, and an engine model number within the personality profile data set does not match a respective one of a genset serial number, an alternator model number, and an engine model number within the user-settable data set.

11. The genset controller of claim 1, wherein the personality profile data set is capable of being downloaded at one of a facility at which the genset controller is manufactured, a facility at which the genset controller and the genset are assembled together, and a field location at which a representative of a distributor is effecting a modification to the genset controller;

and

wherein the user-settable data is capable of being downloaded at any one of the places at which the personality profile data set is capable of being downloaded, and additionally is capable of being at least one of downloaded from a serial communication link, downloaded remotely using a program, and downloaded by the action of a user who intends to operate the genset.

12. The genset controller of claim 1,

wherein the personality profile data set and the user-settable data set are stored separately from the software routines in the memory so that the personality profile data set and the user-settable data set are downloaded without impacting the software routines.

13. A genset controller that is configurable for controlling a variety of types of gensets, the genset controller comprising:

a memory for storing a plurality of software routines, a personality profile data set, and a user-settable data set;

a processor coupled to the memory for executing the software routines and reading data from the personality profile data set and the user settable data set to control the genset; and

an input port coupled to the memory for enabling changes to the personality profile data set and the user-settable data set to be downloaded into the memory; and

wherein the personality profile data set and the user-settable data set include data that configures the genset controller for operation with at least one of a particular genset and an engine/alternator combination within a particular genset,

wherein the input port is an RS-232 serial input port by which the user-settable data set is capable of being inputed and downloaded into memory,

wherein the personality profile data set is capable of being downloaded at one of a facility at which the genset controller is manufactured, a facility at which the genset controller and the genset are assembled together, and a field location at which a representative of a distributor is effecting a modification to the genset controller; and

wherein the user-settable data set is capable of being downloaded at any one of the places at which the personality profile data set is capable of being downloaded, and additionally is capable of being at least one of downloaded from a serial communication link, downloaded remotely using a program, and downloaded by the action of a user who intends to operate the genset.

14. A method of configuring a genset controller for controlling a genset, the method comprising:

storing a plurality of software routines, a personality profile data set, and a user-settable data set;

operating the genset by executing the software routines which employ the personality profile data set and the user-settable data set;

downloading changes to the personality profile data set at a first time to alter the manner in which the genset is operated by execution of the software routines; and

downloading changes to the user-settable data set at at least one of the first time and a second time subsequent to the first time to alter the manner in which the genset is operated by execution of the software routines.

15. The method of claim 14, further comprising:

comparing a first segment of identification information within the personality profile data set with a second segment of identification information within the user-settable data set; and

providing a fault signal if the two segments of identification information do not match one another.

16. The method of claim 14, further comprising:

preventing operation of the genset by way of the genset controller if the personality profile data set is improper in that it contains no information.

17. The method of claim 14, wherein the personality profile data set includes at least one of a transient open circuit time constant of the alternator, a number of alternator poles, a fixed voltage flag, a single maximum power rating for a fixed voltage alternator, a plurality of maximum power ratings, a plurality of alternator current limits corresponding to respective alternator voltage settings, a plurality of voltage regulator gain constants, a default gain for a regulator of an engine of the genset, a speed sensor constant to determine engine RPM, a plurality of engine speed warning and shutdown settings, a genset serial number, an alternator model number, an engine model number, and an engine shutdown oil pressure.

18. The method of claim 14, wherein the user-settable data set includes at least one of a present output voltage of the genset, a present operational frequency of the genset, an identity of an analog input, an identity of a digital input, a genset serial number, an alternator model number, and an engine model number.

19. The method of claim 14, wherein the genset controller is capable of determining whether an engine control module (ECM) is being employed to control the genset based upon at least one of the personality profile data set and the user-settable data set.

20. The method of claim 14, wherein the genset controller is capable of determining whether the genset includes a circuit breaker for preventing excessive current and heat generation within an alternator of the genset.